U.S. patent application number 14/458545 was filed with the patent office on 2015-02-26 for systems and methods for automatically loading and setting a rail fastener driving workhead unit.
The applicant listed for this patent is Nordco Inc.. Invention is credited to Jonathan Dale Dickerson.
Application Number | 20150052730 14/458545 |
Document ID | / |
Family ID | 52479058 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150052730 |
Kind Code |
A1 |
Dickerson; Jonathan Dale |
February 26, 2015 |
SYSTEMS AND METHODS FOR AUTOMATICALLY LOADING AND SETTING A RAIL
FASTENER DRIVING WORKHEAD UNIT
Abstract
A rail fastener driving machine used for performing a spiking
operation is provided, and includes a rail fastener workhead unit
configured for driving a fastener into a rail tie. Also included in
the machine is a position feedback system configured for
controlling the spiking operation of the fastener driving machine
based on a position signal and a mode signal, and a position sensor
connected to the position feedback system for generating the
position signal relative to a cylinder connected to the workhead
unit, the position sensor transmitting the position signal to the
position feedback system. The mode signal indicates an operation
mode selected by an operator, and the workhead unit is actuated by
the cylinder based on the mode signal for automatically positioning
the workhead unit for driving the fastener into the rail tie.
Inventors: |
Dickerson; Jonathan Dale;
(Toledo, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nordco Inc. |
Oak Creek |
WI |
US |
|
|
Family ID: |
52479058 |
Appl. No.: |
14/458545 |
Filed: |
August 13, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61867888 |
Aug 20, 2013 |
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Current U.S.
Class: |
29/432 ;
227/4 |
Current CPC
Class: |
E01B 29/26 20130101;
Y10T 29/49833 20150115 |
Class at
Publication: |
29/432 ;
227/4 |
International
Class: |
E01B 29/26 20060101
E01B029/26 |
Claims
1. A rail fastener driving machine used for performing a spiking
operation, comprising: a rail fastener workhead unit configured for
driving a fastener into a rail tie; a position feedback system
configured for controlling the spiking operation of the fastener
driving machine based on a position signal and a mode signal; and a
position sensor connected to the position feedback system for
generating the position signal relative to a cylinder connected to
the workhead unit, the position sensor transmitting the position
signal to the position feedback system, wherein the mode signal
indicates an operation mode selected by an operator, and the
workhead unit is actuated by the cylinder based on the mode signal
for automatically positioning the workhead unit for driving the
fastener into the rail tie.
2. The rail fastener driving machine of claim 1, further comprising
a mode selection module configured for selecting the operation mode
under which the position feedback system is operated, and
generating the mode signal based on the mode selection.
3. The rail fastener driving machine of claim 1, wherein the
operation mode includes at least one of: an off mode for operating
the position feedback system manually without automation; an
auto-load mode for operating the position feedback system with an
automatic fastener loading sequence; and an auto-load-set mode for
operating the position feedback system with an automatic fastener
loading and setting sequences.
4. The rail fastener driving machine of claim 1, further comprising
a position detection module configured for receiving the position
signal from the position sensor for determining whether the
workhead unit of the rail fastener driving machine is in a fastener
loading position based on the position signal.
5. The rail fastener driving machine of claim 4, wherein the
fastener loading position refers to a position where the workhead
unit is fully retracted and has reached an upper limit of its
operational range relative to the cylinder, such that when the
workhead unit is in the fastener loading position, fastener
gripping jaws are in an open position, thereby preparing to receive
the fastener from a fastener magazine.
6. The rail fastener driving machine of claim 1, further comprising
a spike loading module configured for performing an automatic
fastener loading sequence by operating a fastener magazine in
response to the mode signal.
7. The rail fastener driving machine of claim 6, wherein when the
workhead unit is in a fastener loading position and the mode signal
indicates either an auto-load mode or an auto-load-set mode, the
spike loading module automatically loads the fastener into a
delivery point such that fastener gripping jaws switch to a closed
position and securely grip the fastener for spiking.
8. The rail fastener driving machine of claim 1, further comprising
a spike setting module configured for performing an automatic
fastener setting sequence in response to the mode signal.
9. The rail fastener driving machine of claim 8, wherein when the
mode signal indicates an auto-load-set mode, the spike setting
module automatically transitions the workhead unit to a set
position.
10. The rail fastener driving machine of claim 9, wherein the set
position refers to a position where the fastener is positioned
above a tie plate hole within a predetermined distance between a
lower tip of the fastener and an opening of the tie plate hole.
11. The rail fastener driving machine of claim 1, further
comprising a spiking module configured for actuating the workhead
unit to be in a driving position under the action of the cylinder
such that the fastener is driven into the rail tie using the
workhead unit.
12. A method for performing a spiking operation of a rail fastener
driving machine using a position feedback system, comprising:
controlling the spiking operation based on a position signal and a
mode signal; generating the position signal relative to a cylinder
connected to a workhead unit of the rail fastener driving machine;
receiving the position signal from a position sensor connected to
the position feedback system; transmitting the position signal to
the position feedback system; generating the mode signal based on
an operation mode selected by an operator; and actuating the
workhead unit using the cylinder based on the mode signal for
automatically positioning the workhead unit for driving a fastener
into a rail tie.
13. The method of claim 12, further comprising: selecting the
operation mode under which the position feedback system is
operated; and generating the mode signal based on the mode
selection.
14. The method of claim 12, wherein the operation mode includes at
least one of: an off mode for operating the position feedback
system manually without automation; an auto-load mode for operating
the position feedback system with an automatic fastener loading
sequence; and an auto-load-set mode for operating the position
feedback system with an automatic fastener loading and setting
sequences.
15. The method of claim 12, further comprising: determining whether
the position feedback system is in one of an auto-load mode or an
auto-load-set mode based on the mode signal; receiving the position
signal from the position sensor when the operation mode is in
either one of the auto-load or auto-load-set mode.
16. The method of claim 12, further comprising: performing an
automatic fastener loading sequence in response to the mode signal
when the operation mode is in either one of an auto-load or
auto-load-set mode; and manually performing the fastener loading
sequence when the operation mode is in neither one of the auto-load
or auto-load-set mode.
17. The method of claim 12, further comprising: performing an
automatic fastener setting sequence in response to the mode signal
when the operation mode is in an auto-load-set mode; and manually
performing the fastener setting sequence when the operation mode is
not in the auto-load-set mode.
18. The method of claim 12, further comprising overriding an
automatic fastener loading sequence or an automatic fastener
setting sequence by the operator.
19. The method of claim 12, further comprising automatically
transitioning the workhead unit to a set position when the mode
signal indicates an auto-load-set mode.
20. The method of claim 12, further comprising actuating the
workhead unit to be in a driving position under the action of the
cylinder such that the fastener is driven into the rail tie using
the workhead unit.
Description
CROSS-REFERENCE
[0001] This application claims priority under 35 USC 119(e) from
U.S. Provisional Application Ser. No. 61/867,888 filed Aug. 20,
2013.
BACKGROUND
[0002] The present disclosure generally relates to railroad
right-of-way maintenance machinery, and more particularly relates
to machinery used for driving fasteners into rail ties for securing
rail tie plates and rails to the ties.
[0003] Rail fasteners as contemplated herein include cut spikes,
lag screws, hairpin spikes and other types of rail fasteners used
for retaining tie plates upon ties, and rails upon tie plates, as
are known to skilled practitioners. In some cases in the
specification, "spikes" may be used interchangeably with "rail
fasteners." The use of the term "spikes" is not intended to limit
the scope of the present invention.
[0004] Conventional railroad maintenance machine operations include
spike driving, spike pulling, tie boring, tie replacement, lag
screw application, anchor removing, and other related tasks. Each
machine is designed for mechanically performing a specific task
under operator control. Specifically, a rail fastener driving
machine is provided to drive spikes into ties, also known as
spiking. Such rail fastener driving machines typically include a
frame which is either self-propelled or towable along a railroad
track.
[0005] A fastener driving workhead unit actuated by a fluid power
cylinder is provided with a reciprocating element for impacting a
fastener and driving it into a tie. A fastener magazine is
constructed and arranged for conveying the fasteners sequentially
from the magazine to a selected location in operational
relationship to the reciprocating element. When the workhead unit
is fully retracted, an operator manually loads the spike into the
workhead unit after visually verifying the workhead unit's current
position. Repeated visual verifications are burdensome to the
operator, and lengthen a timed cycle of each spiking operation.
Thus, there is a need for developing an improved system and method
of an automatic fastener loading operation.
SUMMARY
[0006] The present disclosure is directed to a rail fastener
driving machine or a spiker having an automatic position feedback
system. Specifically, the position feedback system improves a timed
cycle of a fastener loading operation, and reduces a number of
manual operator tasks during the operation. As a result, an
improved, e.g., faster and more convenient, fastener loading
operation is achieved without compromising the operational sequence
of the fastener driving machine.
[0007] One aspect of the present machine is that, as described in
further detail below, the position feedback system determines
whether a workhead unit is in a fastener loading position, which
refers to a position where the workhead unit has reached an upper
limit of its operational range relative to a spiker cylinder that
actuates the workhead unit. When the workhead unit is in the
fastener loading position, a fastener magazine automatically loads
a fastener into the workhead unit under the control of the position
feedback system.
[0008] Another important aspect is that the present position
feedback system operates the fastener driving machine automatically
without manual operator intervention, and thus saves time during
railroad maintenance. Consequently, the cycle time of the spiking
operation is significantly reduced. More specifically, the present
position feedback system automatically loads the spike into the
workhead unit when the workhead unit is in the fastener loading
position without having to verify the workhead unit's position.
After the automatic loading, the workhead unit automatically
transitions to a set position, which refers to a position where the
spike is positioned above a tie plate hole within a predetermined
distance between a lower tip of the spike and an opening of the tie
plate hole, thereby being ready for spiking.
[0009] In one embodiment, a rail fastener driving machine used for
performing a spiking operation is provided, and includes a rail
fastener workhead unit configured for driving a fastener into a
rail tie. Also included in the machine is a position feedback
system configured for controlling the spiking operation of the
fastener driving machine based on a position signal and a mode
signal, and a position sensor connected to the position feedback
system for generating the position signal relative to a cylinder
connected to the workhead unit, the position sensor transmitting
the position signal to the position feedback system. The mode
signal indicates an operation mode selected by an operator, and the
workhead unit is actuated by the cylinder based on the mode signal
for automatically positioning the workhead unit for driving the
fastener into the rail tie.
[0010] In another embodiment, a method for performing a spiking
operation of a rail fastener driving machine is provided using a
position feedback system, and includes controlling the spiking
operation based on a position signal and a mode signal; generating
the position signal relative to a cylinder connected to a workhead
unit of the rail fastener driving machine; receiving the position
signal from a position sensor connected to the position feedback
system; transmitting the position signal to the position feedback
system; generating the mode signal based on an operation mode
selected by an operator; and actuating the workhead unit using the
cylinder based on the mode signal for automatically positioning the
workhead unit for driving a fastener into a rail tie.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a fragmentary side perspective view of the present
spike driving machine featuring a spike driving workhead unit in a
set position;
[0012] FIG. 2 is a fragmentary side perspective view of the spike
driving machine of FIG. 1 in a down or driving position;
[0013] FIG. 3 is an enlarged fragmentary side perspective view of
the present jaw assembly in an open position;
[0014] FIG. 4 is an enlarged fragmentary side perspective view of
the jaw assembly of FIG. 3 in a closed position;
[0015] FIG. 5 is a functional block diagram of the present position
feedback system featuring functional modules; and
[0016] FIG. 6 illustrates an exemplary spike loading and setting
method in accordance with an embodiment of the present
disclosure.
DETAILED DESCRIPTION
[0017] Referring now to FIGS. 1-2, the present spike driving
machine is generally designated 10 and is designed to drive a
railroad spike or fastener 12 into a railroad tie 14 for securing a
rail tie plate 16 and a rail 18 to the tie on a railroad track 20.
Conventionally, the spike driving machine 10 is mounted upon a
railway maintenance machine or base unit (not shown). Several types
of spike driving machines are known, and exemplary models are
described in commonly assigned U.S. Pat. Nos. 4,579,061; 4,777,885;
5,191,840; 5,671,679; and 7,104,200, all of which are incorporated
by reference herein.
[0018] Included in the machine 10 is a main maintenance machine
frame 22 supported on wheels (not shown) such that the frame is
constructed and arranged for being movable along the railroad track
20. For driving the spike 12 into the tie 14, a spike driving
workhead unit 24 is provided with a reciprocating hydraulic impact
hammer (not shown), which is reciprocally vertically movable
relative to the rail 18. A fluid power, preferably hydraulic,
spiker cylinder 26 is provided for actuating and controlling
vertical movement of the spike driving workhead unit 24 via a
slider bracket 28 relative to the main railway maintenance machine
frame 22, as taught in co-pending U.S. Patent Application No.
61/867,837 (Attorney Docket No. 1425.114553), incorporated by
reference.
[0019] A lower end 30 of the workhead unit 24 is attached to a
hammer bushing 32 having a substantially cylindrical shape for
accommodating an extension coupler 34. The extension coupler 34 is
releasably secured to the hammer bushing 32 by pivotally fastening
a hammer bushing clamp 36. An anvil assembly, generally designated
38, includes the extension coupler 34 at its upper end. Further
included in the anvil assembly 38 is a tube-like anvil sleeve 40
that defines a passageway for a shaft-like anvil 42 within the
sleeve. During spiking, the anvil 42 travels reciprocally
vertically inside the sleeve 40 to engage the head of the spike
12.
[0020] A jaw assembly, generally designated 44, includes a pair of
spike gripping jaws 46 mounted to a jaw block 48 via a pair of rod
eyes 50 to grasp the spike 12. In operation, the jaws 46 are
pressurized toward a closed or gripping position by the rod eyes
50, which are hydraulically or mechanically biased, e.g., spring
biased, as is well known in the art. When the spike 12 held by the
jaws 46 is positioned for percussion, the sleeve 40 is lowered
toward the tie plate 16 to slidingly separate the jaws 46, and
holds the spike 12 inside the sleeve 40 such that the anvil 42
drives the spike into the tie 14 (FIG. 2).
[0021] Referring now to FIGS. 1-4, also included in the jaw block
48 is a pair of guide rods 52. Not only do the rods 52 guide a
vertical movement of the anvil assembly 38, but also guide a
downward movement of the jaw assembly 44 during spiking. As is
known in the art, the guide rods 52 are slidingly engaged in
corresponding bores of a workhead feeder frame of the type
disclosed in U.S. Pat. No. 5,398,616, which is incorporated by
reference.
[0022] A magazine or spike feed mechanism, generally designated 54,
is provided for accommodating a plurality of the spikes 12 and
feeding them sequentially for driving by the anvil assembly 38.
Preferably, the feed mechanism 54 includes an inclined, elongated
chute 56 made of a pair of parallel bars 58 which guide the spikes
12 toward a delivery point 60. In the preferred embodiment, the
feed mechanism 54 is inclined so that the spikes 12 move toward the
delivery point 60 by gravity. At the delivery point 60, the anvil
42 powered by a hydraulic cylinder (not shown) of the workhead unit
24 engages the top portion or head of the spike 12 to drive it into
the tie 14.
[0023] Referring again to FIGS. 1-4, an exemplary spike loading
operation is shown using the present spike driving machine 10.
Initially, the present spike loading operation begins with the
wokhead unit 24 being fully retracted with the jaws 46 in an open
position, ready for receiving the spike 12 (FIG. 3). Next, the
spike 12 is loaded into the delivery point 60 from the magazine 54,
and the jaws 46 securely grip the spike in place for spiking (FIG.
4). Then, the workhead unit 24 is adjustably positioned relative to
the frame 22 for proper alignment of the gripped spike 12 into a
selected hole 62 in the tie plate 16, also known as a set position
(FIG. 1). While the tie plate 16 typically has multiple such holes
62, only one is shown for illustration purposes. After the
alignment of the spike 12, the sleeve 40 is lowered onto an upper
surface 64 of the tie plate 16, and the spike is subsequently
driven into the tie 14 by the anvil 42, also known as a down or
driving position (FIG. 2).
[0024] An important feature of the present spike driving machine 10
is that the spike loading operation is controlled by a position
feedback device or system, generally designated 66. In a preferred
embodiment, the position feedback system 66 is a software installed
computer device having programmable modules for various functions.
As used herein, the term "module" may refer to, be part of, or
include an Application Specific Integrated Circuit (ASIC), an
electronic circuit, a processor (shared, dedicated, or group), a
programmable logic controller (PLC) and/or memory (shared,
dedicated, or group) that execute one or more software or firmware
programs, a combinational logic circuit, and/or other suitable
components that provide the described functionality.
[0025] Although the children modules residing in their respective
parent modules are shown, the broad teachings of the present system
can be implemented in a variety of forms. Thus, while this
disclosure includes particular examples and arrangements of the
modules, the scope of the present device should not be so limited
since other modifications will become apparent to the skilled
practitioner.
[0026] Referring now to FIGS. 1, 3-5, it is preferred that the
present position feedback system 66 includes a central control
module (CCM) 68, a position sensor 70, and a database 72. Overall
operation of the feedback system 66 is controlled by the CCM 68.
Positional information of the spiker cylinder 26 is provided by the
position sensor 70 located preferably on top of the cylinder 26.
Preferably, the spiker cylinder 26 includes a reciprocating rod as
is known in the art. All relevant information can be stored in the
database 72 for retrieval by the CCM 68, e.g., as a data storage
device and/or a machine readable data storage medium carrying
computer programs.
[0027] Also included in the CCM 68 is an interface module 74, which
provides an interface between the CCM 68, the position sensor 70,
and the database 72. The interface module 74 also controls
operation of, for example, actuators 76, such as the spiker
cylinder 26, and other related system devices, services, and
applications. The other devices, services, and applications may
include, but are not limited to, one or more software or hardware
components, as are known in the art. The interface module 74 also
receives signals, which are communicated to the respective modules,
such as the CCM 68 and its children modules.
[0028] Regarding the children modules, a mode selection module 78
is provided for selecting an operation mode under which the
position feedback system 66 is operated, and generating a mode
signal M based on the mode selection. For example, an operator may
select an OFF mode to operate the position feedback system 66
manually without automation. Other options include an AUTO-LOAD
mode and an optional AUTO-LOAD-SET mode. The AUTO-LOAD mode refers
to an operation mode in which the position feedback system 66 is
operated with an automatic spike loading sequence only. Similarly,
the optional AUTO-LOAD-SET mode refers to an operation mode in
which the position feedback system 66 is operated with both
automatic spike loading and setting sequences. A detailed
description of each mode is described below.
[0029] A position detection module 80 receives a position signal P
from the position sensor 70 via the interface module 74, and
determines whether the workhead unit 24 is in a fastener loading
position based on the position signal P. As discussed above, the
fastener loading position refers to a position where the workhead
unit 24 is fully retracted and has reached an upper limit 82 of its
operational range relative to the spiker cylinder 26. When the
workhead unit 24 is in the fastener loading position, the jaws 46
are in the open position, thereby preparing to receive the spike 12
from the magazine 54 (FIG. 3).
[0030] A spike loading module 84 performs the automatic spike
loading sequence by operating the fastener magazine 54 in response
to the mode signal M. Specifically, when the workhead unit 24 is in
the fastener loading position and the mode signal M indicates
either the AUTO-LOAD mode or the optional AUTO-LOAD-SET mode, the
spike loading module 84 automatically loads the spike 12 into the
delivery point 60 such that the jaws 46 switch to the closed
position and securely grip the spike 12 for spiking (FIG. 4).
[0031] Returning now to FIGS. 1-2 and 5, a spike setting module 86
performs the automatic spike setting sequence in response to the
mode signal M. Similar to the spike loading module 84, when the
mode signal M indicates the optional AUTO-LOAD-SET mode, the spike
setting module 86 automatically transitions the workhead unit 24 to
a set position. As discussed above, the set position refers to a
position where the spike 12 is positioned above the tie plate hole
62 within a predetermined distance D between a lower tip 88 of the
spike and an opening of the tie plate hole (FIG. 1). An exemplary
distance D is approximately 0.25''.
[0032] After transitioning to the set position, a spiking module 90
actuates the workhead unit 24 to be in a down or driving position
under the action of the spiker cylinder 26. The down or driving
position refers to a position where the anvil sleeve 40 is lowered
onto the tie plate 16 such that the anvil 42 inside the sleeve 40
drives the spike 12 into the tie 14 by percussion (FIG. 2). As a
result, the tie plate 16 and the rail 18 are secured to the tie
14.
[0033] Referring now to FIG. 6, an exemplary method of the spike
loading and setting sequences is shown using the present position
feedback system 66. Although the following steps are primarily
described with respect to the embodiments of FIGS. 1-5, it should
be understood that the steps within the method may be modified and
executed in a different order or sequence without altering the
principles of the present disclosure.
[0034] The method begins at step 100. In step 102, as shown in FIG.
5, the mode selection module 78 generates a mode signal M based on
an operation mode selection. For example, an operator can press one
of the mode buttons disposed on a keypad of a hand controller or
keyboard for selecting one of the operation modes. As for a
complete manual mode, the operator presses an OFF mode button, or
does not select any automatic mode. As for available automatic
modes, the operator selectively triggers either an AUTO-LOAD mode
button or an AUTO-LOAD-SET mode button. If a manual spike setting
sequence is desired, the AUTO-LOAD mode button is selected, which
performs only the automatic spike loading sequence. However, if a
full automatic mode is desired, including both the automatic spike
loading and setting sequences, the AUTO-LOAD-SET mode button is
selected.
[0035] In step 104, the mode selection module 78 determines whether
the position feedback system 66 is in one of the automatic modes,
namely the AUTO-LOAD mode or the optional AUTO-LOAD-SET mode based
on the mode signal M. If the selected mode is either one of the
automatic modes, control proceeds to step 106. Otherwise, control
proceeds to step 108.
[0036] In step 106, the position detection module 80 receives the
position signal P from the position sensor 70 via the interface
module 74. In step 108, the operator manually performs the spike
loading sequence.
[0037] In step 110, the position detection module 80 determines
whether the workhead unit 24 is in the fastener loading position
based on the position signal P. If the workhead unit 24 is in the
fastener loading position, then control proceeds to step 112, else
control returns to step 106 to wait until the workhead unit 24
reaches the upper limit 82 of its operational range, as illustrated
in FIG. 1.
[0038] In step 112, the spike loading module 84 receives the mode
signal M from the mode selection module 78, and performs the
automatic spike loading sequence in response to the mode signal M.
In the preferred embodiment, this step is performed regardless of
the automatic mode type as long as the position feedback system 66
is in one of the automatic modes.
[0039] In step 114, based on the mode signal M, if the position
feedback system 66 is in the optional AUTO-LOAD-SET mode, then
control proceeds to step 116. Otherwise, control proceeds to step
118. In step 116, the a spike setting module 86 receives the mode
signal M from the spike loading module 84, and performs the
automatic spike setting sequence in response to the mode signal M.
It is contemplated that the automatic spike loading and setting
sequences can be overridden by the operator and switched to the
manual mode at any step if required.
[0040] In step 118, the operator manually performs the spike
setting sequence. In step 120, the spiking module 90 actuates the
workhead unit 24 to be in the down or driving position, and drives
the spike 12 into the tie 14 by percussion. Control ends at step
122.
[0041] While a particular embodiment of the present spike driving
machine has been described herein, it will be appreciated by those
skilled in the art that changes and modifications may be made
thereto without departing from the present disclosure in its
broader aspects and as set forth in the following claims.
* * * * *