Cordless Spike Puller Control for High-Force Hose-Free Operation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic spike pullers are heavy, require hydraulic hoses, and cause operator fatigue and reduced productivity in remote railroad track environments.
Innovation Solution
A cordless railroad spike puller with a drive motor, threaded drive shaft, and non-rotating pull rod, powered by a rechargeable battery, featuring a control circuit that automatically adjusts motor speed and direction for efficient spike grasping and pulling, and ergonomic handles for reduced fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic power is used to drive spike pullers, then sufficient pulling force is achieved, but the tool becomes heavy and requires hydraulic hoses connecting to a power source
Solution Approach 1:
The patent extracts the power source from the external hydraulic system and integrates it directly into the tool as an onboard battery pack. This eliminates the need for hydraulic hoses and external power sources, making the tool self-contained and portable while maintaining sufficient pulling force through the electric motor.
Solution Approach 2:
The patent replaces the hydraulic mechanical system with an electric motor-driven system. The electric motor converts electrical energy from the battery to mechanical energy, driving the threaded rod to generate pulling force, thereby substituting the complex hydraulic system with a simpler electric system.
2Power
If hydraulic hoses are required to connect to power source, then sufficient power is supplied, but operator mobility in remote areas is restricted
Solution Approach 1:
The patent extracts the power source from the external environment and embeds it within the tool itself through an onboard battery pack. This eliminates the dependency on external power sources and hydraulic infrastructure, enabling operators to work freely in remote areas without mobility restrictions.
3Measurement precision
If manual control is required during return phase, then precise positioning is achieved, but operator fatigue increases and productivity decreases
Solution Approach 1:
The patent implements automatic return functionality where the electric motor autonomously drives the threaded rod back to its initial position after spike extraction. This self-service feature eliminates the need for manual operation during the return phase, reducing operator fatigue and increasing productivity while maintaining precise positioning through motor control.
Solution Approach 2:
The patent employs sensors to detect the position of the threaded rod and provides feedback to the control system. This feedback mechanism enables the automatic return function to precisely position the tool by knowing when the threaded rod has reached the desired position, eliminating manual intervention while maintaining positioning accuracy.
4Ease of operation
If battery power is used instead of hydraulic power, then portability and ease of operation are improved, but continuous operating time may be limited
Solution Approach 1:
The patent addresses the limited operating time by enabling parameter changes in the power source through interchangeable battery packs. Operators can replace depleted batteries with charged ones, effectively extending the continuous operating time while maintaining the portability and ease of operation benefits of battery power.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances operator comfort, reduces physical and mental fatigue, and increases productivity by automating the spike pulling process, allowing operators to focus on positioning the tool for the next spike without manual intervention during the return phase.
Implementation Method 1
A battery mount can be selectively couplable to a rechargeable battery to provide electric power to the drive motor
Implementation Method 2
Rotation of the drive motor in a forward direction can rotate the gear train and the threaded drive shaft
Implementation Method 3
a threaded drive shaft with a gear train operably coupling the drive motor to the threaded drive shaft
Data Source
AI summary
A control circuit can be operably coupled to the drive motor, a manually actuatable trigger switch. A pull rod position sensor can be coupled to the control circuit. The pull rod position sensor can be operable to provide at least one of an extended position signal to the control circuit in response to the non-rotating pull rod and the spike puller jaws being in the extended position, and a retracted position signal to the control circuit in response to the non-rotating pull rod and the spike puller jaws being in the retracted position. A pair of operating handles can each have an operating manual gripping portion for ergonomically operating the spike puller in an upright operating orientation. A pair of carrying handles can each include a carrying manual gripping portion oriented for ergonomically carrying the spike puller in a side-laying carrying orientation that borders an opening through the plastic housing.