Automated Dropper Installation for Overhead Contact Systems
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Solution Overview
Problem
The existing methods for installing droppers in overhead contact systems are labor-intensive, prone to human errors, and time-consuming, especially during repairs when working under tight time constraints and low light conditions, which can lead to inaccuracies in positioning and length of droppers.
Innovation Solution
A method and system utilizing a laser scanner or GPS for precise measurements, a computer to generate a layout plan, and automated machinery for manufacturing and positioning droppers, along with a platform for marking and installing them, reducing manual operations and ensuring accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual installation methods are used with layout plans and lifting platforms, then workers can install droppers, but the process becomes labor-intensive and time-consuming with high risk of human error
Solution Approach 1:
The patent replaces manual mechanical operations with an automated vehicle-mounted system that uses GPS positioning, laser scanning, and automated dropper deployment mechanisms. The vehicle travels along the track and automatically positions and installs droppers based on pre-calculated coordinates, eliminating manual reading of layout plans and manual handling of droppers.
Solution Approach 2:
The system performs self-positioning using GPS and inertial navigation, automatically calculates dropper positions based on measured track geometry, and autonomously deploys droppers at the correct locations without requiring continuous human intervention or decision-making during the installation process.
2Ease of operation
If workers manually read layout plans and position droppers, then installation can be performed, but human errors occur due to misreading and poor visibility conditions
Solution Approach 1:
The patent replaces manual visual reading and positioning with automated optical scanning and electronic positioning systems. Laser scanners measure track geometry and GPS provides precise location data, which are processed by a computer to automatically determine dropper positions, eliminating human reading errors and improving positioning accuracy.
Solution Approach 2:
The system introduces a computer-based control system as an intermediary between the layout plan and the physical installation. The computer processes GPS coordinates, laser scan data, and dropper specifications to generate automated positioning commands, serving as a reliable mediator that eliminates human interpretation errors.
3Productivity
If prefabricated droppers are delivered in yarns and manually selected, then installation can proceed, but the process requires heavy manual operations and time-consuming preparation
Solution Approach 1:
The patent replaces manual dropper selection and handling with an automated delivery system mounted on the vehicle. The system uses a spool mechanism to feed droppers from yarns and an automated cutting/selection mechanism that delivers the correct dropper length to the installation point based on real-time position data, dramatically increasing installation speed.
Solution Approach 2:
The system pre-positions dropper yarns on the vehicle before travel, and pre-calculates all dropper positions and lengths during the planning phase. During installation, the system only needs to execute pre-programmed commands, eliminating on-site decision-making and preparation time.
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
This approach significantly reduces human error, saves time, and ensures precise installation of droppers, allowing for faster and more reliable overhead contact system maintenance with improved accuracy and efficiency.
Implementation Method 1
measuring, by means of a laser scanner, a distance between two successive supporting poles
Implementation Method 2
measuring, by means of a GPS device, a distance between two successive supporting poles
Data Source
AI summary
A method including measuring a distance between two successive supporting poles delimiting a section to be realized, inputting data into a computer programmed to output a layout plan indicating a position and a length for each dropper to install, preparing each dropper with a dedicated machine, moving a first platform along the section, which is equipped with a position unit and a marking device to set a mark on the contact wire at each position where a dropper is to installed, moving a second platform along the section, the second platform being loaded with the droppers that have been prepared, and fixing manually each dropper between the messenger wire and the contact wire in registration with a corresponding mark set on the contact wire.