Automatic Spike Feeder System for Rail Maintenance
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Solution Overview
Problem
Manual loading of rail spikes into feed trays during rail maintenance is tedious and distracts operators, requiring additional labor and resources, as existing automated systems are not efficient in orienting and conveying spikes to spike drivers without operator intervention.
Innovation Solution
An automatic spike feeder system that includes a singulator to receive randomly oriented spikes, a conveyor to deliver them to a spike driving mechanism, and a spike orienting tray that automatically orients spikes in a tip-down, head-up position for efficient feeding into spike driver magazines, reducing the need for manual handling and allowing a single operator to manage both spike feeding and driving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading of spikes into feed trays is performed, then spikes can be oriented and delivered to spike drivers, but operator attention is distracted and additional labor is required
Solution Approach 1:
The system enables self-service operation where the automated feeder mechanism independently performs spike extraction, orientation, and delivery to the magazine without requiring operator intervention. The spike feed tray automatically replenishes itself from the bulk storage bin, eliminating the need for manual loading operations and freeing operator attention for primary spike driving tasks.
2Extent of automation
If automated spike delivery system is implemented, then labor requirements are reduced, but system complexity increases
Solution Approach 1:
The automated feeder system is divided into distinct functional modules: a bulk storage bin for spike reservoir, a feed tray mechanism for individual spike extraction and orientation, and a magazine loading system for delivery to spike drivers. This segmentation allows each component to perform its specific function independently, simplifying the overall system design and maintenance while achieving comprehensive automation.
3Productivity
If spikes are automatically oriented and conveyed, then manual handling is reduced, but the system requires precise orientation mechanisms
Solution Approach 1:
The feed tray mechanism performs preliminary orientation of spikes before they are loaded into the magazine. By pre-orienting spikes in the correct position during the feeding process, the system ensures proper alignment is achieved automatically, enabling high productivity without compromising orientation precision. This preliminary action occurs as spikes are extracted from the bulk bin and prepared for magazine insertion.
Data Source
AI summary
An automatic rail spike feeder system for use with a rail maintenance vehicle having a bulk storage bin for containing a supply of spikes, and at least one spike driving mechanism, includes a mechanism constructed and arranged for receiving a supply of spikes from the storage bin and for automatically delivering individual spikes to the at least one spike driving mechanism in a desired orientation without operator contact of the spikes.