Improvements in Apparatus for Making Chairs on Metal Sleepers.
Year: 1891

page_text: Date of Application, 19th Aug., 1891
Complete Specification Left, 17th May, 1892-Accepted, 18th June, 1892
PROVISIONAL SPECIFICATION.
Improvements in Apparatus for Making Chairs on Metal Sleepers.
I, CHARLES ANDREW EMBLETON, residing at 24 Gloucester Street, Middles
brough-on-Tees, in the County of York, Mechanical Draughtsman, do hereby
declare the nature of this invention to be as follows:-
My invention relates to the forming of chairs, for securing "bullhead" or other
sections of rails, in metal sleepers, by drawing out the metal which forms the sleeper,
at the points where the chairs are required, and forming chairs by means of a
system of "roller levers," which are arranged to act on the metal of the sleeper
by rolling contact and press it against a matrix," on which matrix moulds are
prepared, of the shape of the outside surface of the chairs which are required to
be made.
66
In the effecting of this purpose, I make use of a special arrangement of roller
levers, which arrangement, and the method of operating, I will now describe.
Suitable framing, for the roller levers to be worked in, must be provided, and
may consist of two, or four vertical stannchions, these will form the "pillars," or
legs and feet of the frame. About the middle of the height of these stannchions,
and at right angles to them, are secured two girders, horizontal in position, and
formed on the top surface suitable in shape for the inside of the "channel" which
forms the sleeper, to lie, and fit on. A space is left between these girders, in which
the roller levers work. A matrix having two moulds formed in it, of the shape
which the outside of the chair is required to be made, and of distance apart, equal
to the gauge of the rails, is then prepared, and this matrix is fixed in vertical
slides, or guides, which are attached to, or cast on the stannchions, so that the
matrix may be lowered, or raised up in its guides, as required. To the top ends
of the stannchions, are attached, horizontal girders, which bind the stannchions at
the top, and form a suitable frame.
"
The "roller levers are four in number, the top faces of these rollers have the
form of a segment of a circle, the radius of which is suitable for working in, or
against, the surface of the matrix, and the width of the segment is equal to the
width of the chair required. At the opposite end of the lever is formed an
66 eye," or "bearing," for working on a pin, which connects it to the driving
gear, by means of coupling rods. Between the two ends of each roller lever,
is formed an intermediate "
eye or "bearing," and on each intermediate bearing
one of the roller levers is hung, by means of a stud or pin, to one of four "hanging
links." The "hanging links are four in number, one for each roller lever, and
are fitted with journals at the bottom ends, on which the roller levers work freely.
A second journal, or bearing, is provided in each hanging link, and by means of
this, the hanging link is attached on a journal or bearing which is prepared, on
the top girders of the machine frame. The top ends of the hanging links may
be fitted with "cambs," or "blocks," for locking the matrix in position, during the
operation of rolling.
Two rollers are required for forming each chair, one on each end of the chair.
Also a "die" is provided to form the interior of the chair, one side of this die is
formed the exact shape required for the rail to lie against, and to give it the
required amount of "tilt." "The other side of the die is formed suitable for the
wedge," or other means of securing the rail in the chair. These dies are two in
number, and are secured in guides, which allow them to slide forward or backwards,
in direction, at right angles to the plane of motion of the roller levers. The dies
are moved forward into position, or back, out of gear, by means of cambs, or other

page_text: suitable appliances, connected with, and actuated by the driving shaft of the
motor.
Having now described in outline, the principal details required to construct the
apparatus, I will now proceed to indicate their action, during one revolution of the
driving shaft, which it is assumed will completely form two chairs, on the channel
which is to form the sleeper.
The heated "channel" may be run direct from the finishing rolls of the rolling
mill, on to the bed of the sleeper frame, and when in position, the matrix is
lowered on to the channel, and the two dies slide forward into position simul-
taneously with the matrix. The coupling rods connecting the four roller levers
with the driving shaft, are actuated by two crank pins, which pins are fixed in
position diametrically opposite each other, one on each side of "disc," or toothed
wheel, on the driving shaft, and in such manner, that, as the driving shaft continues
to revolve, the coupling rods, on the one side, "pull" the two roller levers con-
nected with them, "towards" the driving shaft, and the coupling rods on the
"
"from the
opposite side "push" the two roller levers connected with them,
driving shaft. Each pair of roller levers rolling out the metal against the matrix,
and finally finishing the shape of the drawn out metal, by a clasp" or "grip
about each die, given by each of the two pairs of roller levers, coming into
intimate connection with the metal, and pressing it into its form about their
respective dies.
66
"
A compound motion is given to the roller levers by means of the hanging links,
these vibrating as pendulums, and as the roller lever operates on the metal against
the matrix, these hanging links move forward, and carry the centre pin on which
the roller lever partially revolves, along with them. This forward motion of the
hanging link allows the segment on the top of the roller lever, to work freely in
rolling contact against the matrix, and raises the roller lever to a height equal to
the versed sine of the arc formed by the movement of the hanging link, which
height is equal to the depth required in the chair.
The matrix may be held down to its work, by suitable blocks being attached to
the top ends of the hanging links, which acting as cambs, would lock the matrix
during the operation of rolling. The hanging links thus taking all the strain
required for keeping the matrix and the faces of the roller levers in contact, and
giving them the required amount of "draw."
Shear blades may be attached, and the sleeper cut off to length at this stage.
The first half revolution of the driving shaft is required in the drawing and
forming of the chairs, during the second half revolution, the roller levers recede,
the dies are drawn out of gear, the finished sleeper removed, and the "channel
moved forward for the repetition of the operation.
Dated this 18th day of August 1891.
"
CHAS. A. EMBLETON.
COMPLETE SPECIFICATION.
Improvements in Apparatus for Making Chairs on Metal Sleepers.
I, CHARLES ANDREW EMBLETON, of 24 Gloucester Street, Middlesbrough-
on-Tees, in the County of York, Mechanical Draughtsman, do hereby declare the
nature of this invention and in what manner the same is to be performed, to be
particularly described and ascertained in and by the following statement :-
My invention relates to the forming of chairs for the securing of "bullhead" or
other sections of rails, in metal sleepers, by drawing out the metal which forms the
sleeper at the points where the chairs are required, and forming chairs by means
of a system of "roller levers," which are arranged to act on the metal of the
sleeper by rolling contact, and press it against a matrix, on which matrix moulds
are prepared, of the shape of the outside surface of the chairs which are required
to be made.

page_text: In the effecting of this purpose I make use of a special arrangement of roller
levers, which arrangement and the method of operating I will now describe.
Suitable framing for the roller levers to be worked in must be provided, and may
consist of, two, or four vertical stanchions, these will form the "pillars," or legs
and feet of the frame. About the middle of the height of these stanchions, and
at right-angles to them, are secured two girders, horizontal in position and formed
on the top surface, suitable in shape, for the inside of the channel which forms the
sleeper, to lie, and fit on.
A space
is left between these girders in which the roller
levers work. A matrix having two moulds formed in it, of the shape which the
outside of the chair is required to be made, and of distance apart equal to the
gauge of the rails, is then prepared. And this matrix is fixed in vertical "slides"
or guides which are attached to, or cast on the stanchions, so that the matrix may
be lowered, or raised up in its guides as required. To the top ends of the stanchions
are attached horizontal girders, which bind the stanchions at the top, and form a
suitable frame.
The roller levers are four in number, the top faces of these rollers have the form
of a segment of a circle, the radius of which is suitable for working in, or against the
surface of the matrix, and the width (or thickness) of the segment is equal to the
width of the chair required. At the opposite end of the lever a "journal" is
formed, for working in a "bearing" in the coupling rod which connects it with the
driving gear. Between the two ends of each roller lever, is formed an intermediate
"journal," and each roller lever is hung by means of this intermediate journal, into
the bottom bearing eyes of one of the four hanging links. The "hanging links"
are four in number, one for each roller lever, and are fitted with bearings at the
bottom ends in which the roller levers work freely. A second bearing is provided
in each hanging link, and by means of this, the hanging link is attached on a
journal, which is provided for it, on the top girders of the machine frame. These
top journals are fitted with adjusting screws, for setting the working surfaces of the
roller levers in position against the matrix.
Two rollers are required for forming each chair, one for each of the two horns
which form the chair. Also a die is provided to form the interior of each chair,
one side of this die is formed the exact shape required for the rail to lie against,
and to give it the required "tilt." The other side of the die is formed suitable
for the wedge, or other means of securing the rail in the chair. These dies are
two in number, and are secured in guides, which allow them to slide forward or
backward, in direction at right angles to the plane of motion of the roller levers.
The dies are moved forward into position, or backward, out of gear, by means of
cambs, or other suitable appliances, connected with, and actuated by the driving
shaft of the motor.
Referring to the accompanying drawings-
Fig. 1. Sheet 1. is a front elevation of the apparatus (part in section) and
Fig. 2 is an end elevation, in which A. A. are the roller levers. B. B. the hanging
links. C. C. are dies for supporting and guiding the roller levers. D. D. are
adjusting screws for setting up the dies C. C. also E. E. are the dies about which
the interiors of the chairs are formed. F. the matrix. G. the bottom block.
H. H. the coupling rods, connecting up to the motor. J. J. are the levers for
working the dies E. E. and K. K. levers for raising, lowering and locking the
matrix F. L the shaft for working the dies E. E. M. M. are shafts for working
the matrix raising and locking gear. N the shaft which simultaneously actuates
the matrix locking gear, and the dies E. E., this shaft N. being controlled by the
"camb" O. on the driving shaft P.
Referring to Sheet 2. Figs. 3 and 4 shew another method of hanging the roller
levers. By this method, the hanging links B. B. Figs. 1 and 2 (Sheet 1) are
dispensed with, and the intermediate journals of the roller levers are carried in
sliding blocks Q. Q. these blocks being allowed to slide freely in the guides R. R.
the rotary motion being given to the roller levers by means of the spur pinions S. S.

page_text: and the racks T. T. The guides R. R. are fitted on fulcrum journals at U. U.
and any inclination required for a given height of chair, may be obtained by
inserting "packing blocks" between the faces V. V. and W. W. at the end of the
guides opposite to the fulcrum journals. The motions of the dies E. E. and the
matrix raising and locking gear, are the same as for Figs. 1 and 2. Sheet 1.
And if it should be desired, the hanging links B. B. (Sheet 1) Figs. 1 and 2.
may be reversed in position, and arranged to vibrate on centres below the roller
levers, in which case these links would act as "struts," instead of "tension rods."
Having now described the principal details required to construct the apparatus,
I will proceed to indicate their action during one revolution of the driving shaft,
which it is assumed will completely form two chairs on the metal of the sleeper.
The heated "channel" may be run direct from the finishing rolls of the rolling
mill, on to the bed of the sleeper frame, and when in position, the matrix is
lowered on to the metal, and the two dies E. E. slide forward into position simul-
taneously with the matrix. The coupling rods connecting the four roller levers
with the driving shaft are actuated by two "crank pins," which pins are fixed in
position diametrically opposite each other, one on each side of a disc, or toothed
wheel on the driving shaft, and in such manner that as the driving shaft continues
to revolve, the coupling rods on the one side "pull" the two roller levers connected
with them " towards the driving shaft, and the coupling rods on the opposite side
push" the two roller levers connected with them, "from" the driving shaft, each
pair of roller levers rolling out the metal against the matrix, and finally finishing
the shape of the drawn out metal, by a clasp or "grip" about each die E. E.
given by each of the two pairs of roller levers coming into intimate contact with
the metal, and pressing it into its form about their respective dies.
CE
"
A compound motion is given to the roller levers by means of the hanging links;
these vibrating as pendulums, and as the roller lever operates on the metal against
the matrix, these hanging links move forward and carry the centre pin on which
the roller lever partially revolves, along with them. This forward motion of the
hanging link allows the segment on the top of the roller lever to work freely in
rolling contact against the matrix, and raises the lever to a height equal to the
versed sine of the arc formed by the movement of the hanging link, which
height is equal to the depth required in the chair.
"
Shear blades may be attached, and the sleeper may have been cut off to length at
this stage.
The first half revolution of the driving shaft is required in the drawing and
forming of the chairs. During the second half revolution the roller levers recede,
the dies are drawn out of gear, the matrix is raised, the finished sleeper removed,
and the channel is moved forward for the repetition of the operation.
A clutch may be connected between the motor and the driving shaft of the
apparatus, to ensure perfect control of the movements of the machine.
And if it should be required to form the sleeper together with its chairs, direct
from plate metal. The plates should be prepared by being cut so that they may
have a greater width than that required in the finished sleeper, this extra width
being left on each side of each horn of each chair. And the plates being re-heated
and placed on the machine bed, the matrix is lowered in such manner by the
"cambs," that the roller levers as they advance are allowed to draw up the plate
sideways in forming the chairs, and the sleeper receives its final "grip" for
moulding it, between the matrix and the bottom block, simultaneously with the
"grip" given by the roller levers in finishing the chairs
Having now particularly described and ascertained the nature of my said inven-
tion, and the manner in which the same is to be performed, I declare that what I
claim is―
1st. The application of levers "hung," or arranged in such manner as to obtain
a motion suitable for rolling, drawing out, and forming chairs of "box section "

page_text: pattern on metal sleepers. Substantially as described, with reference to the
drawings.
2nd. The manipulation of plate metal in the forming of sleepers together with
chairs of "box section" pattern. Substantially as described.
Dated this 16th day of May 1892.
CHAS. A. EMBLETON.