Numerically controlled cross-tie pre-plating system

Abstract

A machine for fastening rail plates to cross-ties, utilizing spikes or the like, and method therefore, is disclosed in the present invention. The present invention further is configured to facilitate the installation of threaded spikes or screws, as are utilized in high-speed, concrete and other cross-ties. A numerically controlled drilling station is therefore provided for selectively positioning a drill about the length of the cross-tie for drilling bores into the tie, along with a separate screwed pre-plating station which may include a template for positioning the tie, a plate dispenser (or manual plate loading means), and a positionable driving mechanisms for engaging and screwing threaded spikes or screws into the bores formed by the drilling station to securely pre-plate each plate on a tie, which may be wood or concrete, traditional or high-speed. The present system is particularly suitable for pre-plating cross-tie for forming turnouts, which require that each tie along a curve be drilled in a separate location. Accordingly, utilizing CAD or other input information, a computer can automatically control the numerically controlled drill station to drill out each tie to form the desired turnout, greatly reducing the time, expense, and risk associated with this procedure.

Description

STATEMENT OF CONTINUING APPLICATIONS

[0001] The present application is a Continuation of Provisional Patent Application Serial No. 60/328,732 filed Oct. 11, 2001. This application is also a Continuation-in-part of U.S. patent application Ser. No. 09/689,330 filed Oct. 12, 2000, which is a divisional of U.S. Pat. No. 6,131,272 issued Oct. 17, 2000, filed Mar. 22, 1999, which is a continuation-in-part of U.S. patent application Ser. No. 09/161,135, filed Sep. 25, 1998, listing as inventors Gerald D. Girouard, Sr., Gerald D. Girouard, Jr., and Donald Darcey, which is a continuation of U.S patent application Ser. No. 08/665,670, U.S. Pat. No. 5,813,103, filed Jun. 20, 1996, entitled “Cross-Tie Pre-Plating System”, listing as inventors Gerald D. Girouard, Sr., Gerald D. Girouard, Jr., and Donald Darcey, which patent is a continuation of Ser. No. 300,749, U.S. Pat. No. 5,528,807, issued Jun. 25, 1996, filed Sep. 6, 1994, entitled “Cross-Tie Pre-Plating System”, listing as inventors Gerald D. Girouard, Sr., Gerald D. Girouard, Jr., and Donald Darcey, which patent is a continuation of U.S. patent application Ser. No. 207,118, U.S. Pat. No. 5,343,606, issued Sep. 6, 1994, filed Feb. 28, 1994, entitled “Cross-tie Pre-Plating System”, listing as inventors Gerald D. Girouard, Sr., Gerald D. Girouard, Jr., and Donald Darcey, which patent is a continuation of U.S. patent application Ser. No. 08/085,400, filed Jun. 30, 1993, now abandoned.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates to Railroad construction apparatus, and in particular to a machine for fastening rail plates to cross-ties, utilizing spikes or the like, and method therefore, is disclosed in the present invention.

[0003] The preferred apparatus of the present invention teaches a system wherein there is provided a conveyor for conveying a plurality of laterally arranged, juxtaposed ties, a loader or kicker for loading a single tie upon a template conveyer, and positioning means for positioning a single tie at each station during the pre-plating process.

[0004] The present invention further may include a template system for securing the cross-tie or tie in place, feeding and positioning the rail-plate(s) in place, feeding, dispensing, and positioning the spikes in place, driving the spikes, and discharging the processed tie, the template system utilizing reciprocating drive pistons for positioning the template, as well as dispensing the plates.

[0005] The present invention further is configured to facilitate the installation of threaded spikes or screws, as are utilized in high-speed, concrete and other cross-ties. A numerically controlled drilling station is therefore provided for selectively positioning a drill about the length of the cross-tie for drilling bores into the tie, along with a separate screwed pre-plating station which may include a template for positioning the tie, a plate dispenser (or manual plate loading means), and a positionable driving mechanisms for engaging and screwing threaded spikes or screws into the bores formed by the drilling station to securely pre-plate each plate on a tie, which may be wood or concrete, traditional or high-speed.

[0006] The present system is particularly suitable for pre-plating cross-tie for forming turnouts, which require that each tie along a curve be drilled in a separate location. Accordingly, utilizing CAD or other input information, a computer can automatically control the numerically controlled drill station to drill out each tie to form the desired turnout, greatly reducing the time, expense, and risk associated with this procedure.

[0007] The present invention is unique in its relative simplicity when compared to prior art systems, providing a full array of pre-plating capabilities utilizing standard spikes or threaded means, various sized and composition cross-ties, on a relatively compact and road transportable, mobile platform.

GENERAL SUMMARY DISCUSSION OF THE INVENTION

[0008] Unlike the prior art, the present invention provides railroad-tie pre-plating system which is comparatively low maintenance and reliable, while being relatively inexpensive to manufacture, flexible in the type of fastening means, plate and tie configuration, size, and material utilized, while being consistent in cycle time and output quality.

[0009] The preferred embodiment of the present invention teaches a system wherein there is included:

[0010] Feed means for feeding the cross ties in bulk via decline rollers;

[0011] Retrieval means for retrieving an individual cross-tie from the gravity feed;

[0012] A first station comprising a numerically controlled drilling template and drilling means for providing precise bores which can vary from tie-to tie in forming such complex layouts as utilized in curves, turn-outs or the like, which bores are for the insertion of threaded spikes or screws therein.

[0013] A second station, comprising a driving station with manually positionable racheting or screwing machines is provided so as to allow operators(s) to manually load a plate upon the tie in the vicinity of the bores formed at the first station, align the plate in relation to the bores, and drive screws through the plates into the bores so as to fasten the plate(s) to the tie.

[0014] Discharge means for removing the pre-plated cross tie for stacking.

[0015] Unlike the prior art, the present invention contemplates a system wherein all of the various elements interrelate in function and operation, providing a more efficient, less redundant apparatus. As such, the present invention as currently configured in a working embodiment is capable of pre-plating multiple custom-drilled tie via the numerically controlled drill station with a cycle time of a typical 24 foot tie within three minutes, the actual cycle time varying depending upon the differences in the positioning of the drill holes on the ties, the amount of holes, the type of screws, and the size of the tie.

[0016] This is compared to a manual crew of five workers, which typically must take breaks on the hour (more on hot days), and must manually measure the position of custom drilled holes, which accounts for far more time and less accuracy than the present system.

[0017] Unlike prior art pre-plating mechanisms for fastening via threaded spikes, which required a highly specialized, generally fixed, slow, and expensive system, the present preferred embodiment of the invention contemplates a pre-plating system which provides unsurpassed flexibility over the prior art, teaching a mechanism and process which allows for pre-plating of most types of cross-ties, utilizing threaded spikes, in a fast, relatively inexpensive manner.

[0018] While the system may be fixed or relatively portable, and able to be transported via road to a production site in three, readily assembled pieces on a flatbed trailers, an alternative embodiment of the present invention teaches a version of the invention wherein the main conveyor/pre-plating area of the apparatus is located on a railroad flat car.

[0019] It is therefore an object of the present invention to provide a railroad cross-tie pre-plating system which is relatively simple in operation, yet efficient, reliable, and inexpensive to operate.

[0020] It is another object of the present invention to provide a railroad cross-tie pre-plating system which is able to be operated by a team of three to five workers.

[0021] It is still another object of the present invention to provide a railroad cross-tie pre-plating system which provides a per unit total cycle of three minutes or less.

[0022] It is another object of the present invention to provide a railroad cross-tie pre-plating system which fastens plates to cross-ties via threaded spikes, on a variety of sized cross-ties.

[0023] Finally, it is an object of the present invention to provide a railroad cross-tie pre-plating system which allows for quick, automated drilling of custom-drilled ties as is used in railroad turns or turn-outs.

BRIEF DESCRIPTION OF DRAWINGS

[0024] For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein:

[0025] FIG. 1 is an isometric view of the preferred embodiment of the numerical controlled drilling station/cross-tie pre-plating system of the present invention, illustrating the layout of the two main operations stages for processing the ties of the present invention, interconnected by a processing conveyor having first and second ends, the cross-tie loading and unloading ramps communicating with said first and second ends, respectively.

[0026] FIGS. 2A and 2B are end views of the loading ramp and CNC controlled, single bit cross-tie boring system of the present invention.

[0027] FIG. 3 is an end-close-up view of the invention of FIGS. 2A and 2B.

[0028] FIGS. 4A, 4B, 4C, and 4D offer end views of the manually operated threaded fastening system of the present invention.

[0029] FIG. 5 is an end, close-up view of the invention of FIGS. 4A-4D.

DETAILED DISCUSSION OF THE INVENTION

[0030] Referring to FIG. 1 of the drawings, the cross-tie pre-plating system of the present invention I comprises an elongated base B, which, in the preferred embodiment of the present invention may comprise separate work areas and platforms or first and second a modified flatbed trailer(s) or railcar(s), or other non-mobile or mobile platform

[0031] As shown, the base B has a top surface 3, first 1 and second 2 ends, and a longitudinal axis 4 which has aligned therewith a horizontal conveyor 5 along top surface 2, the top surface further having first 6 and second 7 ends situated in agreement with the first 1 and second 2 ends of base, respectively. Situated along the length of the conveyor 5 is a plurality of generally even spaced rollers 8 which may be engaged to one another via chains or belts, and which are powered to rotate via motor or the like, in order to selectively convey a cross-tie C along the length of the conveyor during pre-plating operations, transporting the cross-tie C from station to another, and depositing same from the conveyor after operations, or may be independently driven my electrical pneumatic, or hydraulic motors or the like.

[0032] As shown, a plurality of un-plated cross-ties 14 are loaded upon a loading conveyor 13, which may be a gravity conveyor type (i.e., the end distal the horizontal conveyor is higher than the end closest the horizontal conveyor, with rollers thereupon to facilitate movement of the ties towards the horizontal conveyor 5) or the like configured to urge the ties placed thereupon, in laterally aligned fashion upon the conveyor, to urge the ties towards the horizontal conveyor 5 where the ties are loaded 15 upon the horizontal conveyor one at a time.

[0033] The ties are selectively loaded upon the horizontal conveyor 5 via a loading mechanism; once loaded upon the horizontal conveyor 5, each tie is then processed by, a first drilling station 9 for drilling pilot holes, which may comprise drilling apparatus which may be dynamically positioned via numerical control for forming bores which are utilized in driving lag or coach screws or the like for fastening the plates to the ties at a separate driving station 11 for driving threaded fasteners through manually positioned and aligned plates into the ties.

[0034] The unit is principally automated and controlled by a computer and an operator controlled 20 at a main operating station 19, shown located generally centrally of the system to enable monitoring of all activities.

[0035] Once each tie C is processed at stations 9, 11, the tie C having traversed the horizontal conveyor 5 to the second end 7 is then deposited 18 upon unloading ramp 16, which may be a gravity conveyor downwardly directed from the horizontal conveyor, where each tie processed tie is urged to the distal end 16′ of same, such that the ties are loaded upon the ramp 16, where the processed ties are situated in aligned fashion lateral to the ramp, ready for lifting via forklift or the like for further transport or processing.

[0036] Continuing with FIGS. 1, 2A, 2B, and 3, the loading ramp 13 or conveyor is, as indicated, a gravity type, wherein the first end 13′ of ramp distal to the conveyor 5 is higher than the second end 13″ of ramp adjacent to conveyor 5, with rollers 13 situated along the length of the upper section of the ramp to facilitate gravity transfer to the cross-ties 14 (tie, cross-ties, and railroad cross-ties are intended throughout this document to have the same meaning) along the length of ramp 13.

[0037] As shown, the ties 14 are dispensed individually to the horizontal conveyor 5 via the second, lower end 13″ of the loading ramp 13, which utilizes a blocking member 40′, configured to hold back the bulk of railroad ties and allow for the dispensing of a single loaded tie 35 upon demand. When a tie is desired to be loaded upon the horizontal conveyor for processing, as shown, a reciprocating piston 40 is actuated, lifting 39 a loading bar or kicker 36 at an angle, lifting the tie 35 on the kicker above blocking member 40′, while urging via gravity the tie along the rollers over blocking member 40′, along lifting bar and upon the conveyor 5.

[0038] Concurrent with the loading of tie 35 onto conveyor, the second end 38 of the loading bar is lifted to also facilitate blocking 41 of the next tie to be dispensed 34, preventing the remaining ties from advancing uncontrollably upon the conveyor 5. Once the tie 35 is loaded, the loading bar 36 is lowered 43, allowing the next tie 34 to advance 44 over rollers to blocking member 40′ as shown in FIG. 3B. A proximity switch and/or timer circuit may be utilized to facilitate the lowering of the loading bar, as the tie is loaded, allowing the next tie 34 to be dispensed to advance to the loading position 45 adjacent to blocking member 40′.

[0039] Continuing with the FIGS. 1, 4A-4D, and 5, the drilling station comprises a track mounted motor which is preferably at this time electric, but may also be hydraulic or pneumatic the motor having x-y movement along the track for positioning the drill bit anywhere along the length of the cross-tie, as dictated by coordinates inputted to a computer which drives a positioning motor associated with the drilling unit to propel the drill along x-y coordinates along the track. Further, the drill is vertically manipulated (z coordinates during the drilling procedure, so the system is automatically positioned via x, y and z axis, as dictated by the instructions provided to the control computer.

[0040] The Z axis manipulation of the drilling unit may be via rack and pinion with a driving motor, or via reciprocating piston or other means, so as so as to lift the drill bit such that it is in a clear fashion during positioning of the tie to be drilled.

[0041] The computer numerically controlled (CNC) drilling station relies upon coordinates of each bore to be made into the beam, which are relayed to the CNC system for positioning the drilling apparatus along x-y coordinates via gantry or the like.

[0042] Once pilot bores have been formed in the tie, the tie is directed to the second, threaded fastener or driving station 11, where plates are manually placed, and a manually positioned 106 screw driving array slidingly engaged to vertical support members 107 and which screw driving array 106 is lifted 112 and lowered 111 vertically either manually utilizing a counterbalance, or via mechanical other means such as a reciprocating piston.

[0043] As shown, the screw driving array 106 includes two front 106′, and two rear 106″, motorized screw holding and driving mechanisms, comprising eight screw driving/holding mechanism total, spaced to drive two spaced sets of four screws each, in order to drive each set of fours screws in precise manner through screw passages formed in a single plate. Further, the screw driving array is situated along a track to position said array anywhere along the longitudinal axis of the tie to be plated, wherein it can be manually positioned by hand or via a motorized control.

[0044] The screw driving array 106 in the present system thereby facilitates the insertion of screws through a single plate at a time along a tie.

[0045] Continuing with the figures, each screw driving system comprises a screw holder 114, 114′, which in the preferred embodiment of the present invention is configured each to have a magnet 125 embedded therein to magnetically engage and support the head of a lag screw 113, respectively, which lag screws are loaded in the present embodiment to their respective screw holders manually. The front screw holders 114 are supported by an extension 115 configured to engage motors 116, which are situated in spaced, forward relationship above rear motors 117 of the rear screw driving mechanisms, which motors rear motors 117 may be attached directly to screw holders 114′ without an extension.

[0046] The front motors 116 are supported by upper, independent horizontal support members 118, while the rear motors 117, 117′ are supported by lower horizontal support members 119, respectively, which in turn slidingly engage vertical support members 107.

[0047] In operation, the operator would allow the pre-bored tie 136 (pilot boring accomplished at the first, drilling station) under the raised template 149, which is then longitudinally via control 154. After positioning, the plates are either automatically dispensed or manually positioned into alignment with the bored holes.

[0048] The operator then, by hand loads the lag screws 113, 113′, to the screw holders, and then may apply grease to the threads of same to facilitate easier insertion, and then initiates motors 116, 117, then lowering rotating screws via piston 110 communicating with horizontal support bar via control 154.

[0049] As shown in the figures, the front screws 113 engage the front screw passages formed in tie 135 first, passing through said passages and into pilot bores pre-formed thereunder, with the rear screws 113′ thereafter lowering and boring 145 into their respective screw passages and pre-formed pilot bores thereunder, until the lag screw heads engage the tops of the plates, providing screwed lag screws on a fastened plate to tie 136. The screw driving apparatus is then lifted 153 via piston 110, completing screwed fastening of the plate to the tie.

[0050] Continuing with the figures, the processed tie is urged via the conveyor to the second end 7 of the horizontal conveyor 5, wherein it is discharged to the unloading ramp.

Exemplary Specifications

[0051] Drilling Station

[0052] Drill head: belt driven 10 HP AC Motor; variable speed up to 6 k RPM; quick change spindle for changing bit. Drill head to travel along 30 foot track having x-y axle servo motor drive with brakes, having 0 to 600 inches per minute travel on all axis.

[0053] Drill Bits—First Station: Size: {fraction (11/16)}+− (varies); Configured Depth of Bore: 8″ or less (varies);

[0054] Machine control: Fagor Model 8055 CNC Control with 12 inch LCD screen mounted on a pendant on machine to control all functions utilizing built in programmable logic controller internal to the FAGOR CNC control.

[0055] Servo: Three Fagor AC digital servo motors with brakes for axis drives utilizing encoder fee from servo motor on y-z axis. X Axis will utilize a Fagor steel stretched scale for feedback/rack and pinion mechanical interface.

[0056] Screw Driving Station

[0057] Three Station machine for driving lag screws or the like into bore holes {fraction (11/16)}+− in diameter.

[0058] Machine Control: Can be manually or machine controlled, utilizing two axis, X axis can be positioned via hydraulic motor rack (for example 400 inches/minute) with pinion driven position with a joystick by eye.

[0059] Screw motors via hydraulic motors/power pack system.

[0060] Driver: hydraulic motor at 100 RPM with variable torque.

[0061] Screw type: Lag Screw, diameter: varies, length:varies.

[0062] Conveyor

[0063] Horizontal Conveyor Length: 30′; Width:12″

[0064] In summary, the method of the preferred embodiment of the present invention comprises fastening a plate to a cross-tie, comprising the steps of:

[0065] a) loading a tie upon a horizontal conveyor, providing a loaded tie;

[0066] b) providing pre-existing x-y coordinate instructions to a computer control for designating locations upon said tie to be bored, thereby providing borehole data;

[0067] c) positioning said tie at a boring station;

[0068] d) utilizing said x-y coordinates to position a numerically controlled drill along a track longitudinally aligned with said loaded tie to a first bore coordinate;

[0069] e) automatically actuating and lowering said drill to bore a hole at said first bore coordinate;

[0070] f) utilizing said x-y coordinates to position said numerically drill along said track to a next bore coordinate for said loaded tie;

[0071] g) automatically actuating and lowering said drill to bore a hole at said next bore coordinate;

[0072] h) repeating steps f) and g) until all of said pre-existing x-y coordinate borehole data for said loaded tie has been utilized, providing a bored tie;

[0073] l) loading the next tie to be drilled, providing the next loaded tie;

[0074] j) repeating steps b-h, while

[0075] k) conveying said bored tie to a screwing station.

[0076] c) forming pilot bores into said aligned, loaded tie with said boring apparatus, providing a bored tie;

[0077] d) conveying said bored tie to a pre-plating apparatus;

[0078] e) utilizing a template having first and second plate trays formed therein to align said bored tie such that said first and second plate trays are adjacent to the ends of first and second plate conveyors, respectively;

[0079] f) dispensing first and second plates from said first and second plate trays such that said first and second plates fall into said first and second plate trays, respectively, and rest upon said bored tie such that at least some of apertures formed in said dispensed plates are aligned with said pilot bores formed in said bored tie;

[0080] g) fastening said dispensed plates to said tie by applying a fastener through said apertures formed in said plates aligned with said pilot bores formed in said tie, providing a pre-plated tie;

[0081] h) dispensing said pre-plated tie from said horizontal conveyor.

[0082] I) providing a plate having apertures formed therethrough upon said bored tie

[0083] ii) aligning said apertures formed through said dispensed plates with said bores formed in said loaded tie; and

[0084] driving a screw through each of said aligned apertures formed through each of said dispensed plates and said aligned pilot bore formed in said loaded tie thereunder, fastening said plate to said tie.

[0085] The invention embodiments herein described are done so in detail for exemplary purposes only, and may be subject to many different variations in design, structure, application and operation methodology. Thus, the detailed disclosures therein should be interpreted in an illustrative, exemplary manner, and not in a limited sense.

Claims

1. The method of fastening a plate to a cross-tie, comprising the steps of:

a) loading a tie upon a horizontal conveyor, providing a loaded tie;

b) providing pre-existing x-y coordinate instructions to a computer control for designating locations upon said tie to be bored, thereby providing borehole data;

c) positioning said tie at a boring station;

d) utilizing said x-y coordinates to position a numerically controlled drill along a track longitudinally aligned with said loaded tie to a first bore coordinate;

e) automatically actuating and lowering said drill to bore a hole at said first bore coordinate;

F) utilizing said x-y coordinates to position said numerically drill along said track to a next bore coordinate for said loaded tie;

g) automatically actuating and lowering said drill to bore a hole at said next bore coordinate;

h) repeating steps f) and g) until all of said pre-existing x-y coordinate borehole data for said loaded tie has been utilized, providing a bored tie;

I) loading the next tie to be drilled, providing the next loaded tie;

j) repeating steps b-h, while

k) conveying said bored tie to a screwing station.

c) forming pilot bores into said aligned, loaded tie with said boring apparatus, providing a bored tie;

d) conveying said bored tie to a pre-plating apparatus;

e) utilizing a template having first and second plate trays formed therein to align said bored tie such that said first and second plate trays are adjacent to the ends of first and second plate conveyors, respectively;

f) dispensing first and second plates from said first and second plate trays such that said first and second plates fall into said first and second plate trays, respectively, and rest upon said bored tie such that at least some of apertures formed in said dispensed plates are aligned with said pilot bores formed in said bored tie;

g) fastening said dispensed plates to said tie by applying a fastener through said apertures formed in said plates aligned with said pilot bores formed in said tie, providing a pre-plated tie;

h) dispensing said pre-plated tie from said horizontal conveyor.

2. The method of claim 1, wherein after step “I” there is included the additional steps of:

I) providing a plate having apertures formed therethrough upon said bored tie

ii) aligning said apertures formed through said dispensed plates with said bores formed in said loaded tie; and

driving a screw through each of said aligned apertures formed through each of said dispensed plates and said aligned pilot bore formed in said loaded tie thereunder, fastening said plate to said tie.