Patent Publication Number: US-2011052364-A1

Title: apparatus and method for handling railway rails

Description:
The invention relates to the handling of railway (railroad) rails, railway switch components, panels and the like, for the installation and replacement of railway infrastructure. 
     Various specialised machines have been developed over many years to assist in the installation of railways. Some of these machines are vehicles designed can run alternatively on road and rail, having alternate wheels for each mode. Other machines, including very large and heavy machines, run on rail only. Lifting machines are also known which can span a whole rail track, running on “caterpillar” type tracks on the ballast either side of the railway. In the course of installing or renewing a railway, there may be a need to manoeuvre lengths of steel rail from tens of metres to hundreds of metres in length. Also there may be a need to manoeuvre more awkward-shaped panels of rail and bearer combined, and components of switch points and other types of junction. 
     To assist in this, machines have evolved with specialised functions. Machines which are larger and more specialised may be able to complete certain tasks very efficiently. However, they are more expensive in capital terms, and they can impose great disruption on the rail network, in obtaining access and space to work. To work with machines which have above a certain height or reach, for example, it will be necessary to close neighbouring tracks and/or to isolate electric overhead lines. Many lifting machines are designed to work on one track while riding on an adjacent track. Naturally this disrupts traffic on the adjacent track, and also prevents the application of these machines to single-track projects. 
     Using conventional methods and equipment, therefore, there is often a great deal of disruption incurred to effect even relatively small engineering works, and/or the works take more time or money than one would like, because of the pressure to avoid disruption. 
     In WO 05/095716 A1, the present applicant disclosed a compact, low-cost machine for performing transposition of a very long length of continuous welded rail from a track-side to its location on the bearers (sleepers). The machine is compact yet powerful, by virtue of the fact that the load-bearing parts are located within the footprint of its ground-engaging wheels or tracks. The machine can operate in locations and in windows of opportunity unavailable to conventional techniques. The present invention in its various aspects aims to bring similar benefits to other tasks. 
     The invention in a first aspect provides apparatus for handling railway track components, the apparatus comprising a self-propelled vehicle having ground-engaging rolling means spaced either side of a working space and a load-bearing platform adapted for spanning said working space so as to support a part of a load being transported using said self-propelled vehicle. 
     The load-bearing platform may be mounted on the vehicle so as to permit rotation of the platform and load for steering the vehicle. 
     The load-bearing platform is preferably mounted on the vehicle so as to permit sliding of the platform relative to the vehicle in a direction of travel (referred to hereinafter as the longitudinal direction) to absorb differences in speed of vehicle and load. The vehicle will typically be used in pairs or larger gangs, each vehicle adjusting its speed and steering independently, though in co-ordinated fashion. The sliding and rotating of the platform facilitate this. 
     The apparatus may further comprise an elevated chassis joining the ground-engaging rolling means above said working space. 
     The apparatus may further include a hoist mounted on said elevated chassis for lowering and lifting a load on and off said platform. 
     The platform is preferably mounted to be movable from the vehicle in a direction transverse to the direction of travel, so as to permit lifting and lowering of said load from a position on the ground to a position above the level of the platform. 
     The platform may be provided with adjustable restraining elements to restrict sliding of a load in a direction transverse to the direction of travel of the vehicle. 
     The ground-engaging rolling means may comprise continuous tread tracks running substantially the length of the vehicle at each side. 
     The ground-engaging rolling means may alternatively comprise wheels. 
     The vehicle may optionally be provided with rail wheels deployable to support the vehicle and load in a journey along a rail track. 
     The apparatus is preferably less than 2.5 m, more preferably less than 2 metres, in one or more of height, width and length. The apparatus is preferably less than 2 metres in each dimension. 
     The width between the ground-engaging rolling means is preferably such that the vehicle can straddle one rail but not both rails of a Standard Gauge railway. The width between the ground-engaging rolling means may be approximately the same as the Standard Gauge rail spacing (1435 mm inside spacing). 
     The invention in another aspect provides a load-bearing accessory for a railway maintenance vehicle, the accessory comprising: a supporting member for spanning a working space between two laterally spaced supports; and a platform rotatably coupled to the supporting member so as to provide support for a load whose orientation relative to the supports may vary. 
     The supporting member and platform may each comprise a metal beam. 
     The supporting member may be provided at each end with a wing portion adapted to lie on top of said supports and slide in a longitudinal direction relative to the supports. 
     The platform may be provided with restraining elements for restricting lateral movement of a load resting on the platform. 
     The restraining elements may be adjustable in position. 
     The supporting member may be adapted to span a gap of 900-1500 mm width between said supports, preferably 900-1100 mm. 
     The invention in yet another aspect provides a method of transporting railway rail or rail track components in the vicinity of a railway undergoing construction or refurbishment, the method comprising:
         providing at least two self-propelled vehicles, each vehicle having a working space between spaced-apart ground-engaging rolling means and means for supporting a load at a point within the footprint of said ground-engaging rolling means;   supporting a portion of rail or other elongate load partially on the load-supporting means of each vehicle; and   driving and steering the vehicles in a co-ordinated manner to transport the load to a desired location in the vicinity of the railway.       

     The load-supporting means of at least one vehicle may comprise a hoist suspended from an elevated chassis bridging the spaced-apart ground-engaging rolling means of the vehicle. 
     The load-supporting means of at least one vehicle may comprise a load-bearing platform mounted on the vehicle and bridging the spaced-apart ground-engaging rolling means. 
     The load-bearing platform may be arranged to permit rotation of the platform and load while steering the vehicle and load along a curved path. 
     The load-bearing platform may be mounted on the vehicle so as to permit sliding of the platform relative to the vehicle in a direction of travel (referred to hereinafter as the longitudinal direction) to absorb differences in motion between vehicle and load. 
     The vehicle having the load-bearing platform may further comprise an elevated chassis joining the ground-engaging rolling means above said working space. 
     The apparatus may further include a hoist mounted on said elevated chassis for lowering and lifting a load on and off said platform. 
     The platform may be mounted to be removable from the working space in a direction transverse to the direction of travel, so as to permit lifting and lowering of said load from a position on the ground to a position above the level of the platform. 
     The platform may be provided with adjustable restraining elements to restrict sliding of a load in a direction transverse to the direction of travel of the vehicle. 
     The ground-engaging rolling means may comprise continuous tread tracks running substantially the length of the vehicle at each side. 
     The ground-engaging rolling means may alternatively comprise wheels. 
     At least one vehicle may optionally be provided with rail wheels deployable to support the vehicle and load in a journey along a rail track. 
     The method may include driving the vehicles over a rail track from a track-side location. 
     The method may include driving the vehicles and load through a gap between trackside obstacles such as power line pylons. 
     The method may include more than three vehicles supporting a length of rail more than 100 m long. 
     Such a method may included driving and steering the vehicles so as to bend the rail through a gap between track-side obstacles such as power line pylons. 
     In a preferred embodiment, each vehicle is less than 2.5 m, more preferably less than 2 metres, in one or more of height, width and length. The vehicle is preferably less than 2 metres in each dimension. 
     The width between the ground-engaging rolling means is preferably such that the vehicle can straddle one rail but not both rails of a Standard Gauge railway. The width between the ground-engaging rolling means may be approximately the same as the Standard Gauge rail spacing (1435 mm inside spacing). 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will now be described, by way of example only, by reference to the accompanying drawings, in which: 
         FIG. 1  is a side view of a known track rail transposer machine; 
         FIG. 2  shows the track rail transposer machine in a longitudinal view, handling a rail; 
         FIG. 3  is a plan view of a rail transposing operation performed using the machine in  FIGS. 1 and 2 ; 
         FIGS. 4 and 5  are side and longitudinal views of the same machine being used for transporting rails; 
         FIG. 6  is a plan view of several machines transporting a length of continuous welded rail; 
         FIGS. 7 and 8  are side and plan views of the sliding turntable accessory for use with the machine on  FIGS. 1 to 6 ; 
         FIG. 9  is a cut-away plan view of the accessory of  FIGS. 7 and 8  mounted on the machine; 
         FIG. 10  is a longitudinal view of the machine and turntable accessory carrying a track junction component; 
         FIG. 11  is a plan view of two machines with turntable accessories carrying the track junction component to or from its intended location; 
         FIG. 12  is a side view of a machine modified to include rail wheels in addition to ground-engaging tracks; 
         FIG. 13  is a longitudinal view of the modified machine riding on rails and carrying a track junction component; and 
         FIG. 14  shows two of the modified machines carrying the track junction component on the rail wheels, being towed behind a conventional road/rail vehicle. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     The apparatuses and methods to be described herein are generally used in the installation, maintenance and repair of railway (railroad) infrastructure. Referring to  FIG. 1  of the drawings, typical railway comprises two or more lengths of steel rail  10  mounted on bearers (sleepers)  12 , laid along prepared bed of ballast  14  or concrete ground. The rail  10  historically would be formed of short sections carried to the site and lifted into place by machines and/or men, and joined by fishplates and so forth. In more modern times, particularly for high speed rail traffic, continuous welded rail (CWR) is used, which can be delivered to the work site from the steel works in lengths of over 200 metres. The rails  10  are fixed to the sleepers in chairs  16 . The skilled person will understand that many different forms of bearer, supporting ground, rail and chair or other fixing are available and suitable for use in different applications. The illustration or mention of any particular form of rail, bearer, chair etc. in the present description is merely to serve as an example, without any limitation as to the field of application of the apparatus and processes described herein. 
     WO 05/095716 A1 of the present applicant describes the “track rail transposer” (TRT) machine which can be seen in  FIG. 1  and in the longitudinal view of  FIG. 2 . The machine is self-propelling, by means of motorised tracks  102 ,  104 . The width between the track centres is in this example roughly the same as the space between the rails of the railway (the gauge), for example 1.4 metres. The overall footprint of the machine is roughly square, with dimension 1.7 metres long by 1.7 metres to the extremity of the tracks. The machine chassis  106  is supported just over a metre above the ground on four legs  108  to  114 . (Leg  114  is not visible in these views). On top of the chassis are mounted a power source such as a diesel motor, and associated fuel tank, hydraulic pumps and control systems. Housings for these works are indicated generally at  116 . 
     As seen in  FIG. 2 , the TRT machine is of a scale similar to a human operator, being less than 2 metres, certainly less than 2.5 metres high in total. Load bearing components are carried beneath chassis  106  in the working space, roughly a 1 metre cube, between the legs  108  to  114 . As the machine moves in the course of its operations, this working space may be above ground beside the track, on the track-side ballast, or directly above the bearers. The small dimensions of the machine do not permit it to straddle the entire Standard Gauge rail pair, but rather to straddle one rail or rail bed at a time. As explained in the prior patent application, the fact that loads are supported always within the footprint of the tracks  102 ,  104 , it can be of compact size and light weight, in particular because there is no need for counterweights to balance an off-set load. By its small size, many advantages are gained, while the machine is capable of several different operations to be described further below, which traditionally would be undertaken by very large numbers of men (in developing countries) or by very large and very expensive machinery in more developed countries. The small size of the machine allows operations to be performed with minimal disruption to the regular running of the rail network, either in terms of isolation of overhead supplies or of blocking the traffic on neighbouring tracks. The small size of the machine also allows it to be transported to relatively inaccessible locations, for example, in the back of a small truck or van. Access through roads and tracks allows the machine to operate on single track railways, as it does not require an adjacent track to gain access to its working location. 
     The type of operation specifically described in WO 05/095716 A1 is that of transposing a length of continuous welded rail from a location at the side of a track onto its operating location, and the reverse operation of removing an existing rail for replacement. For this purpose, the TRT machine  100  is provided with two primary accessories, both supported from the chassis. The first accessory is a transposing arm  118  which is extendable and pivotally mounted beneath the centre of the chassis, and carries a transposing head  120 . The pivot mounting at the top of the arm  118  is optionally motorised to drive it from side to side within the chassis. The transposing head comprises a metal device for surrounding a rail, shown in  FIG. 2 , and containing rollers to restrain the rail in vertical and lateral directions as it slides through the head  120  in the longitudinal direction. An opening gate allows the rail to be inserted and removed laterally from the transposing head  120 , it being possible also to thread the rail longitudinally without opening the gate. The other accessory hanging from the chassis is a hoist with rail gripper  122  depending from a variable length of chain  124 , which can either passively or actively be driven along transverse tracks, and is powered by a motorised or manually operated winch in housing  126 . 
     With a length of rail being transposed being loaded into the transposing head  120  using the winch and gripper  122  as shown in  FIG. 2 ,  FIG. 3  illustrates the transposing process by which a length of continuous welding rail is eased from a location where it has been deposited beside the track by a special freight train, to a location on the bearers, where it can be fixed in shoes and the railway very quickly returned to operation. This operation, described already in WO 05/095716 A1, simply involves the TRT machine motoring along the track and moving its transposing head along the length of the rail, while being steered to apply a transverse force to progressively end the rail and deposit it along the desired line. The process can be reversed to remove an existing rail. Experience has shown that the TRT machine is able to remove and replace rail extremely quickly and efficiently, minimising disruption to the rail service and with minimal capital expenditure. 
       FIGS. 4  onwards describe different modes of operation that are performable with the TRT machine. These operations may be performed also with a machine of similar proportions that may not be provided with the transposing arm and head  120 , if transposing operations are not required. Nevertheless it is advantageous if the same machine can serve multiple functions. 
       FIGS. 4 to 6  illustrate the use of the machine  100  in gangs of two or more to transport rails and other elongate loads bodily both transversely and along the track, if desired.  FIGS. 4 and 5  show how the hoist and gripper  122  of each machine engage the rail and restrain it against longitudinal movement. The rail  400  may also, for added support and control, pass through the transposing head  120 . As an alternative to using the gripper  122 , some locking mechanism could be provided on the transposing head itself, but the chain  124  of the hoist provides a useful degree of longitudinal movement to be permitted, and thereby limits the risk of damaging forces being applied either to the rail or the machine. 
       FIG. 6  illustrates how a number of TRT machines can be used to manipulate a single piece of rail. In the case of a short piece of rail, for example 20 metres in length, it is a simple matter for two TRT machines to pick it up, one at either end, and carry it along a track, onto a track and so forth, to and from a storage location.  FIG. 6  in particular illustrates, though not to scale, an operation in which a very long length of continuous welding rail  600 , for example over 200 metres in length, may be carried by a gang of machines  602 ,  604  and  606 . In practice, as many as 8 machines might be provided along such a length of rail  600 . Each machine is provided with its own controls and human operator (not shown) who both drives and steers it by operation of hydraulic motors driving the tracks  102 ,  104 . A unique feature of this method of transporting long rails is the ability of the machines to be steered so as to bend and guide the rail  600  through the gap between obstructions such as overhead power pylons  608 ,  610 , which are a feature of many railways. It will be appreciated that these obstacles are spaced closer together than the length of the rail, making the task of moving the rail onto the track seemingly impossible with existing equipment. In current practice, such obstructions often result in the rail being cut into shorter lengths for transport onto the bearers, which naturally reduces the quality of the rail, and increases the delay and expense caused by the replacement operation. 
     In addition to single lengths of rail, bulkier items such as components of switch points and other types of track junctions and ancillary equipment also need to be manoeuvred on an off the railway. Conventionally, different sizes of crane may be required, including very large gantry cranes that may travel on tracks spanning the whole railway. For that purpose, a complete junction or section of track may be supplied as a “panel” integral with its bearers, and carried to the location. As mentioned already, such large machines are expensive to provide and operate, and their large size means that repair and replacement operations are very disruptive of the railway operations, and access to awkward sites and single-track railways may be impossible. 
       FIGS. 7 and 8  illustrate a turntable accessory  700  which has been devised to allow the TRT machines  100  to serve also in the carrying of switch components and the like onto and along a railway. Referring to the side view of  FIG. 7 , the turntable accessory comprises a main support beam  702  and a rotating platform  704  mounted on top of beam  702  by means of a pivot  706 . Each of the pieces  702 ,  704  can be a section of steel box girder, for example. At each end of the supporting beam  702 , a wing portion  708 ,  710  is provided with a down-turned end  712 ,  714  respectively. In the top side of the rotating platform  704 , a number of blind recesses  716  are provided, and these allow a couple of restraining pins  718 ,  720  to be inserted at different locations, for restraining a load against transverse movement. As seen in the plan view of  FIG. 8 , the beam that is the rotating platform  704  can rotate about the pivot pin  706 , so that it is not necessarily parallel to the supporting beam  702 . 
       FIG. 9  is a plan view of a TRT machine of the type already described, with its chassis  106  and all the works supported on the chassis removed for a clear view of the working area beneath the chassis. The four legs  108  to  114  can be seen in cross-section, as well as two support beams  130  and  132  which extend in a longitudinal direction, parallel to each of the tracks  102 ,  104 , either side of the working space. The turntable accessory  700  is dimensioned so that its support beam  702  can sit between the beams  130 ,  132  with its wing portions  708 ,  710  supporting the accessory on the beams  130 ,  132 , and restrained against rotation and transverse displacement by the hook portions  712 ,  714 . Accordingly, as seen in  FIG. 9 , the accessory  700  provides a platform  704  at the lower part of the working space of the machine  100 , which can not only rotate, but also slide relative to the vehicle, by distance corresponding roughly to the forward/rear distance between the legs  108 ,  110 . This permits the machine  100  to support a load such as a switching component and to transport it in cooperation with one or more similar machines, the sliding and rotating platform allowing the machine to adjust its position and orientation relative to the load during the course of its manually controlled operations. 
       FIG. 10  is a longitudinal view of the machine performing such an operation to carry a load  1000 . The transposing arm  118  and head  120  are shown removed for this operation, although they may in practice simply be stowed out of the way. Hoist and gripper are shown not in use although they may also be used to stabilise the load. 
     The load  1000  in this instance is a section of a track junction or similar panel, which rests on the turntable accessory and is restrained at suitable points by the inserted pins  718 ,  720 . To mount the load on the turntable accessory, the vehicle  100  is manoeuvred over the load, with the accessory  700  removed. The hoist  126  and gripper  122  is used (or an independent hoist where available) to raise the load above the level of the turntable platform, and the accessory  700  is fitted across beams  130 ,  132  beneath the load. The load is then lowered onto the platform  704  using the hoist. The operation can be reversed to drop the load at its destination, that is by raising the load with the hoist, removing the accessory  700  from the working space and lowering the load to the ground. 
       FIG. 11  shows in plan view how two vehicles  1100 ,  1102  can be used in the manner shown in  FIG. 10  to transport a crossing component along the ground and along the railway. The turning and sliding movements of the accessory  700  on each machine allow the human operators (not shown) to drive and steer the machines  1100 ,  1102  independently, but in a coordinated fashion, to carry the component  1000  from a delivery location to its installation location, or vice versa. The load is loaded onto and off the machines by performing the hoist operations just described with reference to  FIG. 10  at both machines, either sequentially or in parallel. 
       FIGS. 12 to 14  show a modified TRT machine  1200 , in which the same components are recognisable as in the machine  100  of  FIG. 1  but there are additionally provided pairs of rail wheels  1202 ,  1204 . The rail wheels can be deployed or retracted, so that the machine has the option, like a road/rail vehicle, to ride on the ground or along the railway in the manner of a train. Linkages  1206  and  1208  are driven by manual or hydraulic jacks  1210 ,  1212 , so that the wheels  1202 ,  1204  can be moved from their stowed position, shown in solid lines in  FIG. 12 , to their operational position, shown in dotted lines. In their operational position, the bearing surfaces of the rail wheels are at a level  1214  just below the lower portion of the ground-engaging tracks  102 ,  104 . 
     As seen in the longitudinal view of  FIG. 13 , the wheels  1202 ,  1204  in their deployed position allow the apparatus  1200 , and any load  1000  which it is carrying to run along an existing railway. The rail wheels  1202 ,  1204  may be powered by hydraulic motors, or may be passive, so that the machine is simply pushed or pulled by another vehicle or human operator. 
       FIG. 14  shows, as one example, a plan view of two of the modified vehicles  1402 ,  1404  being towed along a rail track  1406  by a road/rail truck  1408 . The load  1000  is again carried between the apparatuses, which have their rail wheels  1202 ,  1204  deployed beneath them, so as to run along the track. Towing linkages  1410  and  1412  may be either rigid or flexible. While the machines  1402 / 1404  may be able to propel themselves along the ground on their tracks  102 ,  104  at a speed corresponding to a brisk walking pace (say 5 kmh-10 kmh) deployment of the rail wheels  1202 ,  1204  may allow a faster transit along the railway, for example at speeds in the range 20-30 kmh. 
     The road/rail vehicle  1408  may be of conventional type, including a load space for tools and accessories, as well as a cabin for the crew required to perform the various operations on site. 
     The above and other modifications of the apparatus and methods can be made within the spirit and scope of the invention.