Railcar Mover Laser Alignment for Wheel-to-Track Engagement
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Solution Overview
Problem
The manual alignment of rail wheels on railcar movers is inefficient and potentially hazardous due to the use of different standard railway track gauges, leading to misalignment and potential damage to the mover and track.
Innovation Solution
A laser alignment system mounted to the railcar mover, adjustable via mounts and orientation, emits a laser beam to align rail wheels with the track, optionally activated by a switch, and includes a window for the operator to view the alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual alignment method is used, then device complexity is reduced, but alignment precision and safety deteriorate
Solution Approach 1:
A laser alignment guide is introduced as an intermediary tool between the operator and the wheel-rail alignment task. The laser projects a visible reference line that serves as a mediator, enabling the operator to achieve precise alignment without requiring complex mechanical alignment devices or advanced operator skill.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with an optical-based laser alignment guide. Instead of using mechanical gauges, blocks, or complex positioning mechanisms, a laser beam provides a visual reference that simplifies the alignment process while improving precision.
2Productivity
If manual alignment is performed, then equipment cost is reduced, but productivity and safety deteriorate
Solution Approach 1:
The laser alignment guide acts as a simple intermediary device that dramatically improves productivity during mode transitions. By providing a clear visual reference, it enables faster and more reliable alignment compared to manual methods, without introducing complex automated systems.
Solution Approach 2:
The laser alignment guide is designed to be self-aligning with the rail geometry, eliminating the need for complex calibration procedures. The system automatically adapts to the rail configuration, reducing the complexity burden on the operator while improving transition efficiency.
3Reliability
If manual alignment is used, then device complexity is minimized, but reliability and safety deteriorate
Solution Approach 1:
The laser alignment guide serves as a reliable intermediary that ensures consistent and accurate wheel-rail engagement. By providing a visible and stable reference line, it eliminates the variability and errors associated with manual alignment, significantly improving reliability without requiring complex automated positioning systems.
Solution Approach 2:
The laser alignment guide provides immediate visual feedback to the operator during the alignment process. The operator can directly observe the laser line's position relative to the wheel and rail, enabling real-time adjustments and ensuring reliable engagement without complex sensor systems or automated feedback loops.
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
Improves the efficiency and safety of transitioning from road mode to rail mode by accurately aligning rail wheels with the track, reducing the risk of damage and injury.
Implementation Method 1
a laser mounted to a frame of a railcar mover that assists with the alignment of a rail wheel and the rail of a track
Data Source
AI summary
A laser alignment system for a railcar mover is disclosed herein. The laser alignment system may comprise a laser mounted to a frame of a railcar mover that assists with the alignment of a rail wheel and the rail of a track when switching from road mode to rail mode. In various embodiments, the laser may be mounted to the frame of the railcar mover via a mount and/or mounting structure that enable the laser to be moved and/or the orientation of the laser to be adjusted relative to the railcar mover. In some embodiments, the laser alignment system may include a window underneath the operator of the railcar mover so that a laser beam emitted by the laser can be seen by the operator.