Battery-Operated Portable Rail Web Grinder With Anti-Vibration Handle
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Solution Overview
Problem
Existing rail grinders are large, vehicle-mounted machines that require substantial power and are not suited for smaller-scale, quick repairs or maintenance in remote or difficult-to-access locations, necessitating a portable, battery-powered solution for efficient localized maintenance.
Innovation Solution
A dual-use battery-operated portable grinder designed for the railway industry, capable of grinding the web of railroad rails post-welding, featuring battery-powered operation, a robust brushless motor, a lightweight design, anti-vibration handle, reinforced shaft, improved grinding wheel stability, and versatility in performing rail head and web grinding tasks, with the option to be used hand-held or mounted on a specialized frame device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large vehicle-mounted grinders are used, then grinding power and effectiveness are improved, but portability and accessibility to remote locations deteriorate
Solution Approach 1:
The patent replaces the mechanical engine system of traditional grinders with an electric motor system. The electric motor (112) is coupled to the grinding wheel (136) and powered by a battery pack, eliminating the need for large combustion engines and mechanical transmissions. This substitution enables the grinder to be lightweight and portable while still delivering sufficient grinding power for rail maintenance tasks.
2Power
If vehicle-mounted grinders are used, then grinding capability is improved, but adaptability to remote and difficult-to-access locations deteriorates
Solution Approach 1:
The grinder is designed with universal adaptability for various rail maintenance scenarios. The electric motor system with battery power source enables operation in remote locations without infrastructure. The grinder can be used for multiple tasks including grinding rail heads, webs, and flanges, making it a versatile tool that adapts to different maintenance needs and locations.
3Productivity
If traditional grinders are used, then grinding effectiveness is improved, but operator fatigue and vibration exposure worsen
Solution Approach 1:
The patent incorporates a vibration isolation system with a vibration isolator (118) positioned between the electric motor (112) and the grinding wheel assembly. This isolator reduces the transmission of vibrations generated during grinding operations to the operator, thereby decreasing hand-arm vibration exposure and operator fatigue while maintaining effective grinding performance.
4Weight of moving object
If battery-powered portable grinder is used, then portability and accessibility are improved, but power and grinding capability deteriorate
Solution Approach 1:
The patent employs parameter optimization in the electric motor system design. The electric motor (112) is sized and configured to deliver sufficient torque and power for grinding rail steel, while the battery pack provides adequate energy capacity. The grinding wheel (136) parameters such as diameter, width, and abrasive composition are optimized to achieve effective grinding with the available electric power, maintaining grinding capability comparable to larger machines.
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 battery-operated portable grinder enables efficient, localized maintenance by providing a portable, powerful, and versatile tool that reduces operator fatigue, minimizes vibration and wear, and allows for operation in confined spaces, thereby improving railway safety and operational reliability.
Implementation Method 1
a grinder motor assembly with a brushless motor
Implementation Method 2
a grinder wheel configured to remove imperfections, wear, and surface defects from the rail and web of railroad rails
Implementation Method 3
an anti-vibration handle to alleviate operator fatigue and ensure proper balance during usage
Data Source
AI summary
A dual-use battery-operated portable grinder is utilized for the railway industry, specifically for grinding the web of railroad rails post-welding. The battery-operated portable grinder can be employed in a hand-held configuration or seamlessly integrated with a quick-connect mechanism onto a specialized frame device, serving as both a support structure for the grinder and a means for reducing worker strain by eliminating the need for bending. The battery-operated portable grinder may include: battery-powered operation, a robust brushless motor, a built-in handle-incorporated base portion for safeguarding the motor from potential damage, a lightweight design, an anti-vibration handle to alleviate operator fatigue and ensure proper balance during usage, a reinforced shaft to enhance operational durability, improved grinding wheel stability to minimize vibration and wear during use, and its versatility in performing rail head and web grinding tasks.