Abstract:
A washout detector apparatus includes a detector member movably disposed in at least a portion of a detector housing, the detector housing is configured to be secured to a structure. A biasing device is disposed in and positioned to bias the detector member in a direction out from the portion of the detector housing towards a surface perpendicular to the structure. An indicator is coupled to the detector member to provide a condition of the surface based on movement of the detector member with respect to the surface. A method for making a washout detector apparatus is also disclosed.

Description:
FIELD 
       [0001]    This technology generally relates to washout detector devices and methods and, more particularly, to washout detector and alarm apparatuses and methods thereof. 
       BACKGROUND 
       [0002]    Structures such as homes, bridges, and railroad ties may be negatively affected by the erosion of the ground underneath. In particular, washouts, in which the ground beneath a railroad tie or a bridge is eroded away by flowing water, present a dangerous situation. Prior warnings regarding potential washout conditions are imperative to ensure safety. Washout detectors serve to provide advance warning regarding the conditions. However, such washout detectors need to be cost effective so that a sufficient number of detectors may be acquired and located at various locations, for example along railroad tracks or at the bases of bridges, to detect washout conditions. Cost effective washout detectors are also more practical for home usage. Further, washout detectors applied for such situations, particularly to railroad ties and bridges, must be sturdy enough to withstand both the forces created by, for example, trains passing over the tracks as well the elements to which the washout detectors are subjected. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]      FIG. 1  is a perspective view of an exemplary washout detector apparatus coupled to the end of a railroad tie; 
           [0004]      FIG. 2  is a perspective partial phantom and partial exploded view of the exemplary washout detector as shown in  FIG. 1  with the spring-loaded ram extended from the housing; 
           [0005]      FIG. 3  is a perspective view of spring-loaded ram and indicator housing with indicator blade of the exemplary washout detector without the outer housing; 
           [0006]      FIG. 4  is a perspective partial phantom view of an exemplary washout detector with an optional hydraulic ram with the spring-loaded ram and hydraulic ram extended from the housing; 
           [0007]      FIG. 5  is a perspective view of a composite railroad tie for use with one embodiment of the exemplary railroad roadbed washout detector; 
           [0008]      FIG. 6  is a perspective view of an exemplary railroad roadbed washout detector installed in the composite railroad tie shown in  FIG. 5  with the black plate removed; 
           [0009]      FIG. 7  is a perspective view of the exemplary railroad roadbed washout detector shown in  FIG. 6  with the black plate installed; and 
           [0010]      FIGS. 8-11  are perspective views of an exemplary railroad roadbed washout detector. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    An example of a washout detector  10 ( 1 ) is illustrated in  FIGS. 1-4 . The washout detector  10 ( 1 ) includes a housing  12 , a spring  14 , a spring-loaded ram  16 , an optional hydraulic ram  18  and hydraulic reservoir  19 , a pad  20 , an indicator device  22 , and an optional sensor  24  and remote alarm computing device  26 , although the washout detector  10 ( 1 ) may have other types and/or numbers of systems, device, components and/or other elements in other configurations. The exemplary washout detector  10 ( 1 ) is configured to be coupled to a railroad tie T to determine the status of the ballast B located below the washout detector  10 ( 1 ) and to detect and provide notification of washout conditions both locally and remotely. One or more detectors  10 ( 1 ) may be utilized with a single railroad tie T to indicate the condition of the roadbed in various locations about the railroad tie T. Although the washout detector  10 ( 1 ) is illustrated and described with respect to use on a railroad tie T, it is to be understood that the washout detector  10 ( 1 ) may be applied to any structure with a surface perpendicular to the structure for which washout conditions may be monitored. By way of example only, the washout detector  10 ( 1 ) of the present technology may be utilized to monitor washout conditions on support structures (footers) of bridges or at the base of a building to monitor the condition of the ground perpendicular to those structures. The size and of the washout detector  10 ( 1 ) may be varied based on these different applications. 
         [0012]    In this example, the washout detector  10 ( 1 ) reports washout conditions in three different stages, as described further below, to provide information regarding the condition of the ballast on the roadbed. The exemplary technology provides notification of a potential washout in various stages, from incipient to terminal washout conditions. This exemplary technology advantageously provides a washout detector that may be easily installed on the railroad tie T and provides a visual indication of the condition of the roadbed. 
         [0013]    Referring more specifically to  FIG. 1 , in this example the housing  12  is configured to be coupled to the railroad tie T to connect the washout detector  10 ( 1 ) to the railroad T tie through flanges  28  located on both sides of the housing  12 , although the housing  12  may have other configurations for attachment to the railroad tie T. In one example, the housing  12  provides a small sturdy housing which protects the inner pieces of the detector  10 ( 1 ) from the elements. The flanges  28  include holes  30  configured to receive lag bolts to secure the housing  12  to the railroad tie T, although the washout detector  10 ( 1 ) may include other elements in other locations for securing the washout detector  10 ( 1 ) to the railroad tie T. In one example, the housing  12  includes a detachable back panel (not shown) that permits access to the elements within the housing  12 . The housing  12  is coupled to the railroad tie T at the end of the railroad tie T, although the housing may be coupled to the railroad tie T at other locations, such as along the side of the railroad tie T. 
         [0014]    The housing  12  includes a main body portion  32  configured to house the spring  14  and the spring-loaded ram  16  as shown in  FIG. 2 , although the housing  12  may be configured to house other elements in other configurations, such as, by way of example, the optional hydraulic ram  18  and hydraulic reservoir as shown in  FIG. 4 . Referring more specifically to  FIG. 2 , the spring  14  is located between the top portion of the housing  12  and the spring-loaded ram  16 . In this example, the spring  14  is casted into the housing  12  and the ram  16 , although the spring  14  may be connected to the housing  12  and the ram  16  in other manners. The housing  12  may further include a stabilizing bar  34  located within the coils of the spring  14  in order to keep the spring  14  straight when being pushed in the housing  12 . 
         [0015]    The ram  16  is constructed of a material, such as metal, with sufficient strength to withstand the force of the spring  14 , although the ram  16  may be constructed of other materials. The ram  16  is connected to the pad  20  at the end opposite the spring  14 , such that the spring-loaded ram  16  exerts a downward force on the pad  20 . The housing  12  includes an opening  36  at the bottom portion through which the ram  16  exits the housing  12 . A weather seal  38  is located around the opening  36  to prevent moisture or dirt from entering the housing  12 . 
         [0016]    The pad  20  is a large flat metal plate configured to sit on the ballast of the roadbed and distribute the downward force of the spring-loaded ram  16 , although the pad  20  may have other configurations and be constructed of other materials. The pad  20  includes a collar  40  for receiving the ram  16  such that the ram  16  sets into the collar  40 . In one example, the connection between the ram  16  and the collar  40  may be on a pivot system such that the pad  20  can angle to the contour of the ballast due to erosion and shifting of the ballast which may present washout conditions, although other connections between the ram  16  and the pad  20 , such as welding, may be utilized. 
         [0017]    Referring back to  FIG. 1 , the housing  12  further includes a locking mechanism used to lock the housing  12  to the pad  20  when the washout detector  20  is not in use or prior to installation of the washout detector  10 ( 1 ) on the railroad tie T. By way of example, the locking mechanism may be a tab  42  configured to receive a cotter pin  44 , although other locking mechanisms may be utilized. The pad  20  also includes a locking mechanism, such as a tab  46  configured to align with the tab  42  on the housing to receive the cotter pin  44  to secure the pad  20  to the housing  12  while the washout detector is not in use or prior to installation, although other locking mechanisms may be utilized. 
         [0018]    The washout detector  10 ( 1 ) further includes an indicator device  22  coupled to the housing  12 . Referring now to  FIG. 3 , the indicator device  22  includes an indicator housing  48 , an indicator blade  50 , and a pulley system  52 . The indicator housing  48  is configured to house the indicator blade  50  and includes an opening through the top of the indicator housing  48  through which the indicator blade  50  may emerge. The indicator blade  50  is coupled to the pad  20  through a wire to form the pulley system  52  such that downward motion of the pad  20  causes the indicator blade  50  to rise out of the indicator housing  48 , although the indicator blade  50  may be coupled to the pad  20  through other elements in other configurations. 
         [0019]    In one embodiment, the indicator blade  50  includes three different sections along its length having different colors, although the indicator blade may have other numbers and types of sections. The individual sections may be divided equally along the length of the indicator blade  50 , although the sections may each have different lengths along the indicator blade  50 . The different sections are configured to provide a visual indication of the roadbed condition. The indicator blade  50  may further include an end of travel indicator  54 , as shown in  FIG. 4 , which pops out at the full extent of travel of the indicator blade  50  within the indicator housing  48 . The end of travel indicator  54  can be in the form of a tough flexible football shaped pouch containing an expanded wire spiral form shaped to a similar size, which is compressed and collapsed into the indicator housing  48  and is then decompressed when the end of travel indicator  54  is released from the indicator housing  48 , although the end of travel indicator  54  could have other configurations. By way of example, the end of travel indicator  54  may be a cube corner reflector. 
         [0020]    In another example, as shown in  FIG. 4 , the housing  12  may further include the optional hydraulic ram  18 . In this example, the housing  12  includes an opening  56  in the bottom potion of the housing that allows the hydraulic ram  18  to exit the housing  12 . The opening  56  may include a weather seal  58  to prevent water or dirt from entering the housing  12  through the opening. The hydraulic ram  18  is coupled to the pad  20  through a collar  60  in the pad  20 . By way of example, the hydraulic ram  18  may be welded to the pad  20 . The hydraulic ram  18  is coupled to a hydraulic fluid reservoir  19  through one or more poppet valves  62 , although the hydraulic ram  18  may be coupled to the hydraulic fluid reservoir  19  in other manners using other types of valves. The hydraulic fluid reservoir  19  is configured to hold hydraulic fluid which may be drawn into the area of the housing vacated by the hydraulic ram  18  through the poppet valves  62  as the pad  20  descends pulling the hydraulic ram  18  in a downward direction. 
         [0021]    Referring back to  FIG. 1 , the washout detector  10 ( 1 ) may also include a remote alarm computing device  26  coupled to a sensor  24  to provide remote alerts regarding the condition of the roadbed. The sensor  24  is configured to measure the movement of the pad  20  with respect to the ballast underneath. The sensor  24  may be a manual sensor, such as a rod-and-foot linear drop sensor, or an angled-paddle rotary-horizontal-shaft sensor, although other types and/or numbers of sensors could be used. These units are spring-powered for both the pressing downward of the sensing rod and foot. Alternatively, the sensor  24  may measure the movement of the pad  20  through non-contact mechanisms, such as by way of example, through ultrasonic distance detection, electromagnetic or electro-optical distance or auto-focus sensing methods, although other remote-sensing methods may be utilized. The sensor  24  is coupled to the remote alarm computing device  26  to provide information regarding the position of the pad  20  and provide alerts regarding potential washout conditions. In another embodiment, the sensor  24  may be a self-leveler that detects if the tie T is going unlevel. The sensor  24  may provide information to the remote alarm computing device  26  to indicate that the level of the tie T is going off plane. 
         [0022]    The remote alarm computing device  26  may provide remote alerts regarding the position of the pad  20  and potential washout conditions to one or more computing devices through a communication network. The alarm computing device  26  may include at least one processor, a memory, an input device, a display device, and an input/output (I/O) system, which are coupled together by a bus, although the alarm computing device  26  may comprise other types and numbers of systems, device, components and/or other elements in other configurations and other types of alarm computing devices could be used. 
         [0023]    The processor(s) in the remote alarm computing device  26  may execute one or more computer-executable instructions stored in the memory to provide remote alerts regarding the condition of the roadbed, although the processor(s) can execute other types and numbers of instructions and perform other types and numbers of operations. The processor(s) may comprise one or more central processing units (“CPUs”) or general purpose processors with one or more processing cores, such as AMD® processor(s), although other types of processor(s) could be used (e.g., Intel®). 
         [0024]    The memory may comprise one or more tangible storage media, such as RAM, ROM, flash memory, CD-ROM, floppy disk, hard disk drive(s), solid state memory, DVD, or any other memory storage types or devices, including combinations thereof, which are known to those of ordinary skill in the art. The memory may store one or more programmed instructions of this technology that may be executed by the one or more processor(s), such as by way of example, providing remote alerts based on the roadbed condition information received from the sensor  26 , although other types and numbers of programmed instructions and/or other data may be stored. The memory may also store data from the sensor  26 , although the data could be stored in other locations on other devices. 
         [0025]    The input device of the remote alarm computing device  26  enables a user, such as an administrator, to interact with the remote alarm computing device  26 , such as to input and/or view data and/or to configure, program and/or operate it by way of example only. By way of example only, the input device may include one or more of a touch screen, keyboard and/or a computer mouse. 
         [0026]    The display device of the remote alarm computing device  26  enables a user, such as an administrator, to interact with remote alarm computing device, such as to view and/or input information and/or to configure, program and/or operate it by way of example only. By way of example only, the display device may include one or more of a CRT, LED monitor, LCD monitor, or touch screen display technology although other types and numbers of display devices could be used. 
         [0027]    The I/O system in the remote alarm computing device  26  is used to operatively couple and communicate between alarm computing device and one or more computing devices, which are coupled together by a communication network. The I/O system engages in network communications over a communication network utilizing standard network protocols such as TCP/IP, HTTP, or DNS, by way of example only. In this example, the bus is a hyper-transport bus, although other bus types and links may be used, such as PCI. 
         [0028]    Another embodiment of a washout detector  10 ( 2 ) is shown in  FIGS. 5-7 . The washout detector  10 ( 2 ) is the same in structure and operation as the washout detector  10 ( 1 ) shown in  FIGS. 1-4  except as illustrated and described herein. In this embodiment, the housing  112  is configured to be located inside a composite tie CT as shown in  FIG. 5 . 
         [0029]    As shown in  FIG. 5 , the composite tie CT includes an indentation I at the end of the tie configured to receive the housing, although the composite tie CT may have other features at other locations of the composite tie CT, such as by way of example along the side of the tie, for receiving the housing  112 . The composite tie CT further includes a number of ribs R on the inside surface in order to mate with the housing  112  for a more secure attachment. 
         [0030]    Referring now to  FIG. 6 , the housing  112  is configured to be inserted inside the end of the composite tie CT, although the housing  112  may be located in other locations such as under the railroad tie, or under a tie plate (not shown). In this example, the housing  112  includes a plate  64  that encloses the washout detector  10 ( 2 ) within the composite tie CT. The plate  64  includes a number of holes  66  configured to match up with the holes  30  in the flanges  28  of the housing  112  to secure the housing  112  to the composite railroad tie CT, although other securing mechanisms may be utilized. The plate  64  may completely enclose the washout detector as shown in  FIG. 7 . 
         [0031]    Referring now to  FIG. 7 , the plate  66  may further include a locking bar  68  secured to the plate  66  by one or more tabs  70 . The locking bar  68  may pivot within the tabs  70 . The locking bar  68  is connected at one end to the pad  20  through a fastener  71 , although the locking bar  68  may be coupled to the pad  20  in other manners. The locking bar  68  also includes a tab  72  at the other end that extends over the top cover of the plate  66  when in a locked position. The locking bar  66  is the length of the tie such that when the tab  72  is extended over the top cover of the plate  66  the pad  20  is held in place with the spring fully compressed within the housing  112 . 
         [0032]    Another embodiment of a washout detector  10 ( 3 ) is shown in  FIG. 8-11 . The washout detector  10 ( 3 ) is the same in structure and operation as the washout detector  10 ( 1 ) shown in  FIGS. 1-4  except as illustrated and described herein. In this embodiment, the washout detector is configured to be coupled to a railroad tie as described in U.S. patent application Ser. Nos. 13/841,958 and 14/222,355, which are each herein incorporated by reference in their entirety. 
         [0033]    Referring to  FIG. 8-11 , in this embodiment, a shield plate  74  is inserted between the ties that hold the washout device  10 ( 3 ). In one embodiment, the shield plate  74  includes a male portion  76  and a female portion  78 , although the shield plate  74  may include other elements in other configurations. As illustrated in  FIG. 9 , the male portion  76  is inserted into the female portion to fit within the armature of the railroad ties. As illustrated in  FIGS. 10 and 11 , the shield plate  74  pushes up against the armature of the railroad ties to stabilize the shield plate  74 . The shield plate  74  also serves as a blocker for the stone from the ballast of the railroad bed. The washout device  10 ( 3 ) can be mounted to the middle or the side of the shield plate  74 . Flanges  80  go up the side of the tie, to allow a lag bolts  84  (as illustrated in  FIG. 11 ) to be inserted into holes  82  fasten the shield plate  74 , through the tie plate into the tie to secure the unit. The shield plate  74  will be fastened on the top and side and will push up against the armature of the yoke to prevent the shield plate  74  from caving inward. There is a flange on the inside also from top to bottom that rests against the armature to provide room for the driver to come in and take the fastener out of the side of the tie easily. 
         [0034]    An example of the assembly and operation of the washout detector  10 ( 1 ) on the railroad tie T will now be described with reference to  FIGS. 1-4 . Although the operation is described with respect to a railroad tie T, the washout detector could provide the same operation attached to other structures, such as a bridge or a building. The washout detector  10 ( 1 ) is attached to the railroad tie T by attaching bolts through the holes  30  in the flanges  28  of the housing  12  to the railroad tie T. The locking mechanism between the pad  20  and the spring loaded ram  16  is released when the washout detector  10 ( 1 ) is installed on the tie T allowing the spring-loaded ram  16  to provide a downward force on the pad  20  into the ballast of the roadbed. The washout detector  10 ( 1 ) operates by sensing the erosion of the roadbed ballast dropping away from the pad  20 . 
         [0035]    As the pad  20  is depressed due to erosion of the ballast, the indicator blade  50  is raised from the indicator housing  48  to provide a visual indication of the roadbed condition. In this example, the indicator blade  50  provides a visual indication in various stages as the pad  20  is depressed through the different colors on the indicator blade  50 . Some ballast settlement or bedding-in of the pad  20  may occur after installation, so roughly the first third of the detection distance (beyond an initial zero-response threshold) is an incipient phase of roadbed depression detection, which is indicated by a green portion of the indicator blade  50 . The second stage of roadbed depression, roughly the middle third of the pad  20  depression extent, is a cautionary level of detection and warning indicated by a yellow portion on the indicator blade. The last and largest phase of detection extent will be represented by the last third of detection range, and beyond that as washout of the ballast progresses. This is the terminal or red alert warning stage which is indicated by a red portion of the indicator blade  50 . Once the pad  20  is depressed to a certain level, an end of travel indicator  54 , as described above is released from the indicator housing  48  to indicate a washout condition. 
         [0036]    Optionally, the downward motion of the pad  20  as a result of ballast erosion further may cause the optional hydraulic ram  18  to push down from the housing  12 . As the hydraulic ram  18  is lowered, hydraulic fluid is pulled into the hydraulic ram portion of the housing  12  from the hydraulic fluid reservoir  19  through the one or more poppet valves  62 . The hydraulic ram  18  and the captive fluid drawn from the hydraulic fluid reservoir  19  supports the railroad tie T in order to maintain the position of the tie until the ballast erosion condition is rectified. 
         [0037]    Further, the sensor  26  may monitor the position of the pad  20 . The sensing may be accomplished manually, with a rod-and-foot linear drop sensor, or an angled-paddle rotary-horizontal-shaft sensor. Alternatively, the sensing may also be accomplished through non-contact means, by ultrasonic distance detection, electromagnetic or electro-optical distance or auto-focus sensing methods, or by other remote-sensing methods as appropriate. The alarm computing device may remotely provide alerts to one or more computing devices over a communication network to provide indications of the condition of the roadbed. 
         [0038]    Accordingly, as illustrated and described with reference to the examples herein this technology provides more washout detector apparatuses and methods thereof. Additionally, this technology provides a cost-effective railroad roadbed washout detector confined within a housing that is adapted to withstand the stresses required for performance on a railroad tie. With this technology, both remote and local alarms may be provided to indicate railroad roadbed conditions. Further, with this technology the local alarm computing device provide an indication of the railroad roadbed condition in various stages to provide unique information regarding the roadbed to trains passing the location. 
         [0039]    Having thus described the basic concept of the invention, it will be rather apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements, and modifications will occur and are intended to those skilled in the art, though not expressly stated herein. These alterations, improvements, and modifications are intended to be suggested hereby, and are within the spirit and scope of the invention. Additionally, the recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefore, is not intended to limit the claimed processes to any order except as may be specified in the claims. Accordingly, the invention is limited only by the following claims and equivalents thereto.