Mobile water jet track maintenance system

Abstract

This application relates to a mobile water jet track maintenance system. A translatable ultra-high pressure liquid jetting system (100) includes a translatable frame (200) configured to maintain mechanical contact with a track (124). The liquid jetting system includes a liquid jetting head (408) attached to the frame and configured to maintain a distance from the track and provide liquid jetting to the track. The liquid jetting system also includes an ultra-high pressure liquid pump (116) in fluid communication with the liquid jetting head. The ultra-high pressure liquid pump is configured to supply pressurized liquid to the liquid jetting head.

Description

[0001] This application is a divisional application of Chinese Patent Application CN201980060926.0, filed September 17, 2019, entitled "Mobile Water Jet Track Maintenance System". This application is a non-provisional application of U.S. Provisional Patent Application No. 62 / 732,175, filed September 17, 2018, also entitled "Mobile Water Jet Track Maintenance System". The contents of that application are incorporated herein by reference in their entirety. Technical Field

[0002] This invention generally relates to the field of liquid pressurization systems and processes. More specifically, this invention relates to methods and apparatus for restoring and cleaning tracks using pressurized liquid jets. Background Technology

[0003] Liquid pressurization systems generate high-pressure (e.g., 20,000 to 90,000 pounds per square inch (PSI)) streams of liquid for a variety of applications. High-pressure liquids can be delivered, for example, to liquid jet cutting heads, cleaning tools, pressure vessels, or isostatic presses. In the case of liquid jet cutting systems, liquid is forced at high speed through a small orifice plate to concentrate a large amount of energy in a small area. To cut hard materials, the liquid jet can be “abrasive” or include abrasive particles to increase cutting power. As used herein, the term “liquid jet” includes any substantially pure water jet, liquid jet, and / or slurry jet. However, those skilled in the art will readily understand that the invention can be applied to other systems using liquid pumps or similar techniques.

[0004] Railways are a vital mode of transportation found throughout the world. However, prolonged use and heavy loads can cause tracks to deform and wear over time. Damaged tracks create a bumpy ride, stress on the wheels of the train cars in contact with the track, and other damage, and replacing damaged railway tracks can be very expensive. One known method for repairing railway tracks is to use large grinding trains to work the tracks, but this method is noisy, unpleasant, and expensive, especially when applied to damaged areas. The noise and sparks produced are extremely annoying. Furthermore, this grinding technique is not effective near corners or at intersections. What is needed are improved methods for treating (e.g., repairing, reshaping, and restoring) existing railway tracks. Summary of the Invention

[0005] This invention includes a novel mobile liquid jetting system that uses one or more pressurized liquid jets to treat damaged, worn, or dirty railway tracks. The system can include a mobile platform (e.g., a truck, train, railcar, or other rail transport system) supporting the water jetting system, which is capable of operating while in motion (e.g., while traveling along the track it is treating) while processing the track via one or more pressurized liquid jets. The system can include a robot or other motion system that can be placed on or near the track being repaired, but does not necessarily have to be attached to the track. In some embodiments, the invention may include a mobile truck-mounted unit (e.g., see...). Figure 1A The mobile truck mounting unit may have a set of tires for driving along roads and another set of deployable railway wheels, enabling the vehicle to travel along and / or on railway tracks.

[0006] In one aspect, the invention features a translational ultra-high pressure liquid injection system. The liquid injection system includes a translational frame configured to maintain mechanical contact with a track. The liquid injection system also includes a liquid injection processing head attached to the frame and configured to maintain a distance from the track and / or provide liquid injection to the track. The liquid injection system further includes an ultra-high pressure liquid pump in fluid communication with the liquid injection processing head. The ultra-high pressure liquid pump is configured to supply pressurized liquid to the liquid injection processing head.

[0007] In some embodiments, the frame is attached to one or more wheels configured to contact the track. In some embodiments, the system is configured to translate along the track via one or more wheels during track handling operations. In some embodiments, an ultra-high pressure liquid pump is disposed on the frame. In some embodiments, the ultra-high pressure liquid pump is disposed on a unit separate from the frame and is capable of moving independently of the frame and at a different speed than the frame. In some embodiments, the system is configured to remove the outer portion of the track having a linear dimension between 0.01 mm and 0.1 mm. In some embodiments, the system is configured to remove the outer portion of the track having a linear dimension between 0.1 mm and 1.0 mm. In some embodiments, the system is configured to remove the outer portion of the track having a linear dimension between 1.0 mm and 5.0 mm.

[0008] In some embodiments, the liquid injection head is configured to deliver liquid injection onto the track at an angle relative to the ground plane. In some embodiments, the system further includes a second liquid injection head and a third liquid injection head, the second and third liquid injection heads being in fluid communication with an ultra-high pressure liquid pump and configured to deliver a second liquid injection and a third liquid injection onto the track at second and third angles, respectively, relative to the ground plane. In some embodiments, the system further includes a fourth, fifth, and sixth liquid injection head, the fourth, fifth, and sixth liquid injection heads being in fluid communication with an ultra-high pressure liquid pump and configured to deliver a fourth, fifth, and sixth liquid injection onto a second track opposite to the first track at fourth, fifth, and sixth angles, respectively, relative to the ground plane.

[0009] In some embodiments, a liquid jetting head is attached to a positioning system attached to a frame. The positioning system is configured to adjustably position the liquid jetting head relative to a track. In some embodiments, the positioning system includes at least one of a robotic arm or gantry attached to the frame and is movable independently of the frame. In some embodiments, a second frame is configured to engage the track. The second frame is movable relative to the frame during operation of the ultra-high pressure liquid jetting system. In some embodiments, the second frame includes a liquid reservoir fluidly connected to an ultra-high pressure liquid pump. In some embodiments, the liquid reservoir has a capacity of at least 1000 liters.

[0010] In some embodiments, a generator is mounted on a second frame and operatively connected to an ultra-high pressure liquid pump. In some embodiments, a liquid jet treatment head is configured to treat the track as the second frame translates along the track. In some embodiments, the system includes nozzles fluidly connected to the liquid jet treatment head. In some embodiments, the liquid jet system includes an abrasive supply system fluidly connected to the liquid jet treatment head and configured to introduce a flow of abrasive into the liquid jet. In some embodiments, the ultra-high pressure liquid pump is configured to produce a liquid jet of at least 20,000 PSI (or optionally higher limits, such as 30,000 PSI, 40,000 PSI, 50,000 PSI, 60,000 PSI, 70,000 PSI, 80,000 PSI, 90,000 PSI, or 100,000 PSI) for track cutting or re-profile operations. In some embodiments, the ultra-high pressure liquid pump is configured to produce a liquid jet between 200 and 2,000 PSI for track cleaning or surface treatment operations (e.g., also capable of low-pressure applications).

[0011] In another aspect, the present invention is characterized by a method for operating an ultra-high pressure liquid jet system. The method includes a translateable frame having a liquid jet processing head fluidly connected to an ultra-high pressure liquid pump positioned relative to a track. The method further includes supplying pressurized fluid forming a liquid jet in contact with the track to the liquid jet processing head via the ultra-high pressure liquid pump. The method also includes translating the liquid jet processing head relative to the track, thereby performing a processing operation along the linear length of the track in the direction of translation.

[0012] In some embodiments, the frame includes one or more wheels configured to engage the track. In some embodiments, movement of the ultra-high pressure liquid pump corresponds to translation of the frame. In some embodiments, the ultra-high pressure liquid pump is fixedly connected to the frame. In some embodiments, the ultra-high pressure liquid pump is disposed on a unit separate from the frame and is capable of moving at a different speed than the frame. In some embodiments, the liquid jetting head is configured to deliver liquid jets to the track at an angle relative to the ground plane. In some embodiments, the pressurized fluid during track cutting and refurbishing operations is at least 20,000 PSI, or optionally higher limits, such as 30,000 PSI, 40,000 PSI, 50,000 PSI, 60,000 PSI, 70,000 PSI, 80,000 PSI, 90,000 PSI, or 100,000 PSI. In some embodiments, the pressurized fluid during track cleaning or surface treatment operations is between 200 and 2,000 PSI. In some embodiments, the ultra-high pressure liquid pump is included in a second frame that is movable independently of the first frame during operation of the liquid jetting system. In some embodiments, the method further includes translating a second frame at a different speed than the first frame during operation of the liquid jetting system.

[0013] In some embodiments, the liquid jet processing head is configured to provide liquid jets to the track at an angle relative to the ground plane. In some embodiments, the frame further includes a second liquid jet processing head and a third liquid jet processing head fluidly connected to an ultra-high pressure liquid pump. In some embodiments, the method further includes providing pressurized fluid forming the second and third liquid jets to the second and third liquid jet processing heads respectively via the ultra-high pressure liquid pump, the second and third liquid jets contacting the track at second and third angles relative to the ground plane, respectively. In some embodiments, the ultra-high pressure liquid jet system includes fourth, fifth, and sixth liquid jet processing heads in fluid communication with the ultra-high pressure liquid pump. In some embodiments, the method further includes providing pressurized fluid forming the fourth, fifth, and sixth liquid jets to the fourth, fifth, and sixth liquid jet processing heads respectively via the ultra-high pressure liquid pump, the fourth, fifth, and sixth liquid jets contacting the track at fourth, fifth, and sixth angles relative to the ground plane, respectively.

[0014] In another aspect, the present invention features a curved jet nozzle for an ultra-high pressure liquid jetting system. The curved jet nozzle includes a frame configured to engage a track. The curved jet nozzle also includes at least two liquid jetting heads attached to the frame at different angles relative to the ground plane. The curved jet nozzle further includes an ultra-high pressure liquid pump fluidly connected to the at least two liquid jetting heads and configured to supply pressurized fluid to each of the at least two liquid jetting heads to form a liquid jet contacting the track. In some embodiments, the at least two liquid jetting heads are positioned to provide liquid jets intersecting each other at an acute angle to create jets with different trajectories, which create a smooth finish on the track during processing operations without burls remaining after the initial cutting operation.

[0015] In another aspect, the invention is characterized by a different method of operating an ultra-high pressure liquid jet system. The method includes positioning a translational frame on two tracks spaced apart from each other, the translational frame having (i) a set of wheels for contacting the two tracks, and (ii) two sets of three liquid jet processing heads fluidly connected to an ultra-high pressure liquid pump, each set of the three liquid jet processing heads corresponding to one of the two tracks. The method also includes supplying pressurized fluid from the ultra-high pressure liquid pump to the two sets of the three liquid jets forming contact with the two tracks to the two sets of the three liquid jet processing heads. The method further includes translating the frame relative to the tracks, thereby performing processing operations along the linear length of the tracks in the direction of translation.

[0016] In another aspect, the present invention is characterized by a translational ultra-high pressure liquid injection system. The system includes a first device for maintaining mechanical contact with a track. The system also includes a second device for providing liquid injection into contact with the track, the second device being attached to the first device and configured to maintain a distance from the track. The system further includes a third device for supplying pressurized liquid to the second device, the third device being in fluid communication with the second device.

[0017] In some embodiments, the present invention is capable of refurbishing tracks (e.g., repairing or surface-repairing damaged track areas or volumes), removing track material that requires maintenance, and removing only a small width (e.g., about 0.03 mm) of track material during processing. In some embodiments, a “bent jet” abrasive water jet nozzle is capable of fanning the liquid jet and / or redirecting the water jet in a curved manner. Such a bent jet nozzle can be formed by causing two linear or curved water jets to intersect at an acute angle, such that a merged jet is formed and flows on a changed trajectory before encountering the track, or it can be bent via another device. In some embodiments, the present invention uses two connected moving units that can have different speeds relative to each other (e.g., they can have different or intermittent movements, one carrying a cutting head and the other carrying a liquid reservoir). In some embodiments, the movement of the cutting head can have multiple components (e.g., the movement of the system itself along the track and the movement of the hanger or arm relative to the system). In some embodiments, the water jet cutting head positioning mechanism can slide along one or more tracks being processed. In some embodiments, the surface of the track can be treated with a liquid jet (e.g., a lower pressure water jet below about 20,000 PSI (e.g., 200-2000 PSI)).

[0018] Using one or more of the unique features described above (e.g., including pumps, fluid supply, cutting heads, etc.), the entire liquid injection system can operate while in motion and handle one or more tracks (e.g., repairing one or more tracks and performing preventative maintenance on one or more tracks). This invention thus provides a fast, inexpensive, and clean way to repair old or damaged tracks, and to perform preventative maintenance on existing tracks. The invention can perform handling at most times and places (including near corners and across intersections). In some embodiments, the invention is highly flexible from a logistical perspective, where moving the train would be very difficult and time-consuming. In some embodiments, the invention provides negligible heat input to the track (e.g., track temperatures do not exceed 90°C, which has no perceptible effect on the track), and this can increase the overall lifespan of both the product and the track.

[0019] In some embodiments, the invention is environmentally friendly, for example, capable of using recycled water, sand, and metal. In some embodiments, the invention produces a lower noise level compared to the prior art. In some embodiments, the invention does not produce any sparks, which makes it uniquely suitable for surface rework of tracks in certain higher-risk environments (e.g., near chemical plants, in tunnels, and above waterways). In some embodiments, the invention produces highly accurate results, resulting in less rework or fewer adjustments to be performed. In some embodiments, the invention provides high-quality surface polishing, for example using a nodule removal tool (which can operate on the track after the main cutting operation has been performed), and / or can include one or more “bent” jets (or “bent jet nozzles”) as described herein.

[0020] In some embodiments, the invention supports at least two types of treatment: surface treatment and refurbishment. Surface treatment can involve removing only the chemical layer (e.g., non-steel or track material), and abrasives are typically not used for such applications. Refurbishment can involve removing the surface layer of the track, and abrasives are typically used for such applications. In some applications, only 0.1-0.2 mm of the track is removed. In other applications, the invention can remove 1.0-2.0 mm of track. Such treatment can help the track continue normal use for another 5-10 years before requiring further repair or replacement. In some embodiments, the cutting head can be positioned anywhere between 0.1 mm and 60 mm away from the track (e.g., 0.1 mm, 0.125”, 0.5”, or 1.5”) for cutting applications. In some other embodiments, the cutting head can be positioned anywhere between 20 and 50 cm away from the track for spraying applications. In some embodiments, a polishing machine (e.g., using sandpaper) can be applied to the track after the cutting head without transferring any substantial heat to the track. In some embodiments, only the inner edges of each track are treated, as the outer edges do not contact the wheels of the track-mounted train and therefore do not need to be treated. In some embodiments, the nozzle diameter (e.g., orifice size) can be selected based on the operation to be performed. For example, orifice sizes of about 0.010” to 0.045”, optionally 0.010 to 0.025”, optionally 0.010 to 0.016”, can be used. In some embodiments, a mixing tube with a diameter approximately two to three times larger than the orifice can be used. Attached Figure Description

[0021] The foregoing discussion will be more readily understood in conjunction with the accompanying drawings, based on the following detailed description of the invention.

[0022] Figure 1A-1BThis is a perspective view of a truck-mounted water jet track treatment system mounted on a track, according to an illustrative embodiment of the present invention.

[0023] Figure 2 This is a close-up perspective view of a truck-mounted water jet rail treatment engagement motion system according to an illustrative embodiment of the present invention;

[0024] Figure 3 This is a perspective view of a positioning mechanism for a water jet track handling system that is dragged during operation after a water jet track moving cutting unit (MCU) according to an illustrative embodiment of the present invention.

[0025] Figure 4 This is a top view of a positioning system for a water jet track MCU mounted on two tracks, according to an illustrative embodiment of the present invention.

[0026] Figure 5 This is a perspective view of a cutting head attached to a positioning system when processing a track, according to an illustrative embodiment of the present invention;

[0027] Figure 6 This is a schematic diagram of water jetting from an MCU processing the track surface according to an illustrative embodiment of the present invention;

[0028] Figure 7A This is a side view of three water jet cutting heads processing a track surface according to an illustrative embodiment of the present invention;

[0029] Figure 7B This is a head-on view of three water jet cutting heads processing the track surface according to an illustrative embodiment of the present invention.

[0030] Figure 7C This is a diagram of track 750 that has undergone processing operations according to an illustrative embodiment of the present invention;

[0031] Figure 8 This is a flowchart of a method for operating an ultra-high pressure liquid injection system according to an illustrative embodiment of the present invention;

[0032] Figure 9A This is an illustration of a curved jet nozzle for a liquid jetting material handling system having two cutting heads with straight nozzles, according to an illustrative embodiment of the present invention.

[0033] Figure 9B This is an illustration of a curved nozzle for a liquid jetting material handling system having a straight nozzle and a curved nozzle, according to an illustrative embodiment of the present invention.

[0034] Figures 10A-10CThis is a diagram illustrating several fluid flow profiles of liquid ejected from nozzles of different liquid jet cutting heads according to an illustrative embodiment of the present invention.

[0035] Figure 11A-11B This is a cross-sectional illustration of a trajectory cutting scheme of several geometries through one or more liquid jets according to an illustrative embodiment of the present invention.

[0036] Figure 12A-12G This is an illustration of several grinding and cutting configurations for processing liquid jets in one or more tracks, according to an illustrative embodiment of the present invention. Detailed Implementation

[0037] Figure 1A-1B This is a perspective view of a truck-mounted waterjet rail handling system (mobile cutting unit or MCU) 100 mounted on track 124 according to an illustrative embodiment of the present invention. As shown, the MCU 100 includes a truck 104, which can be any suitable road-rail vehicle (e.g., based on a Volvo D13). The MCU 100 also includes a power source 108 (e.g., a 185 kVA generator), a fluid supply 112 (e.g., one or more water containers), and an ultra-high pressure water jet system 116 (e.g., an Enduromax or Maxiem pump, as supplied by Hypertherm, Inc.). The power source 108 is capable of generating constant and regular power to power the waterjet cutting components of the water jet system 116 (e.g., enhancers and / or pumps that minimize pressure spikes and drops). The fluid supply 112 can include one or more reservoirs (e.g., having a capacity of at least 1000 liters, such as about 4000 liters) to hold the cutting fluid and can be stored in one or more containers, for example, to be concentrated toward the center of the truck or dispersed throughout the truck for a more uniform weight distribution. The cutting fluid can be purified water, water-jet cutting slurry, or another suitable mixture. The water jet system 116 can be configured to process and / or cut at ultra-high pressure (e.g., about 60,000 PSI). In some applications, the system 100 can mix an abrasive (e.g., garnet) with the supplied fluid, which is then fed into the high-pressure water jet to enhance the cutting and / or processing operation.

[0038] The water jet system 116 includes at least one cutting head (e.g., as shown and described below) to process the track 124. The cutting head may be connected to a pump of the water jet system 116 via a flexible tube or hose to cause movement within the system. In some embodiments, the water jet system 116 is capable of including multiple (e.g., six) cutting heads. The water jet system 116 is also capable of including a hanger, robotic arm, or other positioning mechanism to orient the water jet cutting head relative to (e.g., as shown and described below) the track 124 being serviced. The water jet system 116 is also capable of including a CNC controller (such as those provided by Hypertherm). The system connects to position the cutting head and / or control its processing parameters. Therefore, the present invention can include a platform housing a generator, water jet pump and / or enhancer, cutting head, cutting fluid, abrasive, and controller, all of which are fully operable during movement.

[0039] MCU 100 includes a track engagement motion system 120, which is capable of engaging with and maintaining mechanical contact with track 124. Prior to operation, truck 104 is able to travel as it would normally (e.g., as in...). Figure 2 As shown, the track engagement motion system 200 is in the disengaged position to position itself on the track 124. System 120 can include a nodule removal tool that pulls a cutting head to remove and / or crush any present nodules. This nodule removal tool can be part of the trailing wheel on the positioning mechanism 300 or a separate attachment. During operation, the track engagement motion system 120 can be lowered into position and lift the truck 104 so that the truck tires 128 do not maintain contact with the ground or the track 124 (e.g., as shown in…). Figure 1A (As shown in the diagram). The MCU 100 can then utilize the track engagement motion system 120 to move along the track 124 to move near the track during track processing operations (e.g., cleaning or cutting). Therefore, the MCU 100 can be a self-contained, fully functional, and mobile waterjet cutting system. In some embodiments, one or more components of the system may be mobile, even if they are not directly engaged with the track 124.

[0040] Figure 3This is a perspective view of a positioning mechanism 300 of a waterjet track handling system that is dragged during operation after a waterjet track moving cutting unit (MCU) 304, according to an illustrative embodiment of the invention. The positioning mechanism 300 allows for a large number of independent movements of the cutting head along track 308 without dependence on the movement of the MCU 304 itself. In some embodiments, the positioning mechanism 300 can be included within a trailer 312 (or an attachable vehicle or other suitable moving member) connected to the MCU 304. The trailer 312 can be a hanger-type mechanism that controls the movement of the cutting head. As the MCU 304 pulls (or pushes) the trailer 312 forward, the cutting head processes the track 308. In this configuration, the hanger can move the cutting head while the MCU 304 is in motion (e.g., supplementing the processing operation on the track with movement provided by the MCU 304 itself) or allow the system to be operated in a section-by-section manner (e.g., processing sections of track 308 while the MCU 304 is stationary).

[0041] Figure 4 This is a top view of a positioning system 400 for a waterjet track MCU mounted on two tracks 404A, 404B, according to an illustrative embodiment of the invention. In operation, a mobile truck system (e.g., as shown and depicted above) is positioned on the rails 404A, 404B such that the truck can travel along the tracks 404A, 404B it is processing. The positioning system 400 includes at least one cutting head 408, and once positioned on the tracks 404A, 404B, the cutting head 408 is oriented relative to the tracks 404A, 404B to be processed. A generator supplies power to the waterjet pump and / or enhancer, control mechanisms and / or hangers, and the CNC. The enhancer receives water from a water reservoir and pressurizes the water to ultra-high pressure (e.g., above 20,000 psi), and preferably to about 60,000 psi and / or other high pressures known in the waterjet cutting industry (e.g., about 90,000 psi). Pressurized water is directed through pipe 416 to cutting head 408, where it is mixed with abrasive material (e.g., garnet). As water jet 412 leaves cutting head 408, it cuts or abrades a portion of track 404A.

[0042] Figure 5This is a perspective view of a cutting head 500 attached to a positioning system 504 during processing of a track 508 (via liquid jet 512) according to an illustrative embodiment of the invention. The positioning mechanism 504 can provide controlled movement of the cutting head 500 relative to its frame, moving the jet across and / or along the track 508 in any number of patterns and / or contours. In some embodiments, the movement path of the MCU, the positioning mechanism 504, and / or the cutting head 508 relative to each other (as shown above) are varied or controlled sufficiently to result in a desired cut polished surface, shape, and / or contour on the track 508. In some embodiments, the positioning mechanism 504 controls the cutting head 500 relative to the track 508 it cuts. Such a feature may be important because the tracks may be imprecise and capable of varying widths—for example, they may not be perfectly straight or may only be straight enough or well-positioned enough to support the train. In another embodiment, multiple cutting heads are positioned on the positioning mechanism 504 and moved relative to each other to create multiple contours on the track or to cut on more than one track (e.g., as described in more detail below).

[0043] This invention provides improved positioning and movement for conventional liquid jet cutting heads. Typical cutting heads are movable on a fixed grid (e.g., in the xy direction), but in this invention, an angle adjustment mechanism can be provided to move the liquid jet relative to the track. Such a mechanism offers significant advantages in the case of this invention due to the desired unique angle and proximity to the ground. For example, in typical liquid jet cutting equipment, the width of the cutting head is not critical, but here, there are stricter geometric constraints. For instance, the cutting head needs to be positioned high enough off the ground so that it does not encounter debris on the ground, such as stones or screws rising from the base of the track—but low enough to actually contact the track, and adjustable to contact the track at the desired angle. In equipment comprising multiple cutting heads, the available space for the cutting heads becomes particularly tight, especially if they are positioned low off the ground. For such cases, this invention can include narrower, finer cutting heads.

[0044] Figure 6This is a schematic diagram of water jetting of an MCU 600 processing track surface 604 according to an illustrative embodiment of the invention. As shown, small strips of track 608 (e.g., with surface irregularities) can be removed, leaving a clean, polished surface on track surface 604. In some embodiments, the invention can process more than 500 meters of track per hour. In this way, the use of water jetting can provide significant advantages on grinding trains, which are prohibited in tunnels and near chemical plants when there is a high fire hazard (such as in dry conditions) and in many other situations. Furthermore, some tracks used for freight trains are extremely hard and cannot be reshaped using grinding trains. Water jetting enables the trimming, elimination, or postponement of the need for very expensive replacements of these tracks. In some embodiments, the invention includes a pump, a high-pressure water delivery line, and / or a cutting head positioned on a movable frame to be mounted on or above the track. This platform is then physically connected to a stationary generator or grid or land power or local water supply. During a liquid jet refurbishment and / or reshaping of a track (e.g., cutting and / or removing portions of the track), the distance from the nozzle to the track varies between about 0.1 mm and about 39 mm; generally within the range of about 0.1 mm to about 13 mm; and in some embodiments preferably within the range of about 0.1 mm to about 4 mm. The distance between the tips of the nozzles of the liquid jet cutting head can be selected based on the processing operation being performed. In some embodiments, it is preferred to select the smallest possible distance to minimize liquid jet dispersion in the environment and to have a compact and accurate focus and / or impact point on the track being processed.

[0045] The liquid jet is typically circular as it exits from the nozzle of the water jet cutter head and has a diameter controlled by the mixing tube and / or orifice of the liquid jet cutter head. The diameter of the liquid jet as it exits the nozzle tip is in the range of about 0.005 inches to about 0.120 inches; and optionally in the range of about 0.0075 inches to about 0.045 inches; and optionally in the range between about 0.010 inches and 0.025 inches. In some embodiments, a preferred range is between about 0.010 inches and 0.016 inches. Typically, the mixing tube is about three times the size of the orifice; however, in some embodiments it can be about twice as large. The diameter of the liquid jet stream can be adjusted and / or selected based on the chosen process. The cross-sectional area of ​​the liquid jet at the point of impact and / or focal point on the track is typically in the range of about 0.00002 square inches to about 0.06 square inches; and can be in the range of about 0.00004 square inches to about 0.0016 square inches; and can be in the range of about 0.00008 square inches and 0.0005 square inches. In some embodiments, this range is preferably between about 0.00008 square inches and 0.0002 square inches.

[0046] Figure 7A This is a side view of three water jet cutting heads 704, 708, and 712 processing a track surface 716 according to an illustrative embodiment of the present invention. In this figure, water jet cutting head 704 provides a first water jet 720 that impacts the track surface 716 at a first angle relative to the ground. As the system translates in a left-to-right direction, a second water jet cutting head 708 passes through substantially the same processing area as just contacted by the first water jet 720, and provides a second water jet 724 that impacts the track surface 716 at a second angle relative to the ground. Due to the difference in positioning and angle relative to the track surface 716, the second water jet cutting head 712 removes additional track material. A third water jet cutting head 712 provides a third water jet 728 that impacts the track 716 at a third angle relative to the ground, and due to the difference in positioning and angle, the third water jet 728 again removes additional track material. Figure 7B The details of the impact can be seen in the text. Figure 7B yes Figure 7A Front view of the three water jet cutting heads 704, 708, and 712. Figure 7CThis is an illustration of a track 750 that has undergone a processing operation (e.g., by water jetting shown and described above) according to an illustrative embodiment of the invention. The processed track 750 includes a polished inner edge 754, which is capable of having a reduced height and / or width compared to an unpolished outer edge 758, and is capable of having a smooth, new appearance, free from wear and tear, such as oxidation and surface dings. The following... Figure 11A-11B and Figure 12A-12G Further details of the possible cutting geometries for multiple cutting heads are shown in the figure.

[0047] Figure 8 This is a flowchart of a method 800 for operating an ultra-high pressure liquid jetting system according to an illustrative embodiment of the present invention. In a first step 802, a translational frame having a liquid jetting head fluidly connected to an ultra-high pressure liquid pump is positioned relative to a track. In a second step 804, the liquid jetting head is provided, and pressurized fluid is formed into a liquid jet in contact with the track via the ultra-high pressure liquid pump. In a third step 806, the liquid jetting head is translated relative to the track, thereby performing a processing operation (e.g., shaping, refurbishing, or removing a section of the track) along the linear length of the track in the direction of translation.

[0048] Figure 9A This is an illustration of a curved jet nozzle 904 (collectively referred to as a "curved jet nozzle") for a liquid jetting material handling system having two cutting heads 908, 912 with straight nozzles according to an illustrative embodiment of the invention. Cutting head 908 provides a first water jet 916 departing at a velocity indicated by a first vector v1, while cutting head 912 provides a second water jet 920 departing at a velocity indicated by a second vector v2. The first water jet 916 and the second water jet 920 intersect at an angle 924 to form a velocity indicated by a third vector v. 12 The third water jet 928 is shown as a composite velocity. The third vector v 12The ability to have components based on v1 and v2 causes the third water jet 928 to exhibit different trajectories. The third water jet 928 can contact the track 932 at the contact point or surface 936. This contact enables the achievement of a "lighter contact" and the creation of buffed, polished, or smoothed edges, rather than jagged or skewed edges. For example, as the fluid leaves the cutting heads 908, 912 in the form of a liquid jet, it becomes susceptible to environmental factors including air resistance, turbulence, etc. (which can have a net effect on smoothing on harder edges as a whole). These factors can increase as the fluid jet exits the cutting heads 908, 912 and travels a greater distance away from them. The cutting heads 908, 912 can be mounted to the frame 940 that holds them in place. The jet can have many shapes, such as linear, curved, fan-shaped, or bulging fan shapes, as follows: Figure 10A As shown in -C.

[0049] Figure 9B This is an illustration of another curved nozzle 954 for a liquid jetting material handling system having a straight nozzle 958 and a curved nozzle 962 according to an illustrative embodiment of the present invention. The cutting head 958 provides a first water jet 966 departing at a velocity indicated by a first vector v3, while the cutting head 962 provides a second water jet 970 departing at a velocity indicated by a second vector v4. The first water jet 966 and the second water jet 970 intersect at an angle 974 to form a shape indicated by a third vector v4. 34 The third water jet 978 is shown with a combined velocity. The combined velocity vector v 34 The ability to have components based on v3 and v4 causes the third water jet 978 to exhibit different trajectories, such as those described above. Figure 9AAs shown in the diagram. The third water jet 978 is capable of contacting the track 982 at the contact point or surface 986. As above, this contact enables a “lighter contact” and creates a polished, abraded, or buffed edge, rather than a jagged or skewed edge. In some embodiments, the “bent” water jet nozzle redirects the water jet in a bent manner to reach multiple surfaces of the track (e.g., the side or lower surface of the track) or to impact the workpiece at a specific angle. This configuration can reduce or eliminate debris from the process and / or provide much greater control on the beveling. Cutting heads 958, 962 can be mounted to a frame 990 that holds them in place and / or manipulates them with respect to the track 982. One or more cutting heads (e.g., 962) can be bent to allow for more precise and accurate positioning and to avoid the problem of larger straight cutting heads interfering with each other spatially. The jet can have many shapes, such as linear, curved, or fan-shaped. In one embodiment, the water jet is substantially circular and radially symmetrical (e.g., not a flat spray).

[0050] Figures 10A-10C This is a diagram illustrating several fluid flow profiles of liquid ejected from nozzles of different liquid jet cutting heads according to an illustrative embodiment of the present invention. (As can be seen...) Figure 10A As seen in the diagram, the fluid flowing down the left side of a straight nozzle will have a velocity equal to or approximately equal to that of the fluid flowing down the right side, such that v1 = v2, and the fluid will initially be ejected as a straight jet (because the external air resistance across the jet will be roughly uniform) and will gradually dissipate. However, in a curved nozzle, the fluid flowing down the left side can have a lower velocity than the fluid flowing down the right side because the fluid on the right side undergoes a greater curvature during its journey. In this case, v2 can be greater than v1, and an asymmetry can exist in the external forces (such as air resistance) encountered by the fluid as it leaves the nozzle. As a result, a "fan-shaped" jet can be ejected, such as in... Figure 10B As shown in the example. In some examples, in Figure 10A or Figure 10B The flow profile in the middle can appear linear when viewed from the side, such as in Figure 10C The left side shows the flow profile (1), but local deformation of the nozzle geometry can also cause the profile to bulge, such as in Figure 10C The right side shows the flow profile (2).

[0051] Figure 11A-11B This is a cross-sectional illustration of a trajectory cutting scheme of several geometries through one or more liquid jets according to an illustrative embodiment of the present invention. Figure 11AThe first track 1104 is shown, which is divided into three sections: first, section 1108 is removed; second, section 1112 is removed; and third, section 1116 is removed. In some embodiments, air resistance, turbulence, and other effects can have the overall effect of “smoothing” away these hard lines, as described above. Therefore, continuous cutting can contribute to a smoother polished surface overall. Figure 11B The second track 1140 is shown, which is also divided into three segments by three jets 1150, 1152, and 1554, such as first segment 1160, second segment 1162, and third segment 1164.

[0052] Figure 12A-12G This is an illustration of several refurbishment, reshaping, and / or cutting configurations for handling liquid jetting in one or more tracks, according to an illustrative embodiment of the invention. Figure 12A In the middle, track 1202 (shown in cross-section) receives a jet 1206 at a first angle from the first cutting head 1204 for grinding operations. Figure 12B-12C In this process, the same orbits (shown as 1212, 1222 at different points in time) receive second and third jets 1216, 1226 at second and third angles, respectively, from the second and third cutting heads 1214, 1224 for similar operations. Figure 12D-12F In the process, track 1232 (also shown as 1242, 1252 at different points in time) receives liquid jets 1236, 1246, 1256 from cutting heads 1234, 1244, 1254 and removes track segments 1238, 1248, 1258. Figure 12G In the same track 1260, liquid jets 1264A, 1264B, and 1264C are received from cutting heads 1262A, 1262B, and 1262C. These liquid jets 1264A, 1264B, and 1264C intersect the track for refurbishment operations and are each dispersed in a spray form.

[0053] These configurations are exemplary and illustrate a wide variety of cutting and grinding operations achievable through the invention. In some embodiments, the invention can be used for refurbishment and / or overhaul. For example, in a refurbishment operation, multiple nozzles can be positioned longitudinally, perpendicular to the track, or at another angle relative to the track. In some embodiments, to remove material, the nozzles are positioned close to the track (e.g., so the jet velocity is high and less affected by dissipative forces such as air resistance). In some embodiments, in a polishing operation, the nozzles are positioned further away from the track. In some embodiments, the angle of impact can depend on the force required at impact, which in turn can depend on the operation to be achieved (e.g., severe damage can warrant a different angle than minor damage). In an overhaul operation, to remove unwanted layers from the track, one or more nozzles can be positioned longitudinally relative to the track, for example, as in... Figure 12G Just as the speed of the MCU can vary, the amount of abrasive used can also vary. In some embodiments, to remove very thick and hard layers, the MCU can travel at less than 1 mph (e.g., 0.1-0.5 mph). For less adherent layers, the MCU can travel much faster, for example, up to 25 mph.

[0054] Although the invention has been specifically shown and described with reference to particular preferred embodiments, those skilled in the art will understand that various changes in form and detail may be made herein without departing from the spirit and scope of the invention as defined by the following claims.

Claims

1. A movable, ultra-high pressure liquid injection system for track surface repair or refurbishment operations, the system comprising: A translational frame configured to maintain mechanical contact with the track; A first liquid jet processing head is attached to the frame and configured to maintain a distance from the track and provide a first liquid jet that contacts the track at a first angle relative to the ground. A second liquid jet processing head is attached to the frame and configured to be positioned at a distance from the track and to provide a second liquid jet that contacts the track at a second angle relative to the ground. A third liquid jet processing head is attached to the frame and configured to be positioned at a distance from the track and to provide a third liquid jet that contacts the track at a third angle relative to the ground. An ultra-high pressure liquid pump, in fluid communication with the liquid jet treatment head, is configured to supply pressurized liquid to the liquid jet treatment head. An abrasive supply system, wherein the abrasive supply system is in fluid communication with the liquid jet treatment head; as well as A first nozzle is used to direct a focused stream of water and abrasive from the first liquid jet treatment head onto a first portion of the track for surface repair or refurbishment of the first portion of the track. A second nozzle is used to direct a focused stream of water and abrasive from the second liquid jet treatment head onto a second portion of the track for surface repair or refurbishment of the second portion of the track. as well as A third nozzle is used to direct a focused stream of water and abrasive from the third liquid jet treatment head onto a third portion of the track for surface repair or refurbishment of the third portion of the track.

2. The ultra-high pressure liquid injection system of claim 1, wherein the frame is attached to one or more wheels configured to contact the track.

3. The ultra-high pressure liquid injection system of claim 2, wherein the system is configured to translate along the track via the one or more wheels during track handling operations.

4. The ultra-high pressure liquid injection system according to claim 1, wherein the ultra-high pressure liquid pump is mounted on the frame.

5. The ultra-high pressure liquid injection system according to claim 1, wherein the ultra-high pressure liquid pump is disposed on a unit separate from the frame and is capable of moving independently of the frame and at a different speed than the frame.

6. The ultra-high pressure liquid injection system of claim 1, wherein the system is configured to remove the outer portion of the track having a linear dimension between 0.01 mm and 0.1 mm.

7. The ultra-high pressure liquid injection system of claim 1, wherein the system is configured to remove the outer portion of the track having a linear dimension between 0.1 mm and 1.0 mm.

8. The ultra-high pressure liquid injection system of claim 1, wherein the system is configured to remove the outer portion of the track having a linear dimension between 1.0 mm and 5.0 mm.

9. The ultra-high pressure liquid injection system according to claim 1, further comprising a fourth, fifth, and sixth liquid injection processing head, the fourth, fifth, and sixth liquid injection processing heads being in fluid communication with the ultra-high pressure liquid pump and configured to provide the fourth, fifth, and sixth liquid injections to a second track opposite to the first track at fourth, fifth, and sixth angles respectively relative to the ground plane.

10. The ultra-high pressure liquid injection system of claim 1, wherein the liquid injection processing head is attached to a positioning system attached to the frame, the positioning system being configured to adjustably position the liquid injection processing head relative to the track.

11. The ultra-high pressure liquid injection system of claim 10, wherein the positioning system comprises at least one of a robotic arm or a hanger attached to the frame and is movable independently of the frame.

12. The ultra-high pressure liquid injection system of claim 10, further comprising a second frame configured to engage the track, the second frame being movable relative to the frame during operation of the ultra-high pressure liquid injection system.

13. The ultra-high pressure liquid injection system of claim 12, wherein the second frame includes a liquid reservoir fluidly connected to the ultra-high pressure liquid pump.

14. The ultra-high pressure liquid injection system according to claim 13, wherein the liquid reservoir has a capacity of at least 1000 liters.

15. The ultra-high pressure liquid injection system of claim 12, further comprising a generator disposed on the second frame and operably connected to the ultra-high pressure liquid pump.

16. The ultra-high pressure liquid injection system of claim 12, wherein the liquid injection processing head is configured to process the track as the second frame translates along the track.

17. The ultra-high pressure liquid injection system of claim 1, wherein the ultra-high pressure liquid pump is configured to generate a liquid injection of at least 30,000 PSI for use in track cutting or refurbishment operations.

18. The ultra-high pressure liquid jetting system of claim 1, wherein the ultra-high pressure liquid pump is configured to generate a liquid jet between 200 and 2000 PSI for use in track cleaning operations or surface treatment operations.

19. The ultra-high pressure liquid injection system according to claim 1, wherein at least one of the first angle, the second angle, and the third angle is perpendicular to the track.

20. The ultra-high pressure liquid injection system according to claim 1, wherein the first nozzle, the second nozzle, and the third nozzle are longitudinally spaced apart from each other along the track.

21. The ultra-high pressure liquid injection system according to claim 1, wherein the amount of abrasive supplied by the abrasive supply system is variable.

22. A method for operating an ultra-high pressure liquid injection system, the method comprising: The translational frame, relative to the track-positioned frame, has multiple liquid jetting heads fluidly connected to an ultra-high pressure liquid pump; The pressurized fluid that forms a liquid jet in contact with the track is supplied to the liquid jet processing head via the ultra-high pressure liquid pump; A focused flow of water and abrasive is supplied to the liquid jet processing head from an abrasive supply system in fluid communication with the liquid jet processing head for cutting or abrading a portion of the track, such that a first liquid jet cutting head provides a first flow profile onto the track, a second liquid jet cutting head provides a second flow profile onto the track, and a third liquid jet cutting head provides a third flow profile onto the track. as well as The liquid jetting head is translated relative to the track, thereby performing a processing operation along the linear length of the track in the direction of translation.

23. The method of claim 22, wherein the frame includes one or more wheels configured to engage the track.

24. The method of claim 22, wherein the movement of the ultra-high pressure liquid pump corresponds to the translation of the frame.

25. The method of claim 22, wherein the ultra-high pressure liquid pump is fixedly connected to the frame.

26. The method of claim 22, wherein the ultra-high pressure liquid pump is disposed on a unit separate from the frame and is capable of moving at a different speed than the frame.

27. The method of claim 22, wherein the pressurized fluid during the track cutting or refurbishment operation is at least 30,000 PSI.

28. The method of claim 22, wherein the pressurized fluid is between 200 and 2000 PSI during track cleaning or surface treatment operations.

29. The method of claim 22, wherein the ultra-high pressure liquid pump is included within a second frame, the second frame being movable independently of the frame during operation of the liquid injection system, and the method further comprising translating the second frame at a speed different from that of the frame during operation of the liquid injection system.

30. The method of claim 22, further comprising fourth, fifth, and sixth liquid jet processing heads in fluid communication with the ultra-high pressure liquid pump, and the method further comprising providing pressurized fluid forming fourth, fifth, and sixth liquid jets contacting the track, respectively, to the fourth, fifth, and sixth liquid jet processing heads at fourth, fifth, and sixth angles relative to the ground plane, respectively, via the ultra-high pressure liquid pump.

31. The method of claim 22, further comprising adjusting at least one of the abrasive or speed settings to adjust the polished surface of the track.

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