Programmable Railcar Tank Cleaning System with Telescopic Arms
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Solution Overview
Problem
Current methods for cleaning railcar tanks are inefficient and hazardous, with handheld nozzles being slow and labor-intensive, and remotely controlled systems facing visibility issues and resource wastage due to non-targeted cleaning patterns.
Innovation Solution
A hydraulically controlled programmable railcar tank cleaning system with telescoping robotic arms and dual opposing booms that utilize fluid jets to break up and liquefy waste, allowing for simultaneous cleaning from both ends and precise waste collection at the drain outlet, equipped with hydraulic actuators and a control panel for real-time operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If handheld water nozzles are used for cleaning railcar tanks, then cleaning can be performed manually, but the process becomes slow, tedious, and labor-intensive with safety hazards to operators
Solution Approach 1:
The system enables self-service operation where the robotic cleaning system autonomously performs tank cleaning without requiring continuous manual intervention. The programmable controller automatically sequences the cleaning operations, positioning the nozzle assembly and controlling fluid jet application throughout the tank interior.
Solution Approach 2:
The patent replaces manual mechanical nozzle handling with an automated robotic system that uses fluid jets for cleaning. The mechanical system includes a robotic arm or movable platform carrying the nozzle assembly, which is positioned and controlled automatically rather than by hand-held operation.
2Object-affected harmful factors
If remotely controlled systems are used for cleaning, then operator safety is improved, but visibility is limited making it difficult to survey the area and determine appropriate cleaning patterns
Solution Approach 1:
The system employs lighting systems that illuminate the tank interior, and the camera system captures visual information that is displayed to the operator. The lighting and visual display systems enable the operator to see the cleaning area and waste accumulation patterns despite the confined and potentially dark environment.
Solution Approach 2:
The patent introduces a camera system as an intermediary between the cleaning system and the operator. The camera captures images and video of the tank interior, transmitting this visual information to the operator who can then survey the area and determine appropriate cleaning patterns without directly entering the hazardous environment.
3Extent of automation
If rotating or self-propelled nozzles are used, then automated cleaning is achieved, but resources are wasted cleaning areas that do not need cleaning and cycle times are extended
Solution Approach 1:
The system incorporates sensors and detection mechanisms that monitor the cleaning progress and waste accumulation patterns. This feedback information is used by the programmable controller to adjust the cleaning pattern in real-time, directing fluid jets only to areas where waste is present and adjusting the speed and coverage area of the nozzle assembly.
Solution Approach 2:
The patent applies cleaning resources locally and selectively rather than uniformly throughout the tank. The system identifies specific areas with waste accumulation and concentrates the fluid jet application in those zones, rather than cleaning the entire tank surface equally. This localized approach reduces water and energy consumption while maintaining effective cleaning.
4Reliability
If comprehensive 360-degree cleaning is performed, then all areas are cleaned, but resource consumption increases and cycle time is extended
Solution Approach 1:
The system performs partial cleaning actions by focusing fluid jet application only on areas where waste is detected, rather than applying cleaning uniformly across the entire tank. The programmable controller adjusts the nozzle positioning and fluid flow to concentrate effort on problem areas, reducing overall cycle time while maintaining adequate cleaning coverage.
Solution Approach 2:
The cleaning system dynamically adjusts its operation based on real-time conditions. The robotic arm or movable platform speed, nozzle positioning, and fluid flow rate are continuously modified during operation to match the actual waste distribution and cleaning requirements of different tank zones, optimizing both thoroughness and speed.
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
The system significantly reduces cycle times, enhances safety by minimizing exposure to hazardous conditions, and optimizes resource usage through targeted cleaning and efficient waste collection, while operating in challenging environments with hazardous vapors and dusts.
Implementation Method 1
nozzles which utilize fluid jets to break up, liquefy, and motivate tank material
Implementation Method 2
a movable platform or a robotic arm with a hydraulic actuator that moves a nozzle assembly
Data Source
Figure 1A
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Figure 1C
AI summary
Systems, devices, and methods for passing railcar tank cleaning systems through the opening and mounted to existing manways. The invention can extend horizontally more than 25 feet and clean rail cars up to and beyond approximately 102 inches in diameter for manual, automated, or semi-automated programmable railcar tank cleaning systems, devices and methods for providing safe and efficient methods for breaking up oil, tar, chemical, radioactive, hazardous, or any other liquid, solid, or sludge waste inside rail tank cars and the like with nozzles which utilize fluid jets to break up, liquefy, and motivate tank material. The programmable railcar cleaning system can be a standalone, independent unit or integrated into new designs and/or existing systems. Simplified programming and user interface allow an operator to remotely operate the system. The various capabilities of this Invention allow cleaning in a quicker and more efficient manner. The system is hydraulically controlled and can work in the presence of flammable vapors and dust.