Railyard Switch Run Through Electronic Detection and Alarm System

A railyard switch run through (SRT) detection system includes at least one sensor, a detection node in communication with the at least one sensor, where the detection node includes a microcontroller and a power source, and an alert station in communication with the detection node. The alert station includes an indicator and a power source, where the detection node, based on data from the at least one sensor, is configured to detect an SRT event and activate the indicator of the alert station.

BACKGROUND OF THE INVENTION

Field of the Invention

The present disclosure relates to a railyard switch run through electronic detection and alarm system.

Description of Related Art

Railyard switch run through (SRT) events occur in railyards during switching operations within the railyard. An SRT event occurs when a train passes through a switch, generally from the crossover or frog side of the switch, and the switch is misaligned with the direction of train travel. Switch stands, such as non-trailable-type switch stands, are rigid, robust mechanical devices that maintain the direction of the points of the switch. When an SRT occurs, the switch stand components are damaged, connecting rods may be bent during compression type SRT events, and the switch stand gears may be torn out during tension type SRT events. If an SRT event goes undetected and the train operator reverses direction of the train through the switch, the indeterministic state of the switch can cause a derailment within the railyard causing significant repair costs, labor costs, cleanup costs, and production down time. One solution has been to use a trailable-type switch, which is sometimes referred to as a flop switch. A trailable-type switch will automatically direct the points of the misaligned switch in the direction of travel of the train, which prevents damage to the switch, but can leave the switch set in a direction opposite to the original setting of the switch. Some rail operators do not approve of trailable-type switches and continue to use non-trailable-type switches in their railyards.

SUMMARY OF THE INVENTION

In one aspect or embodiment, a railyard switch run through (SRT) detection system includes at least one sensor, a detection node in communication with the at least one sensor, with the detection node including a microcontroller and a power source, and an alert station in communication with the detection node. The alert station includes an indicator and a power source where the detection node, based on data from the at least one sensor, is configured to detect an SRT event and activate the indicator of the alert station.

The at least one sensor may include a plurality of strain gauges. The detection node may include an analog front end controller having an analog to digital converter, with the at least one sensor connected to the analog to digital converter and the analog to digital converter connected to the microcontroller. The analog front end controller may include a temperature sensor input. The power source of the detection node may include at least one of a battery and a solar panel. The power source of the alert station may include at least one of a battery and a solar panel. The system may include a plurality of detection nodes in communication with the alert station. The detection node may be wirelessly connected to the alert station. The indicator of the alert station may include at least one of a light and a horn. The alert station may be configured to be in communication with a local network and/or cloud. The detection node may include an alarm indicator configured to provide an indication once the SRT event is detected.

The detection node may include an enclosure, an installation bracket, and an antenna for wireless communication with the alert station, with the microcontroller received within the enclosure and the installation bracket connected to the enclosure and configured to secure the detection node to an object or ground surface.

In one aspect or embodiment, a railyard switch run through (SRT) detection system includes at least one sensor and a detection node in communication with the at least one sensor. The detection node includes a microcontroller, an analog front end controller, and a power source. The analog front end controller includes an analog to digital converter, with the at least one sensor connected to the analog to digital converter and the analog to digital converter connected to the microcontroller. The detection node, based on data from the at least one sensor, is configured to detect an SRT event.

In a further aspect or embodiment, a method of detecting a railyard switch run through (SRT) event includes: attaching at least one strain gauge to a component of a railyard switch stand;    connecting the at least one strain gauge to a detection node; transmitting data from the at least one strain gauge to the detection node; and identifying the SRT event using a processor by comparing data from the at least one strain gauge to baseline stain gauge data for switch traffic and position changes.

The method may further include providing an alert indication of the SRT event.

DETAILED DESCRIPTION OF THE INVENTION

Spatial or directional terms, such as “left”, “right”, “inner”, “outer”, “above”, “below”, and the like, are not to be considered as limiting as the invention can assume various alternative orientations.

For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations, except where expressly specified to the contrary. It is also to be understood that the specific devices illustrated in the attached drawings, and described in the following specification, are simply exemplary aspects of the invention.

Unless otherwise indicated, all ranges or ratios disclosed herein are to be understood to encompass the beginning and ending values and any and all subranges or subratios subsumed therein. For example, a stated range or ratio of “1 to 10” should be considered to include any and all subranges or subratios between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges or subratios beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less.

The terms “first”, “second”, and the like are not intended to refer to any particular order or chronology, but refer to different conditions, properties, or elements.

As used herein, “at least one of” is synonymous with “one or more of”. For example, the phrase “at least one of A, B, and C” means any one of A, B, or C, or any combination of any two or more of A, B, or C. For example, “at least one of A, B, and C” includes one or more of A alone; or one or more of B alone; or one or more of C alone; or one or more of A and one or more of B; or one or more of A and one or more of C; or one or more of B and one or more of C; or one or more of all of A, B, and C.

Referring toFIGS.1-8, in one aspect or embodiment, an SRT detection system10includes a sensor(s)12, a detection node14in communication with the sensor(s)12, and an alert    station16in communication with the detection node14. The detection node14includes a microcontroller18and a power source20. The alert station16includes an indicator22and a power source24. The detection node14, based on data from the sensor(s)12, is configured to detect an SRT event and activate the indicator22of the alert station16. The microcontroller18may include at least one processor, or any other like computing device for controlling one or more aspects of the system10.

In one aspect or embodiment, the sensor(s)12includes a plurality of strain gauges. In one example, four strain gauges are provided and are configured to be attached to one or more components26of a railyard switch28. The strain gauges may be connected to the railyard switch28via an adhesive, such as epoxy, although other suitable attachment arrangements may be utilized. Although the sensor(s)12are shown on top of a connecting rod inFIG.3, one or more sensor(s)12may be positioned on the top of the connecting rod and one or more sensor(s)12may be positioned on a side of the connecting rod.

Referring toFIGS.5and8, the detection node14includes an analog front end controller30having an analog to digital converter32, with the sensor(s)12connected to the analog to digital converter32and the analog to digital converter32connected to the microcontroller18. The analog front end controller30may include a temperature sensor input34. The analog front end controller30and/or the sensor(s)12may include bridges and amplifiers circuits36. In one aspect or embodiment, the detection node14includes four inputs38and four outputs40. The detection node14may include an alert light output, a horn output, a reset/test button input, and a thermistor input, although other suitable configurations may be utilized. In one aspect or embodiment, the microcontroller18is configured for low power 80 μA per Mhz up to 48 Mhz. In one aspect or embodiment, the analog front end controller30is configured for simultaneous analog to digital conversion at 24 bit of 4 inputs at 8 ksps. The power source20of the detection node includes at least one of a battery and a solar panel42. In one aspect or embodiment, the power source20of the detection node14includes a photovoltaic solar array and a lithium battery. The detection node14is wirelessly connected to the alert station16. In one aspect or embodiment, the detection node14includes a radio module44, such as a 900 Mhz radio module, for communication with the alert station16. The detection node14includes a power monitoring circuit46, a main regulator circuit48, and a header and fuses circuit50. The detection node14includes an alarm indicator56configured to provide an indication when the SRT event is detected. The alarm    indicator56may be an LED light, although other suitable arrangements may be utilized. The alarm indicator56may also provide a status of the detection node14. In one aspect or embodiment, the system10includes a plurality of detection nodes14in communication with the alert station16. The alert station16may support up to 32 detection nodes14in a meshing network configuration or up to 255 detection nodes14if a meshing network is not required for the installation.

Referring toFIGS.6and7, the detection node14includes an enclosure58, an installation bracket60, and an antenna62for wireless communication with the alert station16. The microcontroller18, the analog front end controller30, the power monitoring circuit46, the main regulator circuit48, and the head and fuses circuit50are received within the enclosure58. The installation bracket60is connected to the enclosure58and configured to secure the detection node14to an object or ground surface. The solar panel42is connected to and extends from the installation bracket60. A reset/test button64is positioned outside of the enclosure58. The installation bracket60may be formed from T-slot framing components.

Referring toFIGS.1and4, the alert station16further includes a mounting pole70and an enclosure72. The mounting pole70may include support legs74to support the mounting pole70on a ground surface, although the mounting pole70may be fixed directly to a ground surface or an object. The indicator22of the alert station16includes at least one of a light76and a horn78. In one aspect or embodiment, the indicator22of the alert station16includes an LED light beacon76and an industrial horn78. The power source24of the alert station16may include at least one of a battery and a solar panel80. In one aspect or embodiment, the power source24of the alert station16includes a photovoltaic solar array and a lithium battery. The alert station16may be in communication with the detection node(s)14via a radio module, such as a 900 Mhz radio module, having an antenna82. The LED light beacon76and/or the horn78may be mounted at a top of the mounting pole70or closer to the top of the mounting pole70than a bottom of the mounting pole70. The position of the LED light beacon76and/or the horn78may be adjustable along the length of the mounting pole70. The alert station16is configured to be in communication with a local network and/or cloud. The alert station16is configured to process messages from the detection node(s)14to determine the message type. If an alarm message is received by the alert station16, the alert station16is configured to activate the light76and the horn78local to the alert station16as well as send the alarm message data to a cloud-based monitoring platform to    provide remote alarms via a webpage, email, and/or text message. The alert station16may include a microcontroller and/or processor (not shown).

In one aspect or embodiment, a method of detecting an SRT event includes: attaching the strain gauge(s)12to the component26of the railyard switch stand28; connecting the strain gauge(s)12to the detection node14; transmitting data from the strain gauge(s)12to the detection node14; and identifying the SRT event using a processor by comparing data from the strain gauge(s)12to baseline stain gauge data for switch traffic and position changes. The method may further include providing an alert indication of the SRT event, such as by activating the light76and horn78.

Referring toFIGS.9-12, in one aspect or embodiment, data from the sensor(s)12is processed by the microcontroller18of the detection node(s)14to compare the incoming data to the baseline strain gauge data. An SRT event recognition algorithm is used to verify that the incoming data meets an SRT event signature that has been established through testing and monitoring of data during SRT events. As shown inFIG.10, the stain gauge data during an SRT event displays a rapid buildup of strain to a release and then an oscillation. The oscillation occurs each time a wheel of a passing train passes the points of the railyard switch28. The strain gauge data during an SRT event, as shown inFIG.10, is measured against the baseline strain gauge data for switch position changes, as shown inFIG.11, and normal traffic through the switch28, as shown inFIG.12. In one aspect or embodiment, the SRT event recognition algorithm keeps a long rolling average, keeps an instantaneous average (over a few ms of time), keeps a record of maximum and minimum of instantaneous averages during long rolling average period, calculates and keeps maximum delta between the maximum and minimum, detects several consecutive changes (peaks and valleys), and, if a maximum delta is above a threshold and multiple consecutive peaks and valleys have been detected, the system10triggers an alarm message. The SRT event detection firmware flow chart is shown inFIG.9. The system10is initiated86, local radio is established and mesh network connection is maintained88, and the analog front end controller is initiated for continuous fast reporting90. The microcontroller18includes a main sleep mode92with a maintenance timer94and associated collection of status and telemetry of the detection node(s)96, which is subsequently transmitted to the alert station16and/or network. The microcontroller18also awakens upon receipt of new data98from the analog front end controller30, runs calculations to identify if an SRT event occurred100, and determines whether    an SRT event occurs102. If an SRT event occurs, the alarm message is transmitted to the alert station16and/or network to activate the light76and horn78and transmit the alarm message104to the local network and/or cloud.

Accordingly, the system10is configured to electronically monitor strain on the components of a railyard switch and process strain readings in real-time to determine excessive component stress caused by an SRT event. The system10is also configured to wirelessly transmit an alarm message to the alert station16to alert railyard operators of an SRT event with audible and/or visual indicators until the system10is reset. The system10is configured to be entirely self-powered.