Apparatus and Methods for Deployment of Welding Repair Systems for Railroad Trackwork

Apparatuses configured to be deployed from mobile welding repair vehicles for the repair of railroad trackwork allow a welding system to be stored and deployed from the mobile welding repair vehicles. The apparatuses deploy from the vehicles on a slide system and are supported by one or more legs, the system having 180-degree or greater rotation for full reach of railroad trackwork for welding repair thereof. Methods of using the same are further provided.

TECHNICAL FIELD

The present invention relates to apparatuses configured to be deployed from mobile welding repair vehicles for the repair of railroad trackwork. Specifically, the apparatuses allow a welding system to be stored and deployed from the mobile welding repair vehicles. The apparatuses deploy from the vehicles on a slide system and are supported by one or more legs, the system having 180-degree or greater rotation for full reach of railroad trackwork for welding repair thereof. Methods of using the same are further provided.

BACKGROUND

In-service railroad trackwork is difficult to repair due to increasing railroad traffic requirements resulting in the need for smaller windows to schedule repairs. Specifically, it is difficult to obtain access to in-service railroad tracks and perform welding repairs thereon. Because of train traffic on the railroad tracks, it is often very difficult to deploy an on-track mobile welding unit to the repair site as the on-track mobile welding unit would interfere with passing trains.

In some cases, railroad trackwork is accessible only from beside the track and with varying degrees of reach. In other cases, access can only be from on the track within protected time slots (due to aforementioned traffic). In still other cases, access can only be from an adjacent track requiring an ability to reach the other track. Therefore, typical welding units may be difficult to place and operate to access trackwork requiring repair work.

Indeed, typical welding units for repairing railroad tracks usually involve placing a welding unit near or adjacent the railroad trackwork for repair thereof. However, the welding units are typically large in size and difficult to manipulate. Thus, once a welding unit is placed to access specific railroad trackwork locations for repair thereof, it is typically difficult to move the welding unit to access a different location. Moreover, once placed, it is typically difficult to move the welding unit out of the way for passing trains. In addition, when a track is accessible only from an adjacent track or next to an adjacent track, welding units may not have the necessary range to reach the location on the other track for repair thereof.

A need, therefore, exists for an improved mobile welding unit. Specifically, a need exists for an improved mobile welding unit that provides accessibility to various locations of trackwork. More specifically, a need exists for an improved mobile welding unit that can access locations adjacent to tracks requiring repair, on or over tracks requiring repair, or on or near adjacent tracks to tracks requiring repair.

Moreover, a need exists for an improved mobile welding until that is easily transportable to a site for repair. Specifically, a need exists for an improved mobile welding unit that can store the welding unit therein and deploy the welding unit when at the track requiring repair. More specifically, a need exists for an improved mobile welding unit that deploys and provides the necessary reach to access desired repair locations on railroad tracks.

SUMMARY OF THE INVENTION

The present invention relates to apparatuses configured to be deployed from mobile welding repair vehicles for the repair of railroad trackwork. Specifically, the apparatuses allow a welding system to be stored and deployed from the mobile welding repair vehicles. The apparatuses deploy from the vehicles on a slide system and are supported by one or more legs, the system having 180-degree or greater rotation for full reach of railroad trackwork for welding repair thereof. Methods of using the same are further provided.

To this end, in an embodiment of the present invention, a deployable mobile welding system is provided. The deployable mobile welding system comprises a vehicle, a slidable base unit disposed on a track within the vehicle, a boom extending from the slidable base unit, a mounting platform attached to an end of the boom, and a welding unit extending from the mounting platform.

In an embodiment, the base unit is rotatable such that the extendable boom rotates roughly about 180 degrees when deployed from the vehicle.

In an embodiment, the slidable base unit comprises wheels for rolling along the track within the vehicle.

In an embodiment, the boom is extendable.

In an embodiment, the boom is extendable via a pneumatic or a hydraulic cylinder.

In an embodiment, the welding unit extends from a bottom surface of the mounting platform.

In an embodiment, the welding unit is rotatable relative to the mounting platform.

In an embodiment, the welding unit comprises a rotatable mounting base extending from a bottom surface of the mounting platform.

In an embodiment, the welding unit further comprises a first rotatable arm extending from rotatable mounting base.

In an embodiment, the welding unit further comprises a second rotatable arm extending from an end of the first rotatable arm.

In an embodiment, the welding unit further comprises a rotatable welding head extending from an end of the second rotatable arm.

In an embodiment, the welding unit comprises a cold metal transfer (CMT) welding head, a laser hot wire welding head, a laser powder welding head, or a metal inert gas welding head.

In an alternate embodiment of the present invention, a method of using a deployable mobile welding system is provided. The method comprises the steps of: providing a vehicle comprising a slidable base unit disposed on a track within the vehicle, a boom extending from the slidable base unit, a mounting platform attached to an end of the boom, and a welding unit extending from the mounting platform; placing the vehicle near a railroad track requiring welding; moving the slidable base unit along the track to deploy the boom from the vehicle; positioning the boom near the railroad track requiring welding; and manipulating the welding unit to weld the railroad track.

In an embodiment, the method further comprises the step of: rotating the base unit to rotate the boom toward the railroad track requiring welding.

In an embodiment, the boom is extendable, and further comprises the step of: extending the boom from the slidable base unit when positioning the boom near the railroad track requiring welding.

In an embodiment, the welding unit is disposed on a bottom surface of the mounting platform.

In an embodiment, the welding unit is disposed on a bottom surface of the mounting platform and is rotatable relative to the mounting platform, further comprises the step of: rotating the welding unit when manipulating the welding unit to weld the railroad track.

In an embodiment, the welding unit further comprises a first rotatable arm extending from a rotatable mounting base, wherein the rotatable mounting base is disposed on a bottom surface of the mounting platform, and further comprises a second rotatable arm extending from an end of the first rotatable arm, and further wherein a rotatable welding head extends from an end of the second rotatable arm.

In an embodiment, the welding unit comprises a cold metal transfer (CMT) welding head, a laser hot wire welding head, a laser powder welding head, or a metal inert gas welding head.

It is, therefore, an advantage and objective of the present invention to provide an improved mobile welding unit.

Specifically, it is an advantage and objective of the present invention to provide an improved mobile welding unit that provides accessibility to various locations of trackwork.

More specifically, it is an advantage and objective of the present invention to provide an improved mobile welding unit that can access locations adjacent to tracks requiring repair, on or over tracks requiring repair, or on or near adjacent tracks to tracks requiring repair.

Moreover, it is an advantage and objective of the present invention to provide an improved mobile welding until that is easily transportable to a site for repair.

Specifically, it is an advantage and objective of the present invention to provide an improved mobile welding unit that can store the welding unit therein and deploy the welding unit when at the track requiring repair.

More specifically, it is an advantage and objective of the present invention to provide an improved mobile welding unit that deploys and provides necessary reach to access desired repair locations on railroad tracks.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

The present invention relates to apparatuses configured to be deployed from mobile welding repair vehicles for the repair of railroad trackwork. Specifically, the apparatuses allow a welding system to be stored and deployed from the mobile welding repair vehicles. The apparatuses deploy from the vehicles on a slide system and are supported by one or more legs, the system having 180-degree or greater rotation for full reach of railroad trackwork for welding repair thereof. Methods of using the same are further provided.

Now referring to the figures,FIG.1illustrates a deployable mobile welding system10disposed within a vehicle12in an embodiment of the present invention. The vehicle12may preferably be any land vehicle that is typically known to move via wheels without being bound to tracks, such as a train or a railcar. However, it should be noted that the vehicle12may have wheels that are configured to be driven on tracks as the present invention may be useful to be used in such a configuration. The vehicle12may have an internal space13therein having adequate size and shape to hold the various components of the system described herein. The deployable mobile welding system10comprises a plurality of modules, described hereinbelow to show how the deployable mobile welding unit10is stored and/or deployed for use on railroad trackwork14, as illustrated inFIGS.3and4.

Specifically, the vehicle12and the deployable mobile welding system10may be driven or otherwise piloted to a location on or near railroad trackwork14requiring welding work thereon. The vehicle12may be positioned on or adjacent the trackwork14requiring welding and the modules of the deployable mobile welding system10may be used to access the trackwork14as needed. Because the welding equipment on the deployable mobile welding system10, as described herein, may be deployed and used as quickly as possible, it may be cleared in short notice, especially on an in-use railroad track.

The deployable mobile welding system10comprises a base module20(as shown inFIG.2) comprising a base22having an extendable boom24extending therefrom with a welding module40on an end of the extendable boom24. The base22may be slidably connected to a base track module30which may be disposed within the vehicle12, as illustrated inFIGS.1and2. The base track module30may have a track32on which the base22slides thereon, such as, for example, on rollers (not shown) or other means for moving the base22on the track32. When the base22is moved to a location33on the track32, the base22and the extendable boom24may be positioned completely within the vehicle12, as shown inFIG.1. The location33may be a “stored location,” where the base22and the extendable boom24may be positioned during storage and/or deployment of the vehicle. When positioned within the vehicle12, the vehicle12may be moved to trackwork for use thereon or moved to a storage location for storage of the vehicle12when not in use.

The base22may further be moved to a location35on an opposite end of the track32, which may be a “deployed location,” generally allowing the boom24to extend from the vehicle12, as described in more detail below. Therefore, the base22may slide or otherwise roll along the track32back and forth between the stored location33and the deployed location35, as indicated by arrow43.

The base track module30may optionally have a stabilizing unit34extending on and/or from a rear of the vehicle12. The stabilizing unit may have one or more legs38that may be extended to the ground to stabilize the rear of the vehicle12and provide stability for the base22when slid and disposed at the deployed location35. Moreover, a stabilizing base36may further rigidly hold the end of the track32to provide a stable platform on which the track32may extend outside the interior space13of the vehicle12at the deployed location35.

Thus, when the base22is slid or moved to the deployed location35, the base22and the extendable boom24may be positioned at or outside the rear of the vehicle12, thereby allowing a welding module40, as described below, to access the trackwork, as shown inFIGS.3and4and described in more detail below.

The welding module40may be disposed on a terminal end of the extendable boom24. The welding module40may comprise a mounting platform42on which a welding unit44may be disposed and extend therefrom. When deployed from the vehicle12, the welding module40may be placed in a location allowing the welding unit44access to railroad trackwork14requiring welding work thereon. Specifically, the welding module40may be moved via the extendable boom24, which may rotate or swivel on the base22, as described in more detail below.

The welding unit44may be any welding application that may be useful, such as, for example, Cold Metal Transfer (“CMT”), laser hot wire, laser powder, or standard MIG welding systems. Preferably, the welding unit44may be a CMT system comprising a manipulatable robot arm50having a welding head52thereon which may be utilized for welding railroad trackwork14. A CMT system allows for a much smaller form factor vehicle, as it eliminates the need for a chiller, a laser power unit, and allows for the use of a much smaller generator. Therefore, the welding unit44may be more nimble and more effective at welding trackwork14. As shown inFIGS.3and4, the manipulatable robot arm50extends from a bottom surface of the mounting platform42and may be controlled via a controller (not shown) to precisely position the welding head52where needed to conduct the welding. The controller may be located within the vehicle12, at the platform42, or in any other location that may be useful. The mounting platform42may further have other elements thereon useful for welding, such as a wire spool45, or other like elements that may be useful for welding.

The welding module40may be held aloft and at desired locations via the strength and stability of the extendable boom24and the components thereof. Optionally, extending from the welding mounting platform42may be one or more legs46that may extend from the mounting platform42to the ground to provide stability for the mounting platform42and the welding unit44so that the welding unit44may be moved and controller during welding via the controller, yet the mounting platform42may remain immobile during the welding process. To aid in rigidly holding the mounting platform42in position, the boom24may press the legs down on to the ground and use that force to hold the end of the boom24and, therefore, the mounting platform42rigid. As noted above, however, the welding module40may simply be movable and rendered immobile via the extendable boom24without any stabilizing legs or other elements that may contact the ground.

When deployed, the extendable boom24may extend or retract (as indicated via arrow47) to a desired distance from the rear of the vehicle12via a hydraulic or pneumatic cylinder26that may push the extendable boom24to extend the same and pull the extendable boom to retract the same. The extendable boom24may also be rotated upwardly or downwardly to provide vertical positioning of the mounting platform42and, thus, the welding unit44. One or more cable carriers60may be deployed to route control cables or other like elements to the working units of the system10. The cable carriers60may be disposed in a manner to maintain the cables out of the way of the extendable boom24and other like components but be provided so that the cables reach the welding module40when the extendable boom24is fully extended.

In addition, the extendable boom24may further extend out from the rear of the vehicle12in many directions. Specifically, as noted above, the base22may be rotatable on a swivel23so that the boom24may be rotated freely to any position in a roughly 180-degree arc from the rear of the vehicle12, as indicated by arrow49. Thus, the boom24may be extended to reach the railroad trackwork14in many different locations, whether straight from the rear of the vehicle12or to the side of the vehicle12.FIG.3illustrates an embodiment where the extendable boom24extends straight rearwardly from the vehicle12, which may be useful when the vehicle12is positioned on the railroad track14.FIG.4illustrates an embodiment where the extendable boom24is rotated on the swivel23to extend from the side of the vehicle12, which may be useful when the vehicle12is positioned adjacent to the railroad track14.

When in use, the vehicle12may be driven to the railroad trackwork14requiring welding work thereon, and the rear of the vehicle12may be opened to expose the welding module40within the internal space13of the vehicle12. The base22may slide to the deployed location35on the track32, thereby positioning the extendable boom24, the mounting platform42, and the welding unit44outside the internal space13of the vehicle12. The extendable boom24may extend via the hydraulic or pneumatic cylinder26to position the mounting platform42and, thus, the welding unit44in a desired location near the railroad trackwork14to be worked on, and the welding unit44may extend from the mounting platform to work on the railroad trackwork. Once finished, the welding unit44may be retracted back to the mounting platform42, the boom24may be retracted back to the base22, and the base22may be slid to move the entirety of the welding module40into the vehicle22for storage and/or transport.

It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to “the invention” are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.