Patent Publication Number: US-7216590-B2

Title: Bulk loader for conveying articles

Description:
BACKGROUND 
     The present invention relates generally to a bulk loader for storing and conveying stick-like articles, which includes a hopper associated with a conveyor for moving articles from the hopper to a delivery point. More particularly, the present invention relates to a railroad right of way maintenance device providing a bulk spike loader system for providing railroad articles, such as spikes, from a hopper to a desired location for loading the articles into a spiker. 
     Among various types of railway maintenance equipment, automatic spikers are known and used for driving railroad spikes into railroad ties for securing the rail to the tie plates and tie plates to the ties. The spiker is typically mounted on a spiking machine capable of traveling over railroad tracks and may be self propelled or towable. Suitable examples of such spikers are disclosed in commonly owned U.S. Pat. Nos. 5,191,840 and 6,095,053 which are incorporated by reference. During operation of typical spikers, workers fill kegs with spikes held in a separate car or wagon, and load the filled kegs onto the spiking machine. A first worker then removes spikes from the keg, as needed, and places them in the spiker magazine. A second worker then operates the aiming and driving mechanism of the spiker to drive the spike where desired. 
     This conventional system requires a large amount of manual labor to load the kegs with spikes and then load the kegs onto the spiking machine. In addition, manually reaching into the kegs to get the spikes wastes further time. Furthermore, space is limited on the spiking machine, so that only a few kegs can be carried on the spiking machine at one time. This limits the production capacity of the spiking machine. 
     Some known solutions to the above problems such as those disclosed in commonly owned U.S. Pat. No. 6,095,053, which is incorporated by reference, have proposed using an inclined trough and auger assembly to move spikes or other rail fasteners from the hopper to a desired location for facilitating rapid loading of the fasteners by an operator into the spiker. While such solutions have improved the feeding of railroad spikes being supplied to an operator, problems such as jamming of the auger and/or an insufficient supply of the spikes reaching an operator are known to occur and consequently cause lower operator productivity. That is, productivity is limited by the number of spikes fed to the operator. When the auger becomes jammed, the spikes must be removed from the hopper to have access to those spikes which are jamming the hopper. Once the jammed spikes are disengaged from the auger, a reloading of the spikes into the spiker must occur before the spikes are again provided to the operator. 
     Thus, it is desirable to provide an improved bulk loader that efficiently stores and conveys relatively large quantities of articles to a desired location for further operations and that prevents jamming of the conveyed articles while they are conveyed to the desired location. 
     SUMMARY OF THE INVENTION 
     The above-identified needs are addressed by an apparatus configured for bulk feeding articles, such as railroad spikes. Features of the present invention include a bulk loader having a hopper that receives and stores the articles for later selected use by an operator. A preferably recessed track is provided for guiding a reciprocating member. The reciprocating member is configured for reciprocating between a retracted position wherein the articles may fall into the track, and an extended position wherein the reciprocating member conveys those articles positioned within the track to a position where they may be accessed by an operator. Movement of the reciprocating member between the retracted and extended positions may be controlled by an operator to facilitate positioning of the articles in a convenient location for further handling by the operator. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a fragmentary top perspective view of a spiking machine fitted with a bulk loader incorporating the features of the present invention; 
         FIG. 2  is a fragmentary top perspective view of the spiking machine of  FIG. 1  shown from a position rearward of the operator; 
         FIG. 3  is a top view of the bulk loader of the present invention; 
         FIG. 4  is a sectional view taken along the line  4 — 4  of  FIG. 3  and in the direction generally indicated; 
         FIG. 5  is an enlarged fragmentary perspective view of a portion of the bulk loader as shown in  FIG. 4 ; and 
         FIG. 6  is a fragmentary perspective view of a pusher as shown in  FIG. 5 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIGS. 1 and 2 , a bulk loader, generally designated  10 , is shown on a portion of a spiking machine, generally designated  12 . As is well known in the art, the spiking machine  12  is designed to be self propelled or towed as a separate unit along a railroad track. The spiking machine  12  preferably includes a frame  14  supporting, among other things, the bulk loader  10 , an operator seat  16  facing the bulk loader, operator seats  18  facing a spiker mechanism (not shown) and a post  20  supporting a boom  22 . The boom  22  supports a hook  23  that may be used to hoist containers of articles  24  such as cut spikes, lag screws, anchors, screw spikes, clips, or the like (collectively referred to as spikes) which are deposited in bulk into a portion of the bulk loader  10 . Alternatively, a pay loader having an electromagnet can load the spikes  24  directly into the bulk loader  10 . 
     The frame  14  also defines a retaining wall  26  for receiving and holding the bulk loader  10 . As best seen in  FIG. 2 , the bulk loader  10  rests within a space defined by the retaining wall  26 . The frame  14  also preferably supports a hopper  28 , which is a portion of the loader  10  and is configured for receiving the spikes  24 . In the preferred embodiment, the bulk loader  10  is loaded with the spikes  24 , by a payloader having an electromagnet or by other lifting devices known in the art which are capable of depositing the spikes into the hopper  28 . After the positioning of the bulk loader  10 , the spikes  24  are conveyable from an interior portion  30  of the hopper  28  to an exterior portion  32  of the hopper which includes outer surfaces of external sidewalls  36 . In addition to the sidewalls  36 , the exterior portion  32  may include a separate or integral bin, tray, or the like that is external to the interior portion, and which is positioned to receive the spikes  24  that are pushed out of the hopper  28 . In this manner, operators seated in the seats  16  and  18  have convenient access to the spikes once they are removed from the interior portion of the hopper  28 . Additionally, controls (not shown) are provided to operate the spiking machine  12 . 
     Referring now to  FIGS. 1–3 , the hopper  28  preferably has a generally rectangular configuration with four sidewalls  36 . The interior portion  30  of the hopper  28  is further defined by radially inward sloping or generally funnel shaped surfaces  38  that are configured to direct the spikes  24  deposited into the hopper to a centrally located, recessed track  40 , which is positioned at the bottom of the hopper. One feature of the hopper  28  is that each of the sidewalls  36  can include a door  42  (one shown) for storing tools and other equipment within the bulk loader  10 . This is advantageous, since operators are thus provided ready access to tools and equipment while the spiking machine  12  is in the field inserting and/or removing the spikes  24  from sections of the railroad track (not shown). 
     Referring now to  FIGS. 1–4 , one feature of the present bulk loader  10  is that it includes a reciprocating member or pusher  44  that reciprocates between a retracted position shown in  FIGS. 1–4  and an extended position (shown in phantom in  FIG. 4 ) wherein the pusher extends to an end  45  of the track  40 . While the pusher  44  is in the retracted position, some of the spikes  24  held in the hopper  28  fall into the track  40 . Once the pusher  44  moves to the extended position, those spikes  24  that have fallen into the track  40  are pushed or conveyed to the exterior portion  32 , and preferably to a location where operators can access the conveyed spikes. Preferably, the track  40  is formed to have a length TL that is equal to or greater than a length PL of a stroke of the pusher  44 , however it is contemplated that the pusher could have a stroke that stops before or extends beyond the end  45  of the track  40 . 
     Referring now to  FIG. 4 , the pusher  44  is reciprocated by a fluid power apparatus, generally designated  46 , which includes a fluid power cylinder  48  and a hose  50  connecting the cylinder to a valve  51 . A lever  52  ( FIG. 3 ) connects via a linkage  53  to the valve  51  and can be rotated in a clockwise or counterclockwise direction D as viewed in  FIG. 3  to operate the fluid power apparatus  46 . As described in detail below, the preferably hydraulic fluid power apparatus  46  extends and retracts the pusher  44 . A first end  48 A of the cylinder  48  is secured to a clevis flange  53 A on the hopper  28 . A second end  48 B of the cylinder  48  is secured to a clevis flange or eyelet  53 B on an interior surface  54  of the pusher  44 . It is contemplated that either the first end  48 A or the second end  48 B can be the rod end of the cylinder  48 , and the other end will be the blind end. In operation, pressurization of the cylinder  48  at its respective ends extends and retracts the pusher  44 . While a double acting cylinder  48  is depicted, it is also contemplated that a single acting, spring-return cylinder could also be employed in this application. Furthermore, while a hydraulic fluid power apparatus  46  is shown and described, it is contemplated that various pneumatic and other piston driven assemblies may be implemented with the present invention as is known to those skilled in the art. 
     Referring now to  FIGS. 1–6 , the track  40  has a pair of sidewalls  54   55  and a bottom  56  that are positioned within the interior portion  30  to be disposed in an operational relationship with the pusher  44 . A rear wall  58  defines an opening  59  ( FIG. 5 ) of the track  40  configured for receiving the pusher  44  therethrough as the pusher extends toward the end  45  of the track. When the hopper  28  is filled, a portion of the spikes  24  deposited within the interior portion  30  of the hopper fall to the bottom  56  of the track  40  and are removed from the interior portion upon extension of the pusher  44 . 
     One feature of the track  40  is that it includes at least one guide  60  ( FIG. 5 ) on each of the sidewalls  54 ,  55 , the guides being constructed and arranged so that the pusher  44  and the spikes  24  pushed by it are aligned in the track. By slidably engaging shoulders  62  on at least a front face  63  of the pusher  44 , the guides  60  prevent upward movement of the pusher in the direction of an arrow  64  (shown in  FIG. 6 ). In this manner, a desired linear reciprocation of the pusher  44  is maintained in the track  40 . Moreover, as best seen in  FIGS. 5 and 6 , a close tolerance is maintained between the pusher  44  and the sidewalls  54 ,  55  so that the spikes  24  are prevented from becoming lodged between the pusher and the sidewalls. As such, jamming is prevented. 
     Referring now to  FIGS. 5 and 6 , another feature of the present bulk loader  10  is that a front side  66  of the hopper  28  has an opening  68  in registry with the track  40  that is configured for accommodating passage of the spikes  24  pushed out of the track by the pusher  44 . The opening  68  must be of sufficient size to enable a sufficient amount of the spikes  24  to pass through for each stroke of the pusher  44  to take full advantage of the capacity of the track  40 , while still preventing the pile of pushed spikes  24  from becoming jammed in the opening. In particular, an edge  70  of the front side  66  is positioned sufficiently above a top portion  72  of the pusher  44  so that the spikes  24  do not become jammed between the pusher and the edge as the pusher extends to the end  45  of the track  40 . 
     Another feature of the present bulk loader  10  is that the top portion  72  of the pusher  44  is generally planar to provide a minimum clearance with the rear wall  58 . This minimum clearance enables slidability between the pusher and the wall, yet prevents the spikes  24  from becoming jammed behind a rear portion  78  of the pusher  44 . Moreover, sidewalls  80  (one shown in  FIG. 6 ) of the pusher  44  are generally vertical and planar, promoting a smooth sliding relationship of the pusher  44  in the track  40 . 
     A height  82  of the sidewalls  80  of the pusher  44  is preferably less than a height  84  of the track  40  to prevent jamming of the spikes  24  in the opening  68  upon extension of the pusher. However, it is contemplated in the present invention that the height  82  of the sidewalls  80  may be equal to or less than the height  84  of the pusher  44 . In the preferred embodiment, the front face  63  of the pusher  44  may be inclined at an acute angle θ relative to the bottom  56  of the track  40  ( FIGS. 3 and 4 ) to further prevent jamming of the spikes  24  when the pusher  44  extends by allowing the spikes to move in an upwards direction as viewed in  FIG. 4 . 
     Referring now to  FIGS. 3 and 5 , the exterior portion  32  of the hopper  28  is provided in the form of an access bin  88  for receiving the spikes  24  conveyed by the pusher  44  from the interior portion  30  of the hopper  28 . The access bin  88  is connected to the front side  66  of the hopper  28  and has a pair of sidewalls  90  and a bottom  92  which are configured for containing and receiving the spikes  24  pushed from the interior portion  30  by the pusher  44 . That is, the sidewalls  90  have a height  94  that is greater than or equal to the height  82  of the sidewalls  80  of the pusher  44  ( FIG. 3 ). Moreover, the bottom  92  of the access bin  88  has a width  96  greater than or equal to a width  98  of the pusher  44 . An advantage of the relatively wider and larger volume access bin  88  is that a load of the spikes  24  conveyed by the pusher  44  will spread out and/or settle in the bin. In this way, they become easier to retrieve by the operators, who typically reach for the spikes from a seated position. While preferably attached to the hopper  28 , the access bin  88  may also be a separate unit placed in operational relationship to the hopper. 
     Another feature of the access bin  88  is that it preferably includes a pair of gussets  100  that connect to the front side  66  and the sidewalls  90  of the access bin. The gussets  100  act as shielding members to further prevent the spikes  24  positioned near the edge  70  of the opening  68  from escaping the access bin  88 . In addition, the gussets  100  provide extra support for the cantilevered access bin  88 . The access bin  88  also includes a front panel  102  which is attached to free ends of the sidewalls  90  and the bottom  92 , and closes off the bin and retains the spikes  24 . While preferably inclined forward, the orientation of the panel may vary to suit the application.  FIG. 5  also provides a detailed view of a shaft  104  which connects the rotatable pusher actuator levers  52 , preferably located on each side of the access bin  88 . 
     As illustrated in  FIG. 4 , the present bulk loader  10  is also optionally provided with a vibration motor  106  for vibrating the hopper  28  to facilitate movement of the spikes  24  into the track  40 . In the preferred embodiment, the motor  106  is hydraulic, with a rotating eccentric hammer  108 , but electrical or other types of vibrators are contemplated. The vibration motor  106  is connected (e.g., by skip welding) to an underside  110  of the hopper  28 . Skip welding helps to transfer the forces generated by the vibration motor  106  to the inclined surfaces  38  of the hopper  28 . 
     In operation, the bulk loaded spikes  24  are preferably cut spikes, but are also contemplated as being hairpin spikes, lag screws, rail anchors or even rail clips, and are loaded in random or bulk fashion into the hopper  28  using, for example, the boom  23 . The spikes  24  are then directed toward the recessed track  40  by vibration from the vibration motor  106  and/or the inclined slope of the inclined surfaces  38  of the hopper  28 . When the pusher  44  is retracted, a group of the spikes  24  slide into the track  40 . Upon extension of the pusher  44  to the extended position, this group of spikes  24  is transferred to the access bin  88 . Upon reaching the access bin  88 , the spikes  24  spread out and/or settle on the bottom  92  of the access bin until removed by an operator. After the access bin  88  is emptied of the spikes  24 , the operator may reciprocate the pusher  44  to receive a new supply of spikes in the access bin. 
     Thus, the present bulk loader  10  provides several features designed to address the particular problems of conveying spikes  24  in bulk, such as rail spikes. These features include the use of the reciprocating pusher  44  which employs a relatively simple mechanism for pushing the spikes  24  along the recessed track  40  without experiencing down time due to jammed spikes. In addition, the track  40  includes guides  60  that limit vertical movement of the pusher  44  relative to the bottom  56  and sidewalls  55  of the track, and thus maintain pusher alignment. Furthermore, once the spikes  24  pass through the opening  68  to the access bin  88 , they settle and are more easily accessible due to the larger volume access bin. 
     While a particular embodiment of the bulk spike loader apparatus of the invention has been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.