Loading of granular metal bodies onto freight cars, and related systems, devices, and methods.

Abstract

This specification discloses methods for loading granular metal materials onto freight cars, as well as related systems, devices, and methods. In some embodiments, the apparatus for loading GMU onto a freight car comprises a housing unit, a weighing bin, a weighing bin gate, a hopper, and an articulated chute. When the weighing bin gate is opened, the GMU in the weighing bin is discharged through the weighing bin gate by gravity. The hopper is configured to guide the GMU received from the weighing bin into an articulated chute. The articulated chute is angled and rotatable about the axis of the hopper, and when rotated, the end of the chute approaches the floor of the freight car. In some embodiments, the chute comprises an articulated segment.

Description

[Technical Field]

[0001] [Cross-reference of related applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 581,946, filed on 11 September 2023, entitled “SYSTEM AND METHOD FOR CONTINUOUS GRANULATED PIG IRON (GPI) PRODUCTION,” the disclosure of which is incorporated herein by reference in its entirety. This application relates to the following applications, the disclosures of which are incorporated herein by reference in their entirety: U.S. Patent Application No. [Agent Reference Number 084553.8072.US00], filed September 11, 2024, title "Railcars for Transporting Granulated metallic units, and Associated Systems, Devices, and Methods"; U.S. Patent Application No. [Agent Reference Number 084553.8074.US00], filed September 11, 2024, title "Low-Sulfur Granulated metallic units, and Associated Systems, Devices, and Methods"; U.S. Patent Application No. [Agent Reference Number 084553.8075.US00], filed September 11, 2024, title "Continuous Granulated metallic units Production, and Associated Systems, Devices, and Methods"; U.S. Patent Application No. [Agent Reference Number [084553.8076.US00], filed September 11, 2024, title "Use of a Basic Oxygen Furnace to Produce Granulated metallic units, and associated systems, devices, and methods"; US Patent Application Number [Agent Reference Number 084553.8077.US00], filed September 11, 2024, title "Low-Carbon Granulated metallic units, and Associated Systems, Devices, and Methods"; US Patent Application Number [Agent Reference Number 084553.8078.US00], filed on September 11, 2024, titled "Torpedo Cars for use with Granulated metallic unit PRODUCTION, and Associated Systems, Devices, and Methods"; U.S. Patent Application No. [Attorney Docket No. 084553.8079.US00], filed on September 11, 2024, titled "Treating Cooling Water in Iron Production Facilities, and Associated Systems, Devices, and Methods"; U.S. Patent Application No. [Attorney Docket No. 084553.8080.US00], filed on September 11, 2024, titled "Use of Residual Iron within Granulated metallic unit Production Facilities, and Associated Systems, Devices, and Methods"; U.S. Patent Application No. [Attorney Docket No. 084553.8081.US00], filed on September 11, 2024, titled "Processing Granulated metallic units within Electric Arc Furnaces, and Associated Systems and Methods".

[0002] The present technology relates to systems, apparatuses, and methods for loading granulated metallic bodies onto freight cars.

Background Art

[0003] Granulated Pig Iron (GPI) is a form of pig iron granulated into small, uniform particles, which facilitates handling, transportation, and use in various metallurgical processes compared to conventional pig iron. The demand for GPI is steadily increasing due to its versatility in various industries including automotive, construction, and manufacturing. The growing popularity of GPI can be attributed to its high purity, consistent quality, and the efficiency it brings to the production of steel and other iron-based products.

[0004] Granular pig iron is produced by rapidly cooling molten pig iron with water to form granules. This process, known as granulation, is usually carried out after processing in a blast furnace. [Overview of the project]

[0005] However, current manufacturing methods often feature intermittent production cycles due to various operational constraints, such as the need for regular maintenance, fluctuations in raw material supply, and energy consumption issues. These interruptions not only affect overall efficiency but also lead to increased production costs and variability in product quality. Therefore, there is a need for an improved manufacturing process that can ensure continuous and stable granulation of pig iron, thereby improving productivity and reducing operating costs.

[0006] The features, aspects, and advantages of the technology of this disclosure can be better understood by referring to the following drawings. [Brief explanation of the drawing]

[0007] [Figure 1] This is a schematic block diagram of a continuous granular metal body (GMU) manufacturing system configured according to various embodiments of this technology. [Figure 2] Figure 1 is a plan view of a continuous GMU manufacturing system configured according to an embodiment of this technology. [Figure 3] Figure 2 is an enlarged view of the continuous GMU manufacturing system. [Figure 4] This is a schematic diagram of a system for mounting a GMU on one or more freight cars, configured according to an embodiment of this technology. [Figure 5] This is a partial schematic diagram of a system for mounting a GMU on one or more freight cars, configured according to an embodiment of this technology. [Figure 6] This is a partial schematic side view of a joint device configured according to an embodiment of the present technology. [Figure 7] This is a partial schematic side view of a joint device configured according to a further embodiment of the present technology. [Figure 8A] This is a partial schematic side view of an expandable / contractable device in a contracted state, configured according to an embodiment of this technology. [Figure 8B] This is a partial schematic side view of the telescopic device of Figure 8A in its extended state, configured according to an embodiment of this technology. [Figure 9] This is a partial schematic side view of a telescopic joint device configured according to an embodiment of the present technology. [Figure 10] This is a flowchart illustrating a method for mounting a GMU onto a freight car via an articulated device, configured according to an embodiment of this technology. [Figure 11] This is a flowchart illustrating a method for mounting a GMU onto a freight car via an expandable device, configured according to an embodiment of this technology. [Figure 12] This is a flowchart illustrating a method for mounting a GMU onto a freight car via articulated and telescopic devices configured according to an embodiment of this technology. [Modes for carrying out the invention]

[0008] Those skilled in the art will understand that the features shown in the drawings are for illustrative purposes only, and that variations therein, including different and / or additional features and arrangements, are possible.

[0009] I. overview This technology generally relates to the loading of granular metal materials (GMUs) onto freight cars, as well as related systems, devices, and methods. GMUs (i.e., multiple particles) can be low-carbon granulated iron (GI) and / or GPI. Conventional techniques for loading various industrial products (e.g., GPI) onto freight cars typically require lowering the products from a considerable height into the container compartments of the freight cars. Due to the relatively high density and weight of granulated industrial products, and the significant descent of these products, such loading can cause strong impacts on the interior of the freight cars, leading to rapid wear and erosion of the interior. This not only compromises the structural integrity of the freight cars but also increases maintenance costs and downtime, impacting operational efficiency and profitability, and even the lifespan of the freight cars. These effects worsen over time and can be particularly problematic for vehicles expected to be used for extended periods. Embodiments of this technology address at least some of these problems, in particular, by providing an articulated chute configured to reduce the force with which a GMU impacts a freight car. For example, in some embodiments, the articulated chute is configured to rotate about an axis of a hopper located above the chute, and the rotation brings the end / exit of the chute closer to the floor of the freight car. This lowers the height from which the GMU begins to freefall from the chute onto the freight car, shortens the time the GMU freefalls, and ultimately reduces the speed and force with which the GMU impacts the freight car. In some embodiments, the articulated chute is angled with respect to the direction of gravity and / or based on the angle of repose of the GMU. The angle of the articulated chute reduces the falling speed of the GMU as it passes through the chute, ultimately reducing the impact speed and force on the freight car. In some embodiments, the articulated chute includes one or more telescopic features and / or segments, which, when extended, bring the end / exit of the chute closer to the floor of the freight car, reducing the impact speed and force on the GMU. In some embodiments, the articulated chute includes one or more baffle elements inside the chute, which obstruct the descent of the GMU through the chute, ultimately reducing the impact force and impact velocity.

[0010] For example, in some embodiments, the technology discloses a device for loading GMU onto a freight car comprising a housing unit, a weighing bin and a weighing bin gate, a hopper positioned to receive GMU from the weighing bin through the weighing bin gate, and an articulated chute coupled to the hopper and positioned to receive GMU from the hopper. The housing unit defines the structure of the device by housing the weighing bin, weighing bin gate, hopper, and articulated chute. The weighing bin is configured to weigh and / or measure a predetermined amount of GMU. The GMU in the weighing bin can be discharged through the weighing bin gate by gravity when the weighing bin gate moves from a closed position to an open position. The hopper includes an inlet of a first diameter for receiving GMU discharged from the weighing bin and an outlet of a second diameter smaller than the first diameter, the outlet configured to guide the GMU received at the inlet to the articulated chute. The articulated chute is angled (for example, based on the angle of repose of the GMU) and coupled to the hopper. The chute can rotate further around the hopper's axis, and rotating it from the first position to the second position brings the end of the chute closer to the floor of the freight car.

[0011] GMU production systems are designed for continuous operation. Compared to discontinuous GPI production systems, embodiments of this technology often improve energy efficiency and reduce emissions by minimizing the need for frequent stop-and-start cycles associated with excessive exhaust and / or inefficient operation. As described herein, some embodiments include (i) a desulfurization unit that reduces sulfur dioxide (SO2) emissions by lowering the sulfur content in the molten metal; (ii) a dust collection unit that filters particulate matter to reduce air pollution; (iii) infrastructure that reduces the environmental impact associated with raw material extraction and conserves natural resources by recycling fine powder, slag, scrap iron, and other residual / previously processed iron; and / or (iv) a water management and cooling system that minimizes heat loss, improves the thermal efficiency of the production process, and optimizes water consumption. Overall, continuous GMU production systems improve productivity while minimizing greenhouse gas emissions and waste, contributing to more sustainable industrial practices and helping to mitigate climate change.

[0012] Related to this, conventional iron production has a significant impact on the environment due to its high energy consumption and emission of pollutants. Therefore, embodiments of this technology relating to GMU production systems can mitigate this impact. Sulfur, phosphorus, and silicon in GPI adversely affect the quality and properties of the final metal product, causing problems such as reduced ductility, toughness, and weldability, as well as surface defects and brittleness. These impurities also contribute to the formation of non-metallic inclusions and excess slag, complicating metal processing and impairing product quality. In particular, sulfur accelerates wear and corrosion of metal processing equipment, increasing maintenance costs and shortening the lifespan of the equipment. Embodiments of this technology include methods for partially removing these impurities, improving the quality and durability of the final metal product, increasing the efficiency and lifespan of processing equipment, and leading to cost reductions and a more sustainable production method.

[0013] In the drawings, identical reference numbers generally indicate similar and / or identical elements. Many of the details, dimensions, and other features shown in the figures are merely illustrative of specific embodiments of the disclosed technology. Accordingly, other embodiments may have other details, dimensions, and features without departing from the spirit or scope of the present disclosure. Furthermore, those skilled in the art will appreciate that further embodiments of the various disclosed technologies may be practiced without several of the details described below.

[0014] II. Embodiments of a Continuous Granular Metal Production System Figure 1 is a schematic block diagram of a continuous GMU manufacturing system 100 ("system 100") configured in accordance with various embodiments of the present technology. As described elsewhere herein, the GMU may include granular iron (GI), granular pig iron (GPI), granular steel (GS), or a GMU. Relatedly, the molten metal can include molten pig iron or molten steel. As used herein, the term "continuous" should be construed to mean a continuous operation cycle of at least 4 hours, 6 hours, 8 hours, 10 hours, 12 hours, 16 hours, 20 hours, or 24 hours, including batch or semi-batch operations. The system 100 can include a furnace unit 110, a desulfurization unit 120, a granulator unit 130 including a first granulator unit 130a and a second granulator unit 130b, and a cooling system 140. The furnace unit 110 can receive input materials (e.g., iron ore, coke, limestone, and / or preheated air) and / or recycled materials, which can be sourced from downstream components of the system 100, as described in further detail herein. The following equations (1) to (6) detail some of the chemical processes controlled in the furnace unit.

[0015] [Mathematical formula]

[0016] Equation (1) represents the combustion of coke, which is a form of carbon. When coke reacts with oxygen gas introduced into the furnace (for example, via an oxygen lance), carbon dioxide is generated. This exothermic reaction releases a considerable amount of heat, which is essential for maintaining the high temperature required for subsequent reactions. The carbon dioxide generated in Equation (1) further reacts with additional coke as shown in Equation (2) to produce carbon monoxide. This endothermic reaction helps to regulate the temperature within the furnace unit 110. Equations (3) and (4) represent the reduction of iron ore bodies (Fe₂O₃). As shown in Equation (3), iron oxide reacts with the carbon monoxide generated in Equation (2), acting as a reducing agent to convert iron ore into iron and producing carbon dioxide as a by-product. Alternatively, as shown in Equation (4), iron ore may be directly reduced by coke, but this is less common. Equations (5) and (6) represent the formation of slag. As shown in Equation (5), calcium carbonate / limestone (CaCO₃) can decompose into calcium oxide and carbon dioxide at the high temperature of the furnace unit 110. As indicated by Equation (6), calcium oxide can then react with silica (SiO₂), which is an impurity in iron ore, to form calcium silicate (CaSiO₃), also known as slag. The furnace unit 110 can output molten iron (from Equations (3) and (4)) and slag (from Equations (5) and (6)).

[0017] In some embodiments, input materials (for example, coke, iron ore, and / or limestone) contain sulfur, which may remain in the molten iron output by the furnace unit 110. The torpedo car 102 or other transfer vessel can transfer the molten iron from the furnace unit 110 to the desulfurization unit 120. The desulfurization unit 120 may include equipment for reducing the sulfur content of the molten iron. For example, one or more lances may be used to deliver magnesium (Mg), calcium carbide (CaC₂), or other sulfur reducing agents to the molten iron. In some embodiments, the molten iron is desulfurized while remaining inside the torpedo car 102. Equations (7) and (8) below detail the reactions between sulfur and the sulfur reducing agents.

[0018]

number

[0019] The resulting substance, containing magnesium sulfide (MgS) and calcium sulfide (CaS), is not soluble in molten iron and is therefore in a solid form (e.g., as solid particles) that can be more easily removed in the desulfurization unit 120 and / or further downstream. As further described herein, reducing the sulfur content improves the quality of the GMU product and / or allows the manufacturing process to be carried out continuously. After the desulfurization process, the torpedo car 102 can transfer the molten iron from the desulfurization unit 120 to the granulator unit 130. In some embodiments, as indicated by dashed arrows, the desulfurization unit 120 is bypassed and the molten iron is transferred directly from the furnace unit 110 to the granulator unit 130. In particular, conventional equipment may not include a desulfurization unit or may lack the ability to desulfurize molten iron. One reason for this is that conventional steelmaking facilities feed molten iron directly from the blast furnace to the oxygen converter and only choose to granulate the molten iron when the oxygen converter is shut down. Since GPI production is a backup operation for such facilities, the complexity and cost associated with installing desulfurization equipment may not be economically viable.

[0020] In some embodiments, the temperature of the molten iron is within a predetermined range before it reaches the granulator unit 130. For example, maintaining the molten iron in a sufficiently fluid state helps to better ensure the formation of uniform granules and avoid premature solidification, which can result in irregular granule shape and size. In some embodiments, the system includes one or more heaters 115 before and / or after the desulfurization unit 120, for example, to reheat the molten iron in the torpedo car 102. For example, if the temperature of the molten iron falls below a temperature threshold, the heaters 115 can be used to raise the temperature of the molten iron in the torpedo car 102 to a desired temperature range. The temperature threshold may vary between different compositions and may be 2300-2500°F, 2300-2400°F, or 2340-2350°F. In some embodiments, the heaters 115 include one or more oxygen lances.

[0021] The torpedo car 102 can transfer molten iron to one of the granulator units 130. Figure 1 shows two granulator units 130, but it should be understood that the system 100 can comprise one, three, four, five, six, or more granulator units 130. Each granulator unit 130 may comprise a granulator reactor that receives molten iron, granulates it, and forms a granulated product. For example, the granulator reactor may include a cavity that holds water, and the molten iron can be transferred (e.g., poured, sprayed) onto the object in the granulator reactor that holds the water. The water can be kept at a sufficiently low temperature by a cooling system 140 (e.g., directly cooled by pumping water between the granulator unit 130 and the cooling system 140, or indirectly cooled by pumping a coolant separate from the water that receives the molten iron). In some embodiments, each granulator unit 130 includes one or more components for controlling the flow of molten iron from the torpedo car 102 to the granulator. As those skilled in the art will understand, flow control can affect the shape, size, and quality of the granulated product. The granulator unit 130 may also be equipped with a dehydrator for drying the granulated product from the granulator to output GMU. The granulator unit 130 may further be equipped with a classifier for filtering the filtrate from the dehydrator to output fine granules.

[0022] System 100 may further include a product processing unit 150 that receives GMU output from granulator unit 130 (e.g., by a dewatering unit) and a loadout 155 downstream of product processing unit 150. Additionally, system 100 may further include a particulate processing unit 160 that receives particulates output from granulator unit 130 (e.g., a classifier) ​​and a loadout 165 downstream of particulate processing unit 160. In some embodiments, product processing unit 150 and / or particulate processing unit 160 each include one or more conveyor belts, diverters, storage areas, etc. System 100 may further include a torpedo preparation unit 170 that can remove slag and / or quiche from torpedo car 102. For example, after delivering molten iron to granulator unit 130, torpedo car 102 may proceed to torpedo preparation unit 170 to be washed or prepared for the next cycle of transferring molten iron. The removed slag can then be transferred to a slag processor 175. The system 100 may further include a scrap storage 180 that can receive flaky pig iron and / or iron skulls from the granulator unit 130.

[0023] As shown in Figure 1, fine particles from Load 165, slag and / or iron from Granulator Unit 130, and / or flaky pig iron and / or iron skulls from Scrap Storage 180 can be fed back to Furnace Unit 110 as recycled material. In some embodiments, the recycled material is processed (e.g., pelletized) before being supplied to Furnace Unit 110. Furthermore, waste from various components of System 100 can be collected and led to dust collection units 190 (e.g., baghouse, screw bar, etc.). In Figure 1, for example, waste from the desulfurization unit 120 and Granulator Unit 130 is led to a first dust collection unit 190a, and waste from the torpedo preparation unit 170 is led to a second dust collection unit 190b. Each dust collection unit 190 can filter the waste to remove dust and send the clean exhaust gas to a chimney (not shown) for release into the atmosphere, and lead the removed dust to further processing.

[0024] Figure 2 is a plan view of the continuous GMU manufacturing system 100. The plan view shown in Figure 2 is merely an example, and it will be understood that the components of system 100 can be arranged differently in other embodiments. As shown, system 100 may further include an electrical building 202 and a power generation unit 204 for supplying power to system 100. As will be further described herein, one or more components of system 100 may be powered electrically, as opposed to hydraulically, for example. The furnace unit 110 may be located away from many of the other components of system 100. A torpedo car 102 or other transfer vessel (not shown) can transfer molten iron from the furnace unit 110 to the desulfurization unit 120 along a path indicated by a dashed line.

[0025] Referring to Figure 3, an enlarged plan view of system 200, the desulfurization unit 120 can desulfurize the molten iron while it remains in the torpedo car 102. Once the molten iron is desulfurized, the torpedo car 102 can proceed along its track to the granulator unit 130. The torpedo car 102 can deliver the molten iron to either the first granulator unit 130a or the second granulator unit 130b, for example, depending on the availability of each granulator unit 130. The GMU produced by each granulator unit 130 can be transported downstream via one or more conveyor belts that form part of the product processing unit 150. The fine particles produced by each granulator unit 130 can be transported to a fine particle bunker located adjacent to the granulator unit 130 and finally sent to the loadout(s) 165. As shown in Figure 3, the first dust collection unit 190a is connected via pipes to the desulfurization unit 120 and the granulator unit 130, respectively, and can collect waste from them.

[0026] Returning to Figure 2, the cooling system 140 is positioned adjacent to the granulator unit 130 and can cool the granulator unit 130 as needed. The product processing unit 150 may include a storage area 252 for storing the GMU product. One or more conveyor belts may extend between each of the granulator units 130 and the storage area 252, and between the storage area 252 and the loadout 155. In some embodiments, the loadout 155 includes a building from which a desired amount of GMU can be measured and transported to a freight car or other transport vehicle. In some embodiments, the GMU is then transported to an electric arc furnace (not shown) for steel production. The torpedo car 102 may proceed along a track to a torpedo preparation unit 170 after delivering molten iron to the granulator unit 130. As described above with reference to Figure 1, the torpedo preparation unit 170 can facilitate the removal of slag and / or quiche from the torpedo car 102. The second dust collection unit 190b can be connected to the torpedo preparation unit 170 via a pipe to collect the waste generated therefrom.

[0027] Referring to Figures 1 to 3, it is expected that system 100, unlike conventional GMU production systems, can continuously produce GMU. Firstly, the inclusion of a desulfurization unit 120 offers several advantages. For example, GMU with a low sulfur content produces less slag when melted in a downstream electric arc furnace, saving associated time, cost, and energy consumption. Also, using GMU with a low sulfur content makes it easier to maintain the desired chemical composition and temperature, potentially reducing the frequency of adjustments and interruptions during the melting cycle. Lower sulfur levels may also reduce wear and damage to other components of the system, potentially reducing the need for maintenance and associated downtime.

[0028] Secondly, by providing multiple granulator units 130, molten iron can be granulated in parallel in different granulator units. The granulator units 130 can also function as backups for each other if one of the granulator units 130 is down (for example, due to a component malfunction, maintenance, etc.). Furthermore, in some embodiments, the various components of the granulator unit 130 are modular. For example, each component can be easily and independently removed (for example, for maintenance) and / or replaced (for example, via an overhead crane) without affecting the operation of other components.

[0029] III. System and method for mounting a GMU on a freight car Figure 4 is a schematic diagram of a system 400 for loading GMUs onto one or more freight cars, configured according to an embodiment of the present technology. In some embodiments, one or more components of system 400 are substantially the same as / identical to the loadout 155 described with reference to Figure 1. For example, system 400 comprises a conveyor mechanism 408 (also called an inclined conveyor) and a housing unit 406. The housing unit 406 is composed of various components (further described with reference to Figures 5 to 9) for measuring a desired amount of GMUs before transferring them to one or more freight cars 402. In some embodiments, system 400 further comprises a freight car moving mechanism 404 (e.g., a freight car moving device) configured to move one or more freight cars 402 during loading.

[0030] In some embodiments, the conveyor mechanism 408 is inclined to provide a GMU to components in a housing unit 406 positioned above one or more freight cars 402. In some embodiments, the inclined conveyor 408 comprises multiple chevron-shaped conveyor segments that enhance the gripping and movement of the GMU along the path of the inclined conveyor 408, prevent slippage, and ensure consistent flow of material. In some embodiments, the conveyor segments are reinforced with a hardened material (e.g., a cladding plate, protective plate, etc.) and / or composed of one or more of the following materials: carbon steel, wear-resistant (AR) steel, Hardox®, polyurethane, silicon carbide, tungsten carbide, titanium alloy, etc. The reinforcing cladding plate and / or wear-resistant composition of the conveyor segments provides durability and strength to withstand erosion and wear by the GMU.

[0031] In some embodiments, the inclined conveyor 408 includes one or more catch trays 409 positioned at selected locations below the inclined conveyor 408. The catch trays 409 collect all GMU that may fall from the conveyor during transport, preventing material loss and maintaining a clean and safe working environment. The catch trays 409, like the conveyor segments, may be reinforced and / or constructed with hardened material.

[0032] Figure 5 is a partial schematic diagram of a system 500 for loading GMUs onto one or more freight cars 502, configured according to an embodiment of the present technology. In some embodiments, system 500 includes features that are generally similar to / identical to those of system 400 in Figure 4. As shown in Figure 5, a housing unit 506 contains various components for weighing the GMUs to determine the required quantity and for guiding the GMUs onto one or more freight cars 502. A conveyor 508 is configured to transport the GMUs to the upper region of the housing unit 506 and discharge the GMUs into a surge bin 520 and a weighing bin 530, both of which are coupled to the housing unit 506. The surge bin 520 is located above the weighing bin 530 and is configured to function as a buffer and / or surge capacity to collect excess GMUs that accumulate in the weighing bin 530. A surge bin inlet 521 collects the GMUs from the conveyor 508 and sends them to a surge bin outlet 522 located below the inlet 521. In some embodiments, the surge bin 520 is shaped based on the angle of repose of the product (e.g., GMU, GPI, etc.) loaded onto the freight car. That is, the surge bin 520 may be shaped such that an angle is formed between the body of the surge bin 520 and the plane of the surge bin inlet 521 and / or surge bin outlet 522. Shaping the surge bin 520 based on the angle of repose helps prevent the undesirable accumulation of the product within the surge bin 520. In some embodiments, the angle may be in the range of 15–30 degrees, 30–45 degrees, 45–60 degrees, 60–75 degrees, or 75–90 degrees with respect to the plane of the surge bin inlet 521 and / or outlet 522, or at least 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, or 85 degrees, or any increment between them (e.g., at least 33 degrees). In some embodiments, the angle of repose can be measured using one or more methods, such as an inclined box (e.g., slowly inclining the box until a large amount of product begins to slide through and measuring the inclination angle), a fixed funnel (e.g., pouring the product through a funnel to form a cone), or a static or rotating cylinder (filling a cylinder with the product and measuring the angle of the product relative to the walls of the cylinder).A surge bin gate 524 (e.g., a clamshell gate, a slide gate, etc.) is located below the surge bin outlet 522 and can move between a closed position in which the GMU is held within the surge bin 520 and an open position located below the surge bin gate 524 in which the GMU is discharged into the weighing bin 530 (through the surge bin outlet 522) by gravity.

[0033] In some embodiments, the measuring bin 530 is configured to receive GMU at the measuring bin inlet 531, collect the GMU, and guide it to the measuring bin outlet 532. In some embodiments, the measuring bin 530 is shaped based on the angle of repose of the product (e.g., GMU, GPI, etc.) loaded onto the freight car. That is, the measuring bin 530 may be shaped such that an angle is formed between the body of the measuring bin 530 and the plane of the measuring bin inlet 531 and / or the measuring bin outlet 532. Shaping the measuring bin 530 based on the angle of repose helps prevent undesirable accumulation of the product within the measuring bin 530. In some embodiments, the angle may be in the range of 15–30 degrees, 30–45 degrees, 45–60 degrees, 60–75 degrees, or 75–90 degrees with respect to the plane of the measuring bin inlet 531 and / or outlet 532, or at least 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, or 85 degrees with respect to the measuring bin inlet 531 and / or outlet 532, or any increment between them (e.g., at least 33 degrees).

[0034] A weighing bin gate 534 (e.g., a clamshell gate, a slide gate, etc.) is located below the weighing bin outlet 532. The weighing bin gate 534 can move between a closed position in which the GMU is held within the weighing bin 530 (e.g., for measuring the weight of the GMU and / or verifying whether the weight of the GMU meets the target weight of the GMU) and an open position in which the GMU is ejected through the weighing bin gate 534 by gravity.

[0035] In some embodiments, the hopper 540 is configured to receive the GMU discharged through the weighing bin gate 534 at the hopper inlet 541, which collects the GMU and leads it to the hopper outlet 542 located below the hopper inlet 541. In some embodiments, the hopper inlet 541 has a first diameter (see D1 in Figure 6), and the hopper outlet 542 has a second diameter smaller than the first diameter D1 (see D2 in Figure 6). The hopper outlet 542 discharges the GMU into the chute 550.

[0036] The chute 550 is configured to receive the GMU discharged through the hopper outlet 542 and guide the GMU to a freight car 502 located below the chute 550 (for example, the floor of the freight car 502). In some embodiments, the chute 550 is equipped with an articulation mechanism, which is further described with reference to Figures 6, 7, and 9, and is rotatable relative to the hopper 540 on an axis. In some embodiments, the chute 550 is equipped with an extension mechanism, which is further described with reference to Figures 8A-89. Some embodiments are equipped with both an extension mechanism and an articulation mechanism, which are further described with reference to Figure 9.

[0037] In some embodiments, the system 500 may include a freight car moving mechanism 504 configured to move one or more freight cars 502 while the GMU is being loaded. For example, the freight car moving mechanism 504 may be a freight car moving device.

[0038] In some embodiments, the controller 560 controls the operation of one or more components of the system 500. For example, the controller 560 can control the operation (e.g., open and closed positions) of the metering bin gate 534 and surge bin gate 524, as well as the rotation and / or extension and retraction of the chute 550. In some embodiments, the controller 560 can be configured to interface with a user and / or to coordinate the operation of the system 500. In some embodiments, the controller 560 comprises one or more hardware and software components for controlling the operation of the system 500. For example, the controller 560 may comprise one or more processors (e.g., multiple central processing units (CPUs), multiple graphics processing units (GPUs), multiple holographic processing units (HPUs), etc.), and memory (e.g., volatile storage, non-volatile storage) for storing instructions executed by one or more processors. The controller 560 may comprise one or more controllers, one or more controller circuits, etc., or a combination thereof, or in such forms. Examples of controllers may include microcontrollers, programmable logic controllers (PLCs), digital signal controllers (DSCs), motor controllers, or combinations thereof.

[0039] During operation, the conveyor 508 transports the GMU to the upper region of the housing unit 506, where it discharges the GMU into the surge bin 520. The surge bin 520 collects the GMU and guides it through the surge bin inlet 521 to the surge bin outlet 522. If the surge bin gate 524 is open, the GMU passes through the surge bin outlet 522 and the surge bin gate 524 to the weighing bin 530. If the surge bin gate 524 is closed, the GMU is collected in the surge bin 520 and held there until the surge bin gate 524 is opened. Once the GMU has passed through the surge bin 520, the weighing bin 530 receives the GMU at the weighing bin inlet 531 and guides it to the weighing bin outlet 532. The weighing bin gate 534, located below the weighing bin outlet 532, is held in the closed position so that the GMU can be collected in the weighing bin 530. While in the weighing bin 530, the weight of the GMU in the weighing bin 530 can be measured and / or determined. In some embodiments, when the weight of the GMU reaches a target weight of GMU (representing the desired amount of GMU to be discharged into the freight car 502), the weighing bin gate 534 moves to the open position, allowing gravity to discharge the GMU over the weighing bin gate 534. In some embodiments, the surge bin gate 524 is closed before measuring and / or determining the weight of the GMU in the weighing bin 530 to assist in accurate weight measurement. In some embodiments, the surge bin gate 524 is closed after measuring and / or determining the weight of the GMU to prevent unwanted GMU from leaking from the surge bin 520 and / or weighing bin 530 into the freight car 502.

[0040] The hopper 540 receives the GMU discharged from the weighing bin 530 at the hopper inlet 541 and guides the GMU to the hopper outlet 542. The chute 550 receives the GMU from the hopper outlet 542 and guides the GMU to the freight car 502. In some embodiments, during the loading process, the freight car moving mechanism 504 repositions the freight car 502 to ensure uniform distribution of the GMU load.

[0041] The described apparatus offers several advantages for loading GMUs onto freight cars. The surge bin 520, surge bin gate 524, weighing bin 530, and weighing bin gate 534 ensure accurate measurement and controlled discharge of GMUs, reducing spills and waste, and ensuring that the desired amount of GMU is discharged into the freight car 502. The surge bin 520 acts as a buffer and / or surge capacity for the weighing bin 530, maintaining a stable supply of GMUs to the weighing bin 530, enabling accurate weighing and efficient discharge. The tapered shape of the hopper 540 ensures a smooth and consistent discharge of GMUs from the weighing bin 530 to the chute 550. The shape of the hopper 540 further reduces the speed and / or force of the GMUs as they are discharged from the weighing bin 530. Chute 550 further reduces the speed and / or force at which the GMU is discharged into freight car 502 by positioning the GMU to descend at an angle and to be close to the floor of freight car 502 after it exits chute 550.

[0042] Figure 6 is a partial schematic side view of an articulated device 600 according to some embodiments of the present technology. In these embodiments, the articulated device 600 comprises a hopper 640 and an articulated chute 650. The hopper 640 includes a hopper inlet 641 with a first diameter D1 and a hopper outlet 642 with a second diameter D2, configured to guide the GMU into the chute 650. In some embodiments, D2 is less than D1. In some embodiments, the hopper 640 is shaped based on the angle of repose of the product (e.g., GMU, GPI, etc.) loaded onto the freight car. That is, the hopper 640 can be shaped such that an angle R1 is formed between the body of the hopper 640 and the planes of the hopper inlet 641 and / or hopper outlet 642. Shaping the hopper 640 based on the angle of repose helps prevent the product from accumulating in the hopper 640. In some embodiments, the R1 angle may be in the range of 15–30 degrees, 30–45 degrees, 45–60 degrees, 60–75 degrees, or 75–90 degrees with respect to the plane of the hopper inlet and / or outlet 642, or it may be at least 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, or 85 degrees with respect to the hopper inlet and / or outlet 642, or any increment between them (e.g., at least 33 degrees).

[0043] The chute 650 guides the GMU into a freight car (e.g., any of the one or more freight cars described throughout this specification) and is configured to articulate and / or rotate about axis A of the hopper 640 so that the chute is in an elevated or lowered position. That is, in some embodiments, the chute 650 can rotate in a first (e.g., elevated) direction 655a such that the longitudinal plane P of the chute 650 is substantially perpendicular to the direction of gravity G, and the end section 652 (also called the end portion) is at a first height H1 relative to the floor 603 of the freight car. The chute 650 can also rotate in a second (e.g., lower) direction 655b such that the chute 650 is at an angle R2 with respect to plane P when the end section 652 is positioned at a second height H2 closer to the floor 603 of the freight car. In some embodiments, the second direction 655b may result in the end section 652 being positioned below the plane of the freight car side wall 601.

[0044] In some embodiments, the angle R2 of the chute 650 is based on the angle of repose of the products (GMU, GPI, etc.) loaded onto the freight car. In some embodiments, the angle R2 may be in the range of 15–30 degrees, 30–45 degrees, 45–60 degrees, 60–75 degrees, or 75–90 degrees with respect to the longitudinal plane P, or it may be at least 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, or 85 degrees with respect to the longitudinal plane P, or any increment between them (e.g., at least 33 degrees). Angling the chute 650 helps prevent unwanted accumulation of products within the chute 650, reduces the speed and / or force at which products exit the chute 650, and ultimately reduces the impact force exerted by the products on the freight car.

[0045] In some embodiments, the chute 650 is coupled to an end section 652 and includes a chute gate 654 distal to the hopper 640. The chute gate 654 is movable between a closed position 656a and an open position 656b. The chute gate 654 prevents GMU unintentionally leaking from the weighing bin and / or surge bin (further described with reference to Figure 5) from exiting the chute 650, maintaining the safety of personnel below the chute 650 and mitigating undesirable spills or product loss.

[0046] In some embodiments, the chute 650 is constructed of a rigid material such as steel, other metals / metal alloys, and polyurethane to improve the durability of the chute 650. In some embodiments, the chute 650 is made of a flexible material. In such embodiments, the chute 650 can remain stationary when the freight cars are pulled away after being loaded, and simply slides away from the freight cars based on the movement of the freight cars away from the chute 650.

[0047] The advantages of the disclosed articulated chute 650 include positioning the end section 652 closer to the floor 603 of the freight car compared to conventional technology. Lowering the end section 652 relative to the floor 603 substantially reduces the speed and force at which the GMU impacts the floor 603 of the freight car. This minimizes damage to the freight car and extends its lifespan. Angling the chute 650 (e.g., angle R2) further slows the discharge of the GMU through the chute 650, ensuring that the GMU exits the chute at a relatively low speed, reducing the impact force on the floor 603 of the freight car.

[0048] Figure 7 is a partial schematic side view of a joint device 700 according to a further embodiment of the present technology. In some embodiments, the joint device 700 includes features similar to or identical to those of the joint device 600 in Figure 6. Thus, similar numbers refer to similar functions.

[0049] One of the main differences between the articulated chute 700 and the articulated chute 600 is the inclusion of one or more baffle elements 751 along at least a portion of the interior of the articulated chute 750. The baffle elements 751 are configured to at least partially interrupt the flow of GMU through the articulated chute 750, thereby reducing the velocity and / or force of the GMU as it exits the chute 750, and ultimately preventing / reducing damage to the freight car (e.g., the floor of the freight car 703). In some embodiments, the baffle elements 751 are made of hardened materials such as carbon steel, abrasion-resistant (AR) steel, Hardox®, polyurethane, silicon carbide, tungsten carbide, or titanium alloy. In some embodiments, the baffle elements 751 are made of flexible materials such as rubber. In some embodiments, the baffle elements 751 are arranged in a staggered pattern. In some embodiments, the baffle elements 751 are made of deflection plates and / or deflection belts. In some embodiments, the baffle element 751 comprises one or more trays or boxes (also called “lock boxes”) configured to hold material, so that each tray or box has an open top and can be filled with granular material such as GMU, GI, GPI, GS, aggregate locks, etc. As the GMU passes through the chute 750, it collides with one or more granular layers in the lock boxes, slowing and / or stopping the descent of at least a portion of the GMU. In some embodiments, one or more boxes are initially empty (e.g., without a layer of granular material), and the first portion of the GMU passing through the chute 750 is trapped in the boxes, forming a layer of granular material, which then slows or stops the descent of at least a portion of the other GMU passing through the chute 750. Those skilled in the art will understand that the baffle element 751 can be configured in a variety of shapes, materials, and arrangements.

[0050] Figure 8A is a partial schematic side view of the telescopic device 800 in the retracted state 857a, configured according to an embodiment of the present art. Figure 8B is a partial schematic side view of the telescopic device of Figure 8A in the extended state 857b, configured according to an embodiment of the present art. In some embodiments, the telescopic device 800 includes features that are generally similar to or identical to those of the joint device 600 of Figure 6. Thus, similar numbers refer to similar functions.

[0051] Referring together to Figures 8A and 8B, in this embodiment the telescopic device 800 has a hopper 840 having a hopper inlet 841 and a hopper outlet 842 located below the hopper inlet 841. The hopper 840 is configured to receive GMU at the inlet 841 and guide the GMU to the telescopic chute 850. The telescopic chute 850 consists of one or more telescopic segments 858a to d, each telescopic segment configured to extend away from the hopper 840. That is, each of the telescopic segments 858a to d is configured to extend from a first position 857a to a second position 857b, with the first position 857a being closer to the hopper 840 than the second position 857b, and the first position 857a being further from the floor 803 of the freight car than the second position 857b. Therefore, when the telescopic segments 858a to d are extended, the end portion 852 of the chute 850 is positioned closer to the floor 803. In some embodiments, the telescopic chute 850 has a first length L1 when the telescopic segments 858a-d are retracted, and a second length L2 when the telescopic segments 858a-d are extended, where L2 is longer than L1. In some embodiments, when the telescopic chute 850 is extended to L2 (e.g., when the telescopic segments 858a-d are in position 857b), the end portion 852 is located below the plane 801 of the side wall of the freight car. In some embodiments, the telescopic chute 850 is angled based on the angle of repose (e.g., as described with reference to Figure 6) at one or more of the extended position 857b and / or retracted position 857a. By positioning the end portion 852 below the plane 801 and / or closer to the floor 803, the impact force of the GMU discharged from the chute 850 is significantly reduced, mitigating and / or preventing damage to the freight car.

[0052] Figure 9 is a partial schematic side view of a telescopic device 900 configured according to an embodiment of the present technology. In some embodiments, the articulated device 900 includes features that are generally similar to or identical to any of the articulated devices and telescopic devices described herein. For example, device 900 comprises the articulated / rotational mechanism described in Figure 6 and the telescopic mechanism shown in Figures 8A and 8B. Thus, similar numbers refer to similar features.

[0053] In this embodiment, the chute 950 is configured to articulate and / or rotate about axis A of the hopper 940. In some embodiments, the chute 950 is further in a first position 957a with one or more extension segments (not shown) of the chute 950 retracted. The chute 950 can rotate from a first (e.g., upward) direction 955a to a second (e.g., downward) direction 955b while retracting to the first position 957a. The chute 950 can be rotated to match an angle related to and / or based on the angle of repose of the GMU, for example. Once the chute 950 has rotated in direction 955b and aligned to the desired angle, the chute 950 can extend to a second position 957b. In some embodiments, the combination of rotation in the second direction 955b and extension to position 957b positions the end section 952 closer to the floor 903 of the freight car compared to rotation in the first direction 955a and retraction to position 957a.

[0054] This combination of rotation and extension / contraction provides flexibility in the use of the chute 950 and, at the same time, provides a mechanism for slowing down the descent of GMUs through the chute 950. For example, an operator may determine that a simple contraction to position 957a is appropriate under given working conditions (e.g., pulling the chute 950 over plane 901 to exchange a fully loaded car for an empty one). In another example, the operator may determine that rotation in direction 955a is justified to pull the chute 950 away from plane 901 and at the same time to increase safety against unintentionally spilled GMUs (e.g., from weighing containers), as the chute 950 can be positioned nearly perpendicular to the direction of gravity to block falling GMUs. In an additional embodiment, both retraction to position 957a and rotation in direction 955a may be justified if the chute 950 is expected to be inactive for a certain period of time.

[0055] Figure 10 is a flowchart of Method 1000 for mounting a GMU on a freight car via an articulated device, according to an embodiment of the present technology. In some embodiments, parts of Method 1000 are performed and / or implemented by any of the systems described throughout this Spec. (e.g., System 400 in Figure 4 and System 500 in Figure 5, respectively). In some embodiments, parts of Method 1000 are performed and / or implemented using any of the articulated devices described throughout this Spec. (e.g., Device 600 in Figure 6, Device 700 in Figure 7, and Device 900 in Figure 9, respectively).

[0056] In block 1002, the GMU is transported to a housing unit via a conveyor mechanism. In some embodiments, the housing unit defines a structure including a surge bin, a surge bin gate, a weighing bin, a weighing bin gate, a hopper, and an articulated chute. In some embodiments, one or more wagons are positioned at least partially within the structure, below other components of the structure. In some embodiments, the conveyor mechanism is inclined to provide the GMU at a higher position in the housing unit and / or components of the housing unit structure. In some embodiments, the conveyor mechanism includes a plurality of chevron-shaped conveyor segments. In some embodiments, the conveyor segments are reinforced with hardened material and / or composed of one or more materials such as carbon steel, abrasion-resistant (AR) steel, Hardox®, polyurethane, silicon carbide, tungsten carbide, and titanium alloy. In some embodiments, the inclined conveyor includes one or more catch trays positioned at selected locations below the inclined conveyor (e.g., personnel passage areas and aisles).

[0057] In block 1004, the GMU is received by a surge bin at or near a high position in the housing unit to which the conveyor mechanism transports the GMU. For example, the surge bin can be positioned just below the end of the conveyor mechanism so that it captures the GMU as it falls from the conveyor mechanism as it is transported to or beyond the end of the conveyor mechanism. In some embodiments, the surge bin is positioned above the surge bin gate, weighing bin, hopper, articulated chute, and railcar. The surge bin is configured to guide the falling GMU from the surge bin inlet to the surge bin outlet. In some embodiments, the surge bin is funnel-shaped, with an inlet diameter greater than the outlet diameter, and the shape of the surge bin guides the GMU to the surge bin outlet as it falls. After passing the surge bin outlet, the surge bin gate receives the GMU. In some embodiments, the surge bin gate is positioned below the surge bin but above the weighing bin. In some embodiments, the surge bin gate is pre-positioned in the open position to allow GMUs exiting the surge bin to pass through the surge bin gate. In some embodiments, the surge bin gate is pre-positioned in the closed or blocked position to prevent GMUs from passing through the surge bin gate and to retain / hold the GMUs within the surge bin.

[0058] In block 1006, the GMU is supplied to the measuring bin. In some embodiments, if the surge bin gate is in the closed position, the surge bin gate is opened and the GMU descends into the measuring bin. In some embodiments, the surge bin gate is pre-positioned in the open position, and when the GMU is discharged from the surge bin outlet, the GMU descends into the measuring bin.

[0059] In block 1008, the GMU is filled into the metering bin (e.g., via the surge bin outlet). The metering bin is positioned above the metering bin gate located at the metering bin outlet. In some embodiments, the metering bin gate is pre-positioned and / or initially in the closed position so that the GMU is received through the metering bin, descends, and accumulates to form a pile.

[0060] In block 1010, the weight of the GMU in the weighing bin is measured. For example, in some embodiments, the weight of the GMU in the weighing bin is measured by one or more sensors (e.g., load cells) configured to measure the force and / or weight of the GMU in the weighing bin. In some embodiments, one or more sensors provide a signal to a controller (including a processor) that performs weight calculations. In some embodiments, a target weight for the GMU (e.g., 100 short tons, 75 short tons, 50 short tons) is set, and the measured weight of the GMU in the weighing bin is compared to the target weight of the GMU. If the measured weight does not meet the target weight, an additional GMU is supplied to the weighing bin (e.g., block 1006). In some embodiments, the comparison of the measured weight with the target weight is performed automatically, for example, by a controller and / or other electronic equipment. In some embodiments, the comparison is performed manually by an operator. In some embodiments, the target weight is based at least in part on the total weight limits of the track and / or freight cars (e.g., weight limits such as 200,000 pounds, 250,000 pounds, 268,000 pounds, 286,000 pounds, etc.). In some embodiments, the measurement of the weight of the GMU in the weighing bin is performed continuously as the weighing bin is filled. In some embodiments, the determination of the weight of the GMU is performed iteratively, and the surge bin gate is closed at various points (e.g., block 1014 discussed below) to stop the descent of the GMU into the weighing bin. While the surge bin gate is closed, the weight of the GMU is measured and compared to the target weight.

[0061] In some embodiments, the weight of the GMU is measured after it has been discharged into the freight car (for example, block 1010 is omitted). In such embodiments, the weight of the GMU in the freight car can be measured, for example, by placing the freight car on a weighing mechanism configured to obtain the total weight of the freight car and the GMU on it and / or the weight of the GMU in the freight car minus the weight of the freight car.

[0062] In block 1012, the articulated chute is rotated from a first position to a second position, thereby positioning the chute's exit and / or end section near the floor of the freight car. In some embodiments, the first position aligns the longitudinal plane of the articulated chute perpendicular to the direction of gravity. In some embodiments, the articulated chute is pre-positioned (e.g., pre-rotated) to the second position, and block 1012 is omitted. In some embodiments, the articulated chute is rotated while measuring the weight of the GMU in the weighing bin. In some embodiments, the articulated chute is rotated after the weight of the GMU has been determined. In some embodiments, the rotation of the articulated chute is controlled at least in part by a controller (e.g., via one or more motor controllers).

[0063] In some embodiments, if the measured weight meets the target weight, the surge bin gate is closed in block 1014 to stop the GMU from descending into the weighing bin. In block 1016, the weighing bin gate is opened, and the GMU contained in the weighing bin is discharged through the weighing bin gate by gravity. In some embodiments, the weighing bin gate is opened based on whether the weight of the GMU meets the target weight. In some embodiments, the weighing bin gate is opened based on whether the articulated chute has rotated to a first position or a second position.

[0064] In block 1018, the GMU is received by an articulated chute. In some embodiments, the GMU descending through a weighing bin gate is first received by a hopper, which then guides the GMU into the chute. In some embodiments, the hopper is omitted, and the GMU is received directly from the weighing bin by the articulated chute. In block 1022, the GMU is guided into the freight car via an articulated chute. In some embodiments, the articulated chute is angled (e.g., based on the angle of repose of the GMU) so that the GMU descending through the articulated chute is decelerated relative to the free fall velocity of the GMU. In some embodiments, the articulated chute optionally includes one or more baffle elements configured to obstruct the descent of the GMU through the articulated chute. In such embodiments, the baffle elements further decelerate the GMU, as shown in block 1020 of choice. Figure 11 is a flowchart of a method 1100 of loading a GMU into a freight car via a telescopic device according to an embodiment of the present art. In some embodiments, parts of Method 1100 are performed and / or carried out by any of the systems described throughout this specification (e.g., System 400 in Figure 4 and System 500 in Figure 5, respectively). In some embodiments, parts of Method 1100 are performed and / or carried out using any of the telescopic devices described throughout this specification (e.g., Device 800 in Figures 8A-8B and Device 900 in Figure 9, respectively). In this embodiment, one of the main differences between Method 1100 and Method 1000 is that this method omits the articulated chute and includes a telescopic chute.

[0065] In block 1102, the GMU is filled into the weighing bin (e.g., via a conveyor mechanism that provides the GMU to descend into the weighing bin through a surge bin and surge bin gate). In block 1104, the weight of the GMU is determined (e.g., via one or more load cells and / or associated electronic equipment). In block 1106, the telescopic segments in the telescopic chute are extended so that the telescopic chute (e.g., end sections of the telescopic chute) is positioned closer to the floor of the freight car. In some embodiments, extending the telescopic segments involves extending each of the first and second telescopic segments, the second telescopic segment being distal to the first telescopic segment and closer to the floor of the freight car than the first telescopic segment. In some embodiments, the telescopic segments are pre-positioned in the extended position before the weighing bin is filled and / or before the weight of the GMU in the weighing bin is measured. In some embodiments, the telescopic segments are extended while the weight of the GMU is being determined. In some embodiments, the telescopic segments are extended after the weight of the GMU has been measured. In block 1108, the weighing bin gate is opened (e.g., via a controller), and the GMU contained in the weighing bin is discharged through the weighing bin gate by gravity. In some embodiments, the weighing bin gate is opened based on whether the telescopic segment is in a retracted or extended position. In block 1110, the telescopic chute receives the GMU descending through the weighing bin gate. In block 1112, the telescopic chute guides the GMU into the freight car. In some embodiments, the telescopic chute is angled (e.g., based on the angle of repose of the GMU) to slow the descent speed of the GMU. In some embodiments, the telescopic chute includes one or more baffle elements to further slow the descent speed of the GMU.

[0066] Figure 12 is a flowchart of Method 1200 for loading a GMU onto a freight car via articulated and telescopic devices according to embodiments of the present technology. In some embodiments, parts of Method 1200 are performed and / or implemented by any of the systems described throughout this specification (e.g., System 400 in Figure 4 and System 500 in Figure 5, respectively). In some embodiments, parts of Method 1200 are performed and / or implemented using any of the articulated devices with telescopic mechanisms described throughout this specification (e.g., Device 900 in Figure 9). In this embodiment, one of the main differences between Method 1200 and Methods 1000 and 1100 is that Method 1200 includes both articulated and telescopic chute functions.

[0067] In block 1202, the weighing bin is filled with GMU. In block 1204, the weight of the GMU is measured. In block 1012, the chute is rotated from a first position to a second position, thereby positioning the chute's exit and / or end section near the floor of the freight car. In some embodiments, the first position aligns the longitudinal plane of the chute perpendicular to the direction of gravity. In some embodiments, the chute is pre-positioned (e.g., pre-rotated) to the second position before filling the weighing bin and / or before measuring the weight of the GMU in the weighing bin. In some embodiments, the chute is rotated while measuring the weight of the GMU in the weighing bin. In some embodiments, the chute is rotated after the weight of the GMU has been measured.

[0068] In block 1208, the telescopic segment in the chute is extended so that the chute (e.g., the end section of the chute) is positioned closer to the floor of the freight car than when it is in the retracted position. In some embodiments, extending the telescopic segment involves extending each of the first and second telescopic segments, the second telescopic segment being distal to the first telescopic segment and closer to the floor of the freight car than the first telescopic segment. In some embodiments, the telescopic segment is pre-positioned in the extended position before filling the weighing bin and / or before measuring the weight of the GMU in the weighing bin. In some embodiments, the telescopic segment is extended while the weight of the GMU is being measured. In some embodiments, the telescopic segment is extended after the weight of the GMU has been measured. In some embodiments, the telescopic segment is extended after the chute has rotated. In some embodiments, the telescopic segment is extended before the chute rotates. In some embodiments, the telescopic segment is rotated while the chute rotates.

[0069] In block 1210, the weighing bin gate is opened, and the GMU contained in the weighing bin is discharged through the weighing bin gate by gravity. In some embodiments, the weighing gate is opened based on the fact that the telescopic segment is in a retracted or extended position and / or based on the fact that the chute is rotating in a first or second position. In block 1212, the chute receives the GMU descending through the weighing bin gate. In block 1214, the chute guides the GMU into the freight car. In some embodiments, the chute is angled (for example, based on the angle of repose of the GMU) to slow the descent speed of the GMU. In some embodiments, the chute includes one or more baffle elements to further slow the descent speed of the GMU.

[0070] In some embodiments, a chute gate is located at the end of the chute. The gate is configured to shift between a closed position, where the gate covers the opening of the end section of the chute, and an open position, where the opening of the end section is exposed. In some embodiments, the gate is pre-positioned in the closed position when the GMU is received by the chute, so that the GMU accumulates and is held in the chute and / or hopper. As the GMU from the weighing bin accumulates in the chute and / or hopper, and the end section of the chute is relatively close to the floor of the freight car, the gate opens and the GMU descends into the chute freight car. In some embodiments, the chute is retracted (e.g., the telescopic segment is retracted), and the GMU in the chute and / or hopper descends further and is stacked in the freight car.

[0071] IV. conclusion Those skilled in the art will see that modifications may be made to the details of the embodiments described above without departing from the underlying principles of the present art. In some cases, well-known structures and functions are not illustrated or described in detail to avoid unnecessarily obscuring the description of the embodiments of the present art. While steps of a method may be presented in a specific order herein, in alternative embodiments, the steps may be performed in a different order. Similarly, certain aspects of the present art disclosed in light of a particular embodiment may be combined with or excluded in other embodiments. Furthermore, while advantages related to a particular embodiment of the present art may be disclosed in the context of that embodiment, other embodiments may also exhibit such advantages, and not all embodiments are required to exhibit such advantages or other advantages disclosed herein so that they do not necessarily fall within the scope of the present art. Thus, the present disclosure and the associated art may encompass other embodiments not expressly shown or described herein, and the present invention is not limited except by the appended claims.

[0072] Throughout this disclosure, the singular forms “a,” “an,” and “the” include plural references unless the context explicitly indicates otherwise. The terms “comprising,” “including,” and “having” should be interpreted as including at least the listed(plural) features so as not to exclude any more than a number of the same features and / or additional types of features.

[0073] Any reference herein to “one embodiment,” “embodiment,” “several embodiments,” or similar formulations means that certain features, structures, operations, or characteristics described in relation to an embodiment may be included in at least one embodiment of the Art. Therefore, not all occurrences of such words or formulations herein necessarily refer to the same embodiment. Furthermore, various specific features, structures, operations, or characteristics may be combined in any preferred manner in one or more embodiments.

[0074] Unless otherwise specified, all digits representing concentrations and other numerical values ​​used herein and in the claims should be understood to be modified in all cases by the term “approximately”. Therefore, unless otherwise indicated, the numerical parameters shown in the following specification and the appended claims are approximations that may vary depending on the desired properties to be obtained by the Art. Each numerical parameter should be interpreted, at least in light of the reported significant digits and by applying common rounding techniques, and not in any attempt to limit the application of the doctrine of equivalents to the claims. Furthermore, all scopes disclosed herein should be understood to encompass all sub-ranges included therein. For example, the range “1 to 10” includes all sub-ranges between (and including) the minimum value 1 and the maximum value 10, i.e., all sub-ranges having a minimum value greater than or equal to 1 and a maximum value less than or equal to 10, e.g., 5.5 to 10.

[0075] The foregoing disclosure should not be interpreted as reflecting an intention that any claim requires more features than those explicitly stated in that claim. Rather, as reflected in the following claims, the embodiments of the invention are in fewer combinations than all the features of any single aforementioned disclosed embodiment. Thus, the claims following the embodiments for carrying out the invention are explicitly incorporated into the embodiments for carrying out the invention, and each claim stands independently as a separate embodiment. This disclosure includes all substitutions of independent claims with their dependent claims.

[0076] This technology is described in accordance with various embodiments, for example, as numbered clauses or embodiments (1, 2, 3, etc.) described below for convenience. These are provided as examples and are not limiting to this technology. Note that any of the dependent clauses can be combined in any combination and each can be placed as an independent clause.

[0077] 1. A method for loading granular metal materials (GMU) onto a freight car, wherein the method is: Filling the measuring bottle with GMU, To measure the weight of the GMU in the weighing bottle, Opening the weighing bin gate located at the outlet section of the weighing bin, The GMU is received by an articulated chute positioned below the weighing bin gate, wherein the articulated chute is rotatable and angled with respect to the weighing bin about an axis, The method comprising guiding the GMU to the freight car through the articulated chute.

[0078] 2. The method according to any claim herein, further comprising rotating the articulated chute from a first position to a second position, wherein the end section of the articulated chute is at a first height with respect to the floor of the freight car when the articulated chute is in the first position, and at a second height when the articulated chute is in the second position, and the second height is closer to the floor of the freight car than the first height.

[0079] 3. The method according to any claim herein, further comprising rotating the articulated chute from a first position to a second position, wherein the end section of the articulated chute is at a first height with respect to the floor of the freight car when the articulated chute is in the first position, and at a second height when the articulated chute is in the second position, the second height being closer to the floor of the freight car than the first height, and the longitudinal plane of the articulated chute is perpendicular to the direction of gravity when the articulated chute is in the first position.

[0080] 4. The method according to any claim herein, wherein the second height is lower than the height of one or more walls of the freight car.

[0081] 5. The method according to any claim herein, wherein the articulated chute further comprises one or more baffle elements, and the method further comprises slowing at least a portion of the GMU guided through the articulated chute via one or more baffle elements.

[0082] 6. The articulated chute further comprises an extendable segment, and the method further includes extending the extendable segment from a contracted state to an extended state. The articulated chute has a first length when the telescopic segment is in the retracted state. When the telescopic segment is in the extended state, the articulated chute has a second length that is longer than the first length. The method according to any claim herein, wherein when the telescopic segment is in the extended state, the end section of the articulated chute is positioned closer to the floor of the freight car.

[0083] 7. The method according to any claim herein, wherein the telescopic segment is a first telescopic segment, and the articulated chute further comprises a second telescopic segment distal to the first telescopic segment, and the method further comprises extending the second telescopic segment distal to the first telescopic segment.

[0084] 8. Transporting the GMU via a conveyor mechanism, The GMU is received by a surge bin via the conveyor mechanism, the surge bin is positioned above the weighing bin, and the receiving is... To supply the GMU to the measuring bin via the surge bin, The method according to any claim herein, further comprising closing the surge bin gate when the GMU supplied to the weighing bin is approximately the target weight of the GMU.

[0085] 9. The method according to any claim herein, further comprising repositioning the freight car while the GMU is being guided through the articulated chute into the freight car.

[0086] 10. The method of any claim herein, further comprising establishing a target weight for the GMU, wherein the target weight is at least partially based on the total weight limit of the track and / or the freight car, and opening the weighing bin gate is at least partially based on the GMU meeting the target weight.

[0087] 11. The method according to any claim herein, wherein the total weight limit of the track and / or the freight car is at least 200,000 pounds.

[0088] 12. A device for loading granular metal materials (GMU) onto a freight car, wherein the device is A housing unit that defines the structure of the aforementioned device, A measuring bin coupled to and located within the housing, the measuring bin comprising a measuring bin gate positioned at the outlet of the measuring bin, the measuring bin gate being movable from a closed position in which the GMU in the measuring bin is held within the measuring bin gate to an open position in which the GMU is discharged through the measuring bin gate by gravity, A hopper positioned below the weighing bin gate and configured to receive the GMU discharged by the weighing bin gate, the hopper includes an inlet having a first diameter and an outlet having a second diameter smaller than the first diameter, the outlet being located below the inlet, and the hopper, The system comprises an articulated chute coupled to the hopper and positioned to receive the GMU from the hopper, The articulated chute is angled and configured to guide the GMU from a first height to a second height that is closer to the floor of the freight car than the first height. The articulated chute is rotatable around an axis relative to the hopper.

[0089] 14. The apparatus according to any claim herein, wherein the articulated chute includes an outlet gate at the end portion of the articulated chute, and the end portion is distal to the hopper.

[0090] 15. The apparatus according to any claim of this specification, wherein when the articulated chute is rotated in a first direction about the axis, the end portion is positioned from approximately the first height to approximately the second height, and when the articulated chute is rotated in a second direction about the axis, the end portion is positioned from approximately the second height to approximately the first height.

[0091] 16. The apparatus according to any claim herein, further comprising an inclined conveyor configured to transport GMUs, wherein the housing unit is configured to receive GMUs from the inclined conveyor.

[0092] 17. The apparatus according to any claim herein, wherein the inclined conveyor comprises a plurality of chevron-shaped segments.

[0093] 18. The apparatus according to any claim herein, wherein the plurality of conveyor segments are composed of one or more of metal, metal alloy, metal cladding, and polyurethane.

[0094] 19. The apparatus according to any claim of this specification, further comprising one or more catch trays positioned below the inclined conveyor.

[0095] 20. The apparatus according to any claim herein, wherein the articulated chute comprises one or more baffle elements disposed inside the articulated chute, the baffle elements being configured to partially restrict the flow of GMU through the articulated chute.

[0096] 21. The apparatus according to any claim herein, wherein the articulated chute further comprises one or more telescopic segments configured to extend from a first position to a second position and to retract from a second position to a first position, wherein when the telescopic segments are extended to the second position, the end portion of the articulated chute is positioned even closer to the floor of the freight car.

[0097] 22. A surge bin coupled to the housing, the surge bin being positioned above the measuring bin and comprising a surge bin gate positioned at the outlet of the measuring bin, the surge bin gate being movable from a closed position in which the GMU is held within the surge bin to an open position in which the GMU is discharged through the surge bin gate by gravity. The apparatus according to any claim herein, wherein the measuring bin is configured to receive GMU from the surge bin.

[0098] 23. A system configured to guide industrial products into a freight car, wherein the system is It's a hopper, It is configured to receive the aforementioned industrial product and has an inlet having a first diameter, The hopper includes an outlet having a second diameter smaller than the first diameter, A rotatable chute positioned below the hopper and configured to receive industrial products from the hopper, The rotatable chute is angled based on the angle of repose of the industrial product, and the rotatable chute is configured to guide the industrial product from a first height to a second height, the second height being closer to the floor of the freight car than the first height. It is rotatable around the axis relative to the hopper, The rotatable chute, having an end portion distal to the hopper, A controller operably coupled to the aforementioned rotatable chute, The system comprises a controller that controls the rotation of the rotatable chute, such that when the rotatable chute is rotated in a first direction about the axis, the end portion is positioned from approximately the first height to approximately the second height, and when the rotatable chute is rotated in a second direction about the axis, the end portion is positioned from approximately the second height to approximately the first height.

[0099] 24. The system according to any claim herein, wherein the industrial product is a GMU, and the rotatable chute is angled based on the angle of repose of the GMU.

[0100] 25. The system according to any claim of this specification, wherein the angle of repose is at least 35 degrees.

[0101] 26. A device for mounting a GMU on a freight car, wherein the device is A housing unit that defines the structure of the aforementioned device, A measuring bin coupled to the housing and located within the housing, the measuring bin comprising a measuring bin gate located at the outlet of the measuring bin, the measuring bin gate being movable from a closed position in which the GMU in the measuring bin is held within the measuring bin gate to an open position in which the GMU is discharged through the measuring bin gate by gravity, A hopper positioned below the weighing bin gate and configured to receive the GMU discharged by the weighing bin gate, the hopper includes an inlet having a first diameter and an outlet having a second diameter smaller than the first diameter, the outlet being located below the inlet, and the hopper, The system comprises a retractable chute coupled to the hopper and positioned to receive the GMU from the hopper, The telescopic chute comprises one or more telescopic segments configured to extend from a first position to a second position and retract from the second position to a first position, wherein when the telescopic segment is extended to the second position, the end portion of the telescopic chute is positioned closer to the floor of the freight car. The apparatus according to any claim herein, wherein the telescopic chute is angled based on the angle of repose of the GMU, and the telescopic chute is configured to guide the GMU from a first height to a second height, the second height being closer to the floor of the freight car than the first height.

Claims

1. A method for loading granular metal bodies (GMU) onto a freight car, wherein the method is: Fill the measuring bottle with GMU, To measure the weight of the GMU in the weighing bottle, Opening the weighing bin gate located at the outlet section of the weighing bin, The GMU is received by an articulated chute positioned below the weighing bin gate, wherein the articulated chute is rotatable and angled with respect to the weighing bin about an axis, the axis being positioned above the end section of the articulated chute, and the receiving is such that The method comprising guiding the GMU to the freight car through the articulated chute.

2. The method according to claim 1, further comprising rotating the articulated chute from a first position to a second position, wherein the end section is at a first height with respect to the floor of the freight car when the articulated chute is in the first position, and the end section is at a second height when the articulated chute is in the second position, and the second height is closer to the floor of the freight car than the first height.

3. The method according to claim 1, further comprising receiving the GMU from the measuring bin in a hopper positioned above the articulated chute.

4. The method according to claim 1, further comprising rotating the articulated chute relative to the measuring bottle.

5. The method according to claim 1, wherein the articulated chute further comprises one or more baffle elements extending inward from the inner surface of the articulated chute, and the method further comprises slowing down at least a portion of the GMU guided through the articulated chute via the one or more baffle elements.

6. The method according to claim 1, wherein the articulated chute further comprises an extendable segment, and the method further includes extending the extendable segment from a retracted state to an extended state, wherein when the extendable segment is in the extended state, the end section of the articulated chute is positioned closer to the floor of the freight car.

7. The method according to claim 6, wherein the telescopic segment is a first telescopic segment, and the articulated chute further comprises a second telescopic segment distal to the first telescopic segment, and the method further comprises extending the second telescopic segment distal to the first telescopic segment.

8. The GMU is transported via a conveyor mechanism to a surge bin positioned above the weighing bin, wherein the conveyor mechanism is configured to reduce the loss of industrial products via one or more catch trays compared to a conventional conveyor mechanism. To supply the GMU to the measuring bin via the surge bin, The method according to claim 1, further comprising closing the surge bin gate of the surge bin based on the target weight of the weighing bin.

9. The method according to claim 1, further comprising repositioning the freight car relative to the chute while the GMU is being guided into the freight car through the articulated chute.

10. The method according to claim 1, further comprising determining the target weight of the GMU at least in part on the total weight limit of the tracks and / or the freight cars, and opening the weighing bin gate at least in part on the fact that the GMU at least satisfies the target weight.

11. A device for loading granular metal bodies (GMU) onto a freight car, wherein the device is A housing unit that defines the structure of the aforementioned device, A measuring bin coupled to and located within the housing, the measuring bin comprising a measuring bin gate positioned at the outlet of the measuring bin, the measuring bin gate being movable from a closed position in which the GMU in the measuring bin is held within the measuring bin gate to an open position in which the GMU is discharged through the measuring bin gate by gravity, A hopper positioned below the weighing bin gate and configured to receive the GMU discharged by the weighing bin gate, the hopper includes an inlet having a first diameter and an outlet having a second diameter smaller than the first diameter, the outlet being located below the inlet, and the hopper, The system comprises an articulated chute coupled to the hopper and positioned to receive the GMU from the hopper, The articulated chute is angled and configured to guide the GMU from a first height to a second height that is closer to the floor of the freight car than the first height.

12. The apparatus according to claim 11, wherein the articulated chute is rotatable around an axis relative to the hopper.

13. The apparatus according to claim 11, wherein the articulated chute is (i) rotatable relative to the hopper and (ii) extendable from a retracted position to an extended position.

14. The apparatus according to claim 11, wherein when the articulated chute is rotated in a first direction about an axis, the end portion is positioned from approximately the first height to approximately the second height, and when the articulated chute is rotated in a second direction about an axis, the end portion is positioned from approximately the second height to approximately the first height.

15. The apparatus according to claim 11, wherein the articulated chute comprises one or more baffle elements disposed inside the articulated chute, the baffle elements being configured to partially restrict the flow of GMU through the articulated chute.

16. The apparatus according to claim 11, wherein the articulated chute has a first outer surface portion and a second outer surface portion distal to the first outer surface portion, and the second outer surface portion is angled with respect to the first outer surface portion.

17. The apparatus according to claim 11, further comprising a surge bin coupled to the housing, the surge bin being positioned above the measuring bin and comprising a surge bin gate positioned at the outlet of the measuring bin, the surge bin gate being movable from a closed position in which the GMU is held within the surge bin to an open position in which the GMU is discharged through the surge bin gate by gravity, and the measuring bin being configured to receive the GMU from the surge bin.

18. A device for mounting a GMU onto a freight car, wherein the device is A housing unit that defines the structure of the aforementioned device, A measuring bin coupled to the housing and located within the housing, the measuring bin comprising a measuring bin gate located at the outlet of the measuring bin, the measuring bin gate being movable from a closed position in which the GMU in the measuring bin is held within the measuring bin gate to an open position in which the GMU is discharged through the measuring bin gate by gravity, The system comprises an extendable chute positioned to receive the GMU from the measuring bottle, The telescopic chute comprises one or more telescopic segments configured to extend from a first position to a second position and retract from the second position to a first position, wherein when the telescopic segment is extended to the second position, the end portion of the telescopic chute is positioned closer to the floor of the freight car. The device wherein the retractable chute is angled based on the angle of repose of the GMU, and the retractable chute is configured to guide the GMU from a first height to a second height, the second height being closer to the floor of the freight car than the first height.

19. The apparatus according to claim 18, further comprising a hopper positioned below the weighing bin gate and configured to receive the GMU discharged by the weighing bin gate.

20. The apparatus according to claim 19, wherein the hopper includes an inlet having a first cross-sectional dimension and an outlet having a second cross-sectional dimension smaller than the first cross-sectional dimension.

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