U.S. patent application number 15/218591 was filed with the patent office on 2016-11-17 for method and apparatus for milling of railroad track.
The applicant listed for this patent is Loram Maintenance of Way, Inc.. Invention is credited to Jon Thomas Behrens.
Application Number | 20160333531 15/218591 |
Document ID | / |
Family ID | 48797336 |
Filed Date | 2016-11-17 |
United States Patent
Application |
20160333531 |
Kind Code |
A1 |
Behrens; Jon Thomas |
November 17, 2016 |
METHOD AND APPARATUS FOR MILLING OF RAILROAD TRACK
Abstract
A milling system for milling a track surface with at least one
rotatable milling plate. A modular blade system for each milling
plate allows individual blades to be removed and replaced when an
individual blade becomes dull or broken. The blade system also
allows the milling plates to be oriented in both Type 2 and Type 3
configurations depending upon track surroundings and the presence
of encumbrance. The milling plates can be mounted to a positioning
assembly for adjusting the relative distance between the milling
plate and the track surface as well as the angle at which the
milling plate engages the track surface. The milling system can
include a depth guide so as to physically prevent the milling plate
from cutting too deeply into the track surface.
Inventors: |
Behrens; Jon Thomas; (St.
Michael, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Loram Maintenance of Way, Inc. |
Hamel |
MN |
US |
|
|
Family ID: |
48797336 |
Appl. No.: |
15/218591 |
Filed: |
July 25, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13745430 |
Jan 18, 2013 |
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15218591 |
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61588472 |
Jan 19, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 409/306384
20150115; E01B 31/13 20130101; Y10T 409/303808 20150115; B23C 3/005
20130101; B23C 5/2269 20130101; Y10T 407/192 20150115; B23C 5/20
20130101; B23C 2200/0455 20130101; Y10T 407/1908 20150115 |
International
Class: |
E01B 31/13 20060101
E01B031/13; B23C 3/00 20060101 B23C003/00 |
Claims
1-2. (canceled)
3. The railway milling plate of claim 12, wherein each milling
blade assembly includes a threaded bore and each blade slot
includes a threaded slot bore and wherein a set screw individually
connects each milling blade assembly within the corresponding blade
slot.
4. (canceled)
5. The railway milling plate of claim 13, wherein the milling side
further comprises a plurality of blade slots arranged around the
perimeter edge and wherein each milling blade assembly is
individually mounted in a corresponding one of the blade slots, and
wherein each adjustable vice member includes a threaded vice bore,
and wherein a set screw is positioned through the threaded vice
bore and into a threaded slot bore in the corresponding blade slot
to mount the milling blade assembly into the corresponding blade
slot.
6. A railway milling system, comprising: a rail car including at
least one positioning assembly; and at least one milling module
including a motor and a milling plate; wherein the positioning
assembly selectively positions the milling plate with respect to a
track surface such that the milling plate engages the track surface
in either a Type II milling configuration or a Type III milling
configuration.
7. The railway milling system of claim 6, further comprising: a
control system, wherein the control system monitors a brake
horsepower of the motor required to rotate the milling plate such
that the control system can cutoff operation of the motor it a
brake horsepower threshold is exceeded.
8. The railway milling system of claim 6, wherein the positioning
assembly further comprises a horizontal positioning, assembly and a
vertical positioning assembly.
9. The railway milling system of claim 8, wherein the positioning
assembly further comprises a depth guide that operably engages the
track surface to limit a milling depth of the milling plate,
10. The railway milling system of claim 9, wherein the depth guide
includes at least one guide wheel that is in continual contact with
the track surface to prevent the vertical positioning assembly from
directing the milling plate past a predetermined height from the
track surface.
11. The railway milling system of claim 6, wherein the milling
plate further comprises a circular plate body having a milling side
and a connecting side on opposed sides of the circular plate both
milling side including a plurality of milling blade assemblies
positioned on a perimeter edge of the milling side, wherein each
milling blade assembly presents an angled milling surface for
individually engaging the track surface.
12. The railway milling system of claim 11, wherein the milling
side further comprises a plurality of blade slots arranged around
the perimeter edge and wherein each milling blade assembly is
individually mounted in a corresponding one of the blade slots.
13. The railway milling system of claim 11, wherein each milling
blade assembly comprises a milling blade and an adjustable vice
member, wherein the angled milling surface is defined on the
milling blade.
14. The railway milling system of claim 6, further comprises a
plurality of positioning assemblies and a plurality of milling
modules such that each positioning assembly individually
positioning the corresponding milling module with respect to the
track surface such that each milling plate mills a selected facet
of a track profile.
15-20. (canceled)
21. A railway milling system, comprising: a rail car including at
least one positioning assembly; and at least one milling module
including a motor and a milling plate, wherein the milling plate
further comprises a circular plate body having a milling side
including a plurality of milling blade assemblies positioned around
a perimeter edge of the milling side, wherein each milling blade
assembly presents an angled milling surface for individually
engaging the track surface; wherein the positioning assembly
selectively positions the milling plate with respect to a rail such
that the milling plate engages the track surface of the rail.
22. The railway milling system of claim 21, wherein the milling
plate engages the track surface such that the rail bisects an
approximate center of the milling plate.
23. The railway milling system of claim 21, wherein the milling
plate engages the track surface such that the rail intersects a
periphery of the milling plate.
24. The railway milling system of claim 21, wherein the positioning
assembly selectively positions the milling plate such that the
milling plate engages the track surface such that the rail bisects
an approximate center of the milling plate or such that that the
rail intersects a periphery of the milling plate.
25. The railway milling system of claim 21, wherein each milling
module includes a plurality of motors and milling plates, and
wherein each milling plate is selectively positioned to engage and
mill a unique facet of the track surface.
26. The railway milling system of claim 25, wherein the plurality
of milling plates cooperatively engage and mill an entire rail
profile of the track surface.
Description
RELATED APPLICATIONS
[0001] This application is a division of application Ser. No.
13/745,430 filed Jan. 18, 2013, which claims the benefit of U.S.
Provisional Application No. 61/588,472 filed Jan. 19, 2012, each of
which is hereby fully incorporated herein by reference.
FIELD OF THE DISCLOSURE
[0002] The present invention relates generally to railway
maintenance. More specifically, the present invention is directed
to an apparatus and related methods for milling a track surface to
remove irregularities in the track surface.
BACKGROUND OF THE DISCLOSURE
[0003] Railroad tracks generally comprise a pair of metal rails
arranged in a parallel configuration so as to guide and support
metal wheels of train cars. Use of these tracks to support heavy
loads travelling at high speeds results in the formation of
irregularities such as pits, burrs, cracks and deformations along
the track surface. These irregularities can create excessive noise
and vibrations as the wheels of the train car contact the
irregularities. Similarly, the irregularities can also increase the
fatigue on the rails and the train cars themselves creating
substantial safety and maintenance problems. Although the
irregularities can often be easily smoothed out of the track by
grinding or milling the surface of each track section in a machine
shop, removing each section for regular maintenance is impractical
and expensive.
[0004] A common method of removing irregularities from the track in
situ comprises pulling at least one rotating grinding stone that
includes an abrasive surface along the track to grind the track
surface so as to smooth out any irregularities without having to
remove the section. One of the primary concerns with grinding out
the irregularities without removing the track section is ensuring
that the entire track surface is contacted by the abrasive surface
so as to avoid missing any irregularities. Because of factors
including different load weights and configurations of the trains
traveling over the rails or even installation factors such as, for
example, differing soil conditions beneath the rails, the track
surface can wear unevenly along the railway. This makes it even
more important that that the entire rail profile be contacted by an
abrasive surface during the grinding operation. In response to this
requirement, a variety of different grinding configurations have
been developed are currently available to grind the entire rail
profile.
[0005] In a Type 1 grinding configuration, a rotating grinding
element rotates in a vertical plane above the rail. The abrasive
surface is positioned on a perimeter edge of the rotating element
and is beveled or shaped to match the rail profile such that it
contacts the entire face of the rail surface as the rotating
element is directed along the rail. The drawback of the Type 1
configuration is that the large surface area of the abrasive
surface for each rotating element creates a substantial amount of
friction requiring a relatively powerful motor to rotate the
rotating element. Furthermore, the rotating element is typically
rotated such that the abrasive surface travels past the track
surface in the direction opposite the direction the rotating
element is being pulled down the track to maximize the friction
generated by the abrasive pad so as to efficiently grind the track
surface. While maximizing the effectiveness of the abrasive pad,
the friction created by the grinding acts as a brake slowing the
grinding process, which can lead to increased amounts of downtime
for the rail line being grinded.
[0006] In a Type 2 grinding configuration, the amount of power
required to rotate the rotating element and the braking effect of
the abrasive surface are both reduced by positioning the abrasive
surface on the plane of the rotating element instead of the edge.
The rotating element is positioned against the track surface such
that the rail approximately bisects the center of the rotating
element. By positioning the rotating element such that the rail is
located proximate the center of the rotating element, the abrasive
surface creates a desirable grinding pattern in which the abrasive
surface is drawn across the rail surface perpendicular to the rail
rather than parallel to the rail. In this grinding configuration,
the abrasive surface of an individual rotating element only
contacts a single facet of the rail profile, which significantly
reduces the amount of power required to rotate the rotating
element. However, in order to grind the entire track surface, a
plurality of rotating elements operating in a variety of planes
must be used to each contact different facets of the track surface
so as to cooperatively grind the entire track surface. The drawback
of the Type 2 configuration is that the position of the rotating
elements prevents the Type 2 configuration from being successfully
used on rail sections having encumbrances such as, for example, an
inset in a road or a platform where an upper rail surface is even
with a surrounding surface such as a road or platform.
[0007] A Type 3 grinding configuration somewhat resembles the
appearance of a Type 2 grinding configuration in that it also
utilizes a plurality of rotating elements with each rotating
element rotating in a different plane so as to engage an individual
facet of the rail profile rather the entire track surface. However,
the rotating elements of the Type 3 configuration are beveled
proximate to the edge of the rotating elements such that the
rotating elements can rotate in planes that do not prevent the
rotating element from being used in track sections having
encumbrances such a roads or platforms. As shown in U.S. Pat. No.
7,156,723 to Nataraj an et al., which is herein incorporated by
reference in its entirety, the Type 3 configuration is currently
used with grinding processes where the abrasive surface can be
easily beveled or shaped to properly contact the track surface. The
inherent tradeoff between the Type 2 and Type 3 configuration is
that because the abrasive surface of the Type 3 configuration is at
the edge of the rotating element, the abrasive surface is drawn
across the track surface parallel to the track rather than the more
desirable perpendicular grinding pattern found with the Type 2
configuration.
[0008] Regardless of the configuration type, the contact between
the abrasive grinding pad used in all grinding processes and the
metal track surface creates a substantial amount of heat and
sparking. As a result, most grinding systems for rail lines are
required to include fire suppression systems for combating any
fires resulting from sparking along the track. The potential fire
risk posed by grinding processes has led to a recent trend in track
maintenance to use a milling process to maintain the track instead
of a grinding process.
[0009] Unlike a grinding process, a milling process uses rotating
blades and/or bits to mill down the track surface to remove
irregularities rather than using friction generated by an abrasive
pad. Milling processes generate less heat and sparking than
grinding processes, thereby minimizing the risk of fire. A drawback
of milling processes is that the rotating blade or bit assembly
must be carefully monitored as the blade or bit can easily cut too
deeply into the track surface reducing the operating life of the
track or creating an irregularity rather than removing the
irregularities. Similarly, the milling blade or bit can become
broken or dulled from repeated use. Replacing a broken blade or bit
can cause significant delays if the blade or bit breaks in a remote
location and a new blade assembly must transported to the work
site.
[0010] Although significant development has been made in the area
of removing irregularities from a track surface, it would be
advantageous to further improve upon these current processes.
SUMMARY OF THE DISCLOSURE
[0011] The present invention is directed to a railway milling
system that can be pulled along sections of track and comprises a
plurality of milling plates, each plate including a plurality of
milling blades for engaging the track surface so as to remove
irregularities from the track surface. The plurality of milling
blades are generally arranged along the periphery of the milling
plate. The milling blades can be oriented above a length of rail
such that the milling blades contact and mill the rail in a
perpendicular orientation to the rail along sections of track that
lack encumbrances. Alternatively, the milling blades can be angled
and oriented such that milling blades contact and mill the rail in
a parallel orientation to the rail along sections of track that
include encumbrances such as, for example, roads or platforms. Each
milling plate can comprise a modular blade assembly including a
plurality of individual locking slots, each locking slot
corresponding with a single milling blade. The locking slots allow
individual milling blades to be easily removed and replaced if a
blade becomes dull or broken. The modular blade assembly reduces
down time required for the replacement of broken blades and
increases the useful life of the milling plate as the individual
milling blades can be replaced instead of the entire milling
plate.
[0012] A rail milling system, according to an embodiment of the
present invention, can comprise at least one milling module having
a plurality of milling plates with each milling plate including a
motor for rotating the milling plate. Each plate comprises a
plurality of individual milling blades and a plurality of locking
slots positioned along the periphery of the milling plate, each
locking slot being adapted to releasably receive one of the milling
blades. Each locking slot can further comprise an adjustable vice
for individually gripping the corresponding milling blade. The
milling module can comprise a positioning assembly for each milling
plate such that the milling position and angle of milling plate can
be controlled and adjusted. The positioning assembly can position
each milling plate above a length of rail so as to contact and mill
the rail in a perpendicular orientation for lengths of track that
are free of encumbrances. Alternatively, the positioning assembly
can angle each milling plate above the length of rail so as to
contact and mill that rail in a parallel orientation for lengths of
track that include encumbrances.
[0013] In operation, each of a plurality of milling plates is
positioned at a unique angle such that each milling plate mills a
unique facet of a rail profile. In combination, the plurality of
milling plates cooperatively mill the entire rail profile as a
milling module traverses a length of rail. Depending upon track
location and surroundings, the milling plates can be positioned
such that an edge portion of each milling plate engages the rail to
provide a parallel milling pattern such as when encumbrances are
present or alternatively, the milling plates can be positioned over
the rail such that the rail bisects or nearly bisects the center of
the rotating milling plate to provide a perpendicular milling
pattern.
[0014] According to an embodiment of the present invention, a rail
milling system can further comprise at least one depth guide
adapted to contact a rail surface as a milling module is being
pulled down the rail surface. The depth guide can operably attached
to each of the milling modules so as to prevent individual milling
blades of the milling module from cutting too deeply into the track
surface. The depth guide is positionable to control a maximum
milling depth of the milling module thereby controlling the extent
to which the milling blades cut into or mill the track surface.
[0015] In another aspect, a method for milling a track surface
according to the present invention can comprise providing a
rotatable milling plate having a plurality of locking slots each
adapted to receive a milling blade. The method can further comprise
attaching a milling blade into each of the locking slots and
positioning the milling blade to present a milling surface that is
angled relative to a plane of the milling plate. The method can
also comprise positioning the milling plate such that the plurality
of milling blades engage a track surface, either in a parallel or
perpendicular orientation to the track surface, dependent upon
track surroundings such as, for example, the presence of
encumbrances. Finally, the method can further comprise rotating the
milling plate to cut or mill the track surface and remove
irregularities from the track surface.
[0016] The above summary of the various representative embodiments
of the invention are not intended to describe each illustrated
embodiment or every implementation of the invention. Rather, the
embodiments are chosen and described so that others skilled in the
art can appreciate and understand the principles and practices of
the invention. The figures in the detailed description that follow
more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention can be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in combination with the accompanying
drawings in which:
[0018] FIG. 1 is a perspective, bottom view of a milling plate
according to an embodiment of the present invention.
[0019] FIG. 2 is a bottom view of the milling plate of FIG. 1.
[0020] FIG. 3 is an enlarged, bottom perspective view of the
milling plate of FIG. 1.
[0021] FIG. 4 is a bottom, perspective view of a milling blade
according to an embodiment of the present invention.
[0022] FIG. 5 is a top view of the milling blade of FIG. 4.
[0023] FIG. 6a is a side view of a milling plate engaging a track
surface in a Type 2 configuration according to an embodiment of the
present invention.
[0024] FIG. 6b is a top, hidden view of the milling plate of FIG.
6a.
[0025] FIG. 6c is a front view of the milling plate of FIG. 6a
illustrating milling an entire profile of a track surface according
to an embodiment of the present invention.
[0026] FIG. 7a is a front, partially hidden view of a pair of
milling plates engaging a track surface in a Type 3 configuration
according to an embodiment of the present invention.
[0027] FIG. 7b is a partially hidden top view of the two milling
plates of FIG. 7a.
[0028] FIG. 8 is a detailed perspective top view of a portion of a
milling system according to an embodiment of the present
invention.
[0029] FIG. 9 is a side view of the milling system of FIG. 8.
[0030] FIG. 10 is a front view of the milling system of FIG. 8.
[0031] FIG. 11 is a perspective, front view of the milling system
of FIG. 8.
[0032] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
DETAILED DESCRIPTION
[0033] As illustrated in FIGS. 1 and 2, a representative embodiment
of a milling plate 6 according to the present invention generally
comprises a plurality of blade slots 10 each having a corresponding
adjustable vice grip 12 and milling blade 14. The plurality of
blade slots 10 are generally positioned proximate to a perimeter
edge 11 of the plate 6 and each blade slot 10 further comprises a
threaded slot bore (not shown) along one side of the slot 10. Each
adjustable vice grip 12 further comprises a threaded vice bore 18
corresponding to the threaded slot bore of one of the plurality of
slots 10. As shown in FIGS. 4 and 5, an embodiment of the milling
blade 14 can comprise a generally rectangular shape having an
angled milling surface 19 for milling the track surface
[0034] As shown in FIGS. 1-2, each milling blade 14 is insertable
into a corresponding slot 10 and retained by the adjustable vice
grip 12. The adjustable vice grip 12 further comprises a flat side
20 for aligning the vice grip 12 with the side of the slot 10 and
an angled side 22 for engaging the milling blade 14. A threaded set
screw 24 is insertable through the threaded bore 18 of the vice
grip 12 and into the threaded bore 16 of the corresponding slot 10.
As the set screw 24 is tightened, the angled side 22 of the vice
grip 14 will tighten against the milling blade 14 to lock the
milling blade 14 within the slot 10.
[0035] As shown in FIGS. 6a-6c and 7a-7c, in operation, the milling
plate 6 is positioned proximate to a rail track 100 such that the
at least one milling blade 14 engages a facet of a track surface
102. In a Type-2 configuration, the milling plate 6 is positioned
such that the rail track 100 bisects the milling plate 6 and is
simultaneously engaged by at least two milling blades 14 positioned
on opposite sides of the milling plate 6 as shown in FIGS. 6b and
6c. Alternatively, in a Type-3 configuration, the milling plate 6
is positioned such that rail track 100 intersects the milling plate
6 proximate to the periphery of the milling plate 6 as shown in
FIG. 7b. Once positioned proximate to the rail track 100, the
milling plate 6 can be rotated to quickly mill and smooth the track
surface 102. According to an embodiment of the present invention,
an amount of brake horsepower required to rotate the milling plate
6 can be monitored to ensure the milling blades 14 do not cut into
the track surface 102. If the brake horsepower required to rotate
the milling plate 6 exceeds a predetermined threshold indicating
that the milling blades 14 are cutting into the track surface 102,
a control system can be configured to automatically trigger cutoff
of the milling operation so as to prevent further damage to the
track surface 102.
[0036] As shown in FIGS. 8-11, various embodiments of a milling
system 2 can further comprise a rail car 30 for supporting and
positioning at least one milling module 4. The rail car 30
generally comprises a frame 32, a plurality of rail wheels 34 and a
positioning assembly 36.
[0037] The frame 32 further comprises at least two vertical
supports 38 supporting an elevated portion 40 between the vertical
supports 38. The rail wheels 34 are mounted to a wheel assembly 39
that is operably connected to the vertical supports 38 so as to
support the frame 32 and allow the rail car 30 to be pulled down
the rail track 100. The positioning assembly 36 can further
comprises a positioning platform 42, at least one vertical
positioning assembly 44 and at least one horizontal positioning
assembly 46. The positioning platform 42 is hung below the frame
32. Each vertical positioning assembly 44 further includes a
rotatable positioning arm 48 and a vertical piston assembly 50.
Similarly, the horizontal positioning assembly 46 includes a
horizontal piston assembly 52. The vertical and horizontal piston
assemblies 50, 52 can be electrically or hydraulically actuated.
The vertical positioning assembly 44 and horizontal positioning
assembly 46 are each operably attached to the positioning platform
42 as well as the milling module 4 such that extension of a piston
arm in both the vertical piston assembly 50 and horizontal piston
assembly 52 controls the movement and orientation of the milling
module 4 relative to the rail track 100. Each milling module 4
includes a motor 55 operably coupled to the milling plate 6. The
brake horsepower required to operate motor 55 can be continually
monitored by a control system, such as, for example, a remotely
located control system to monitor the state of the milling
operation. For instance, higher brake horsepower readings can be an
indication that milling plate 6 is cutting too deeply into the
track surface 102. In certain instances, the control system can
continually monitor and shutdown milling module 4 if a brake
horsepower setpoint for motor 55 is above or below the
setpoint.
[0038] As shown in FIGS. 9-12, at least one milling module 4 is
mounted to the positioning platform 42. The vertical piston
assembly 50 is affixed to the positioning platform 42 and is
adapted to adjust the relative distance between the milling plate 6
and the track surface 102 by extending or retracting the piston arm
which is coupled to rotatable positioning arm 48. The horizontal
piston assembly 52 is affixed to the positioning platform 42 as
well as the milling module 4 so as to adjust the angle at which the
milling plate 6 intersects the track surface 102.
[0039] According to an embodiment of the invention, the positioning
assembly 36 can further comprise at least one depth guide 56 for
preventing damage to the track surface. The depth guide 56 can
further comprise at least one wheel 58 for continually contacting
the track surface 102 as the milling system 2 is pulled down the
track. The depth guide 56 operably engages the track surface 102
and can physically prevent the vertical positioning assembly 44
from directing the milling module 4 past a predetermined height
from the track surface 102 so as to prevent the milling plate 6
from cutting too deeply into or otherwise damaging the track
surface.
[0040] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and described in detail. It is understood,
however, that the intention is not to limit the invention to the
particular embodiments described. On the contrary, the intention is
to cover all modifications, equivalents, and alternatives falling
within the spirit and scope of the invention as defined by the
appended claims.
* * * * *