Railroad Tie Plate Positioning via Optical Sensor Feedback
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Solution Overview
Problem
Existing machinery for positioning railroad tie plates along railroad tracks faces challenges with mis-positioning due to mechanical tolerances over time, leading to the need for precise detection and placement of replacement tie plates.
Innovation Solution
A system comprising a carrier vehicle with a gravity feed roller conveyor, a sensor, and an actuator that detects in-service tie plates and ejects replacement tie plates in a preselected spaced pattern, using hydraulic, pneumatic, or mechanical actuation to ensure accurate placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If timing arrangements are used to deposit railroad tie plates, then the apparatus can deliver tie plates at each railroad tie, but mis-positioning of railroad tie plates increases over longer distances and periods of time due to mechanical tolerances
Solution Approach 1:
The patent replaces the mechanical timing transmission arrangement with an optical sensor system that detects the actual position of railroad ties and controls tie plate deposition accordingly. The sensor assembly uses optical fields instead of mechanical linkages to determine placement locations, eliminating cumulative positioning errors over long distances.
Solution Approach 2:
The system incorporates feedback by using the optical sensor to detect the actual position of railroad ties and adjusting the deposition timing based on real-time detection. The controller receives signals from the sensor and actuates the deposition mechanism only when a tie is detected at the correct position, ensuring accurate placement regardless of distance traveled.
2Duration of action of stationary object
If mechanical tolerances are allowed to accumulate over time, then the timing transmission arrangement can operate continuously, but the positioning accuracy of tie plates deteriorates
Solution Approach 1:
The patent replaces the mechanical timing system with an optical detection and control system that does not suffer from mechanical wear or tolerance accumulation. The optical sensor and electronic controller maintain positioning accuracy over extended operation periods without degradation from mechanical tolerances.
Solution Approach 2:
The system performs self-correction by continuously detecting tie positions and adjusting deposition timing automatically. The sensor-controller-actuator loop compensates for any deviations in real-time, eliminating the need for manual adjustment even after prolonged operation.
3Manufacturing precision
If a sensor system is implemented to detect tie plate locations, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The optical sensor assembly serves multiple functions: detecting railroad ties, determining their positions, and providing feedback for deposition control. This multi-functionality reduces the need for separate mechanical measurement and timing devices, offsetting the added complexity with consolidated functionality.
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 effectively reduces mis-positioning errors by accurately detecting existing tie plates and depositing replacement tie plates in the correct location, enhancing the efficiency and accuracy of railroad maintenance.
Implementation Method 1
The sensor may be magnetic or an optical sensor
Implementation Method 2
The sensor may be magnetic or an optical sensor
Implementation Method 3
a roller conveyor formed of frame members and a plurality of idler rollers, the roller conveyor having an upper input end and a lower output end for gravity feeding the plurality of tie plates
Implementation Method 4
The actuator is a hydraulic cylinder and piston
Data Source
AI summary
A method for positioning a replacement railroad tie plate along a railroad, comprising the steps of positioning a carrier vehicle on a railroad track, positioning a feed conveyor on the railroad track for movement with the carrier vehicle, moving a sensor assembly in a longitudinal direction of the feed conveyor and relative to a release point a first distance based upon a second distance between two adjacent ties, moving the carrier vehicle and the feed conveyor along the railroad track, detecting an in-service tie plate with the sensor assembly and, actuating a gate assembly upon the detection of the in-service tie plate.