Bridge Crane Tool Carriage for Railcar Lid Automation
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Solution Overview
Problem
Manual opening and closing of railcar lids pose safety risks and inefficiencies, and existing automated solutions often incur high capital and maintenance costs, with limited applicability to standard lid sizes and configurations.
Innovation Solution
A system comprising a bridge frame with a tool carriage and a selectively vertically moveable tool engagement interface, capable of positioning tools to operate railcar lids, latches, and seals, utilizing sensors and machine learning for precise operation and adaptability to various lid types, and allowing for operation while the railcar is in motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual opening and closing of railcar lids is performed, then personnel can directly operate the lids, but safety risks increase due to working at height and potential for slip/trip/fall hazards
Solution Approach 1:
The patent replaces manual mechanical operation with an automated robotic system that uses sensors, actuators, and control systems to open and close railcar lids. The robotic arm with gripper mechanism eliminates the need for personnel to physically work on top of moving railcars, thereby removing safety risks associated with working at height while maintaining the lid opening/closing function.
2Device complexity
If manual opening and closing of railcar lids is performed, then no automated equipment is required, but throughput decreases and operational costs increase due to inefficiencies and delays
Solution Approach 1:
The robotic system operates autonomously to open and close railcar lids without requiring manual intervention. The system uses sensors to detect lid position and latch status, automatically actuates latches, and manipulates lids at optimal speeds, thereby eliminating delays associated with manual operations and increasing overall throughput while maintaining operational simplicity through automated control.
3Extent of automation
If existing automated solutions with robot arms and sensors are implemented, then automation level increases, but capital cost and ongoing maintenance costs increase
Solution Approach 1:
The patent divides the automated lid operation system into modular functional components: a robotic arm for positioning, a gripper mechanism for latch engagement, sensors for detection, and a control system. This segmentation allows for targeted selection of cost-effective components for each function rather than implementing expensive complete robotic systems, thereby achieving necessary automation while controlling capital and maintenance costs.
4Extent of automation
If existing automated solutions are implemented, then lid operation can be automated, but applicability is restricted to specific lid types and configurations
Solution Approach 1:
The robotic system incorporates dynamic adjustment capabilities including variable gripper forces, adjustable arm positions, and adaptive control algorithms that can accommodate different lid types, sizes, and latch configurations. The system can modify its operation parameters in real-time based on sensor feedback, thereby achieving broad applicability across various railcar lid configurations while maintaining automated operation.
Data Source
AI summary
A bridge-supported tool for opening and closing lids located on top of railcars. The bridge has two sides and a cross member between the sides that moves along the sides, the cross member supports a tool carriage that moves along the cross member, the tool carriage has a tool engagement interface for retaining a selected tool and the interface is vertically moveable, such that the tool is moveable to any selected location in the space defined by the bridge. A controller can be used to direct the positioning of the tool by controlling the movements of the cross member, tool carriage and tool engagement interface.