Instrument Case Replacement Without Wiring Disconnection
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Solution Overview
Problem
The existing method for replacing instrument cases in the railroad industry is labor-intensive and causes downtime due to the need to disconnect and reconnect electrical components, posing safety hazards and increased costs.
Innovation Solution
A method that allows instrument cases to be replaced without disconnecting any wires or electrical equipment, using a temporary holding structure to support the instrument panel, allowing the old case to be removed and a new one to be installed while keeping the panel operational, with the new case designed to accommodate wiring through apertures in the floor sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the current replacement procedure is used (disconnecting and removing all wiring and electrical components), then the old instrument case can be removed and replaced, but the process requires tremendous labor cost, causes track downtime, and increases safety risks
Solution Approach 1:
The invention divides the replacement process into two independent stages: first replacing only the instrument case while keeping the instrument panel and wiring connected, then later replacing the instrument panel separately. This segmentation allows the case to be swapped quickly without disconnecting any electrical components, thus reducing both labor requirements and track downtime while maintaining safety.
Solution Approach 2:
The invention prepares the replacement case in advance with pre-installed mounting structures and alignment features that match the existing instrument panel. This preliminary preparation allows the case to be quickly attached to the panel without requiring any electrical disconnection or complex installation procedures on-site, thereby minimizing track downtime.
2Ease of manufacture
If all wiring and electrical components are disconnected for replacement, then the old case can be removed, but the process involves tremendous labor cost and risks of misconnection
Solution Approach 1:
The invention extracts the instrument panel with its wiring and electrical components from the old case, then attaches it to the new case. By separating the panel (which contains all the complex electrical connections) from the case (which is simple structural housing), the replacement procedure becomes much simpler - only the case needs to be swapped, not the entire assembly with its complex wiring.
3Reliability
If the instrument case is replaced by stopping track traffic, then safety is maintained during replacement, but track operation is reduced for a relatively long period
Solution Approach 1:
The invention enables the instrument panel to remain electrically connected and functional throughout the case replacement process. By keeping the wiring and electrical components attached to the panel while only replacing the external case, the useful electrical action continues uninterrupted, allowing track operations to proceed normally without stopping traffic for safety reasons.
Data Source
AI summary
A method designed to replace a compromised instrument case with a new case without the need to disconnect any wire, relay or any other electric equipment is described herein. The instrument panel is supported for example by a temporary support frame during the dismantling of the old case and the assembly of the new case. The new case is therefore assembled on site around the instrument panel. The new instrument case includes a floor which is made of at least two parts, one on each side of the wiring. The instrument case therefore remains in a normal working mode during the entire replacement procedure thus preventing downtime. As well, the amount of manpower required for the replacement of an instrument case is drastically reduced.