Pre-plating of wooden railroad ties

Information

  • Patent Grant
  • 6546612
  • Patent Number
    6,546,612
  • Date Filed
    Monday, June 25, 2001
    23 years ago
  • Date Issued
    Tuesday, April 15, 2003
    21 years ago
Abstract
Apparatus and methods are disclosed by which wooden railroad ties are pre-plated prior to use in constructing and/or repairing railroad lines. Methodology disclosed comprises placing two plates on top of each of a succession of wooden ties, temporarily positioning disclosed one of the two plates on each tie with a distance or spacer template temporarily clamping the two plates accurately to the tie using a jig, starting a field spike and a gauge spike (usually with one or more sledge hammers) into each wooden tie through the selected apertures in each plate, and further driving the started spikes into the associated tie (usually using a jackhammer). Typically, the field spike is located outside the field flange of the plate and is driven until the head of the spike is contiguous with the plate. Typically, the gauge spike is displaced through an aperture in the gauge flange of the plate until the head is about 1½ inches above the plate.
Description




FIELD OF THE INVENTION




The present invention relates generally to the use of wooden ties, steel plates and steel spikes in building and/or repairing of railroads and, more particularly, to methods and apparatus for pre-plating wooden railroad ties for subsequent receipt of railroad rails in the initial construction and/or the repair of railroad lines.




BACKGROUND




Railroad lines are comprised of spaced cross ties with superimposed plates, which carry two top spaced rails. The space of the rails determines the gauge of the railroad line. The ties traditionally rest upon ballast, which has been compacted and graded (contoured) to define the path of the railroad line, including axial slope as appropriate and transverse banking to accommodate turning in respect to a change in direction of the rails and ties.




While concrete ties are sometimes used, wooden ties, usually treated with a chemical such as creosote, have historically been used. The present invention is concerned with wooden railroad ties.




Each wooden railroad tie receives two steel railroad plates on the top of the tie. Each plate is secured in position by steel spikes driven into the associated wooden railroad tie through apertures in the plate. Ultimately, at least one field spike and one gauge spike is driven through apertures in the associated plate into the wooden tie until the head of the spike is either contiguous with the top surface of the associated plate or is above the associated plate a distance sufficient to accommodate placement of one side of the lower flange of a rail beneath the head of that spike. This creates a fixed and permanent relationship between the plate and the wooden railroad tie. At the time of rail installation, other spikes are driven through the remaining apertures in each plate. Two apertures exist in each of two central parallel flanges or ridges of each plate and one aperture in each of two plate regions spaced from the flanges. The flanges of each plate are parallel to the direction of the railroad line and perpendicular to the axis of the associated tie. All of the spikes driven through apertures in the flanges of the associated plate into the wooden tie ultimately become contiguous with the top surface of one or the other of two oppositely-directed base, lower or bottom flanges of a railroad rail to hold the rail in a secure position on the plate between the flanges. The rail is thus securely positioned between and parallel to the plate flanges.




In earlier times, it was commonplace to assemble plates, ties, spikes and rails at the site of a railroad line being constructed or repaired. This approach is sometimes still used. Precision in correctly locating each plate on top of the associated tie presented significant problems in the field. Accuracy in field placement of the plates on the ties has been particularly difficult when the plates were worn between the flanges due to prior use.




BRIEF SUMMARY AND OBJECTS OF THE PRESENT INVENTION




In brief summary, the present invention overcomes or substantially alleviates problems associated with the construction and repair of railroad lines and particularly in respect to pre-plating wooden railroad ties. Temporary and permanent placement of two plates (either new or used) on each wooden tie is exceptionally accurate, resulting in few, if any, rejects. Accordingly, subsequent assembly of railroad rails on a series of such pre-plated ties produces corresponding accuracy in the resulting railroad line. Unique jigs provide for the temporary and accurate placement of the plates on the ties, while spikes provide for the permanent and accurate placement of the plates on the ties. Novel methods and apparatus are provided by the present invention for so pre-plating railroad ties. Mass production of pre-plated railroad ties is preferred, although individual pre-plating of railroad ties is within the scope of the present invention. The methodology may comprise placing two plates on top of each of a succession of wooden ties, positioning one of the two plates on each tie with a distance or spacer template, temporarily clamping the two plates accurately to the tie using a jig, starting a field spike and a gauge spike (usually with one or more sledge hammers) into each wooden tie through selected apertures in each plate, and further driving the started spikes into the associated tie (usually using a jackhammer). Typically, the field spike is located outside the field flange of the plate and is driven until the head of the spike is contiguous with the plate. Typically, the gauge spike is displaced through an aperture in the gauge flange of the plate until the head thereof is about 1½ inches above the plate. This gauge spike ultimately is driven downward farther to help hold a rail in position when the rail is superimposed upon the plate between the flanges thereof.




A series of work stations may be employed in carrying out the pre-plating assembly process. One or more of the work stations may use conveyor systems to displace ties as they are pre-plated and to return removed jigs for re-use. Normally, although not necessarily, the spikes are started with one or more sledge hammers, while the driving of spikes is preferable by use of a power tool, such as a jack hammer.




When the pre-plating of the ties is completed, they may be stored for subsequent use or shipped for more immediate use.




For purposes of efficiency and cost effectiveness, a mass production or continuous process of pre-plating ties sequentially is preferred, which requires inventories of ties, plates, spikes and jigs, all made available at an ingress work location. The jigs are recycled, while the ties, plates and spike are transformed into completed pre-plated ties. Testing templates or spacers may be used to initially locate the plates on the ties before spikes are started and to check the permanent locations of the plates of completed pre-plated ties for accuracy or compliance with applicable tolerances. The preferred reference is to the inside surface of the field flange of each plate. One jig is used to so locate both plates in respect to a given wooden railroad tie.




The preferred jig, for accurately locating plates on railroad ties being pre-plated, comprises a frame which seats around side surfaces of a railroad tie, at least one plate position-establishing cross bar or stop extending between frame members for contiguous engagement with an inside surface of a flange of a railroad plate placed on top of the tie, and at least one displaceable clamping member for engagement with an adjacent edge of plate to compressively place the plate in a desired fixed position upon the tie prior to an aperture in the plate receiving a railroad spike. At least one clamping member may be actuated in any desired way, e.g., using a hydraulic or pneumatic cylinder or a mechanical crank of the jig, to engage the field edge of the adjacent plate, for example, insuring that a cross bar or stop of the jig bears against the inside surface of the adjacent field flange of the plate.




With the foregoing in mind, it is a primary object of the present invention to overcome or substantially alleviate problems associated with the construction and/or repair of railroad lines and particularly in respect to pre-plating wooden railroad ties.




Another important object is the temporary and permanent placement of the plates (either new or used) on a wooden tie with exceptional accuracy, resulting in few, if any, rejects, and producing corresponding accuracy within the resulting railroad lines.




A further valuable object is the provision of unique jigs which provide for the temporary and accurate placement of plates on the wooden railroad ties, while spikes, used in conjunction with each jig, provide for the permanent and accurate placement of the plates on the ties.




It is another dominant object of the present invention to provide novel methods and apparatus for pre-plating wooden railroad ties.




It is an additional significant object to provide mass production methods and apparatus for pre-plated wooden railroad ties.




Another valuable object is the provision of methodology which comprises placing two plates on top of each of a succession of wooden railroad ties, temporarily positioning of each of the two plates accurately on each tie using a jig, starting a field spike and a gauge spike into each wooden tie through selected apertures in each plate, and further driving the started spikes into the associated tie.




A further important object is the provision for locating a field spike outside the field flange of an associated plate and driving it until the head of the spike is contiguous with the plate and locating a gauge spike through an aperture into the gauge flange of the plate and driving it until the head thereof is a predetermined distance above the plate so that the gauges spike can ultimately be driven downward farther to help hold a rail in position when the rail is superimposed upon the plate between the flanges thereof.




A further primary object is the provision of a series of work stations for carrying out a pre-plating assembly process for wooden railroad ties.




It is another significant object of the present invention to provide one or more work stations which may use conveyors to displace wooden railroad ties as they are pre-plated and to return removed jigs for re-use.




Another object of value is the provision of mass production or continuous processes of pre-plating wooden railroad ties sequentially, which require inventories of ties, plates, spikes and jigs all made available at an ingress work location.




It is a further object of significance to provide pre-plating jigs for wooden railroad ties which are reusable.




It is a further object of dominance to provide testing templates or spacers used to initially locate the plates on wooden railroad ties before spikes are started and to check the permanent locations of the plates of completed pre-plated wooden railroad ties for accuracy or compliance with applicable tolerances.




An additional object of importance is the provision of pre-plating jigs for accurately locating plates on wooden railroad ties being pre-plated.




It is another valuable object to provide a pre-plating jig for a wooden railroad tie which comprises a frame which seats around side surfaces of a wooden railroad tie, at least one plate position-establishing cross bar or stop extending between frame members for contiguous engagement with an inside surface of a flange of a railroad plate placed on top of the tie, and at least one displaceable clamping member for engagement with an adjacent edge of the plate to compressively place the plate in a desired fixed position upon the tie prior to an aperture in the plate receiving a railroad spike.




It is another object of importance to provide a pre-plating jig for a wooden railroad tie comprising at least one clamping member which is actuated in any desired way, e.g., using a hydraulic or pneumatic cylinder or a mechanical crank of the jig, to engage the field edge of the adjacent plate causing a cross bar or stop of the jig to bear against the inside surface of the adjacent field flange of the adjacent plate.




These and other objects and features of the present invention will be apparent from the detailed description taken with reference to the accompanying drawings.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a flow chart is a flow chart of methodology according to the present invention by which wooden railroad ties are pre-plated;





FIG. 2

is a block diagram showing the way in which

FIGS. 2A

,


2


B and


2


C interrelate one with another;





FIG. 2A

is a fragmentary perspective of an ingress work station or site where wooden railroad ties, steel railroad plates, steel railroad spikes and steel plate-locating jigs are brought together and assembled up to the point where two spikes are started into a wooden tie through apertures in two plates temporarily held in correct positions on top of the tie by the jig comprising opposed crank clamping mechanisms;





FIG. 2B

is a fragmentary perspective of a central work station to further drive the spikes into the associated wooden tie and through which ties from the ingress work station are successively displaced to a jig removal station by a first conveyor system, whereby the removed jigs are returned to the ingress station and the completed pre-plated ties are placed at a discharge station for shipment and/or storage;





FIG. 2C

is a fragmentary perspective of the downstream end of the central work station of FIG.


2


B and the accumulation discharge station or site for shipment and/or storage;




FIG.


2


B′ is a fragmentary perspective of a conveyorless central work station which started spikes are farther driven into an associated wooden railroad tie through apertures in the two railroad plates to pre-plate the tie;





FIG. 3

is an enlarged perspective of a hand tool or distance template or spacer with which a plate loosely on a tie is preliminarily located for later receipt of a clamping jig and spikes;





FIG. 4

is an enlarged perspective of a tolerance gauge tool or template or spacer, comprising a stepped foot, with which the location of the spike-secured plates are checked for railroad gauge accuracy;





FIG. 5

is an enlarged perspective of a typical steel railroad plate;





FIG. 6

is an enlarged perspective, with a portion broken away for ease of presentation, of a completed pre-plated wooden railroad tie;





FIG. 7

is a cross sectional view of a jig comprised of a hydraulic or pneumatic cylinder used to temporarily clamp a railroad plate in a correct position on a wooden railroad tie;





FIG. 8

is a perspective of a jig embodying principles of the present invention comprising two end clamps each comprised of a plate flange-engaging cross bar or stop and a crank mechanism with a displaceable clamping head or moveable stop; and





FIG. 9

is a cross section taken along line


9





9


of FIG.


8


.











DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS




Reference is now specifically made to the drawings wherein like numerals are used to designate like parts throughout.

FIG. 1

is in flow chart form and illustrates one form of methodology which embodies principles in accordance with the present invention by which wooden railroad ties are pre-plated in advance of use in initially constructing or repairing a railroad line. In respect to

FIG. 1

, inventories of wooden railroad ties, steel railroad plates, steel railroad spikes and custom jigs are provided. The ties, plates and spikes may be new or used. Sometimes reconditioned or reclaimed wooden railroad ties are pre-plated. Whether new or used, the railroad ties are positioned so that each one being processed receives on the top thereof, in loose condition, two rail-receiving plates. The preliminary location of one of the two plates in respect to the associated tie may be established using a distance-establishing tool or template or spacer. With the two rail-receiving plates positioned generally correctly on top of the associated railroad tie, a jig is superimposed over the top of the tire at the perimeter thereof, namely along the sides adjacent to the top of the jig such that a position-locating stop or cross bar passes through a channel or rail seat surface of each plate between parallel flanges of the plate.




It is preferred that the methodology depicted in

FIG. 1

be one which comprises mass production techniques so that a series or succession of ties are processed one after another in continuing manner.




Once the jig is correctly placed as if a crown upon the railroad tie, a clamping member at each end of the jig is actuated to clamp against the field edge of the adjacent plate so that the bar or stop forcibly and contiguously engages the inside surface of the field flange of the plate. As a consequence, the two plates are rigidly, though temporarily, held in precisely the desired position on top of the associated railroad tie. Thus, the distance from the inside surface the field flange of one plate to the inside surface of the field flange of the other plate is precisely set to accurately later receive two rails having exactly the correct railroad gauge needed.




At this point, a field spike and a gauge spike are started into the wooden railroad tie through appropriate apertures in each jig-held plate. Specifically, a gauge spike is driven into the wooden railroad tie through an aperture in the field side of each plate which is located remote from the field flange. The gauge spike is driven into the wooden railroad tie through an aperture in the gauge flange of each plate. In both cases, each spike is merely started into the wooden railroad tie. This may be done by manual manipulation of one or more sledge hammers or otherwise as appropriate.




The field spike mentioned above is, thereafter, machine-driven fully into the wooden railroad tie until the head of the field spike is contiguous with the top surface of the associated plate. Preferably a jack hammer or like automated tool is used to so drive the field spike. The gauge spike is likewise machine-driven until the head thereof is on the order of 1½ inches above the gauge flange. The gauge spike is left in this position, with the eccentric portion of the head of the spike directed toward the field flange of the same plate to accommodate later receipt of one side of the bottom flange of a railroad rail when the pre-plated tie is used to construct or repair a railroad line.




Ordinarily, the described pre-plating of railroad ties occurs at a factory or similar location remote from the location where the ties are used to construct or repair a railroad line, although a pre-plating plant could be located near the site where the railroad line is being constructed or repaired and could be portable so as to keep pace with the construction or repair of the railroad line.




Once the one field spike and the one gauge spike are driven in the manner indicated above, the clamping mechanisms of the jig are released and the jig is entirely removed from the tie and the plates. The jig is returned to the ingress area of the pre-plating plant for reuse, while the completed pre-plated tie is checked with a tolerance tool or template or spacer to ensure that the two spiked plates are positioned within the necessary tolerances required for accuracy. The pre-plated ties are removed from an egress station, using a forklift, for example, and either stored or shipped for use in constructing or repairing a railroad line or both.




Reference is now made to

FIG. 2

which illustrates the manner in which the work stations depicted in

FIGS. 2A

,


2


B, and


2


C interrelate. It is to be appreciated that the orientation depicted in

FIG. 2B

is essentially the reverse of and distinct from the orientation depicted in

FIGS. 2A and 2C

. In respect to

FIG. 2A

, an ingress or entry work station, generally designated


10


, is depicted. The ingress work station or site


10


is illustrated as comprising spaced structured I-beams


12


and


14


, which may be supported on the ground, on a floor or above the ground or floor on columns (not shown), for example. The I-beams could be replaced by a platform if desired. Typically, a supply or stack of ties, generally designated as


16


and comprising individual ties


18


, is transported to the work station


10


and deposited across the spaced, parallel I-beams


12


and


14


. A forklift, for example, may be used to place the ties


18


in the position illustrated in FIG.


2


A. The stack


16


of ties


18


may be held together by one or more steel bands (not shown), which are cut before or after placement at the ingress station


10


, as illustrated in FIG.


2


A. Each tie


18


is illustrated as having a metal cleat


20


secured on each end, to prevent damage. It is to be appreciated that not all ties used to form railroad lines have end cleats. It is further to be appreciated that different ties have different dimensions. For example, some ties are approximately nine feet long, while others are shorter.




The ties


18


are removed one-by-one from the stack


16


and are placed sequentially across the rails


12


and


14


, one after another. With continued reference to

FIG. 2A

, two individual ties


18


are illustrated in spaced relation at the right portion of FIG.


2


A. The first separate tie


18


shows two steel railroad plates, generally designated


22


, placed loosely on top of the tie. The unattached placement of right plate, to begin with, may be ascertained by use of a hand tool or spacer, generally designated


24


. As shown in

FIGS. 2A and 3

, placement tool


24


has an L-shaped configuration comprising a long leg


26


and a short leg


28


. The tool


24


is preferably formed from steel, although other suitable materials may be used. The tool


24


is manipulated by a U-shaped handle


30


, which may be welded to the L-shaped portion. The legs


26


and


24


, being respectively planar and disposed at 90 degrees one to the other, accommodate placement of the leg


28


contiguous with one end edge


32


of the tie, with the leg


26


running contiguously along the top surface of the tie. See FIG.


2


A. By placing the field edge


34


of one plate


22


against the free edge


35


of the tool


24


, the one plate is loosely positioned approximately where it will need to be when the pre-plating operation has been completed. The second plate


22


is thereafter correctly positioned on the tie


18


using a jig


70


, as explained hereinafter.




Not all steel railroad plates are dimensionally the same. There are variations in size. The steel railroad plates


22


, which are illustrated in the drawings and described herein, are intended to be representative and not restrictive. As best shown in

FIG. 5

, each illustrated plate


22


comprises a field side and a gauge side, the gauge side being juxtaposed one end of the associated tie


18


and the gauge side being juxtaposed the central portion of the associated tie


18


. The plate


22


is essentially symmetrical about a central line


36


, except for a rail seat surface


40


. The plate


22


comprises a rail-receiving channel


38


, comprising top surface


40


which is slightly sloped toward the gauge side of the plate


22


. Surface


40


spans between a field flange or ridge


42


and a gauge flange or ridge


44


. In use, two plates


22


are held by steel railroad spikes at space locations on top of a railroad tie


18


with the channel


38


extending perpendicular to the axis of the tie. Two railroad rails are positioned respectively in the channels


38


on the sloped surfaces


40


of the two spaced plates


22


, the rails ultimately being secured to the plates against inadvertent displacement by steel railroad spikes passing through two apertures


46


in the field flange


42


and two apertures


48


in the gauge flange


44


, as more fully described hereinafter. The oppositely sloped surfaces


40


on the two plates


22


cause the two rails to slightly toe in toward each other for better performance.




It follows that each field flange


42


defines a channel or interior linear surface


50


, while the gauge flange


44


defines a similar interior surface


52


. The field flange


42


tapers into a field region


54


, which terminates in field edge


34


. Similarly, each gauge flange


44


tapers outwardly across a gauge region


56


, which terminates in edge


58


. Each plate


22


also comprises a trailing edge


60


and a leading edge


62


which are both oriented essentially parallel to the direction of the tie and perpendicular to surfaces


50


,


52


,


58


and


34


. The field region


54


has an aperture


64


for receiving a steel railroad spike during pre-plating at a location remote or spaced from the field flange


42


. Similarly, the gauge region


56


defines a rectangular aperture


66


for receiving a steel railroad spike during rail installation at a location remote from the gauge flange


44


. The spikes which are ultimately driven through apertures


64


and


66


into the associated wooden railroad tie are so displaced until the heads of the spikes are contiguous with the top surface of the associated plate


22


, for the purpose of anchoring the plate


22


to the wooden railroad tie in a precise location. Spikes placed through apertures


64


and


66


may be number one grade or less, while spikes placed in apertures


46


and


48


need to be number one grade.




It is to be understood that the present invention applies to utilization of both new and used or recycled steel railroad plates in the pre-plating of wooden railroad ties. After the two plates


22


have been placed loosely on top of one of the ties


18


, as shown in the lower portion of

FIG. 2A

, the next step in the pre-plating process herein disclosed is to temporarily or releasibly secure each of the two plates in a fixed position in respect to the tie so that relative movement between either plate


22


and the tie


18


is prevented and so that the plates are precisely positioned on the top of the tie to meet tolerance requirements and to avoid rejection of pre-plated ties for being out of tolerance.




A jig, generally designated


70


, is used to hold both plates rigidly in the desired positions. See

FIGS. 2A

,


8


and


9


. As best seen in

FIG. 2A

, the jig


70


is superimposed over both the top of the associated tie


18


and over the two plates


22


. More specifically, each side surface of the associated railroad tie


18


is contiguously engaged by one, vertically-directed leg of parallel, spaced structural angle members


72


of the jig. The jig


70


, with the clamping mechanisms retracted, is placed in an angular orientation to the associated tie


18


with the jig end down which is adjacent to the right plate (as viewed in FIG.


2


A). The right cross bar


74


of the jig


70


is next placed in the channel


38


of the right plate


22


, as the left end of the jig


70


is rotated downwardly with the vertical legs of the angle members


72


contiguous with the opposed sides of the tie


18


. The jig rotation is continued until the left cross bar


74


is in the channel


38


of the left plate


22


and the spaced angle members


72


are horizontally disposed and the vertical legs of members


72


are respectively contiguous with the side surfaces of the tie


18


near the top of the tie.




Six cross bars are provided comprising interior parallel cross bars


74


, intermediate parallel cross bars


76


and parallel and/or outside cross bars


78


. Each of the six cross bars


74


,


76


and


78


are welded at their respective ends to the vertical leg of both angle members


72


, to form a rigid frame. While cross bars


78


are illustrated as being arranged to extend across the top surface of the associated tie


18


, if desired, they can be arranged so as to engage tie end surfaces


32


. Cross bars


78


are in a plane slightly above a plane containing cross bars


76


, while cross bars


74


are in a third plane disposed somewhat above and parallel to the plane containing cross bars


78


. See FIG.


8


. The distance between the two planes containing cross bars


76


and cross bars


74


is essentially the thickness of plate


22


at channel


38


. This accommodates placement of the cross bars


74


through the channels


38


of the spaced plates


22


on top of tie


18


, as best depicted in FIG.


2


A.




By locating the cross bars


78


above the cross bars


76


, clamping members of the jigs are slightly sloped to insure firm engagement by the clamping mechanism of the plate edge


34


. The cross bars


74


,


76


and


78


are essentially the same length so that the jig


70


is a rectangle. The length of each cross bar


74


,


76


and


78


is also essentially equal to the width of the railroad tie


18


. Since the dimensions of railroad ties can vary, not only in terms of the height and width but also in terms of the length, jigs for any particularly sized tie are custom manufactured. For larger or smaller railroad ties, jigs of the type illustrated in the drawings are fabricated to match the dimensions of the tie with which they are intended to be used.




Centrally located on each cross bar


76


is a journal block


80


. Each journal block


80


is anchored, as by welding, to its associated cross bar


76


and provides a throughbore


82


, which is centrally disposed and oriented transverse to the associated bar


76


. A distal portion of a shaft


84


, which is smooth, extends through the associated bore


82


for rotation in respect to the bore


82


. Each journal block


80


is welded to a canopy-type plate


86


which eccentrically extends toward the center of the jig


70


beyond the limits of the block


80


, as best shown in

FIGS. 8 and 9

. A clamping end or moveable stop or plate engagement head


88


is disposed immediately below extension plate


86


, plate


86


serving as an anti-rotate member preventing the wedge-shaped clamping head or movable stop


88


from rotating.




Each shaft


84


comprises a threaded distal end


90


(FIG.


9


). Thus, the rounded portion of shaft


84


, which journals in block


80


accommodates rotation of the shaft


84


in respect to the journal block


80


, while the threads


90


of the distal end of the shaft


84


are threaded into or out of a blind threaded bore


92


in head


88


, depending on the direction of rotation. Because the shaft


84


is limited to rotation without axial displacement (as explained hereinafter in greater detail) and because anti-rotation plate


86


prohibits rotation of clamping head


88


, rotation of shaft


84


causes the clamping block


88


to move left or right as viewed in

FIG. 9

in relationship to the shaft


84


, depending upon the direction in which the shaft


84


is rotated. Thus, the movable clamping stop or wedge-shaped head


88


may be advanced toward the adjacent plate


22


or retracted from the adjacent plate


22


, for reasons explained in greater detail later. Each cross bar


78


supports in superposition a journal block


100


, which may be welded centrally to the associated cross bar


78


so that a journaling throughbore


102


of block


100


is located parallel to the journal bore


82


of the journal block


80


. The size of the shaft


84


and that of the throughbore


102


are such that a snug fit is achieved which accommodates selective rotation of the shaft


84


in respect to the stationary journal block


100


. Spaced steel sleeves


104


and


106


are welded to the shaft


84


adjacent the opposed sides of the journal block


100


so as to accommodate rotation of the shaft


84


within the journal blocks


80


and


100


, with the sleeves


104


and


106


preventing axial displacement of the shaft


84


relative to the journal blocks


80


and


100


. See FIG.


9


.




Each shaft


84


is joined at its proximal end to a crank arm mechanism


108


by which rotation of the shaft


84


is accomplished. As shown best in

FIGS. 8 and 9

, the crank arm mechanism


108


comprises a stepped bar


110


, welded to the distal end of the shaft


84


and an eccentric grasping handle


112


, welded to the eccentric end of the plate


110


. Thus, by grasping the handle


112


and causing it to rotate either clockwise or counterclockwise, as desired, the shaft


84


rotates within journal blocks


80


and


100


, with the threads of movable stop


88


inter-reacting with the threads


90


at the distal end of the shaft


84


so that the wedge-shaped movable clamping member


88


is advanced or retracted in respect to the adjacent cross piece


74


.




This motion is important to clamp each of the two plates temporarily but fixedly in respect to the top of the associated tie


18


. This is done by rotating each crank mechanism


108


in the appropriate direction so as to move clamping heads


88


toward the adjacent plate


22


. When the field edge


34


of the adjacent plate


22


is engaged, cranking is continued until such time as the adjacent cross bar or stop


74


is forcibly contiguous with the inside surface


50


of the field flange


42


of the associated plate


22


. The clamping head


88


is similarly firmly contiguous with the edge


34


. Thus, when both clamps of jig


70


have been so activated, both associated plates


22


are temporarily though firmly held in a tolerance-accommodating position. When this position has been achieved, two or more spikes


114


are started, using one or more sledge hammers, into the associated wooden railroad tie


18


through selected apertures in the two plates


22


. While the aperture selection could vary, the selection illustrated in

FIGS. 2A

,


2


B,


2


C and


2


B′ works well. More specifically, one steel railroad spike is illustrated as having been started through plate aperture


64


, which is disposed in the plate region


54


of the associated plate and a second spike is placed in one of the two spike-receiving apertures


48


disposed in the gauge flange


44


. Since the standard railroad spike has an eccentrically-disposed head, the head of the spike


114


in the aperture


64


of each plate is oriented toward the center of the tie


18


, while the head of the spike


114


placed in aperture


48


of each plate


22


is oppositely oriented, i.e. outwardly toward the adjacent crank handle


108


. The assembled nature of the spikes


114


, the plates


22


, the jig


70


and the associated tie


18


is illustrated in

FIG. 2A

, at the upper right location.




While

FIG. 2A

comprises a work station where movement of the ties is manual, it is to be understood that the ties


18


may be placed upon a conveyor system for automatically moving the ties through the work station illustrated in FIG.


2


A.




Each partially pre-plated tie emanating from the work station of

FIG. 2A

is displaced to a second work station, one form of which is illustrated in FIG.


2


B and another in FIG.


2


B′. In reference to

FIG. 2B

, the orientation of that work station, as shown, is essentially the reverse of the orientation of

FIG. 2A

, for clarity of illustration. Each partially pre-plated tie


18


emanating from the work station of

FIG. 2A

is displaced through the work station of

FIG. 2B

via a conveyor system. The tie conveyor system of

FIG. 2B

is generally designated


120


and comprises two parallel chain link conveyors


122


, each of which is conventional and, accordingly, an extensive disclosure thereof is not essential to an understanding of the present invention by those skilled in the art. The ties


18


processed through the work station of

FIG. 2B

move in the direction of the arrows


124


, i.e., from right to left. The parallel conveyors


120


each comprises spaced abutment studs


126


, two of which (one from each conveyor


122


) engage and push on the back side of each tie


18


delivered from the work station of FIG.


2


A. The conveyors


122


preferably are variable speed conveyors so that the rate at which partially pre-plated ties


18


from work station


2


A are displaced through the work station of


2


B may be controlled to ensure both efficiency and accuracy.




The work station of

FIG. 2B

comprises a canopy


128


, cross supports


130


and


132


and three floor segments or catwalks


134


,


136


and


138


comprised of conventional steel grating. The canopy


128


, the cross supports


130


and


132


and the grating platforms


134


,


136


and


138


are suitably supported by conventional structural members in the air above both the conveyors


122


and the partially pre-plated ties


18


so as to accommodate displacement of the ties beneath the canopy


128


, the cross supports


130


and


132


and the grating platforms


134


,


136


and


138


, as shown in

FIG. 2B. A

worker


140


is illustrated in

FIG. 2B

as standing upon grating platforms


134


and


136


while holding a spike-driving tool


144


, which may be a jackhammer with an appropriate tip or driving head


144


. Other suitable automated driving tools, such as pneumatic and hydraulic cylinder assemblies, may also be used. The jackhammer may be electric, pneumatic or hydraulic and is used to drive the spikes


114


disposed in each aperture


64


fully into the associated wooden railroad tie so that the head thereof is contiguous with the plate region


54


. The jackhammer


142


is also used to drive the spike


114


disposed in one of the apertures


48


until the head thereof is on the order of an inch and a half or so above the plate flange


44


. This provides a suitable space for later placement of a railroad rail in the channel


38


so that one side of the bottom flange is spaced directly below the head of the spike


114


disposed in one of the two apertures


48


. It should be apparent that the last mentioned spike


114


will later be driven further so as to become contiguous with the adjacent bottom flange of the rail during field installation of the rail. At that time, spikes would also be suitably driven through the remaining apertures in each plate


22


whereby the spikes in apertures


64


and


66


hold the plate in position on the tie and the spikes in the four apertures


46


and


48


engage the rail at opposed bottom flanges to secure the rail to the plate


22


.




As a consequence, when the pre-plated ties


18


emerge at the back side of the canopy


128


on conveyors


122


, the plates


22


are illustrated as being secured by the two spikes


114


against displacement relative to the associated tie


18


. Accordingly, the jig


70


associated with the tie


18


may be removed by turning the two crank handles so as to loosen the two clamping heads


88


from engagement with the edge


34


of the adjacent plate


22


. At this point, the jig is lifted from the associated tie and is returned to the work station of

FIG. 2A

to be reused.




Preferably, the work station of

FIG. 2B

comprises a second conveyor system, generally designated


140


, which comprises two spaced conventional chain conveyors


142


. The conveyors


142


comprise outwardly directed studs


144


upon which the removed jigs


70


are hung and conveyed from left to right, as viewed in

FIG. 2B

, to a location directly adjacent the work station of FIG.


2


A. The jigs


70


being so conveyed engage two sloped ramp members


146


adjacent to the

FIG. 2A

work station, which removes each jig


70


from the conveyors


142


, following which the jigs


70


are manually reused, in the manner described earlier in conjunction with FIG.


2


A.




When the jig


18


has been removed from a completed pre-plated tie


18


, the tie


18


has the appearance as shown at the extreme left in FIG.


2


B. It is shown as resting upon two spaced I-beams


148


and


150


, which may in turn be supported on columns or the like (not shown).




One of the advantages of the work station of

FIG. 2B

is that the worker


140


stands on platforms separated from and located above the partially pre-plated ties


18


so that worker damage to the jigs


70


is either entirely eliminated or substantially so.




In lieu of the conveyor-mechanized work station of

FIG. 2B

, the stationary work station of FIG.


2


B′ may be used. While the work station of FIG.


2


B′ is illustrated as being supported upon two I-beams


12


′ and


14


′, almost any type of stationary platform configuration would be suitable for providing support for partially pre-plated ties


18


coming sequentially from the work station of FIG.


2


A. The partially pre-plated tie


18


, with plates


22


, started spikes


114


and jig


70


of the type illustrated in the upper right hand portion of

FIG. 2A

, is also illustrated in FIG.


2


B′ and has been correspondingly numbered. No further description is necessary, except to say that the worker


140


with jackhammer


142


equipped with socket


144


will stand at least some of the time on the jig


70


in the course of driving the spikes


114


, in the manner heretofore indicated. Where the worker


140


does stand and walk upon jigs


70


, it may be necessary for the jigs to comprise components which are structurally larger and stronger than those used at the work station of FIG.


2


B.




Reference is now made to

FIG. 2C

, which illustrates, in the upper right hand portion, the downstream end of the work station of FIG.


2


B. The pre-plated tie


18


shown at the left in

FIG. 2B

is reproduced on the right in FIG.


2


C. It is to be understood that the pre-plated tie


18


illustrated in

FIG. 2C

may arrive from either the spike-driving work station of

FIG. 2B

or the spike-driving work station of FIG.


2


B′.




The pre-plated tie


18


illustrated at the right in

FIG. 2C

includes a U-shaped distance-measuring tool or template or spacer, generally designated


160


. This distance-measuring tool is illustrated in enlarged perspective in FIG.


4


and comprises opposed plate-like pedestals or feet


162


and


163


. The foot


162


comprises an outside edge surface


164


adapted to engage the inside surface


50


of the field flange


42


of the right plate


22


on top of the pre-plated tie


18


. The left foot


163


comprises an outside edge surface


165


and a bottom notch comprising horizontal surface


167


and vertical surface


169


. The distance of surface


167


from surface


165


to surface


169


equals the permitted tolerance for plate placement. For example, this may be ⅛″ or {fraction (1/16)}″ or otherwise, depending on the specified tolerance. With the right pedestal or foot


162


engaging right plate surface


50


at edge


164


, the plates


22


are within tolerance if the edge


169


is within the channel


38


of the left plate


22


and edge


167


is not within this channel


38


. The tool


160


is preferably formed of steel, although other materials could be used, and comprises opposed short columns


166


of equal length and a connecting beam


168


. Beam


168


may appropriately be welded to columns


166


, which in turn may be welded to plates


162


and


163


.




Since each completed pre-plated tie


18


is manually tested with the tool


160


, it is immediately known whether each tie is within tolerances. Those few which are not, if any, are corrected. However, all or nearly all completed pre-plated ties


18


are found to be within the require accuracy tolerances and, therefore, there are few, if any, rejects.




With continued reference to

FIG. 2C

, the completed pre-plated ties


18


which have been checked for plate location tolerance are next displaced down parallel ramps


170


, until a suitable number have been accumulated, at which time, a forklift or other suitable mechanized lifting apparatus is used to simultaneously hoist several of the completed pre-plated ties


18


for placement in storage or upon or in a suitable vehicle for transportation to another storage site and/or to an installation site where a railroad line is being constructed or repaired. The sloped ramps


170


are illustrated as being connected, as by welding, to a transverse abutment


172


, from which two upwardly-directed triangularly-shaped stops


174


project. Stops


174


are engaged by the initial completed pre-plated tie


18


moving down ramps


170


to establish the aligned grouping of completed ties shown toward the left in FIG.


2


C. It is to be appreciated that ramps


170


may comprise roller conveyors or any other suitable structure for satisfactorily processing completed pre-plated ties


18


from the work station of

FIG. 2C

to another location.




Reference is now made to

FIG. 7

, which illustrates another clamping mechanism which may be used to form part of the above-described jig


70


, in lieu of the crank mechanisms. Specifically, a pneumatic or hydraulic cylinder may be mounted upon cross bar


78


(or cross bar


76


) as by welding at site


80


. The orientation of the cylinder is sloped somewhat downward from left to right. The cylinder


182


is conventional and comprises a piston rod


184


which is reciprocated, the direction of displacement depending upon whether a piston within the cylinder


182


is being advanced or retracted. A clamping block


186


is welded or otherwise secured rigidly to the distal end of the piston rod


184


so that clamping block


186


engages the edge surface


134


of the adjacent plate


22


when advanced to cause the plate surface


50


to forcibly and contiguously engage the associated cross bar


74


of the jig.




The invention may be embodied in other specific forms without departing from the spirit of the essential characteristics thereof. The present embodiments, therefore, are to be considered in all respects as illustrative and are not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.



Claims
  • 1. A method of pre-plating railess ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later to later receive thereunder a base flange of a railroad rail; the placing and positioning acts taking place at a stationary work station remote front railroad rails.
  • 2. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; the displacing acts taking place at least in part as ties are successively conveyed past a work station remote from railroad rails.
  • 3. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike trough an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; displacing acts each comprising manually starting each spike through an aperture in its associated wooden plate into its associated tie at a stationary work station at which a rail is not present and machine driving each spike a further distance into the associated wooden tie as the tie is conveyed past another work station at which a rail is not present.
  • 4. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; handling the completed pre-plated ties selected from the group consisting of transporting completed pre-plated ties to a storage location and shipping completed pre-plated ties to a remote railroad site.
  • 5. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; removing the tie and plate engaging jigs from the associated completed pre-plated railess ties and reusing each jig to further practice the positioning act on another tie; returning each removed jig from a downstream site to an upstream site after the removing act and before the reusing act; the returning act comprising sequentially conveying the removed jigs from the downstream site, over a work station where the displacing acts are practiced to an upstream site where the positioning act is practiced on another tie.
  • 6. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; removing the tie and plate engaging jigs from the associated completed pre-plated railess ties and reusing each jig to further practice the positioning act on another tie; returning each removed jig from a downstream site to an upstream site after the removing act and before the reusing act; the returning act comprising sequentially conveying the removed jigs from the downstream site, over a work station where the displacing acts are practiced to an upstream site where the positioning act is practiced on another tie; the sequentially conveying act comprising moving the jigs to be reused consecutively along a conveyor up and over the work station.
  • 7. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie wit a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous wit its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; the positioning act comprising engaging an inside surface of a field flange of both of two plates on top of each tie and one end of the tie with stops of the associated jig.
  • 8. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; the positioning act comprising engaging an inside surface of a field flange of both of two plates on top of each lie and one end of the tie with stops of the associated jig; the engaging act comprising clamping a field edge and the inside surface of the field flange of each tie-engaging plate between clamping components, at least one of which comprises one of said stops.
  • 9. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad lies each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; the positioning act comprising engaging an inside surface of a field flange of both of two plates on top of each tie and one end of the tie with stops of associated jig; the engaging act comprising clamping a field edge and the inside surface of the field flange of each tie-engaging plate between clamping components, at least one of which comprises one of said stops; the clamping act comprising tightening two plate-engaging components, causing the jig to contiguously engage the field edge and the inside surface of the field flange of each tie-engaging plate.
  • 10. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad tics each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; the positioning act comprising engaging an inside surface of a field flange of both of two plates on top of each tie and one end of the tie with stops of the associated jig; the engaging act comprising clamping a field edge and the inside surface of the field flange of each tie-engaging plate between clamping components, at lest one of which comprises one of said stops; the clamping act comprising tightening two plate-engaging components, causing the jig contiguously engage the field edge and the inside surface of the field flange of each tie-engaging plate; the clamping act comprising displacing one plate-engaging component towards the other plate-engaging component.
  • 11. A method according to claim 10 wherein the displacing act comprises use of an eccentric crank arm, a threaded shaft and at least one threaded fitting to generally linearly move the one plate-engaging component towards the other plate-engaging component when the eccentric crank arm is turned.
  • 12. A method of pre-plating railess railroad ties, comprising the acts of:placing two generally planar plates on top of each of a sequential number of railess wooden railroad ties each having a generally smooth top surface; positioning the two plates associated with each railroad tie with a plate-locating removable jig which engages the tie and the two plates; displacing a field spike through an aperture in a field side of each plate into its associated wooden tie until a head of each field spike is contiguous with its associated plate to secure each plate to the associated tie; displacing a gauge spike through an aperture in a gauge side of each plate into its associated wooden tie until a head of each gauge spike is disposed at a distance above the plate ample to later receive thereunder a base flange of a railroad rail; the positioning act comprising engaging an inside surface of a field flange of both of two plates on top of each tie and one end of the tie with stops of the associated jig; the engaging act comprising clamping a field edge and the inside surface of the field flange of each tie-engaging plate between clamping components, at least one of which comprises one of said stops; the clamping act comprising tightening two plate-engaging components, causing the jig to contiguously engage the field edge and the inside surface of the field flange of each tie-engaging plate; the clamping act comprising displacing one plate-engaging component towards the other plate-engaging component; the displacing act comprising use of pneumatic or hydraulic cylinder to generally mineral move the one plate-engaging component towards the other plate-engaging component.
CONTINUITY

This application is a division of our U.S. patent application Ser. No. 09/322,280 filed May 28, 1999, now U.S. Pat. No. 6,292,997.

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