Abstract:
A rail alignment system for locating a first end piece and a second end piece of a first rail section and a second rail section. The rail alignment system comprises (a) a first rail alignment tool for engaging and applying force to said first rail section; and (b) a second rail alignment tool for engaging and applying force to said second rail section. The first rail alignment tool includes: (1) a planar plate for extending transversely beneath said first rail section; (2) a pair of block members, each secured to said planar plate and each defining a threaded cavity which is substantially orthogonal to said first rail section and which are aligned with one another; (3) a pair of externally threaded bolts, each adapted for engaging one of said threaded cavities of said pair of block members; and (4) a pair of contoured rail engagement end pieces, each secured to an inner terminating portion of said pair of externally threaded bolts for engaging said first rail section. The second rail alignment tool includes: (1) a planar plate for extending transversely beneath said second rail section; (2) a pair of block members, each secured to said planar plate and each defining a threaded cavity which is substantially orthogonal to said second rail section and which are aligned with one another; (3) a pair of externally threaded bolts, each adapted for engaging one of said cavities of said pair of block members; and (4) a pair of contoured rail engagement end pieces, each secured to an inner terminating portion of said pair of externally threaded bolts for engaging said second rail section. Said first end piece of said first rail section and said second rail section may be aligned by selectively applying torque to said two pair of externally threaded bolts.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-in-Part of U.S. application Ser. No. 09/634,899, filed Aug. 9, 2000, titled “Rail Alignment Tool,” now U.S. pat. No. 6,358,861 which claimed the benefit of U.S. Provisional Application No. 60/147,963, filed Aug. 9, 1999, titled “Rail Alignment Tool.” 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates in general to tools which are utilized to align railroad rails, and in particular to tools which are utilized to align abutting rails in order to allow welding of the rails together. 
     2. Description of the Prior Art 
     All railroads have a considerable investment in their infrastructure. However, the infrastructure requires continuous attention and repair. For example, as rail becomes worn or damaged, it must be replaced. Currently, rail is in relatively long continuous sections; however, these sections must be butt welded together in order to allow for safe and efficient locomotion over the rail. In the prior art, in order to get a good weldment between the end pieces of rail sections, work crews have utilized manual equipment, such as mauls, hammers, and wedges to align the ends of the rails prior to welding. Having railroad crews operate this heavy equipment inherently carries a risk of injury to the employee. For example, when aligning rails with wedges, metal chips may fly off of the wedges when they are struck by hammers during the hammering and wedging operations, resulting in injuries to the workers. Additionally, using the heavy equipment is also inherently risky. Any new rail equipment which can reduce the risk of injury to rail crews is typically quickly and readily adopted by the industry. 
     SUMMARY OF THE INVENTION 
     It is one objective of the present invention to provide a rail alignment tool which replaces the utilization of mauls, hammers, and wedges in order to align rail ends prior to welding. 
     It is another objective of the present invention to provide an improved rail alignment tool which allows rail pieces to be aligned, but which only requires the work crew to apply torque to a plurality of threaded bolt members, which is far safer than utilizing mauls, hammers, and wedges. 
     It is yet another objective of the present invention to provide an improved rail alignment tool which is durable, lightweight, and which requires little or no maintenance, but which is safe to operate and which provides for good alignment of rail sections to allow for good welds to be made between adjoining rail sections. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of the preferred embodiment when read in conjunction with the accompanying drawings, wherein: 
     FIG. 1 plan view of the rail alignment tools according to one embodiment of the present invention in use to align two sections of rail prior to welding; 
     FIG. 2 is a right side view of the rail alignment tools of FIG. 1; 
     FIG. 3 is an enlarged plan view of one of the rail alignment tools of FIG. 1; 
     FIG. 4 is a front view of one of the rail alignment tools of FIG. 1; 
     FIG. 5 is a right side view of one of the rail alignment tools of FIG. 1; 
     FIG. 6 is a partial front view of the rail alignment tool of FIG. 4; 
     FIGS. 7A and 7B are plan and left side views, respectively, of the preferred embodiment of the rail alignment tool according to the present invention; 
     FIG. 8 is a front view of a sliding plate of the rail alignment tool of FIG.  7 A. 
     FIGS. 9A and 9B are front views of a jack member of the rail alignment tool of FIG. 7A illustrated in retracted and extended modes, respectively. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1 in the drawings, one embodiment of the rail alignment system according to the present invention is illustrated. Rail alignment tools  11 ,  13  are shown being utilized to align rail segments  15 ,  17  in abutting relationship in order to obtain alignment between rails  15 ,  17  prior to the welding together of rails  15 , 17 . Rail alignment tool  11  is utilized to selectively locate an end  23  of rail  15 , while rail alignment tool  13  is utilized to selectively locate an end  25  of rail  17 . Rail alignment tools  11 ,  13  may be adjusted incrementally in order to provide for a desired alignment of rails  15 ,  17 . Rail alignment tool  11  includes a base member  27  that is configured for attachment to a cross tie  19 . Similarly, rail alignment tool  13  includes a base member  29  that is configured for attachment to a cross tie  21 . Although it is preferred that rail alignment tools  11 ,  13  be mirror images of each other, it should be understood that in certain applications, it may be desired that rail alignment tool  11  have a different configuration than rail alignment tool  13 . 
     The rail alignment system according to the present invention includes a means for securing rail alignment tools  11 ,  13  to cross ties  19 ,  21 , such that rail alignment tools  11 ,  13  may be used with wooden cross ties, concrete cross ties, or cross ties made of any other conventional material. To accommodate use with wooden ties, base member  27  includes spike ports  31 ,  33  through which may driven conventional railroad spikes  40  (see FIG. 3) to secure base member  27  in a fixed position relative to cross tie  19 . Likewise, base member  29  includes spike ports  35 ,  37  through which may driven conventional railroad spikes  40  to secure base member  29  in a fixed position relative to cross tie  21 . To accommodate use with concrete ties, base member  27  includes tabs  36 ,  38  which are configured for connection to rail clips (not shown) to secure base member  27  in a fixed position relative to cross tie  19 . The rail clips are used to secure the rails to the concrete cross ties. Similarly, base member  29  includes tabs  40 ,  42  which are configured for connection to the rail clips (not shown) to secure base member  29  in a fixed position relative to cross tie  21 . It will be appreciated that the means for securing rail alignment tools  11 , 13  to cross ties  19 ,  21  may take on other forms. 
     It is preferred that base member  27  be disposed between rail  15  and cross tie  19 ; however, it should be understood that base member  27  may be disposed at other locations relative to rail  15  and cross tie  19  without affecting the functionality of rail alignment tool  11 . For example, base member  27  may be configured to function from positions above or to either side of rail  15 . 
     Rail alignment tool  11  includes adjustment members  41 ,  45  which are preferably disposed transverse to rail  15 . Adjustment members  41 ,  45  are utilized to adjustably move end  23  of rail  15  in a transverse direction relative to cross tie  19 . Adjustment member  41  is coupled to base member  27  via a coupling  43 , and adjustment member  45  is coupled to base member  32  via a coupling  47 . Adjustment member  41  terminates with a rail engagement member  49 , and adjustment member  45  terminates with a similar rail engagement member  51 . Rail engagement members  49 ,  51  are configured to engage rail  15 . In other words, rail engagement members  49 ,  51  are profiled or contoured in a manner which provides for good mating contact with a portion of rail  15 . It is preferred that adjustment members  41 ,  45  include external threads and that couplings  43 ,  47  include fixed, mating internal threads in order to allow for efficient transfer of force from adjustment members  41 ,  45  to rail  15 . Thus, as adjustment members  41 ,  45  are rotated back and forth, rail engagement members  49 ,  51  advance and retract in a transverse direction relative to rail  15  in a manner which collectively fixes the location of end  23  of rail  15 . 
     In a similar fashion, rail alignment tool  13  includes adjustment members  61 ,  67  which are preferably disposed transverse to rail  17 . Adjustment members  61 ,  67  are utilized to adjustably move end  25  of rail  17  in a transverse direction relative to cross tie  21 . Adjustment member  61  is coupled to base member  29  via a coupling  63 , and adjustment member  67  is coupled to base member  34  via a coupling  69 . Adjustment member  61  terminates with a rail engagement member  65 , and adjustment member  67  terminates with a similar rail engagement member  71 . Rail engagement members  65 ,  71  are configured to engage rail  17 . In other words, rail engagement members  65 ,  71  are profiled or contoured in a manner which provides for good mating contact with a portion of rail  17 . It is preferred that adjustment members  61 ,  67  include external threads and that couplings  63 ,  69  include fixed, mating internal threads in order to allow for efficient transfer of force from adjustment members  61 ,  67  to rail  17 . Thus, as adjustment members  61 ,  67  are rotated back and forth, rail engagement members  65 ,  71  advance and retract in a transverse direction relative to rail  17  in a manner which collectively fixes the location of end  25  of rail  17 . 
     Rail alignment tool  11  includes at least one means  80  for adjusting the height of rail alignment tool  11 , and rail alignment tool  13  includes at least one means  84  for adjusting the height of rail alignment tool  13 . Means  80  is preferably a threaded adjustment screw that is coupled to base member  27  via a coupling  82  and passes through base member  27  to contact cross tie  19 . Likewise, means  84  is preferably a threaded adjustment screw that is coupled to base member  29  via a coupling  86  and passes through base member  29  to contact cross tie  21 . Means  80 ,  82  are utilized to adjustably raise ends  23 ,  25  of rails  15 ,  17  in a vertical direction relative to cross ties  19 ,  21 , respectively. It is preferred that means  80 ,  84  include external threads and that couplings  82 ,  86  include fixed, mating internal threads in order to allow for efficient transfer of force from means  80 ,  84  to rails  15 ,  17 . Thus, as means  80 ,  84  are rotated back and forth, base members  27 ,  29  raise and lower in a vertical direction relative to cross ties  19 ,  21 , thereby, raising and lowering ends  23 ,  25  of rails  15 , 17 , respectively. It should be understood that means  80 ,  84  may include other methods of raising ends  23 ,  25 . 
     Referring now to FIG. 2 in the drawings, rail alignment tools  11 ,  13  are illustrated in a right side view. As is shown, base members  27 ,  29  are disposed between cross ties  19 ,  21  and rails  15 ,  17 . As torque is applied to adjustment members  41 ,  45 ,  61 ,  67 , rail engagement members  49 ,  51 ,  65 ,  71  are moved inward and outward relative to base members  27 ,  29  in order to determine the lateral location of ends  23 ,  25  of rails  15 ,  17 , thereby placing ends  23 ,  25  of rails  15 ,  17  in proper lateral alignment for welding. In addition, as torque is applied to means  80 ,  84 , base members  27 ,  29  are moved upward and downward relative to cross ties  19 ,  21  in order to determine the vertical location of ends  23 ,  25  of rails  15 ,  17 , thereby placing ends  23 ,  25  of rails  15 ,  17  in proper vertical alignment for welding. Once ends  23 ,  25  of rails  15 ,  17  are properly aligned, a welding crew may perform a butt weld between rails  15 ,  17  in order to create a continuous section of rail. In other words, a gap  24  between ends  23 ,  25 , which is exaggerated in the views of FIGS. 1 and 2, is closed by the butt weld. After rails  15 ,  17  have been welded together, adjustment members  41 ,  45 ,  61 ,  67  are loosened, spikes  40  are removed from cross ties  19 ,  21  by conventional means, and rail alignment tools  11 , 13  are removed. 
     Referring now to FIG. 3 in the drawings, a detailed view of rail alignment tool  11  of FIG. 1 is illustrated. As is shown, adjustment member  41  includes exterior threads  81  and coupling  43  includes interior threads  83 . Rotation of adjustment member  41  in one direction advances rail engagement member  49  inward toward rail  15 , while rotation of adjustment member  41  in the opposite direction moves rail engagement member  49  outward relative to rail  15 . Likewise, adjustment member  45  includes external threads  85 , while coupling  47  includes internal threads  87 . Rotation of adjustment member  45  in one direction will advance rail engagement member  51  inward toward rail  15 , while rotation of adjustment member  45  in the opposite direction will move rail engagement member  51  outward from rail  15 . 
     Referring now to FIG. 4 in the drawings, a simplified longitudinal section view of rail alignment tool  11  as utilized to engage rail  15  is illustrated. As is shown, base member  27  is disposed between rail.  15  and cross tie  19 . Adjustment members  41 ,  45  may be adjusted relative to couplings  43 ,  47  in order to put rail engagement members  49 ,  51  in force-transference engagement with the bottom flanges of rail  15 . As is shown, rail engagement members  49 ,  51  include contoured outer ends  97 ,  99  which are configured to matingly engage the bottom flanges of rail  15  at the corner or shoulder portion of the flanges so that force is transferred in the vertical and transverse directions. Preferably, rail engagement members  49 ,  51  include swivel couplings  100 ,  102  which have some inherent “adaptability” as they engage rail  15 , but which become more rigid as force is applied through the adjustment of adjustment members  41 ,  45 . As is shown, couplings  100 ,  102  may be secured to adjustment members  41 ,  45  at cavities  101 , 103  formed in the ends of adjustment members  41 ,  45 . 
     Referring now to FIGS. 5 and 6 in the drawings, rail alignment tool  11  is illustrated in a right side view and a slightly enlarged front view, respectively. The relative position of adjustment member  41  and means  80  is shown. In these views, the operation of means  80  for adjusting the height of rail alignment tool  11  is depicted. As is shown, means  80  preferably includes external threads  105 . Coupling  82  includes a vertical port having internal threads  107  that mate with external threads  105 . A counter bore  113  is provided at the lower end of means  80 . Counter bore  113  is adapted to receive a jack member  111 . When means  80  is fully retracted relative to base member  27 , jack member  111  is disposed within a recess  109  on the bottom surface of base member  27 . As means  80  is rotated, it extends through base member  27  causing jack member  111  to come into contact with cross tie  19 . Further downward extension of means  80  causes base member to rise relative to cross tie  19 . In this manner, base member  27  may be raised and lowered relative to cross tie  19  in order to fix the vertical position of end  23  of rail  15 . 
     Referring now to FIGS. 7A,  7 B,  8 ,  9 A, and  9 B, the preferred embodiment of the rail alignment tool and system according to the present invention is illustrated. In this embodiment a rail alignment tool  201  performs the same functions of rail alignment tool  11  by employing a slightly different methodology. Although only one rail alignment tool  201  is illustrated, it will be understood that in this embodiment, two such rail alignment tools  201  are employed, one on each section of adjoining rail. 
     Referring now specifically to FIGS. 7A and 7B in the drawings, rail alignment tool  201  is illustrated in a top plan view and a left side view, respectively. Rail alignment tool  201  includes a base member  203  and a sliding carriage member  205  that translates longitudinally relative to base member  203 , and transversely relative to a rail  207 . Base member  203  includes at least one spike port  209  through which a conventional rail road spike (not shown) may be driven to secure rail alignment tool  201  to a wooden cross tie (not shown). To accommodate use with concrete ties, base member  203  includes tabs  211 ,  213  which are configured for connection to rail clips (not shown) to secure rail alignment tool  201  in a fixed position relative to the concrete cross tie (not shown). As mentioned above, the rail clips are used to secure the rails to the concrete cross ties. 
     Base member  203  carries at least one jack member  213  for lifting base member  203  relative to the cross tie. Jack member  213  includes a protective sleeve portion  214 , and a vertical adjustment means  216 . Jack members  213  will be discussed in more detail with respect to FIGS. 9A and 9B. 
     Base member  203  includes an upraised block member  215 . In the preferred configuration of this embodiment, block member  215  includes an aperture through which is fitted thrust bearings  217  having internal threads (not shown). A threaded shaft  219  having mating external threads  221  passes through thrust bearings  217 . At least one handle  223  to aid in carrying rail alignment tool  201  is coupled to base member  203 . 
     Additionally referring now to FIG. 8 in the drawings, carriage member  205  is illustrated in a front view. Carriage member  205  translates longitudinally relative to base member  203 , and transversely relative to a rail  207 . In the preferred configuration, base member  203  includes an elongated aperture  225 . Aperture  225  includes a counter bored portion that forms a recessed portion  227  having a flanged surface that is exposed to the underneath surface of base member  203 . Carriage member  205  includes an upper plate  231  and a lower plate  233 . Upper plate  231  is wider and longer than elongated aperture  225 , such that upper plate translates upon the upper surface of base member  203  over elongated aperture  225 . Lower plate  233  is wider than elongated aperture, but not as wide and not as thick as the counter bored portion, such that lower plate  233  is either flush with the underneath surface of base member  203 , or entirely disposed within recessed portion  227 . Upper plate  231  is coupled to lower plate  233  via one or more pivot pins  255 ,  257 . In this manner, base member  203  is sandwiched between upper plate  231  and lower plate  233  of carriage member  205 . 
     Because upper plate  231  is disposed on the upper surface of base member  203 , and because the rail is carried on the upper surface of upper plate  231 , an upraised lip  235  is provided to ensure that base member  203  and the underneath surface of rail  207  remain substantially coplanar. It should be understood that upper plate  231  may be configured to be flush with the upper surface of base member  203  without affecting the functionality of rail alignment tool  201 . 
     At least one guide means  241  may be coupled to base member  203  to ensure that carriage member  205  translates in the desired direction. In addition, sleeve portions  214  of jack members  213  may include guide means  243  to further ensure that carriage member  205  translates in the desired direction. Other guide members and alignment tabs, such as alignment tab  246 , may be included on rail alignment tool  201  to aid in properly attaching and aligning rail alignment tool  201  to and with the cross tie. 
     Carriage member  205  includes clamping means  251 ,  253  for clamping rail  207  to rail alignment tool  201 . Clamping means  251 ,  253  are pivotally coupled to carriage member  205  by pivot pins  255 ,  257 , respectively. Clamping means  251  includes a handle portion  257  and a rail engagement portion  259 . Likewise, clamping means  253  includes a handle portion  263  and a rail engagement portion  265 . By rotating clamping means  251  with handle portion  257  in the directions of arrow A, rail engagement portion  259  engages and disengages one lower flange  271  of rail  207 . In a similar fashion, by rotating clamping means  253  with handle portion  263  in the directions of arrow B, rail engagement portion  265  engages and disengages the opposing lower flange  273  of rail  207 . In this manner, rail  207  is secured to carriage member  205 . 
     Carriage member  205  includes a receiver  281  having internal threads  283  for matingly receiving threaded shaft  219 . Thus, rotation of threaded shaft  219  causes carriage member  205  to translate longitudinally relative to base member  203  along elongated aperture  225 . Once base member  203  is secured to the cross tie, and rail  207  is clamped and secured to carriage member  205 , rotation of threaded shaft  219  causes rail  207  to translate transversely relative to the cross tie. In this manner, transverse alignment of an end  291  of rail  207  with the end of an adjoining rail (not shown) can be achieved so that the two rails can be welded together. 
     Rail alignment tool  201  may include visual indicia  292  of a trim or default alignment condition. For example, a first indicator mark  294  may be placed on base member  203 , and a second indicator mark  296  may be placed on carriage member  205 . Alignment of indicator mark  294  with indicator mark  296  prior to installation of rail alignment tool  210  onto the cross tie ensures that carriage member  205  will be adjustable in either direction after installation. It will be understood that other types of indicator marks, such as graduated marks, may be used to position rail alignment tools  201  and align the adjacent rails for welding. 
     Referring specifically now to FIGS. 9A and 9B in the drawings, jack member  213  is illustrated in a retracted mode and an extended mode, respectively. Adjustment means  216  of jack member  213  includes a threaded shaft  295  disposed within sleeve portion  214 . Threaded shaft  295  passes through a fixed thrust bearing  297  disposed at the upper end of sleeve portion  214 . A jack foot  299  telescopes into sleeve portion  214 . A receiver  301  having internal threads (not shown) matingly receives threaded shaft  295 . Receiver  301  is fixed to the upper portion of jack foot  299 . Jack foot  301  includes an internal shaft  303  into which threaded shaft is disposed when jack member is in the retracted mode. Jack foot  299  may include a key way  305  which receives a key  307 . Key  307  and key way  305  ensure that jack foot  299  telescopes into an out of sleeve portion in a properly aligned manner. Jack foot  299  terminates with a toe portion  309  that is configured and adapted to engage the cross tie. Toe portion  309  may be pivotally coupled to jack foot  299  to provide a slight amount of angular tolerance between rail alignment tool  201  and the cross tie. It should be understood that one function of sleeve portion  214  is to prevent debris, such as welding debris, from being deposited on threaded shaft  295  and preventing jack member  213  from functioning properly. 
     Because adjustment means  216  and threaded shaft  295  pass through fixed thrust bearing  297 , and because receiver  301  is fixed to jack foot  299 , rotation of adjustment means  216  causes jack foot  299  to translate between the retraced mode of FIG.  9 A and the extended mode of FIG.  9 B. In the retracted mode, base member  203  is either in contact with or in close proximity to the cross tie. In the extended mode, base member  203  is lifted away from the cross tie. In this manner, vertical alignment of end  291  of rail  207  with the end of an adjoining rail (not shown) can be achieved so that the two rails can be welded together. 
     Although the invention has been described with reference to particular embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover any such modifications or embodiments that fall within the scope of the invention.