Automatic Spike Feeder System for Rail Maintenance
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Solution Overview
Problem
Manual loading of rail spikes into feed trays during rail maintenance operations is tedious and distracts operators, requiring additional labor when two operators are needed to perform the task efficiently.
Innovation Solution
An automatic spike feeder system that includes a singulator to receive randomly oriented spikes from a bulk storage bin, orient them, and convey them to a spike driver, allowing a single operator to manage both spike delivery and driving operations without manual orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading of spikes into feed trays is performed, then spikes can be oriented and delivered to the spike driver, but operator attention is distracted and additional labor is required
Solution Approach 1:
The system segments the spike handling process into distinct functional modules: a reciprocating ram extracts spikes from bulk storage, a singulator separates and orients individual spikes, and a conveyor delivers them to the feed tray. This segmentation allows each component to specialize in one task, enabling automated operation without distracting the operator from primary duties.
Solution Approach 2:
The spike feeding system is designed to be self-servicing through automated mechanisms. The reciprocating ram automatically extracts spikes from bulk storage, the singulator automatically orients them with heads up, and the conveyor automatically delivers them to the feed tray at the required rate, eliminating the need for manual intervention and operator distraction.
2Reliability
If two operators are used for spike loading and driving, then spike supply and driving operations can be performed simultaneously, but labor cost increases
Solution Approach 1:
The system merges the functions of spike extraction, orientation, and delivery into a single integrated automated feeding system that operates concurrently with the spike driving operation. This allows one operator to manage both tasks simultaneously, reducing labor costs while maintaining reliable spike supply to the driver magazine.
Solution Approach 2:
The reciprocating ram and singulator perform preliminary actions by automatically extracting spikes from bulk storage and orienting them with heads up before delivery to the feed tray. This preliminary automated preparation ensures spikes are ready for immediate insertion by the driver, maintaining operational reliability without requiring a second operator.
3Productivity
If spikes are delivered at high speed to supply the spike driver, then adequate spike supply is maintained, but system complexity increases
Solution Approach 1:
The reciprocating ram operates through periodic reciprocating strokes, alternately moving forward to extract spikes from bulk storage and returning to its starting position. This periodic motion, synchronized with the singulator and conveyor, delivers spikes at the required high speed (approximately 20 spikes per minute per rail) while using simple, repeatable mechanical cycles that minimize system complexity.
Data Source
AI summary
An automatic rail spike feeder system for use with a rail maintenance vehicle having a bulk storage bin for containing a supply of spikes, and at least one spike driving mechanism, includes a mechanism constructed and arranged for receiving a supply of spikes from the storage bin and for automatically delivering individual spikes to the at least one spike driving mechanism in a desired orientation without operator contact with the spikes.