Method for bogie replacement for a turntable station

Abstract

Aspects of the present disclosure relate to methods, apparatuses, and systems for replacing drive assemblies of carousel loading stations. A system includes a structural pier, a track formed on a top surface of the structural pier, a carousel, a bogie assembly removably coupled to an underside of the carousel, the bogie assembly including a wheeled drive assembly, an exchange rail mounted to a radial side surface of the structural pier, and a translation box movably mounted to the exchange rail in a serviceable orientation. The translation box is configured to move along the radial side surface of the structural pier below the bogie assembly to an unloading position via the exchange rail while in the serviceable orientation, pivot from the serviceable orientation to an upright functional orientation to couple with the wheeled drive assembly, and decouple the wheeled drive assembly from the bogie assembly.

Description

[0001] Cross-reference to related applications This application claims priority and benefit to U.S. Utility Model Application Serial No. 17 / 362,769, filed June 29, 2021, entitled “METHOD OF BOGIE REPLACEMENT FOR TURNTABLE STATION,” and U.S. Provisional Application Serial No. 63 / 047,149, filed July 1, 2020, entitled “METHOD OF BOGIE REPLACEMENT FOR TURNTABLE STATION,” the entire contents of which are incorporated herein by reference, as if fully set forth herein and for all applicable purposes. Technical Field

[0002] The technology discussed below generally relates to a carousel loading station for loading passengers onto / unloading passengers from a ride-on system, and more specifically to a system and method for efficiently removing non-operating drive components of a carousel loading station and installing working replacements. Background Technology

[0003] Amusement parks attract hundreds of millions of visitors every year. To help visitors enjoy certain attractions or rides, amusement park operators have developed various types of systems and methods for loading (and unloading) passengers onto and from attractions / rides. In one example, a carousel loading station can be used to load / unload passengers.

[0004] In many cases, turntable loading stations for ride-on systems may need to be available for continuous operation for most of the day (e.g., 16 hours a day), 365 days a year. The turntable loading station can be driven by one or more drive assemblies, each with various combinations of motors, gearboxes, brakes, etc. Drive assemblies may be highly reliable, but will fail at some point during their service life. When a failure occurs, the station operator will benefit from an efficient method for replacing the drive assembly with minimal impact on uptime. Current methods are too manual and require cumbersome clamping of the assembly to the adjacent station structure. Therefore, a system and method are needed for quickly and safely removing the non-working drive assembly and installing a working replacement. Summary of the Invention

[0005] The following provides an overview of one or more aspects of this disclosure in order to provide a basic understanding of these aspects. This overview is not a comprehensive summary of all anticipated features of this disclosure, and is neither intended to identify key or essential elements of all aspects of this disclosure, nor to define the scope of any or all aspects of this disclosure. Its sole purpose is to present some concepts of one or more aspects of this disclosure in a simplified form as a prelude to the more detailed description that follows.

[0006] This disclosure relates to methods, apparatus, and systems for replacing drive assemblies in a turntable loading station. One system includes a structural pier; a track formed on the top surface of the structural pier; a movable turntable structure; and a first bogie assembly detachably coupled to the underside of the movable turntable structure, the first bogie assembly including a first wheel drive assembly configured to drive wheels for rolling on the track. The system further includes an exchange guide mounted to a radial side surface of the structural pier, and a first translation box movably mounted to the exchange guide in a maintainable orientation. The first translation box is configured to move via the exchange guide along the radial side surface of the structural pier to an unloading position below the first bogie assembly coupled to the movable turntable structure when in a maintainable orientation, pivot from the maintainable orientation to an upright functional orientation to engage with the first wheel drive assembly, and detach the first wheel drive assembly from the first bogie assembly, or detach the first bogie assembly including the first wheel drive assembly coupled to the first translation box from the movable turntable structure. The first translation box can also be configured to move to a position connected to the wheel drive assembly, detach the wheel drive assembly from the movable turntable structure and move it, from an upright functional orientation pivot to a maintainable orientation, and, while in the maintainable orientation, move from the unloading position to the removal position via exchange rails along the radial side surface of the structural pier. Other aspects, embodiments, and features are also claimed and described.

[0007] In one example, a system for replacing a drive assembly of a turntable loading station is disclosed. The system includes a structural pier; a track formed on the top surface of the structural pier; a movable turntable structure; a first bogie assembly detachably coupled to the underside of the movable turntable structure, the first bogie assembly including a first wheel drive assembly configured to drive wheels to roll on the track; an exchange guide mounted to a radial side surface of the structural pier; and a first translation box movably mounted to the exchange guide in a maintainable orientation, the first translation box configured to pivot from a maintainable orientation to an upright functional orientation to engage with the first wheel drive assembly, and to detach the first wheel drive assembly coupled to the first translation box from the first bogie assembly, or to detach the first bogie assembly including the first wheel drive assembly coupled to the first translation box from the movable turntable structure. The disc structure is separated (e.g., the first wheel drive assembly is moved away from the movable turntable structure and the first wheel drive assembly is reoriented to a maintainable orientation); a second translation box is movably mounted to the exchange rail in a maintainable orientation, the second translation box is coupled to the second wheel drive assembly (hot spare) or a second bogie assembly including the second wheel drive assembly, and is configured to pivot (or reorient) from the maintainable orientation to an upright functional orientation when coupled to the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, and to couple the second wheel drive assembly to the first bogie assembly or to couple the second bogie assembly including the second wheel drive assembly to the underside of the movable turntable structure.

[0008] In one example, a method for replacing a drive assembly of a turntable loading station is disclosed. The method includes identifying a first bogie assembly detachably coupled to the lower side of a movable turntable structure for replacement (e.g., via manual or automatic methods, including methods based on inspection sensors), the first bogie assembly including a first wheel drive assembly configured to drive wheels to roll on a track formed on the top surface of a structural pier; moving a first translation box along a radial side surface of the structural pier to an unloading position below the first bogie assembly coupled to the movable turntable structure while in a maintainable orientation; pivoting the first translation box from the maintainable orientation to an upright functional orientation; coupling the first translation box to the first wheel drive assembly while in the upright functional orientation; detaching the first wheel drive assembly coupled to the first translation box from the first bogie assembly, or removing the first wheel drive assembly including the first wheel drive assembly coupled to the first translation box... A bogie assembly is detached from a movable turntable structure; in a maintainable orientation, a second translation box, connected to a second wheel drive assembly, or a second bogie assembly including the second wheel drive assembly, is moved along the radial side surface of the structural pier to a loading position, the loading position being below the first bogie assembly detached from the first wheel drive assembly, or below the position of the movable turntable structure where the first bogie assembly including the first wheel drive assembly is detached from the movable turntable structure; when connected to the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, the second translation box is pivoted from maintainable orientation to upright functional orientation; and the second wheel drive assembly is connected to the first bogie assembly, or the second bogie assembly including the second wheel drive assembly is connected to the underside of the movable turntable structure.

[0009] In one example, a method for replacing a drive assembly of a turntable loading station is disclosed. The method includes identifying a drive assembly to replace a bogie assembly detachably coupled to a movable turntable structure, the drive assembly being configured to drive wheels to roll on tracks formed on the top surface of a structural pier; moving and engaging a translation box to the drive assembly while in an upright functional orientation; detaching the drive assembly engaged to the translation box from the bogie assembly; moving the translation box, along with the drive assembly, away from the movable turntable structure and pivoting the translation box to a maintainable configuration; moving the translation box from an unloading position to a removal position along a radial side surface of the structural pier while in a maintainable orientation; moving a second translation box, engaged to a second drive assembly (hot spare), along a radial side surface of the structural pier to a loading position below a non-drive bogie assembly under the movable turntable structure while in a maintainable orientation; pivoting the second translation box from maintainable orientation to upright functional orientation while engaged to the second drive assembly; and attaching the second drive assembly to the bogie assembly.

[0010] In one example, a rotary loading station is disclosed. The turntable loading station includes a structural pier, a track formed on the top surface of the structural pier, a movable turntable structure, a first bogie assembly detachably connected to the lower side of the movable turntable structure, the first bogie assembly including a first wheel drive assembly configured to drive wheels to roll on the track, wherein when the wheels roll on the track, they cause the movable turntable structure to rotate about an axis, an exchange guide mounted on the radial side surface of the structural pier, and a first translation box movably mounted to the exchange guide in a maintainable orientation, the first translation box being configured to move via the exchange guide along the radial side surface of the structural pier to an unloading position below the first bogie assembly connected to the movable turntable structure when in maintainable orientation, pivot from maintainable orientation to upright functional orientation to engage with the first wheel drive assembly, detach the first wheel drive assembly connected to the first translation box from the first bogie assembly, or detach the first bogie assembly including the first wheel drive assembly connected to the first translation box from the movable turntable structure, and pivot from upright functional orientation to maintainable orientation when engaged with the first wheel drive assembly. The turntable loading station further includes a second translation box, which is movably mounted to the exchange guide in a maintainable orientation. The second translation box is coupled to a second wheel drive assembly or a second bogie assembly including the second wheel drive assembly, and is configured to move along the radial side surface of the structural pier to a loading position (below the first bogie assembly detached from the first wheel drive assembly, or below the location of the movable turntable structure where the first bogie assembly including the first wheel drive assembly is detached from the movable turntable structure) when in a maintainable orientation. When the second bogie assembly with a two-wheel drive component is pivoted from maintainable orientation to upright functional orientation, the second-wheel drive component is connected to the first bogie assembly, or the second bogie assembly including the second-wheel drive component is connected to the underside of the movable turntable structure, the second-wheel drive component is separated from the second-wheel drive component or the second bogie assembly including the second-wheel drive component, and when the second-wheel drive component is separated from the first bogie assembly, or when the second bogie assembly including the second-wheel drive component is separated from the underside of the movable turntable structure, the second-wheel drive component is pivoted from upright functional orientation to maintainable orientation. Attached Figure Description

[0011] Figure 1 A perspective view of an exemplary rotary loading station according to one aspect of this disclosure is shown; Figure 2 This is a side view of a bogie installed in a turntable loading station according to one aspect of this disclosure; Figure 3 This is a side view of a bogie installed in a turntable loading station, according to another aspect of this disclosure; Figure 4A replacement system according to one aspect of this disclosure is shown for safely removing non-functional drive components from a rotary loading station and installing working replacements; Figure 5 One aspect of this disclosure is shown. Figure 4 The exemplary position / orientation and movement of the replacement system depicted in the figure; Figure 6 An exemplary implementation of an alternative system according to one aspect of this disclosure is shown; Figure 7 Another exemplary implementation of an alternative system according to one aspect of this disclosure is shown; Figure 8 This is a flowchart illustrating an exemplary process for replacing a drive component of a turntable loading station according to one aspect of this disclosure. Detailed Implementation

[0012] The detailed description below, illustrated with reference to the accompanying drawings, is intended as a description of various constructions and is not intended to represent only constructions that can implement the concepts described herein. The detailed description includes specific details for the purpose of providing a thorough understanding of the various concepts. However, it will be apparent to those skilled in the art that these concepts can be implemented without these specific details. In some cases, well-known structures and components are shown in block diagram form to avoid obscuring such concepts. Although aspects and embodiments are described in this application by way of illustration of some examples, those skilled in the art will understand that additional implementations and use cases may arise in many different arrangements and scenarios. The innovations described herein can be implemented across many different platform types, devices, systems, shapes, sizes, and / or packaging arrangements.

[0013] Figure 1 A perspective view of an exemplary carousel loading station 100 according to one aspect of this disclosure is shown. Station 100 can be used to load (and unload) guests / passengers onto (and from) theme park attractions or rides. Station 100 can also be used in other applications, such as rail or trackless transportation systems. Station 100 may include a carousel 102 configured to rotate about axis 120 (e.g., a movable carousel structure). Guests / passengers may stand on top of the carousel 102 to be transported to or from attractions / rides as the carousel 102 rotates about axis 120. Wheels (e.g., passive loading wheels) may be mounted to the central lower portion of the carousel 102 to aid in rotating the carousel 102 about axis 120.

[0014] Station 100 may further include bogie assemblies 104 (e.g., eight or more bogie assemblies) mounted to the lower outer periphery of turntable 102. Each bogie assembly 104 serves as a chassis or frame for carrying wheels 106. Station 100 may also include structural piers (or rings) 110 (e.g., concrete piers / rings) formed around axis 120 and a track 108 located on the top surface of the structural piers 110. Each of the wheels 106 is configured to roll along track 108. Thus, when a wheel 106 is driven to roll along track 108 (e.g., via a drive motor), it causes each bogie assembly 104 carrying the corresponding wheel 106 to move along track 108 and rotate about axis 120, which in turn causes the turntable 102 coupled to the bogie assembly 104 to also rotate about axis 120. When wheel 106 stops rolling along track 108 (e.g., by wheel braking or by disabling the drive motor), each bogie assembly 104 carrying the corresponding wheel 106 stops rotating about axis 120, which in turn causes turntable 102 to also stop rotating about axis 120.

[0015] Figure 2 This is a side view of a bogie assembly 104 installed in a turntable loading station 100 according to one aspect of this disclosure. Figure 3 This is a side view of a bogie assembly 104 installed in a turntable loading station 100, according to another aspect of this disclosure.

[0016] See Figure 2 and 3 The bogie assembly 104 is mounted on the underside of the turntable 102 and on the track 108. The bogie assembly 104 may include mechanical fittings and / or support structures configured to adjust the position of the bogie assembly 104 / wheel 106 relative to the track 108 (e.g., toe-in adjustment). The bogie assembly 104 may further include a drive assembly 202 operatively coupled to (or including) the wheel 106 carried by the bogie assembly 104. The drive assembly 202 may be a combination of various devices / systems configured to generate torque to drive the wheel 106 to roll. For example, the drive assembly 202 may be a combination of at least a motor, a transmission (gearbox), and a shaft coupled to the wheel 106. This combination may further include a braking system configured to decelerate and / or stop the wheel from rolling. In one aspect, the drive assembly 202 is electric. For example, a sliding ring connected via the central portion of the turntable 102 may provide power to the drive assembly 202. The sliding ring can also provide an Ethernet connection, through which the drive assembly 202 can receive input signals from the control system and / or send output signals to the control system.

[0017] When the corresponding wheel 106 of station 100 is driven by drive assembly 202 to roll along track 108, the bogie assembly 104 carrying the corresponding wheel 106 moves along track 108 and rotates about axis 120. Therefore, the assembly of the rotating bogie assembly 104 causes the turntable 102 connected to the rotating bogie assembly 104 to also rotate about axis 120. When the corresponding wheel 106 stops rolling along track 108 via drive assembly 202, the bogie assembly 104 carrying the corresponding wheel 106 stops along track 108 and ceases rotation about axis 120. Therefore, the assembly of the stopped bogie assembly 104 causes the turntable 102 connected to the stopped bogie assembly 104 to also cease rotation about axis 120.

[0018] Axis 120 (see) Figure 1 It is located in the center of turntable 102. (For example...) Figure 2 and 3 As shown, axis 120 is positioned relative to bogie assembly 104 in direction A. Therefore, in Figure 2 In the aspects shown, the bogie assembly 104 can be mounted below the turntable 102 and above the track 108, such that the rear portion 204 of the drive assembly 202 is positioned closer to the axis 120 (oriented towards direction A) than the wheel 106. Consequently, the wheel 106 is positioned closer to the outer peripheral surface B of the turntable 102 than the rear portion 204 of the drive assembly 202. Figure 3 In another aspect shown, the bogie assembly 104 may be mounted below the turntable 102 and above the track 108, such that the wheel 106 is positioned closer to the axis 120 (oriented toward direction A) than the rear portion 204 of the drive assembly 202. Consequently, the rear portion 204 of the drive assembly 202 is positioned closer to the outer peripheral surface B of the turntable 102 than the wheel 106.

[0019] On the one hand, drive assembly 202 may become inoperable during its service life; for example, the motor, gearbox, shaft, and / or braking system of drive assembly 202 may fail. Therefore, in the event of a failure, station technicians may need to perform various procedures that result in prolonged downtime at station 100 and / or expose technicians to potentially hazardous conditions. For example, to replace a non-operating drive assembly, station technicians may need to sequentially secure the drive assembly to a support structure (e.g., using beam clamps), separate the drive assembly from the wheel / bogie assembly, suspend the drive assembly, and lower the non-operating drive assembly (e.g., using a crane) to the floor. Station technicians may then repeat these steps in reverse to install a working replacement. Given the weight of the drive assembly (e.g., approximately 2600 pounds) and the height at which the drive assembly is installed on the turntable loading station (e.g., approximately 12 feet or more above the ground), performing all the necessary steps to replace the failed drive assembly exposes station technicians to numerous potentially harmful ergonomic and safety risks. For example, the station's technicians are exposed to the risk of the weight of the drive assembly falling on their bodies and / or falling from a height where the drive assembly is installed. Furthermore, performing such sequential manual operations is time-consuming, resulting in extended downtime for station 100.

[0020] Figure 4 A replacement system 400, according to one aspect of this disclosure, is shown for the safe and rapid removal of a non-functional drive assembly from a turntable loading station 100 and the installation of a working replacement. In one aspect, system 400 includes a self-contained drive assembly 402 coupled to wheels 106. Although not shown, Figure 4 The drive assembly 402 and wheel 106 depicted are connected to the bogie assembly 104 (e.g., Figure 2 and 3 (As depicted in the text).

[0021] On one hand, the drive assembly 402 can be mounted in the turntable loading station structure without being coupled to the wheels. For example, the drive assembly 402 can be tangentially mounted to the inner radial side surface of the structural pier 110 (e.g., if the bogie 104 is mounted such that the rear portion of the drive assembly, for example...). Figure 2 The wheel 106 depicted is closer to the central axis 120 of the station 100. Alternatively, the drive assembly 402 may be tangentially mounted to the outer radial side surface of the structural pier 110 (e.g., if the bogie 104 is mounted such that the wheel 106 is, for example...). Figure 3 The rear portion of the drive assembly depicted is closer to the central axis 120 of station 100. Therefore, drive assembly 402 can be pre-installed in the station structure as a backup drive assembly in order to replace the working drive assembly that may become faulty.

[0022] System 400 further includes a translation box 404 configured to mount the drive assembly 402 to the inner / outer radial side surfaces of the structural pier 110. The translation box 404 may include an adapter plate 406 detachably coupled to the underside of the drive assembly 402, and at least one upright 412 extending from the adapter plate 406 and detachably coupled to the side surface of the drive assembly 402. The translation box 404 may further include one or more linear sliding rails 408 coupled to the underside of the adapter plate 406 and an inclined sliding frame 410 also coupled to the underside of the adapter plate 406. The one or more sliding rails 408 engage the sliding frame 410 such that when the drive assembly 402 is disengaged from the wheel 106 / bogie assembly 104, the translation box 404 (and the drive assembly 402 coupled to the translation box 404) is pulled away from the wheel 106 (e.g., along...). Figure 4 When the direction B is pulled (as shown), one or more sliding guide rails 408 can pass through the sliding frame 410 in the longitudinal direction. On one hand, the wheel 106 can remain connected to the drive assembly 402, and therefore, when the translation box 404 moves in this direction, both the drive assembly 402 and the wheel 106 can pass through the sliding frame 410 in the longitudinal direction (or when the translation box 404 moves in this direction). Figure 5 The wheel 106 is pulled in direction E as shown. Therefore, a jack can be used to increase the space between the track 108 and the turntable 102 (e.g., by approximately 0.75 inches) to make room for the wheel 106 and allow it to move in direction B (or direction E). On one hand, the sliding frame 410 can be mounted to the inner / outer radial side surface of the structural pier 110 (directly or indirectly via a support member or structure).

[0023] Figure 5 One aspect of this disclosure is shown. Figure 4 The exemplary position / orientation and movement of the replacement system 400 depicted herein. Here, drive assembly 402 is coupled to translation box 404. At position 502, drive assembly 402 is in an upright functional orientation (e.g., horizontal or near-horizontal orientation). In the upright functional orientation, drive assembly 402 may be coupled to wheel 106 / bogie assembly 104. For example, if drive assembly 402 becomes inoperable (e.g., the motor stops working), drive assembly 402 may be disengaged from wheel 106 / bogie assembly 104. After disengagement, drive assembly 402 may be pulled away from wheel 106 (i.e., pulled in direction B). That is, drive assembly 402 may be pulled in direction B such that one or more sliding rails 408 pass longitudinally through sliding frame 410 until drive assembly 402 reaches position 504. At position 504, sliding frame 410 may facilitate tilting of drive assembly 402 relative to wheel 106 in a downward and away direction (e.g., direction C). Figure 5As shown, before finally reaching a maintainable orientation (e.g., vertical or near-vertical orientation) at position 508, the drive assembly 402 moves from an upright functional orientation (e.g., horizontal or near-horizontal orientation) at position 504 to an intermediate position 506. As will be described below, when the drive assembly 402 is in a maintainable orientation at position 508, the translation box 404 (carrying the drive assembly 402) can move radially along the inner / outer radial side surfaces of the structural pier 110.

[0024] As described above, the drive assembly 402, connected to the translation box 404, begins to move from the upright functional orientation (at position 502) and ends at the maintainable orientation (at position 508). However, on one hand, the translation box 404 can move independently from the upright functional orientation (position 502) to the maintainable orientation (position 508) without being connected to the drive assembly 402. On the other hand, the wheel 106 / bogie assembly 104, including the drive assembly 402 connected to the translation box 404, can move from the upright functional orientation (position 502) to the maintainable orientation (position 508).

[0025] On the other hand, the drive assembly 402 and / or translation box 404 may begin moving from a maintainable orientation (position 508) and end at an upright functional orientation (position 502). For example, the drive assembly 402 and / or translation box 404 may initially be in the maintainable orientation (position 508). The slide frame 410 may then facilitate the tilting of the drive assembly 402 and / or translation box 404 relative to the wheel 106 in the upward and forward directions (e.g., direction D). The drive assembly 402 and / or translation box 404 may move from the maintainable orientation at position 508 to an intermediate position 506 before reaching the upright functional orientation at position 504. Notably, as the drive assembly 402 / translation box 404 moves from the intermediate position 506 to the upright functional orientation at position 504, the center of mass of the drive assembly 402 / translation box 404 moves through a pivot position, allowing the drive assembly 402 / translation box 404 to slide toward the wheel 106. At position 504, the drive assembly 402 and / or the translation box may be pushed toward the wheel 106 (i.e., pushed in direction E), such that one or more sliding guides 408 pass longitudinally through the slide frame 410 until the drive assembly 402 reaches the upright functional orientation at position 502. At position 502, the drive assembly 402 may be coupled to the wheel 106 / bogie assembly 104.

[0026] As described above, the drive assembly 402 and / or the translation box 404 begin to move from the maintainable orientation (at position 508) and end at the upright functional orientation (at position 502). However, in one aspect, the wheel 106 / bogie assembly 104, including the drive assembly 402 coupled to the translation box 404, can move from the maintainable orientation (position 508) to the upright functional orientation (position 502).

[0027] Figure 6 An exemplary embodiment 600 of a replacement system 400 according to one aspect of this disclosure is shown. Figure 7 Another exemplary embodiment 700 of the replacement system 400 according to one aspect of this disclosure is shown.

[0028] On one hand, the exchange guide 602 can be connected to the radial side surface of the structural pier 110. As shown, the exchange guide 602 extends along the outer radial side surface of the structural pier 110. However, on the other hand, the exchange guide 602 can extend along the inner radial side surface of the structural pier 110 (e.g., if the bogie assembly 104 is mounted such that the rear portion of the drive assembly 402, for example...). Figure 2 The wheel 106 depicted is closer to the central axis 120 of station 100. The translation box 404 can be movably mounted to the exchange guide rail 602. Therefore, when the translation box 404 is positioned in a maintainable orientation (e.g., Figure 5 When in position 508, the translation box 404 can move along the radial side surface of the structural pier 110 by sliding along the exchange guide rail 602.

[0029] On the one hand, a second translation box 604 (similar to the translation box 404 described above) can also be mounted to the exchange rail 602. Therefore, when the second translation box 604 is positioned in a maintainable orientation (e.g., Figure 5 When in position 508, the second translation box 604 can also move along the radial side surface of the structural pier 110 by sliding along the exchange guide 602. On one hand, the second translation box 604 may be pre-loaded with a working drive assembly 606 (hot spare or replacement unit). On the other hand, the second translation box 604 may be pre-loaded with a second wheel / bogie assembly including the working drive assembly 606.

[0030] In an exemplary operation, when drive assembly 402 fails (e.g., becomes inoperable) and can no longer roll wheel 106 to assist in rotating turntable 102 about axis 120, an empty translation box 404 positioned in a maintainable orientation can be moved via exchange rail 602 along the radial side surface of structural pier 110 to rest beneath the inoperable drive assembly 402. Alternatively, the inoperable drive assembly 402 can be moved toward the empty translation box 404, for example by rotating turntable 102 such that wheel 106 / bogie assembly 104 positions the inoperable drive assembly 402 above the empty translation box 404. For example, the control system of turntable loading station 100 can utilize encoders and absolute positioning to automatically index turntable 102 until the inoperable drive assembly 402 is in an unloading position along track 108 (e.g., above the empty translation box 404).

[0031] Once the non-functional drive component 402 is positioned on the empty translation box 404, the translation box 404 can be positioned in the upward and forward directions (e.g., Figure 5 The direction shown (D) is tilted towards the upright functional orientation. Upon reaching the upright functional orientation, the translation box 404 can be pushed forward toward the wheel 106 (e.g., Figure 5 As shown in direction E), the translation box 404 may be pushed sufficiently close to engage with the drive assembly 402. For example, the translation box 404 may be pushed along direction E until the adapter plate 406 and / or one or more uprights 412 of the translation box 404 can engage with mounting points formed on the underside and / or side surface of the drive assembly 402. In another embodiment, the adapter plate 406 and / or one or more uprights 412 may be engaged with the underside and / or side surface of the drive assembly 402 via a vise clamp or a strapping mechanism.

[0032] On the one hand, to help minimize the total duration of replacing the non-functional drive assembly 402 and to improve safety by minimizing operator / technician exposure to hazards, any movement of the translation box described herein can be automated. For example, after the control system indexes the turntable 102 to a position until the non-functional drive assembly 402 is in an unloading position along track 108, the control system can further deploy the translation box 404 to automatically position itself under the non-functional drive assembly 402 and / or tilt itself to an upright functional orientation to enable engagement with the non-functional drive assembly 402.

[0033] When the translation box 404 is engaged with the drive assembly 402, the drive assembly 402 can then be disengaged from the bogie assembly 104 (e.g., by loosening the fasteners connecting the drive assembly 402 to the bogie assembly 104). Alternatively, when the translation box 404 is engaged with the drive assembly 402, the bogie assembly 104, including the drive assembly 402 engaged with the translation box 404, can be disengaged from the turntable 102. In one aspect, the translation box 404 engaged with the drive assembly 402 is configured to reduce or remove compressive forces between the drive assembly 402 and the bogie assembly 104 (and / or between the bogie assembly 104 and the turntable 102). Therefore, when the compressive forces are reduced or removed, the disengagement of the drive assembly 402 from the bogie assembly 104 (or the disengagement of the bogie assembly 104 from the turntable 102) can be performed in a more convenient and safer manner. Subsequently, the translation box 404 carrying the non-operating drive assembly 402 (or the bogie assembly 104 including the non-operating drive assembly 402) can move in the downward and away directions (e.g., Figure 5 The direction shown (C) is tilted to return to the maintainable orientation. Once in the maintainable orientation, the translation box 404 / inactive drive assembly 402 can be moved away from the wheel 106 / bogie assembly 104 (or away from the turntable 102) along the radial side surface of the structural pier 110 (e.g., in direction 610). In one aspect, taking into account the weight of the drive assembly 402 carried by the translation box 404, the translation box 404 can be mounted to the exchange guide 602 via a balance pivot 702. The balance pivot 702 can help to keep the translation box 404 / drive assembly 402 in the upward and forward directions by counteracting the weight of the drive assembly 402 applied in one direction or the other. Figure 5 The direction shown is D) and / or the downward and outward directions (as shown). Figure 5 The direction shown is tilted upwards (C). In one aspect, the balance pivot 702 may employ a spring, cylinder, or other type of balancing device.

[0034] After the translation box 404 / non-operating drive assembly 402 moves away from wheel 106 / bogie assembly 104 (or away from turntable 102), the second translation box 604, pre-loaded with the working drive assembly 606 (hot spare, replacement unit, or second drive assembly) and positioned in a maintainable location (or pre-loaded with a second bogie assembly including the working drive assembly 606), can move along the radial side surface of the structural pier 110 (e.g., in direction 612) to rest under the bogie assembly 104 (or turntable 102). Once the second translation box 604 is positioned under the bogie assembly 104 (or turntable 102), the second translation box 604 carrying the working drive assembly 606 (or carrying the second bogie assembly including the working drive assembly 606) can move in the upward and forward directions (e.g., Figure 5The direction shown (D) is tilted towards an upright functional orientation. In one aspect, considering the weight of the working drive assembly 606 carried by the second translation box 604, the second translation box 604 can be mounted to the exchange rail 602 via a second balance pivot (similar to balance pivot 702). The second balance pivot helps to balance the weight of the working drive assembly 606 applied in one or the other direction, thus aligning the second translation box 604 / working drive assembly 606 in the upward and forward directions ( Figure 5 The direction shown is D) and / or the downward and outward directions (as shown). Figure 5 The direction shown is tilted upwards (C).

[0035] When the upright functional orientation is achieved, the second translation box 604 / working drive assembly 606 can be oriented toward the bogie assembly 104 (e.g., Figure 5 As shown in direction E), push forward until the working drive assembly 606 is close enough to be engaged with the bogie assembly 104. The working drive assembly 606 can then be engaged with the bogie assembly 104 (e.g., by tightening the fasteners that engage the working drive assembly 606 with the bogie assembly 104). In one aspect, the second translation box 604, engaged with the working drive assembly 606, is configured to increase the compressive force between the working drive assembly 606 and the bogie assembly 104 (or between the second bogie assembly including the working drive assembly 606 and the turntable 102) during the installation of the working drive assembly 606. Therefore, when the compressive force is increased, the engagement of the working drive assembly 606 to the bogie assembly 104 (or the engagement of the second bogie assembly including the working drive assembly 606 to the turntable 102) can be performed more easily and safely.

[0036] After the working drive assembly 606 is coupled to the bogie assembly 104 (or the second bogie assembly including the working drive assembly 606 is coupled to the underside of the turntable 102), the second translation box 604 can be detached from the working drive assembly 606 (or from the second bogie assembly including the working drive assembly 606). For example, the second adapter plate and / or one or more second uprights of the second translation box can be detached from the mounting points on the underside and / or side surface of the working drive assembly 606. Thereafter, the second translation box 604 can be detached in direction B ( Figure 5 As shown, it is pulled away and caused to move in the downward and away directions (e.g., Figure 5 The direction shown in C) is tilted upwards to return to the maintainable orientation. Once in the maintainable orientation, the empty second translation box 606 can remain empty in anticipation of receiving a future failed drive component, or can be reloaded with a working drive component.

[0037] Figure 8This is a flowchart illustrating an exemplary process 800 for replacing a drive assembly of a rotary loading station according to one aspect of this disclosure. In some instances, process 800 may be performed by the control system of the rotary loading station or by any suitable device or apparatus for performing the functions or algorithms described below.

[0038] At frame 802, the control system identifies a first bogie assembly (e.g., bogie assembly 104) detachably coupled to the underside of a movable turntable structure (e.g., turntable 102) for replacement. The first bogie assembly includes a first wheel drive assembly configured to drive wheels (e.g., wheel 106) to roll on a track (e.g., track 108) formed on the top surface of a structural pier (e.g., pier 110). In one aspect, the first bogie assembly can be identified for replacement via manual or automatic methods, including methods based on inspection sensors. In another aspect, the wheels are coupled to the underside of the movable turntable structure via the first bogie assembly, wherein when the first wheel drive assembly drives the wheels to roll on the track, it causes the movable turntable structure to rotate about an axis (e.g., axis 120).

[0039] At frame 804, the control system, while in a maintainable orientation (e.g., the orientation at position 508), moves the first translation box (e.g., translation box 404) along the radial side surface of the structural pier (e.g., by sliding along exchange guide 602) to an unloading position below the first bogie assembly coupled to the movable turntable structure. At frame 806, the control system may optionally rotate the movable turntable structure about an axis to move the first bogie assembly to an unloading position above the first translation box.

[0040] At frame 808, the control system pivots the first translation box from a maintainable orientation to an upright functional orientation (e.g., the orientation at position 502), and engages the first translation box to the first wheel drive assembly while in the upright functional orientation. Subsequently, the control system disengages the first wheel drive assembly engaged with the first translation box from the first bogie assembly, or disengages the first bogie assembly including the first wheel drive assembly engaged with the first translation box from the movable turntable structure, and pivots the first translation box from the upright functional orientation to the maintainable orientation while engaged with the first wheel drive assembly. In one aspect, pivoting the first translation box from the upright functional orientation to the maintainable orientation may include offsetting the weight of the first wheel drive assembly engaged with the first translation box (e.g., using a balance pivot 702). The control system may further move the first translation box away from the unloading position along the radial side surface of the structural pier while in the maintainable orientation and engaged with the first wheel drive assembly.

[0041] At frame 810, when in a maintainable orientation, the control system moves a second translation box (e.g., second translation box 604) coupled to a second wheel drive assembly (e.g., second drive assembly 606) or a second bogie assembly including the second wheel drive assembly along the radial side surface of the structural pier (e.g., by sliding along the exchange guide 602) to a loading position below the first bogie assembly detached from the first wheel drive assembly, or below the location of the movable turntable structure where the first bogie assembly including the first wheel drive assembly is detached from the movable turntable structure.

[0042] At frame 812, the control system pivots the second translation box from maintainable orientation to upright functional orientation when coupled to the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, and connects the second wheel drive assembly to the first bogie assembly or the second bogie assembly including the second wheel drive assembly to the underside of the movable turntable structure. In one aspect, pivoting the second translation box includes counteracting the weight of the second wheel drive assembly coupled to the second translation box (e.g., using a balance pivot) when the second translation box pivots from maintainable orientation to upright functional orientation. Thereafter, the control system disengages the second translation box from the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, and pivots the second translation box from upright functional orientation to maintainable orientation when disengaged from the second wheel drive assembly coupled to the first bogie assembly, or when disengaged from the second bogie assembly including the second wheel drive assembly coupled to the underside of the movable turntable structure. The control system can move the second translation box further away from the loading position along the radial side surface of the structural pier when it is in a maintainable orientation and separated from the second drive assembly.

[0043] In this disclosure, the term "exemplary" is used to mean "used as an example, illustration, or description." Any implementation or aspect described herein as "exemplary" is not necessarily to be construed as superior or better than other aspects of this disclosure. Similarly, the term "aspect" does not require that all aspects of this disclosure include the features, advantages, or modes of operation discussed. The term "connection" is used herein to indicate a direct or indirect connection between two objects. For example, if object A is in physical contact with object B, and object B is in contact with object C, then objects A and C can still be considered connected to each other—even if they are not in direct physical contact with each other. For example, a first object can be connected to a second object even if the first object never has direct physical contact with the second object.

[0044] Figure 1-8One or more components, steps, features, and / or functions shown may be rearranged and / or combined into a single component, step, feature, or function, or implemented in several components, steps, or functions. Additional elements, components, steps, and / or functions may be added without departing from the novel features disclosed herein. Figure 1-7 The devices, apparatuses, and / or components shown may be configured to perform one or more of the methods, features, or steps described herein. The novel algorithms described herein may also be efficiently implemented in software and / or embedded in hardware.

[0045] It should be understood that the specific order or hierarchy of steps in the disclosed method is an illustration of an exemplary process. Based on design preferences, it is understood that the specific order or hierarchy of steps in the method may be rearranged. The appended method claims present the elements of each step in a sample order and are not intended to be limited to the specific order or hierarchy presented, unless specifically stated therein.

[0046] The preceding description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these aspects will be apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects. Therefore, the claims are not intended to be limited to the aspects shown herein, but are to be consistent with the full scope of the language of the claims, wherein, unless specifically stated otherwise, the singular form of an element referred to is not intended to mean “one and only one”, but rather “one or more”. Unless specifically stated otherwise, the term “some” means one or more. The phrase referring to “at least one” of a series of items means any combination of such items, including a single member. As an example, “at least one of a, b, or c” is intended to cover: a; b; c; a and b; a and c; b and c; and a, b, and c. All structural and functional equivalents of the elements throughout the various aspects described in this disclosure (which are known to a person skilled in the art or will become known thereafter) are expressly incorporated herein by reference and are intended to be included by the claims. Furthermore, whatever is disclosed herein, whether or not such disclosure is expressly stated in the claims, is not intended to be offered to the public. No element of the claim shall be construed in accordance with 35 U.S.SC §112(f) unless the element is explicitly stated using the phrase “apparatus for…” or, in the case of a method claim, the element is stated using the phrase “step for…”.

Claims

1. A system for replacing drive components of a rotary loading station, the system comprising: Structural piers; The track formed on the top surface of the structural pier; Movable turntable structure; A first bogie assembly detachably coupled to the lower side of the movable turntable structure, the first bogie assembly including a first wheel drive assembly configured to drive wheels to roll on the track; Exchange guide rails mounted on the radial side surface of the structural pier; and A first translation box is movably mounted to the exchange guide rail in a maintainable orientation, the first translation box being configured to pivot from the maintainable orientation to an upright functional orientation for connection with the first wheel drive assembly, and to detach the first wheel drive assembly connected to the first translation box from the first bogie assembly, or to detach the first bogie assembly including the first wheel drive assembly connected to the first translation box from the movable turntable structure.

2. The system of claim 1, wherein the first translation box is configured to move, when in the maintainable orientation, via the exchange guide along the radial side surface of the structural pier to an unloading position below the first bogie assembly coupled to the movable turntable structure.

3. The system of claim 2, wherein the first translation box is configured as follows: When coupled to the first wheel drive assembly, it pivots from the upright functional orientation to the maintainable orientation, and while in the maintainable orientation and coupled to the first wheel drive assembly, it moves via the exchange guide along the radial side surface of the structural pier to a position away from the unloading position.

4. The system according to claim 1, wherein the first translation box comprises: An adapter plate is detachably connected to the lower side of the first wheel drive assembly; A tilting sliding frame is attached to the lower side of the adapter plate, the tilting sliding structure causing the translation box to pivot between the maintainable orientation and the upright functional orientation; as well as One or more sliding rails are connected to the lower side of the adapter plate, the one or more sliding rails being configured as follows: The first translation box is slid toward the first bogie assembly using the upright functional orientation to connect the adapter plate to the first wheel drive assembly. When the adapter plate is attached to the first wheel drive assembly and the first wheel drive assembly is separated from the first bogie assembly, the first translation box slides away from the first bogie assembly with the upright functional orientation; or when the adapter plate is attached to the first wheel drive assembly and the first bogie assembly including the first wheel drive assembly is separated from the movable turntable structure, the first translation box slides away from the movable turntable structure with the upright functional orientation.

5. The system according to claim 4, further comprising: A balance pivot is formed between the first translation box and the exchange guide rail, the balance pivot being configured to counteract the weight of the first wheel drive assembly coupled to the first translation box when the first translation box pivots between the maintainable orientation and the upright functional orientation.

6. The system according to claim 1, wherein: The first bogie assembly is configured to connect the wheels to the underside of the movable turntable structure; and When the first wheel drive assembly drives the wheel to roll on the track, it causes the movable turntable structure to rotate about the axis.

7. The system of claim 6, wherein the movable turntable structure is configured to rotate about the axis to move the first bogie assembly to an unloading position above the first translation box.

8. The system of claim 4, further comprising a second translation box, the second translation box being movably mounted to the exchange guide rail in the maintainable orientation, the second translation box being coupled to a second wheel drive assembly or a second bogie assembly including the second wheel drive assembly, and configured such that: When coupled to the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, the pivot point is shifted from the maintainable directional pivot to the upright functional orientation; The second wheel drive assembly is coupled to the first bogie assembly, or the second bogie assembly including the second wheel drive assembly is coupled to the lower side of the movable turntable structure; Separation from the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, and separation from the second wheel drive assembly coupled to the first bogie assembly, or separation from the second bogie assembly including the second wheel drive assembly coupled to the lower side of the movable turntable structure, from the upright functional orientation pivot to the maintainable orientation.

9. The system of claim 8, wherein the second translation box comprises: A second adapter plate is detachably connected to the lower side of the second wheel drive assembly; A second tilting slide frame is attached to the lower side of the second adapter plate, the second tilting slide frame causing the second translation box to pivot between the maintainable orientation and the upright functional orientation; as well as One or more second sliding rails are connected to the lower side of the second adapter plate, the one or more second sliding rails being configured as follows: When the second adapter plate is connected to the second wheel drive assembly, the second translation box is slid in the upright functional orientation to connect the second wheel drive assembly to the first bogie assembly. When the second adapter plate is attached to the second wheel drive assembly, the second translation box is slid in the upright functional orientation to attach the second bogie assembly, including the second wheel drive assembly, to the underside of the movable turntable structure. When the second wheel drive assembly is coupled to the first bogie assembly and the second adapter plate is separated from the second wheel drive assembly, the second translation box slides away from the first bogie assembly with the upright functional orientation; or when the second bogie assembly including the second wheel drive assembly is coupled to the lower side of the movable turntable structure and the second adapter plate is separated from the second wheel drive assembly, the second translation box slides away from the movable turntable structure with the upright functional orientation.

10. The system according to claim 9, further comprising: A second balance pivot is formed between the second translation box and the exchange guide rail, the second balance pivot being configured to counteract the weight of the second wheel drive assembly coupled to the second translation box when the second translation box pivots between the maintainable orientation and the upright functional orientation.

11. The system of claim 9, wherein the second translation box is configured as follows: When in the maintainable orientation and connected to the second wheel drive assembly, it moves via the exchange guide along the radial side surface of the structural pier to a loading position, the loading position being below the first bogie assembly detached from the first wheel drive assembly, or below the location of the movable turntable structure where the first bogie assembly, including the first wheel drive assembly, is detached from the movable turntable structure; and When in the maintainable orientation and separated from the second wheel drive assembly, it moves along the radial side surface of the structural pier via the exchange guide to a position away from the loading position.

12. A method for replacing a drive assembly in a rotary loading station, the method comprising: A first bogie assembly detachably coupled to the lower side of a movable turntable structure is identified for replacement. The first bogie assembly includes a first wheel drive assembly configured to drive wheels to roll on a track formed on the top surface of the structural pier. When in a maintainable orientation, the first translation box is moved along the radial side surface of the structural pier to an unloading position below the first bogie assembly connected to the movable turntable structure; The first translation box is rotated from the maintainable orientation pivot to the upright functional orientation; When in the upright functional orientation, the first translation box is connected to the first wheel drive assembly, and The first wheel drive assembly connected to the first translation box is separated from the first bogie assembly, or the first bogie assembly including the first wheel drive assembly connected to the first translation box is separated from the movable turntable structure.

13. The method of claim 12, further comprising: When connected to the first wheel drive assembly, the first translation box is pivoted from the upright functional orientation to the maintainable orientation; as well as When in the maintainable orientation and connected to the first wheel drive assembly, the first translation box is moved along the radial side surface of the structural pier to a position away from the unloading position.

14. The method of claim 13, wherein the first translation box pivots from the upright functional orientation to the maintainable orientation, comprising: When the first translation box pivots from the upright functional orientation to the maintainable orientation, it offsets the weight of the first wheel drive assembly coupled to the first translation box.

15. The method of claim 12, wherein the first bogie assembly is configured to engage the wheel with the lower side of the movable turntable structure and cause the movable turntable structure to rotate about an axis when the first wheel drive assembly drives the wheel to roll on the track.

16. The method of claim 15, further comprising: The movable turntable structure is rotated about the axis to move the first bogie assembly to the unloading position above the first translation box.

17. The method of claim 12, further comprising: When in the maintainable orientation, the second translation box, which is connected to the second wheel drive assembly or includes the second bogie assembly, is moved along the radial side surface of the structural pier to a loading position, which is below the first bogie assembly separated from the first wheel drive assembly, or below the location of the movable turntable structure where the first bogie assembly including the first wheel drive assembly is separated from the movable turntable structure. When coupled to the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, the second translation box is pivoted from the maintainable orientation to the upright functional orientation; The second wheel drive assembly is coupled to the first bogie assembly, or the second bogie assembly including the second wheel drive assembly is coupled to the lower side of the movable turntable structure; Separate the second translation box from the second wheel drive assembly or from the second bogie assembly including the second wheel drive assembly; as well as When the second wheel drive assembly is disengaged from the first bogie assembly, or when the second bogie assembly including the second wheel drive assembly is disengaged from the lower side of the movable turntable structure, the second translation box is pivoted from the upright functional orientation to the maintainable orientation.

18. The method of claim 17, wherein the second translation box pivots from the maintainable orientation to the upright functional orientation, comprising: When the second translation box pivots from the maintainable orientation to the upright functional orientation, it offsets the weight of the second wheel drive assembly coupled to the second translation box.

19. The method of claim 17, further comprising: When in the maintainable orientation and separated from the second wheel drive assembly, the second translation box is moved along the radial side surface of the structural pier to a position away from the loading position.

20. A rotary loading station, the rotary loading station comprising: Structural piers; The track formed on the top surface of the structural pier; Movable turntable structure; A first bogie assembly detachably coupled to the lower side of the movable turntable structure, the first bogie assembly including a first wheel drive assembly configured to drive wheels to roll on the track, wherein when the wheels roll on the track, they cause the movable turntable structure to rotate about an axis; Exchange guide rails mounted on the radial side surface of the structural pier; and A first translation box is mounted to the exchange guide rail in a maintainable, directional, and movable manner, the first translation box being configured as follows: When in the maintainable orientation, the bogie moves via the exchange guide along the radial side surface of the structural pier to an unloading position below the first bogie assembly coupled to the movable turntable structure. From the maintainable directional pivot to the upright functional orientation for connection with the first wheel drive assembly. Separating the first wheel drive assembly, which is connected to the first translation box, from the first bogie assembly, or separating the first bogie assembly, which includes the first wheel drive assembly connected to the first translation box, from the movable turntable structure, and When connected to the first wheel drive assembly, the pivot point shifts from the upright functional orientation to the maintainable orientation.

21. The turntable loading station of claim 20, further comprising a second translation box, the second translation box being maintainably and orientably movable to the exchange guide rail, the second translation box being coupled to a second wheel drive assembly or a second bogie assembly including the second wheel drive assembly, and configured such that: When in the maintainable orientation, the bogie assembly is moved along the radial side surface of the structural pier to a loading position, which is below the first bogie assembly detached from the first wheel drive assembly, or below the location of the movable turntable structure where the first bogie assembly, including the first wheel drive assembly, is detached from the movable turntable structure. When coupled to the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, the pivot point shifts from the maintainable directional pivot to the upright functional orientation. The second wheel drive assembly is coupled to the first bogie assembly, or the second bogie assembly including the second wheel drive assembly is coupled to the lower side of the movable turntable structure; Separate from the second wheel drive assembly or the second bogie assembly including the second wheel drive assembly, and When disengaged from the second wheel drive assembly coupled to the first bogie assembly, or when disengaged from the second bogie assembly including the second wheel drive assembly coupled to the lower side of the movable turntable structure, the pivot point shifts from the upright functional orientation to the maintainable orientation.

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