Patent Application
20250108471
The present invention pertains generally to portable battery-operated tools for railways and more particularly, to a battery-operated portable grinder designed for the railway industry, specifically for grinding the web of railroad rails post-welding.
Railway maintenance is critical for ensuring the smooth and safe operation of trains. Rail grinding is commonly used to remove surface irregularities, correct wear, and prolong the lifespan of the track. Existing rail grinders are typically large, vehicle-mounted machines that require substantial power and are not suited for smaller-scale, quick repairs or maintenance in remote or difficult-to-access locations. There is a need for a portable, battery-powered grinding tool that allows workers to conduct localized maintenance and repairs efficiently without the need for large equipment or external power sources.
The present invention is generally a dual-use battery-operated portable grinder that may be utilized for the railway industry, specifically for grinding the web of railroad rails post-welding. The battery-operated portable grinder can be employed in a hand-held configuration or seamlessly integrated with a quick-connect mechanism onto a specialized frame device, serving as both a support structure for the grinder and a means for reducing worker strain by eliminating the need for bending. The battery-operated portable grinder may include: battery-powered operation, a robust brushless motor, a built-in handle-incorporated base portion for safeguarding the motor from potential damage, a lightweight design, an anti-vibration handle to alleviate operator fatigue and ensure proper balance during usage, a reinforced shaft to enhance operational durability, improved grinding wheel stability to minimize vibration and wear during use, and its versatility in performing rail head and web grinding tasks.
According to one embodiment, a battery-operated portable grinder for grinding the rail and web of railroad rails may comprise a grinder motor assembly with a brushless motor and a grinder wheel assembly connected to the grinder motor assembly. The grinder motor assembly may comprise: a rear handle that extends to the rear of the grinder motor assembly configured to be utilized by a user to hold and operate the battery-operated portable grinder; a battery compartment located adjacent to the rear handle, wherein the battery compartment is sized and shaped to accept and receive a rechargeable battery pack to power the battery-operated portable grinder; and a motor enclosure located adjacent to the battery compartment configured to house and hold the brushless motor, wherein the motor enclosure includes a motor support handle configured to be utilized to hold and steady the grinder motor assembly and the battery-operated portable grinder. The grinder wheel assembly may comprise: a base portion configured to attach to and engage with the grinder motor assembly; a wheel assembly handle attached to and extending from the base portion configured to be utilized by the user to hold and handle the grinder wheel assembly and connect the grinder wheel assembly to the grinder motor assembly; a grinder wheel shaft connected to the brushless motor that extends perpendicularly from the base portion; a grinder wheel attached to and connected to the grinder wheel shaft, wherein the grinder wheel is configured to remove imperfections, wear, and surface defects from the rail and web of railroad rails; and a grinder wheel guard that extends around a portion of the grinder wheel configured to provide safety and protection to the user, wherein the grinder wheel guard includes an adjustable grinding wheel guard that is adjustable with rotation through 360 degrees.
Additionally, the grinder wheel assembly may further include a support guard extending from the motor enclosure configured to provide protection and safety to the user when holding the motor support handle. The grinder wheel shaft may include a reinforced shaft. The grinder wheel may be made of a material composition of a high-strength abrasive from one or more of the following: aluminum oxide, silicon carbide, or diamond grit. The grinder motor assembly and the grinder wheel assembly may be engaged together using one or more attachment posts located on either the grinder motor assembly or the grinder wheel assembly and one or more attachment holes located on the other of the grinder motor assembly or the grinder wheel assembly, wherein the one or more attachment posts slide into and engage with the one or more attachment holes. One or more of the rear handle, the motor support handle, and the wheel assembly handle may include an anti-vibration handle configured to enhance operator comfort, reduce hand-arm vibration, and ensure proper balance during operation of the battery-operated portable grinder. The battery-operated portable grinder may further comprise a frame device configured to hold and connect to the battery-operated portable grinder, the frame device includes one or more pivoting and locking mechanisms configured to allow and provide rotation, adjustment, and movement of the battery-operated portable grinder at a plurality of designation rotations along the rail and web of railroad rails. The battery-operated portable grinder may further comprise a frame device configured to hold and connect to the battery-operated portable grinder, the frame device includes a quick connect mechanism configured to change the battery-operated portable grinder from hand-held to a body moveable grinder and frame device that moves up and down the rail and web of railroad rails.
In another embodiment, a battery-operated portable grinder assembly for grinding the rail and web of railroad rails may comprise: a grinder motor assembly with a brushless motor, a grinder wheel assembly connected to the grinder motor assembly, and a frame device configured to hold and connect to the battery-operated portable grinder. The grinder motor assembly may comprise: a rear handle that extends to the rear of the grinder motor assembly configured to be utilized by a user to hold and operate the battery-operated portable grinder; and a battery compartment located adjacent to the rear handle, wherein the battery compartment is sized and shaped to accept and receive a rechargeable battery pack to power the battery-operated portable grinder. The grinder wheel assembly may comprise: a base portion configured to attach to and engage with the grinder motor assembly; a grinder wheel shaft connected to the brushless motor that extends perpendicularly from the base portion; and a grinder wheel attached to and connected to the grinder wheel shaft, wherein the grinder wheel is configured to remove imperfections, wear, and surface defects from the rail and web of railroad rails. The frame device may comprise a handle bar, a stabilizing bar extending from and perpendicular to the handle bar, and a support bar extending from and perpendicular to the stabilizing bar. The support bar may include a rest tube assembly located at an end of the support bar, wherein the rest tube assembly includes a tubular structure configured to provide support and alignment for the battery-operated portable grinder during operation on the rail and web of railroad rails. The handle bar may be U-shaped and may include two handles and a frame lever connected to a cam lock lever assembly located on the support bar by a cable that extends from the frame lever to the cam lock lever assembly to control and connect the battery-operated portable grinder. The frame device may further comprise one or more pivoting and locking mechanisms located along support bar, configured to allow and provide rotation, adjustment, and movement of the battery-operated portable grinder at a plurality of designation rotations along the rail and web of railroad rails. The plurality of designated rotations may include one or more of the following: 45 degrees, 90 degrees, 135 degrees, 180 degrees, 225 degrees, 270 degrees, 315 degrees, or 360 degrees.
Additionally, the support bar may include bends in the support bar, such that the bends in the support bar and the one or more pivoting and locking mechanisms are configured to provide rotation, adjustment, and movement of the battery-operated portable grinder in two different directions, in both a vertical direction, and a horizontal direction. The one or more pivoting and locking mechanisms may include one or more adjustment knobs located along the support bar. The stabilizing bar may include a handlebar weldment to connect the handle bar and the stabilizing bar. The battery-operated portable grinder assembly may further include a clamping assembly configured to connect the stabilizing bar and the support bar, wherein the clamping assembly is a U-bolt clamping assembly. The frame device may further include a quick connect mechanism configured to change the battery-operated portable grinder from hand-held to a body moveable grinder and frame device that moves up and down the rail and web of railroad rails.
In yet another embodiment, a battery-operated portable grinder assembly for grinding the rail and web of railroad rails may comprise: a grinder motor assembly with a brushless motor; a grinder wheel assembly connected to the grinder motor assembly; and a frame device configured to hold and connect to the battery-operated portable grinder. The grinder motor assembly may comprise: a rear handle that extends to the rear of the grinder motor assembly configured to be utilized by a user to hold and operate the battery-operated portable grinder; and a battery compartment located adjacent to the rear handle, wherein the battery compartment is sized and shaped to accept and receive a rechargeable battery pack to power the battery-operated portable grinder. The grinder wheel assembly may comprise: a base portion configured to attach to and engage with the grinder motor assembly; a grinder wheel shaft connected to the brushless motor that extends perpendicularly from the base portion; and a grinder wheel attached to and connected to the grinder wheel shaft, wherein the grinder wheel is configured to remove imperfections, wear, and surface defects from the rail and web of railroad rails. The frame device may comprise a handle bar, a stabilizing bar extending from and perpendicular to the handle bar, and a support bar extending from and perpendicular to the stabilizing bar. The support bar may include a rest tube assembly located at an end of the support bar, wherein the rest tube assembly includes a tubular structure configured to provide support and alignment for the battery-operated portable grinder during operation on the rail and web of railroad rails. The handle bar may be U-shaped and may include two handles and a frame lever connected to a cam lock lever assembly located on the support bar by a cable that extends from the frame lever to the cam lock lever assembly to control and connect the battery-operated portable grinder. The frame device may further comprise a quick connect mechanism configured to change the battery-operated portable grinder from hand-held to a body moveable grinder and frame device that moves up and down the rail and web of railroad rails. The quick connect mechanism may include the cam lock lever assembly. The cam lock lever assembly may comprise: a cam lock lever attached to a base of the cam lock lever assembly using a cam, a bolt, and one or more washers and locking washers; a trigger mechanism rotatably connected to and extending from the base; an extension spring that extends between the trigger mechanism and the base; and a cable guide that receives, attaches to, and connects to an end of the cable. When the user engages the frame lever on the handle bar, the cable may be tightened through the cable guide to move the trigger mechanism on the base and bias the extension spring, which moves the cam lock lever to start or stop the operation of the grinder wheel of the battery-operated portable grinder. The stabilizing bar may include a handlebar weldment to connect the handle bar and the stabilizing bar and a clamping assembly configured to connect the stabilizing bar and the support bar, wherein the clamping assembly is a U-bolt clamping assembly. The frame device may include one or more pivoting and locking mechanisms configured to allow and provide rotation, adjustment, and movement of the battery-operated portable grinder at a plurality of designation rotations along the rail and web of railroad rails.
Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.
The following Detailed Description will be better understood when considered in conjunction with the accompanying drawings in which like reference numerals refer to the same or similar elements in all of the various views in which that reference number appears.
In the following description of various examples of the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example parts, structures, systems, and steps in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of example parts, structures, systems, and steps may be utilized, and structural and functional modifications may be made without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “front,” “back,” “side,” “rear,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures. Nothing in this specification should be construed as requiring a specific three-dimensional orientation of structures in order to fall within the scope of this invention.
This application and/or claims may use the adjectives, e.g., “first,” “second,” “third,” and the like, to identify certain components and/or features relating to this technology. These adjectives are used merely for convenience, e.g., to assist in maintaining a distinction between components and/or features of a specific structure. Use of these adjectives should not be construed as requiring a specific order or arrangement of the components and/or features being discussed. Also, use of these specific adjectives in the specification for a specific structure does not require that the same adjective be used in the claims to refer to the same part (e.g., a component or feature referred to as the “fourth” in the specification may correspond to any numerical adjective used for that component or feature in the claims).
The present invention pertains to a dual-use battery-operated portable grinder designed for the railway industry, specifically for grinding the web of railroad rails post-welding. The battery-operated portable grinder can be employed in a hand-held configuration or seamlessly integrated with a quick-connect mechanism onto a specialized frame device, serving as both a support structure for the grinder and a means for reducing worker strain by eliminating the need for bending. Key features of this invention include its battery-powered operation, utilizing readily available batteries, a robust brushless motor, a built-in handle-incorporated base portion for safeguarding the motor from potential damage, a lightweight design, an anti-vibration handle to alleviate operator fatigue and ensure proper balance during usage, a reinforced shaft to enhance operational durability, improved grinding wheel stability to minimize vibration and wear during use, and its versatility in performing rail head and web grinding tasks. Additionally, the adjustable grinding wheel guard, capable of 360° rotation, allows for operation in confined spaces, enhancing the overall utility of this dual grinder.
As depicted and illustrated in
Further, as depicted in
The battery-operated portable grinder 100 and frame device 200 may include various advantages over the prior art. The battery-operated portable grinder 100 and frame device 200 may include a quick connect mechanism 250 to change from hand-held to a body movable frame device 200 that moves up and down the railway tracks.
The battery-operated portable grinder 100 and frame device 200 may include a handle-incorporated base portion. The inclusion of a base portion with an ergonomic handle not only protects the motor from accidental damage but also facilitates comfortable handling, reducing operator strain and fatigue during extended use.
The battery-operated portable grinder 100 and frame device 200 may include a lightweight design. The lightweight construction of the battery-operated portable grinder 100 ensures ease of maneuverability and minimizes operator fatigue, making it an ideal choice for rail maintenance tasks that require mobility and precision.
The battery-operated portable grinder 100 and frame device 200 may include dual functionality. The battery-operated portable grinder 100 may be a versatile piece of equipment capable of grinding both the rail head and web, streamlining rail maintenance processes and reducing the need for multiple tools.
The dual-use battery-operated portable grinder 100 for railway running rails may offer a comprehensive solution to rail maintenance challenges. The battery-operated portable grinder 100 may include innovative features and a versatile design to make the grinder 100 an indispensable tool for grinding the rail web and head efficiently, ultimately contributing to improved railway safety and operational reliability. The dual-use battery-operated portable grinder 100 increases production, reduces injuries, and eliminates the need for hydraulics.
As illustrated in
The rear handle 102 may be connected to and/or adjacent to a battery compartment 104. The battery compartment 104 may be sized and shaped to accept and fit a rechargeable battery pack 106. In various embodiments, the battery-operated portable grinder 100 may be battery-powered (or battery-operated) device. The battery-operated portable grinder 100 may be battery operated and use battery operation as opposed to hydraulics. In various embodiments, powering the battery-operated portable grinder 100 with a battery eliminates weight and difficulties associated with hydraulic devices and tools.
In various embodiments, the rechargeable battery pack 106 of the battery-operated portable grinder 100 may comprise a rechargeable battery. The rechargeable battery pack 106 may be configured to provide power to the battery-operated portable grinder 100. In some embodiments, the battery-operated portable grinder 100 may be powered via additional and/or alternative power means, such as via AC power, replaceable fuel cell, and/or other stored/created electric power techniques known in the art. In some embodiments, the battery-operated portable grinder 100 may be integrally-powered by a DC motor, servo motor, or stepper motor. In some embodiments, the battery-operated portable grinder 100 may be powered by a set of batteries (AC or DC) or battery packs. In some embodiments, the battery-operated portable grinder 100 may include or be connected to a battery management system. For example, the battery-operated portable grinder 100 may be powered by a set of batteries (AC or DC) or battery packs and/or include or be connected to a battery management system.
Additionally, the grinder motor assembly 110 may include a motor enclosure 112 located adjacent to the battery compartment 104. The motor enclosure 112 may include a grinder motor (not shown) that connects to the rechargeable battery 106 and powers the rotation of a grinder wheel 136. The battery-operated portable grinder 100 may be battery-powered with a strong brushless motor. The battery-operated portable grinder 100 may be powered by a rechargeable battery system, eliminating the need for cumbersome power cords or generators. The motor may include an integrated brushless motor that ensures reliable and high-performance operation, enhancing both efficiency and longevity.
Additionally, the motor enclosure 112 may include a motor support handle 116 that may be utilized by the user to hold and steady the battery-operated portable grinder 100. The motor support handle 116 may include an anti-vibration handle that enhances operator comfort, reduces hand-arm vibration, and ensures proper balance during operation, ultimately contributing to improved grinding accuracy. Additionally, the grinder motor assembly 110 may include a support guard 118 that extends from the motor enclosure 112. The support guard 118 may provide protection and safety to the user when holding the motor support handle 116.
The grinder wheel assembly 130 may attach to and connect to the grinder motor assembly 110 as shown in
The base portion 120 may be utilized for safeguarding the motor from potential damage. The inclusion of a base portion 120 with an ergonomic handle 122 not only protects the motor from accidental damage but also facilitates comfortable handling, reducing operator strain and fatigue during extended use.
The grinder wheel assembly 130 may also include a motor guard 114 that provides guard and protection for the motor and connection portions of the battery-operated portable grinder 100. Additionally, the grinder wheel assembly 130 may include a grinder wheel shaft 132 that extends perpendicularly from the base portion 120. The grinder wheel shaft 132 may include a reinforced shaft. The reinforced shaft design of the grinder wheel shaft 132 may significantly increase the durability of the battery- operated portable grinder 100, enabling the battery-operated portable grinder 100 to withstand the rigors of railway maintenance applications and extending its operational lifespan.
The grinder wheel shaft 132 may be connected to and attached to the grinder wheel 136. The grinder wheel shaft 132 and the grinder wheel 136 may include enhanced grinding wheel stability. The enhanced stability of the grinding wheel 136 with the grinder wheel shaft 132 reduces vibration and wear during operation, enhancing grinding precision and prolonging the life of consumable components.
The grinder wheel 136 may include an abrasive wheel designed for maintaining and refurbishing the surface of railway tracks. The grinder wheel 136 may be used to remove imperfections, wear, and surface defects from the rail, thus improving track smoothness and extending its lifespan. The grinder wheel 136 may include a material composition that is made from high-strength abrasives like aluminum oxide, silicon carbide, or diamond grit to handle the hardness of steel rails. The grinder wheel 136 may be a shape and size that is generally disc-shaped with a flat or slightly convex surface. The grinder wheel 136 may be various diameters and thicknesses to suit different grinding applications. The grinder wheel 136 may include a hardness and grit size that may be designed with varying hardness levels and grit sizes, depending on whether the task is coarse grinding (removing large imperfections) or fine grinding (smoothing the rail surface).
The grinder wheel 136 may include a grinder wheel guard 134 that extends around a portion of the grinder wheel 136 to provide safety and protection to the user. The grinder wheel guard 134 located around the grinder wheel 136 may also prevent accidental contact and contain debris generated during the grinding process. The grinder wheel guard 134 may include an adjustable grinding wheel guard. The adjustable grinding wheel guard 134 may be adjustable with rotation through 360°. The rotatable grinding wheel guard 134 may allow for operation in confined or tight areas, offering enhanced flexibility and adaptability in various railway maintenance scenarios.
The frame device 200 may include a handle bar 210, a stabilizing bar 220, and a support bar 230. The handle bar 210 may be connected to the stabilizing bar 220. The stabilizing bar 220 may be connected to the support bar 230. The stabilizing bar 220 and the support bar 230 may be connected by a clamping assembly 222. The clamping assembly 222 between the stabilizing bar 220 and the support bar 230 may be a clamping plate (as shown in
The handle bar 210 may be U-shaped and include two handles 212. The handles 212 may also include a handle bar locking grip 214 with anti-slip. Additionally, the handle bar 210 may include a frame lever 216 connected to the handle 212. The frame lever 216 may be connected to a cam lock lever assembly 250 located on the support bar 230 and engaged with the battery-operated portable grinder 100 when the battery-operated portable grinder 100 is attached to the frame device 200. The frame lever 216 may be connected to the cam lock lever assembly 250 via a cable 218. The cable 218 may extend from the frame lever 216 to the cam lock lever assembly 250 along the various portions of the frame device 200 utilizing various loop clamps 232 to hold the cable 218.
The stabilizing bar 220 may extend from the handle bar 210 perpendicular to the handle bar 210. The stabilizing bar 220 may include a handlebar weldment 224 to connect the handle bar 210 to the stabilizing bar 220.
The support bar 230 may extend from and perpendicular to the stabilizing bar 220. The support bar 230 may be connected to the stabilizing bar 220 using the clamping assembly 222. The battery-operated portable grinder 100 may sit on and attach to the support bar 230 and the cam lock lever assembly 250 on the support bar 230.
The support bar 230 may include one or more pivoting and locking mechanisms 234 may be located along the support bar 230. Additionally, as shown in
The pivoting and locking mechanism 234 may allow and provide rotation and adjustment in the vertical direction and/or the horizontal direction of the handle and/or battery-operated portable grinder 100 at designated rotations, such as at 45 degrees, 90 degrees, 135 degrees, 180 degrees, 225 degrees, 270 degrees, 315 degrees, and 360 degrees. Other designated rotations may be utilized without departing from the invention. The one or more pivoting and locking mechanisms 234 may include one or more adjustment knobs 234 located along the support bar 230. The adjustment knobs 234 may be plastic knobs with seven-arm grips. Other adjustment knobs 234 may be utilized with the support bar 230 and the frame device 200.
The support bar 230 may also include a rest tube assembly 236 located at the end of the support bar 230. The rest tube assembly 236 may be designed to provide support and alignment for the battery-operated portable grinder 100 during operation on the rail. The rest tube assembly 236 may include a tubular structure 238 that acts as a stabilizing guide, ensuring that the battery-operated portable grinder 100 maintains the correct angle and position relative to the rail surface. The rest tube assembly 236 may also include a height adjustment rod 240 to assist the user with ensuring the height of the battery-operated portable grinder 100 is correct. The rest tube assembly 236 may hold the grinder wheel 136 and the battery-operated portable grinder 100 in place, preventing it from wobbling or shifting during use, which is critical for precision grinding, The rest tube assembly 236 may help align the battery-operated portable grinder 100 with the rail profile to ensure even grinding across the entire surface of the rail. The rest tube assembly 236 may also reduce user fatigue by supporting part of weight of the battery-operated portable grinder 100 and maintaining proper contact with the rail.
Additionally, the cam lock lever assembly 250 may include a trigger mechanism 266 that is rotatably connected to and extends from the base 254. The cam lock lever assembly 250 may also include an extension spring 268. The extension spring 268 may include hook ends connecting the trigger mechanism 266 to the base 254. The cam lock lever assembly 250 may also include a cable guide 270 that receives, attaches to, and connects to an end of the cable 218. When the user squeezes the frame lever 216 on the handle bar 210, the cable 218 is tightened through the cable guide 270 to move the trigger mechanism 266 on the base 254 and bias the extension spring 268, which moves the cam lock lever 252 to start or stop the operation of the grinder wheel 136 on the battery-operated portable grinder 100.
The present disclosure is disclosed above and in the accompanying drawings with reference to a variety of examples. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the disclosure, not to limit the scope of the invention. It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth herein. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It should be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.
While the preferred embodiments of the invention have been shown and described, one skilled in the relevant art will recognize that numerous variations and modifications may be made to the examples described above without departing from the scope of the present disclosure. Thus, the spirit and scope of the invention should be construed broadly as set forth in the appended claims.
This application claims priority to U.S. Provisional Application No. 63/541,210, filed Sep. 28, 2023; and U.S. Provisional Application No. 63/544,908, filed Oct. 19, 2023, all of which are herein incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63544908 | Oct 2023 | US | |
| 63541210 | Sep 2023 | US |
