SYSTEMS AND METHODS FOR TIE PLATE DISTRIBUTION AND COLLECTION

PRIORITY CLAIM/INCORPORATION BY REFERENCE

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference herein and made a part of the present disclosure.

TECHNICAL FIELD

The present disclosure relates to railroad infrastructure maintenance, and more particularly, but without limitations, to railroad track maintenance involving tie plate distribution and collection.

BACKGROUND

Railroad tracks need to be regularly maintained to ensure optimal performance. This maintenance may require temporary shutdowns, which can affect train operations. Unfortunately, manually installing tie plates is both laborious and time-consuming. Accordingly, a need exists for a tie-plate distribution system to improve the efficiency of railroad track maintenance and reduce downtime.

SUMMARY

The present application discloses one or more of the features recited in the appended claims and/or the following features which alone or in any combination, may comprise patentable subject matter.

The disclosed embodiments are directed to a tie plate distribution system having a vehicle and a movable arm. The tie plate distribution system may spontaneously detect tie plates along the railroad track or/and ties and use the movable arm to place the tie in association with the tie. For example, the tie may be placed onto any empty ties of the ties, or any predetermined or requested location. The tie plate distribution system provides automated operation in distributing tie plates and enhances railroad maintenance processes in terms of efficiency, working conditions, and adaptability to contribute to more desirably functioning of railroad networks. Likewise, the system may be used to pick up disqualified tie plates, which will be, or have been, replaced.

According to some embodiments, a tie plate distribution system includes a vehicle comprising a motion mechanism and a floor, a movable arm positioned on the vehicle, and a vision sensor positioned on the vehicle or the movable arm. The movable arm has a plurality of degrees of freedom and has a retaining mechanism at an end of the movable arm. The vehicle is configured to move along a path comprising multiple ties. The vision sensor is configured to detect a target tie plate along the path and an empty tie of the multiple ties, the empty tie missing at least one the tie plate thereon. The movable arm isn configured to lift the target tie plate and places the target tie plate in association with the empty tie.

In some embodiments, the retaining mechanism may comprise one of a magnet, an electromagnet, a permanent magnet, or a combination thereof. The retaining mechanism may be an impactive end effector, an ingressive end effector, an astrictive end effector, or a contigutive end effector.

In some embodiments, the movable arm may further comprise a base, a shoulder joint, an elbow, and a wrist joint. The base may be mechanically coupled to the floor of the vehicle at a bottom part of the base and is pivotally coupled to a first end of the elbow with the shoulder joint at a top part of the base. A second end of the elbow may be pivotally coupled to the retaining mechanism with the wrist joint.

In some embodiments, the motion mechanism may comprise a selection of rubber wheels, rail wheels, continuous tracks, or a combination thereof. The vehicle may be operable to move along the path adjacent to a rail or move on the rail along the path.

In some embodiments, the vision sensor may be a proximity sensor, a camera, a light detection and ranging (LIDAR) sensor, a thermal image sensor, an infrared sensor or an ultrasonic sensor.

In some embodiments, the vehicle may further comprise a container configured to store one or more tie plates. The movable arm may be capable of placing a stored tie plate from the container on the empty tie or depositing the target tie plate into the container. The system may further comprise a stationary position comprising one or more tie plates along the path. The movable arm may be capable of transferring the one or more tie plates from the stationary position to the container when the vehicle passes the stationary position.

In some embodiments, the vehicle may further comprise a flipping station, wherein the movable arm is capable of placing the target tie plate in the flipping station to adjust an orientation of the target tie plate to align with a designated installation position of the target tie plate on the empty tie.

According to some embodiments, a method for tie plate distribution includes detecting, using a vision sensor coupled to a vehicle or a movable arm, a target tie plate along a path comprising multiple ties coupled to a rail, lifting, using the movable arm, the target tie plate, detecting, using the vision sensor, an empty tie of the multiple ties, missing at least one the tie plate, and placing, using the movable arm, the target tie plate onto or in proximity to the empty tie.

In some embodiments, the vehicle may further comprise a container. The method may further comprise after lifting the target tie plate and before placing the target tie plate onto or in proximity to the empty tie, placing, using the movable arm, the target tie plate in a container of the vehicle, wherein placing the target tie plate further comprises placing the target tie plate from the container onto or in proximity to the empty tie.

In some embodiments, the target tie plate is disposed in a container of the vehicle.

In some embodiments, the target tie plate is disposed in a stationary position, the stationary position comprising one or more tie plates. The method may further comprise determining, using the vision sensor, the stationary position within reach of the movable arm, and in response to determining that the stationary position is within the reach of the movable arm, transferring, using the movable arm, the one or more tie plates from the stationary position to a container of the vehicle.

In some embodiments, the vehicle may further comprise a flipping station and the method may further comprise placing, using the movable arm, the target tie plate in the flipping station after determining that an orientation of the target tie plate misaligns with a designated installation position of the target tie plate on the empty tie, and adjusting, using the movable arm, the orientation of the target tie plate to align with the designated installation position of the target tie plate on the empty tie in the flipping station.

In some embodiments, the vehicle may further comprise a container and the method may further comprise detecting, using the vision sensor, an existing tie plate between a tie of the multiple ties and a target rail to be replaced, and placing, using the movable arm, a tie plate onto or in proximity to the tie from the container.

According to some embodiments, a tie plate distribution system includes a vehicle having rail wheels, one or more containment beds capable of containing a plurality of tie plates, a path extending longitudinally on the vehicle and adjacent to the one or more containment beds, a movable arm disposed on the path, and a conveyor extending along the vehicle and within a reach of the arm. The one or more beds extend in a longitudinal direction of the vehicle. The movable arm moves along the path in the longitudinal direction. The arm has a plurality of degrees of freedom and has a retaining mechanism at an end of the arm. The movable arm is capable of moving along the path and obtaining one or more tie plates from the one or more containment beds. The arm can retain one or more of the plurality of tie plates and deposit the tie plates on the conveyor.

In some embodiments, the path may be defined by a track. The track may be disposed above the conveyor. The conveyor may be a belt conveyor or a roller conveyor. The one or more containment beds may be two beds. The conveyor and the path may be formed between the two beds.

In some embodiments, the tie plate distribution system may further comprise a cart that moves along the path, the movable arm disposed in the cart.

In some embodiments, the tie plate distribution system may further comprise a vision system. The tie plate distribution system may further comprise a controller which receives input from the vision system. The controller may provide an output in the form of movement of the arm (e.g., a trigger for movement of the arm) to obtain a tie plate. The tie plate distribution system may further comprise a controller operably moving a cart along the path, with the cart moving adjacent to the one or more containment beds.

In some embodiments, the vehicle may be a railcar or a rail-truck. The arm may have at least three movable joints.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. All of the above outlined features are to be understood as exemplary only and many more features and objectives of the various embodiments may be gleaned from the disclosure herein. Therefore, no limiting interpretation of this summary is to be understood without further reading of the entire specification, claims and drawings, included herewith. A more extensive presentation of features, details, utilities, and advantages of the present invention is provided in the following written description of various embodiments of the invention, illustrated in the accompanying drawings, and defined in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

FIG. 1 schematically depicts a tie plate distribution system of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 2 schematically depicts non-limiting components of the devices on the tie plate distribution system of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 3A schematically depicts a tie plate distribution system having a movable arm of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 3B schematically depicts a tie plate distribution system having a flipping station of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 3C schematically depicts a tie plate distribution system having a movable arm of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 4A schematically depicts a tie plate distribution system lifting and placing tie plates during the tie plate distribution of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 4B schematically depicts an example of a tie-plate manipulation during tie inspection using the current disclosed tie plate distribution system of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 4C schematically depicts an example of a tie-plate manipulation during tie replacement using the current disclosed tie plate distribution system of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 5A schematically depicts a tie plate distribution system moving on a railway of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 5B schematically depicts a tie plate distribution system moving off the railway of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 6 schematically depicts a tie plate distribution system having a containment bed and a conveyor of the present disclosure, according to one or more embodiments shown and described herein;

FIG. 7 schematically illustrates a flow diagram of illustrative steps for tie plate distribution of the present disclosure, according to one or more embodiments shown and described herein; and

FIG. 8 schematically illustrates a flow diagram of illustrative steps for collecting used/spent tie plates.

DETAILED DESCRIPTION

The present disclosure provides one or more embodiments of a tie plate distribution system having a vehicle and a movable arm. The tie plate distribution system may spontaneously detect tie plates along the railroad track or/and ties and use the movable arm to place the tie plates onto any empty ties along the railroad track, or any pre-determined or requested location. The tie plate distribution system may also distribute the tie plates, using the movable arm, from a container on the vehicle to the empty ties. In some embodiments, the tie plate distribution system may use the movable arm to place the tie plates on the vehicle to a conveyor for further distribution. Still further, the movable arm may retain used/spent tie plates and deposit them on a vehicle or at a specific location adjacent to the railroad track. While tie plates are discussed primarily throughout this application, is should be understood that the vision system described herein may be used to identify structures other than tie plates. For example, ties, spikes, anchors, and various other track materials may also be identified for processing and/or processed.

The tie plate distribution system offers several practical benefits for railroad maintenance operations. Through its automated process, it enhances the distribution of tie plates onto empty ties, resulting in improved operational efficiency and a streamlined workflow. This automation not only reduces the reliance on manual labor but also ensures consistent and precise placement of tie plates, thereby contributing to railroad integrity and minimizing service disruptions. Furthermore, the system allows remote monitoring to facilitate ongoing maintenance activities, promoting overall efficiency within railroad networks. By automating tasks and minimizing the need for manual labor, the tie plate distribution system presents a positive impact on working conditions. Its adaptable design, along with its ability to allocate resource utilization and adapt to varying railroad track layouts, makes it a desirable option for different railroad networks.

Various embodiments of the systems and methods for tie plate distribution are described in more detail herein. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a” component includes aspects having two or more such components unless the context clearly indicates otherwise.

Throughout the disclosure, “railroad” refers to a transportation infrastructure consisting of a network of tracks made from metal or non-metal rails upon which trains or other vehicles operate. The “rails” refer to one or more parallel metal or non-metal rails that provide a pathway for trains or other vehicles to move. The disclosed rails may be laid on a trackbed, such as track ballast, to hold the railroad track in place as the trains roll over it, to bear the compression load of the rails and ties, to facilitate drainage, and to keep down vegetation that can compromise the integrity of the combined track structure. The track ballast may include crushed stone, washed gravel, bank run gravel, torpedo gravel, slag, chats, coal cinders, sand, or burnt clay.

Throughout the disclosure, “ties” refer to supports, for example wooden, laid perpendicular or non-perpendicular to the rails. The ties hold the rails in place and distribute the weight of the vehicles moving on the rails to the railroad track bed. The disclosed ties may include, but are not limited to, stone block ties, wooden ties, concrete ties, steel ties, or plastic ties.

Throughout the disclosure, “tie plates” refer to metal or non-metal plates that are placed between the bottom of the rails and the top of the ties, which provide a larger surface area for the rails to rest on and distribute the impact loads from the rails to the tie. The disclosed tie plates may include a selection of single-shoulder tie plates, double-shoulder tie plates, hook twin tie plates, and/or a combination thereof. A “single-shoulder tie plate” refers to a tie plate with a single shoulder on the top surface of the tie plate, which is usually placed on the outside of a rail. A “double-shoulder tie plate” refers to a tie plate having two shoulders on the top surface. A “hook twin tie plate” refers to a tie plate including a slotted hole, which works in pairs to a single tie for frog, guide rail, and behind the heel of rail switch.

Throughout the disclosure, an “empty tie” refers to a railroad tie that lacks one or more tie plates to be distributed on or in proximity to the railroad tie based on various maintenance sequences, such as, without limitations, railroad inspection, railroad replacement, and tie plate upgrades. In one embodiment, when the maintenance sequence includes distributing tie plates to any ties that lack a tie plate between the tie and the rail, an empty tie may be a tie that lacks a tie plate positioned between the tie and the rail and has no tie plate placed on or in proximity to the tie.

Throughout the disclosure, a “movable arm” refers to a sequential arrangement of interconnected links that undergo motion facilitated by joints. The movable arm may be actuated by motors or human manipulation. The interconnected links connected by joints may allow either rotational motion or translational (e.g., linear) displacement.

Throughout the disclosure, vehicles moving on or adjacent to the railroad track may include, without limitations, a locomotive, a railcar, a rail truck, maintenance-of-way equipment, a road-rail vehicle, or any vehicle designed to move on or adjacent to the rails. The disclosed vehicle may be a self-propelled vehicle and include an engine or motor to propel the vehicle along the railroad track and for on-road usage. The disclosed vehicles may include, without limitations, wheels (e.g., flange wheels adept at navigating the track contours), axles, braking systems (e.g., air brakes), propulsion mechanisms (e.g., electric motors or diesel-electric engines), communication systems, and illumination systems (e.g., headlights, taillights, or marker lights). Particularly, a “road-rail vehicle” refers to a vehicle equipped with both rail wheels and road wheels, allowing the vehicle to travel on both railway tracks and regular roads. The motion mechanism may include, without limitations, a selection of rubber wheels, rail wheels, flanged wheels, metal wheels, continuous tracks, or a combination thereof. The continuous tracks may be, without limitations, metal link tracks, rubber tracks, single pin tracks, or double pin tracks.

Turning to the figures, FIG. 1 schematically depicts a tie plate distribution system 100. The tie plate distribution system 100 includes a vehicle 101, one or more movable arms 103, and one or more vision sensors 208. The vehicle 101 includes one or more motion mechanisms 111 and a floor 113. In some aspects, a movable arm 103 is positioned on the floor 113 of the vehicle 101. The movable arm 103 has a plurality of degrees of freedom and has a retaining mechanism 131 at an end of the movable arm 103. The movable arm 103 may be operable to lift and place a tie plate 105 via the retaining mechanism 131 as a target tie plate 155. The vision sensors 208 may be positioned on the vehicle 101 or the movable arm 103.

The tie plate distribution system 100 may include a controller 201, which may be referred to as a component of the tie plate distribution system 100. The controller 201 includes an input/output interface 205 and one or more connections 215. The controller 201 may be a local controller that is included in the vehicle 101 or the one or more movable arm 103, or may be a remote controller that operates from a distance from the vehicle 101 or the one or more movable arm 103. The one or more connections 215 connect components of the tie plate distribution system 100 to the controller 201 and allow signal transmission between the components of the tie plate distribution system 100. A connection 215 may be a wired connection or a wireless connection. The connections 215 may connect the vision sensors 208, the vehicle 101, and the movable arms 103 via the connections 215. The connections 215 may be formed from any medium that is capable of transmitting a signal such as, for example, conductive wires, conductive traces, optical waveguides, or the like. In some embodiments, the connections 215 may facilitate the transmission of wireless signals, such as according to a communication protocol (e.g., WiFi, Bluetooth®, Near Field Communication (NFC), or the like). Moreover, the connections 215 may be formed from a combination of mediums capable of transmitting signals. In some embodiments, the connections 215 may include a combination of conductive traces, conductive wires, connectors, and/or buses that cooperate to permit the transmission of electrical data signals to components such as processors, memories, sensors, input devices, output devices, and/or communication devices. Accordingly, the connections 215 may include a vehicle bus, such as for example a LIN bus, a CAN bus, a VAN bus, and the like. Additionally, it is noted that the term “signal” means a waveform (e.g., electrical, optical, magnetic, mechanical or electromagnetic), such as DC, AC, sinusoidal-wave, triangular-wave, square-wave, vibration, and the like, capable of traveling through a medium.

The controller 201 may receive inputs from the components and provide outputs to the components, such as, without limitations, an output triggering a movement of the movable arm 103. In some embodiments, a remote controller as the controller 201 may communicate with the components of the tie plate distribution system 100 through wireless communication technologies, such as, without limitations, radio frequency (RF) communication, Bluetooth (a short-range wireless communication technology), Wi-Fi (a local wireless network based on IEEE 802.11 standards), Zigbee (a low-power, short-range wireless technology based on IEEE 802.15.4 standards), Z-Wave (a mesh network using low energy radio waves), cellular networks (2G, 3G, 4G, 5G, or 6G), satellite communication, or Narrowband Internet of things (NB-IoT, a low-power wide-area network radio technology). The remote controller may monitor, operate, and/or control the vehicle 101, the one or more movable arms 103, and/or the vision sensors 208. For example, the remote controller can be used (in some aspects, by a user) to operate the vision sensors 208 such that the vision sensors 208 inspect the tie plates of the railroad track when the vehicle 101 moves on or along the railroad track. The performance of the vehicle 101 or the one or more movable arms 103 may be monitored (in some aspects, by a user) and the operations of the vehicle 101 or the one or more movable arms 103 may be changed or updated based on the performance (in some aspects, by a user). Further, data from the vehicle 101 such as number of tie plates picked up or deposited, any error conditions, and/or any general operating data may be monitored (in some aspects, by a user).

In some embodiments, such as illustrated in FIGS. 1 and 3A, the retaining mechanism 131 of the movable arm 103 may include, without limitations, one of a magnet, an electromagnet, a permanent magnet, or a combination thereof. The controller 201 may control the retaining mechanism 131 (e.g., as the electromagnet) to produce or restrain from producing a magnetic field to attract for lifting and holding or release the tie plates 105, respectively. The retaining mechanism 131 may include a mechanical part to overcome the magnetic attractive force and release the tie plate 105 held by the retaining mechanism 131, for example, when the retaining mechanism 131 (e.g., as the permanent magnet) constantly produces magnetic fields. For example, as illustrated in FIG. 1, each movable arm 103 employs a retaining mechanism 131, which lifts one target tie plate 155 per retaining mechanism 131 from the ground on the side of the rail 108 by using magnetic attractive force.

In some embodiments, the retaining mechanism 131 may be, without limitations, an impactive end effector, an ingressive end effector, an astrictive end effector, or a contigutive end effector. The impactive end effector, such as the retaining mechanism 431 illustrated in FIGS. 4A-6, may be a jaw or claw-like effector that physically grasps the object to relocate or reorient objects (such as the tie plates 105) based on the need. The ingressive end effector may include, for example, pins, needles, or hackles to physically penetrate the surface of the objects or hook the objects through a hole in the object. The astrictive end effector may include a vacuum, a magneto, or an electro-adhesion mechanism to create an attractive force that is then applied to the objects in order to grasp the objects. The contigutive end effector may create adhesive force between the effector and the object through direct contact such as, without limitations, gluing, surface tension, or freezing.

In some embodiments, as illustrated in FIGS. 3A and 4, the movable arm 103 may include a base 139, a shoulder joint 137, one or more elbows (such as a front elbow 134 and a rear elbow 136), a wrist joint 133, and the retaining mechanism 131 or 431. The base 139 may include a top part 140 and a bottom part 141. The elbows 134 and 136 may include a first end 138 and a second end 132. The elbows 134 and 136 may be mechanically coupled with each other through one or more elbow joints 135. The base 139 may be mechanically coupled to the floor 113 of the vehicle 101 at the bottom part 141 of the base 139. The base 139 may be pivotally coupled to the first end 138 of the elbow with the shoulder joint 137 at the top part 140 of the base 139, and the second end 132 of the elbow may be pivotally coupled to the retaining mechanism 131 or 431 with the wrist joint 133.

In some embodiments, the movable arm 103 may have a plurality of degrees of freedom. The number of degrees of freedom may be, without limitations, from 2 to 10, from 2 to 8, or from 2 to 6. Throughout the disclosure, six degrees of freedom refers to the six mechanical degrees of freedom of movement of a rigid body in three-dimensional space, including changes position in three perpendicular axes as forward/backward (surge), up/down (heave), left/right (sway) and changes in orientation through rotation about three perpendicular axes as yaw (normal axis), pitch (transverse axis), and roll (longitudinal axis). For example, as illustrated in FIGS. 3A, 3B, and 4, the movable arm 103 may rotate via the base 139 having a yaw degree of freedom. The shoulder joint 137 adds a roll degree of freedom to the front elbow 134 and the rear elbow 136. The elbow joint 135 adds a roll or a pitch degree of freedom to the front elbow 134. The wrist joint 133 adds a yaw, a roll, or a pitch degree of freedom to the retaining mechanism 131 or 431. The impactive end effector 431 as illustrated in FIG. 4A as the retaining mechanism 131 adds a surge or a sway degree of freedom to the movable arm 103.

Referring back to FIG. 1, the vehicle 101 may be, without limitations, a railcar, a rail truck, or a road-rail vehicle. The vehicle 101 may move on the motion mechanism 111 along a path. The motion mechanism 111 of the vehicle 101 may be, without limitations, a selection of rubber wheels, rail wheels, continuous tracks, and/or a combination thereof. The vehicle 101 may operably move on a path 109. In some embodiments, the path may be along a rail 108. The rail 108 may be installed on a plurality of ties 107. Between the rail 108 and each tie 107, a tie plate 105 may be installed to mechanical couple the rail 108 and tie 107. In some embodiments, as illustrated in FIG. 5A, the vehicle 101 may move on the rail 108. In some embodiments, as illustrated in FIG. 5B, the vehicle 101 may move along the path adjacent to the rail 108.

The one or more vision sensors 208 may include a selection of, without limitations, a proximity sensor, a camera, a light detection and ranging (LIDAR) sensor, a thermal image sensor, an infrared sensor, an ultrasonic sensor, and/or a combination thereof. The camera may be, without limitation, an RGB camera, a depth camera, an infrared camera, a wide-angle camera, or a stereoscopic camera. The vision sensors 208 may be operable to acquire image or video data of the vehicle 101, the movable arms 103, the rail 108, the tie 107, the tie plates 105, and the environments around the vehicle 101. The vision sensors 208 may be equipped on the movable arm 103 or the vehicle 101. In some embodiments, the vision sensors 208 may be equipped, without limitations, on a smartphone, a tablet, a computer, a laptop, or a virtual head unit.

The vehicle 101 may further include a container 115. The container 115 may be used to store one or more tie plates 105. The container 115 may have multiple slots 151. For example, as illustrated in FIGS. 1 and 3A, the container 115 includes four slots 151. The container 115 may be within the reach of the movable arms 103. The vehicle 101 may further include one or more flipping stations 117. In some embodiments, as illustrated in FIGS. 1, 3A, and 3B, the flipping stations 117 may be attached to the container 115. The flipping station 117 is within the reach of the movable arms 103. The flipping station 117 may be used to manipulate an orientation of the target tie plate 155 lifted by the movable arm 103. In some embodiments, the orientations of the target tie plate 155 may be upside down or in other deviation orientations that are not in alignment with the designated position for the tie plate 245 to be placed. The flipping station 117 may flip or re-orientate the target tie plate 155 to be in alignment with the designated position to be placed on the empty tie 407. Details regarding the flipping station 117 and the mechanism of tie plate flipping and/or reorientation are provided further below.

In some embodiments, the tie plate distribution system 100 may further be situated at a stationary position along the path 109. One or more tie plates 105 may be present at the stationary position and the one or more tie plates 105 may be within the reach of the movable arms 103.

Referring to FIG. 2, example non-limiting components of the tie plate distribution system 100 are depicted. The tie plate distribution system 100 may include the controller 201. The controller 201 may include various components, such as a memory component 202, a processor 204, an input/output interface 205, a network interface hardware 206, a data storage component 207, and a local interface 203. The controller 201 may include one or more vision sensors 208. The controller 201 may include one or more modules, such as a vehicle control module to operate the vehicle 101 and 601 (e.g. as illustrated in FIGS. 1 and 3A-6), a vision module to operate the vision sensors 208, a conveyor control module to operate conveyor 609 (e.g. as illustrated in FIG. 6), or a movable arm control module to operate the movable arm 103 and 403 (e.g. as illustrated in FIGS. 1 and 3-6).

The controller 201 may be any device or combination of components comprising the processor 204 and the memory component 202, such as a non-transitory computer readable memory. The processor 204 may be any device capable of executing the machine-readable instruction set stored in the non-transitory computer readable memory. Accordingly, the processor 204 may be an electric controller, an integrated circuit, a microchip, a computer, or any other computing device. The processor 204 may include any processing component(s) configured to receive and execute programming instructions (such as from the data storage component 207 and/or the memory component 202). The instructions may be in the form of a machine-readable instruction set stored in the data storage component 207 and/or the memory component 202. The processor 204 is communicatively coupled to the other components of the controller 201 by the local interface 203. Accordingly, the local interface 203 may communicatively couple any number of processors 204 with one another, and allow the components coupled to the local interface 203 to operate in a distributed computing environment. The local interface 203 may be implemented as a bus or other interface to facilitate communication among the components of the controller 201. While the embodiment depicted in FIG. 2 includes a single processor, other embodiments may include more than one processor.

The memory component 202 (e.g., a non-transitory computer-readable memory component) may include RAM, ROM, a flash memory, a hard drive, or any non-transitory memory device capable of storing machine-readable instructions such that the machine-readable instructions can be accessed and executed by the processor 204. The machine-readable instruction set may include logic or algorithm(s) written in any programming language of any generation (e.g., 1GL, 2GL, 3GL, 4GL, or 5GL) such as, for example, machine language that may be directly executed by the processor 204, or assembly language, object-oriented programming (OOP), scripting languages, microcode, etc., that may be compiled or assembled into machine readable instructions and stored in the memory component 202. Alternatively, the machine-readable instruction set may be written in a hardware description language (HDL), such as logic implemented via either a field-programmable gate array (FPGA) configuration or an application-specific integrated circuit (ASIC), or their equivalents. Accordingly, the functionality described herein may be implemented in any conventional computer programming language, as pre-programmed hardware elements, or as a combination of hardware and software components. For example, the memory component 202 may be a machine-readable memory (which may also be referred to as a non-transitory processor-readable memory or medium) that stores instructions that, when executed by the processor 204, causes the processor 204 to perform a method or control scheme as described herein. While the embodiment depicted in FIG. 2 includes a single non-transitory computer-readable memory component, other embodiments may include more than one memory module. The memory may be used to store the one or more modules. The one or more modules during operating may be in the form of operating systems, application program modules, and other program modules. Such program modules may include, but are not limited to, routines, subroutines, programs, objects, components, and data structures for performing specific tasks or executing specific abstract data types according to the present disclosure as will be described below. For example, the program module may include the vehicle control module to operate the vehicle 101 and 601 (e.g. as illustrated in FIGS. 1 and 3-6), the vision module to operate the vision sensors 208, the conveyor control module to operate conveyor 609 (e.g. as illustrated in FIG. 6), and the movable arm control module to operate the movable arm 103 and 403 (e.g. as illustrated in FIGS. 1 and 3-6).

The tie plate distribution system 100 may be an artificial intelligence system such that the tie plate distribution system 100 may predict and operate based on the collected images and data related to the railroad systems and environment. Particularly, the tie plate distribution system 100 may have machine learning functions. The various modules may include one or more machine learning algorithms or neural networks. The vehicle control module, the vision module, the conveyor control module, and the movable arm control module may be trained and provided with machine learning capabilities via a neural network as described herein. By way of example, and not as a limitation, the neural network may utilize one or more artificial neural networks (ANNs). In ANNs, connections between nodes may form a directed acyclic graph (DAG). ANNs may include node inputs, one or more hidden activation layers, and node outputs, and may be utilized with activation functions in the one or more hidden activation layers such as a linear function, a step function, logistic (sigmoid) function, a tanh function, a rectified linear unit (ReLu) function, or combinations thereof. ANNs are trained by applying such activation functions to training data sets (such as the vision sensor data about tracks, vehicles, movable arms, and other railroad maintenance devices and equipment associated with various maintenance tasks) to determine a solution from adjustable weights and biases applied to nodes within the hidden activation layers to generate one or more outputs as the solution with a minimized error. In machine learning applications, new inputs may be provided (such as the generated one or more outputs) to the ANN model as training data (such as the vision sensor data about tracks, vehicles, movable arms, and other railroad maintenance devices and equipment associated with various maintenance tasks) to continue to improve accuracy and minimize error of the ANN model. The one or more ANN models may utilize one-to-one, one-to-many, many-to-one, and/or many-to-many (e.g., sequence to sequence) sequence modeling. The one or more ANN models may employ a combination of artificial intelligence techniques, such as, but not limited to, Deep Learning, Random Forest Classifiers, Feature extraction from audio, images, clustering algorithms, or combinations thereof. In some embodiments, a convolutional neural network (CNN) may be utilized. For example, a convolutional neural network (CNN) may be used as an ANN that, in a field of machine learning, for example, is a class of deep, feed-forward ANNs applied for video and images collected by the vision sensor 208. CNNs may be shift or space invariant and utilize shared-weight architecture and translation. Further, each of the various modules may include one or more generative artificial intelligence algorithms. The generative artificial intelligence algorithm may include a general adversarial network (GAN) that has two networks, a generator model and a discriminator model. The generative artificial intelligence algorithm may also be based on variation autoencoder (VAE) or transformer-based models.

The input/output interface 205 may include a monitor, keyboard, mouse, printer, camera, microphone, speaker, and/or other device for receiving, sending, and/or presenting data. The network interface hardware 206 may include any wired or wireless networking hardware, such as a modem, LAN port, Wi-Fi card, WiMax card, mobile communications hardware, and/or other hardware for communicating with other networks and/or devices. The data storage component 207 may store the one or more modules. The input/output interface 205 and the network interface hardware 206 allow a user to send input to the controller 201 of the tie plate distribution system 100 to control and manipulate the components of the tie plate distribution system 100, such as the vision sensors 208, the movable arms 103, and the vehicle 101, and receive output from the controller 201. The input/output interface 205 and the network interface hardware 206 may connect to Internet of Things (IoT) devices in the tie plate distribution system 100 to receive real-time or recorded image/video and sensory data. The IoT may include the network of physical devices, vehicles, buildings, and other objects that are embedded with sensors, software, and connectivity, enabling them to collect and exchange data over the internet. IoT devices such as sensors may monitor the condition of tracks, vehicles, movable arms, or other railroad maintenance devices and equipment in real-time. The IoT devices may collect data on factors like vibration, temperature, or wear, which enables a user to schedule repairs or replacements before breakdowns occur. The IoT devices may further allow the tie plate distribution system 100 to remotely diagnose issues in manipulating the tie plates, rails, and ties, and to remote control the vehicle 101 and the movable arms 103. As a non-limiting example, an IoT device may provide a strain measurement indicating whether a track material has been subject to a threshold level of strain, or may provide a temperature measurement indicating whether a track material has been subject to a threshold temperature. In some embodiments, the controller 201 may connect to the IoT devices through the network interface hardware 206 to acquire the images or the videos of the vehicle 101 (e.g. as illustrated in FIGS. 1 and 3A-6), the movable arms 103 (e.g. as illustrated in FIGS. 1 and 3A-6), tie plates, rails, ties, the environment around the vehicle 101 and the railroad. The tie plate distribution system 100 may monitor the installation, distribution, and other maintenance tasks via the one or more vision sensors 208, IoT devices, and any available resources for the purpose and transfer real-time and/or recorded data (such as videos, images, messages, status, warning, and instructions, etc.) to the user via wired or wireless connections, such as, without limitations, cellular connection (2G, 3G, 4G, 5G, or 6G), internet, and any radio-wave based communication.

A vision sensor 208 may be any device having an array of sensing devices capable of detecting radiation in an ultraviolet wavelength band, a visible light wavelength band, or an infrared wavelength band. The vision sensor 208 may have any resolution. In some embodiments, one or more optical components, such as a mirror, fish-eye lens, or any other type of lens may be optically coupled to the vision sensors 208. In some embodiments described herein, the vision sensor 208 may provide image data to the processor 204 or another component communicatively coupled to the local interface 203. The image data may include image data of the environment around the vehicles 101 and 601 (e.g., as illustrated in FIGS. 1 and 3-6). The vision sensors 208 may detect, without limitations, the empty tie 407 (e.g. as illustrated in FIG. 4A), the target tie plate 155 (e.g. as illustrated in FIGS. 1 and 4), the container 115 (e.g. as illustrated in FIGS. 1, 3, and 4), the containment beds 613 (e.g. as illustrated in FIG. 6), the conveyor 609 (e.g. as illustrated in FIG. 6), and the stationary position. The one or more vision sensors 208 may operate in the visual and/or infrared spectrum to sense visual and/or infrared light. Additionally, while the particular embodiments described herein are described with respect to hardware for sensing light in the visual and/or infrared spectrum, it is to be understood that other types of sensors are contemplated. For example, the systems described herein could include one or more LIDAR sensors, proximity sensors, radar sensors, sonar sensors, or other types of sensors, and such data could be integrated into or supplement the data collection described herein to develop images and videos.

In operation, the one or more vision sensors 208 capture image data and communicate the image data to the processor 204. The image data may be received by the processor 204, which may process the image data using one or more image processing algorithms. Any known or yet-to-be developed video or image processing algorithms may be applied to the image data in order to identify an item or situation. Example video or image processing algorithms include, but are not limited to, kernel-based tracking (such as, for example, mean-shift tracking) and contour processing algorithms. In general, video or image processing algorithms may detect objects and movements from sequential or individual frames of image data. One or more object recognition algorithms may be applied to the image data to extract objects and determine their relative locations to each other. Any known or yet-to-be-developed object recognition algorithms may be used to extract the objects or even optical characters and images from the image data. Example object recognition algorithms include, but are not limited to, scale-invariant feature transform (“SIFT”), speeded up robust features (“SURF”), and edge-detection algorithms. Particularly, the vision sensors 208 may detect and recognize, without limitations, ties, tie plates, spikes, anchors, rail fasteners, track maintenance equipment, rail welding materials, and any objects or parts of the railroad. The vision sensors 208 may detect whether the target tie plate 155 is in a deviation orientation, the type of the tie plates 105 (e.g. as illustrated in FIGS. 1 and 2-6), such as, without limitations, the single shoulder tie plate, the double shoulder tie plates, and the hook twin tie plates. The vision sensor 208 may detect whether the tie plate 105 is a used/spent tie plate. The vision sensors 208 may be further used to monitor the operations and functions of the movable arms 103 and collaborate with the movable arms 103 and other track maintenance equipment and tools to manipulate the tie plates 105. For example, the vision sensor 208 may monitor the movable arm 103 placing a single-shoulder tie plate on the tie 107 and determine whether the single-shoulder tie plate is installed with the shoulder outside the rail 108.

In operation, the one or more vision sensors 208 may be set up to capture images of each tie plate as the vehicle or the robot arm passes through an inspection area. The processor 204 may analyze the images using a tie-plate vision algorithm to detect defects, such as, without limitation, improper installation of the tie plates, cracks, warping, deformed shape, or corrosion of the tie plates. In some embodiments, machine-learning techniques may be used to train the tie-plate vision algorithm to recognize tie-plates, various defect patterns and/or other structures that are desired for recognition. In some embodiments, the one or more vision sensors 208 may be used to inspect new tie plates before placing the new tie plates on or in proximity to the tie 107. The one or more vision sensors 208 may capture the images of the new tie plates and the processor 204 may use the tie-plate vision algorithm assessing the quality of the tie plates, ensuring that the new tie plates meet standards and/or demands before being distributed and/or installed. Further, in some embodiments, the one or more vision sensors 208 may be used to capture images and the processor 204 may use the tie-plate vision algorithm to recognize the specific features of each type of tie plate and further verify whether the deposited or distributed tie plates are the correct type being used based on their visual characteristics. Upon determining the existence of defects or incorrect type, the processor 204 may replace or remove the defective or incorrect tie plate.

Referring to FIGS. 3A and 3B, the tie plate distribution system 100 having one or more flipping stations 117 is depicted. The flipping stations 117 may be powered or powerless. The flipping stations 117 may use the movable arm 403 having grippers or clamps (e.g. as illustrated in FIGS. 4-6) to hold and manipulate tie plates 105. The flipping stations 117 may use a mechanical leverage system having, without limitations, levers, pulleys, or inclined planes to flip the tie plates 105. For example, as illustrated in FIG. 3B, the flipping stations 117 may include an aperture 171, an aperture brace 173, a sliding surface 175 (e.g., a slope beneath the aperture 171 and the aperture brace 173), and an arresting fixture 179 at the lower end of the sliding surface 175. The outer frame of aperture 171 may be greater than the tie plate 245 to allow a tie plate 245 to pass through. The aperture brace 173 may be at one side of the aperture 171 to temporarily hold one side of the tie plate 245 when the other side of the tie plate 245 may fall through the aperture 171. The tie plate 245 that falls through the aperture 171 may flip and be captured by the sliding surface 175. The flipped tie plate 255 may slide on the sliding surface 175 and be captured by the arresting fixture 179.

In some embodiments, the vision sensors 208 may locate a tie plate 245 for the movable arm 103 to lift. After the movable arm 103 lifts the tie plate 245, the vision sensors 208 may further detect that the tie plate 245 lifted by the movable arm 103 is upside down or in some other deviation orientations not in alignment with the designated position for the tie plate 245 to be placed. The deviation orientations may include, without limitations, angular deviation, face-to-rail misalignment (e.g. tie plate face upside down), gauge, or fastener hole misalignment (e.g., the orientation of the tie plate causing the fastener (such as, without limitations, bolt, spike, screw, or other anchor) hole misaligning the tie underneath). The movable arm 103 may lift the tie plate 245 and place the tie plate 245 at the aperture 171 to the flipping station 117. After the tie plate 245 is flipped or reoriented through the flipping station 117, the movable arm 103 may lift the flipped tie plate 255 from the sliding surface 175. The vision sensor 208 may be used to confirm the flipped tie plate 255 is in alignment with the designated position for the flipped tie plate 255 to be placed on the empty tie 407 (e.g. as illustrated in FIG. 4A).

Referring to FIG. 3C, the tie plate distribution system 300 lifting and placing tie plates 105 during tie plate distribution is depicted. Notably, FIG. 3C illustrates an embodiment in which the tie plate distribution system 300 has a single movable arm 103. The vehicle 101 may move on the rail 108 with the container 115 at one end of the vehicle 101. The movable arm 103 may be coupled to the vehicle 101 around the container 115 at the end of the vehicle 101. The flipping station 117 may be coupled to the container 115 at one end 365 while the other end 366 of the container 115 may be coupled to the vehicle 101. The movable arm 103 may lift the tie plate 105 from the container 115 and place the tie plate 105 on or near the ties 107. In some embodiments, it may be desirable to deposit the tie plate 105 along a centerline of the railroad ties 107. In some other embodiments, it may be desirable to position the tie plates 105 on the central line 389 of the railroad ties 107 near ends of the ties 107, or on the ballast 377 near ends of the railroad ties 107, if necessary. Conventionally, a straight portion of the rail 108 will have cross-ties 107 laid on longitudinal centerlines which are, for example and without limitation, about twenty-two inches (22″) apart, as measured along rail 108. It should be understood that this dimension may vary between differing railroad operators and differing terrain conditions, such as for example bridges which may be more closely spaced. As the tie plates 105 are deposited, one or more workmen who follow behind the vehicle 101 may replace old tie plates on each individual tie 107 after the old tie plates have been removed with the new tie plates 105, preparatory to placement of new rails or replacement of old rails (referred to as target rails) on the newly placed tie plates.

Referring to FIG. 4, the tie plate distribution system 400 lifting and placing tie plates 105 during the tie plate distribution is depicted. The vehicle 101 may move on the rail 108 with one or more vision sensors 208 captures the images and videos of the vehicle 101, the movable arm 403, and the environment including the tie plates 105, the rail 108, and the ties 107. In some embodiments, the tie plate distribution system 400 may use each of the vision sensors 208 to monitor different components of the tie plate distribution system 400. In some other embodiments, the tie plate distribution system 400 may assign each vision sensor 208 to monitor a specific component of the tie plate distribution system 400. For example, the tie plate distribution system 400 may assign one or more vision sensors 208 to a group of multiple groups, where each group of the vision sensors 208 may be assigned to capture the images and videos of one or more of the vehicle 101, the movable arm 403, the tie plates 105, the rail 108, or the ties 107. The vehicle 101 may move along a path 109 that may be defined by the rail 108 and/or ties 107. During the tie plate distribution, the vision sensors 208 (e.g. as illustrated in FIGS. 1 and 2) may detect a target tie plate 155 along the path. The vision sensors 208 may further detect an empty tie 407 of the multiple ties 107, where the empty tie 407 misses at least one tie plate 105. The movable arm 103 may lift the target tie plate 155 and place the target tie plate 155 on or in proximity to the empty tie 407.

In some embodiments, the movable arm 403 is capable of placing a stored tie plate from the container 115 on the empty tie 407, or depositing the target tie plate 155 into the container 115. In some embodiments, after the vision sensors 208 detects that the lifted target tie plate 155 is in one of the deviation orientations, the movable arm 403 may be capable of placing the target tie plate 155 in the flipping station (as illustrated in FIGS. 1 and 3) to adjust the orientation of the target tie plate 155. In some embodiments, when the vehicle 101 passes the stationary position, the movable arm 403 may be capable of transferring the one or more tie plates 105 from the stationary position to the container 115.

Referring to FIG. 4B and 4C, the tie plate distribution system 100 is demonstrated in examples of tie-plate manipulations during tie inspection and replacement. In FIG. 4B, the process unfolds as follows. In step 461, a side of the rail may be removed, exposing the tie plates underneath for manipulation. In step 462, with one or more rails 108 positioned centrally on the ties, as depicted, the vehicle 101 may move alongside the rail 108 in step 462. Using the movable arm 403, the tie plates 105 may be lifted from their installed locations and relocated to a position adjacent to the rails 108 at the center area of the ties 107. This relocation of the tie plates 105 allows thorough inspection of the ties 107. The ties 107 may be inspected by a worker or by the tie plate distribution system 100 using the vision sensor 208. In step 463, once the inspection of the ties 107 is complete, for example by vision sensor 208 or manually, the movable arm 403 may return the tie plates 105 from the center area of the ties 107 to their original installation positions. The removed rail or a new rail 108 may next be placed on top of the exposed tie plates 105.

Turning to FIG. 4C, when a replacement tie 487 is identified for replacement, one tie plate is removed and the replacement tie 485 may be pulled out, in the opposite direction from a direction in which the tie plate is removed, from beneath rail 108 to one side of the railroad. After the replacement tie 487 is pulled out from beneath the rail 108, a tie plate 485 may ride on the replacement tie 487 or may remain in the installation position under the rail 108 (both approaches are illustrated here). The vehicle 101 may move adjacent to the replacement tie 485, and the movable arm 103/403 (e.g. as illustrated in FIGS. 1, 3A, and 4) may pick up the tie plates 485. Then, a new tie 497 may be inserted beneath the rails 108, and the movable arm 103/403 may place the tie plates 485 on or in proximity to the new tie 497.

Referring to FIGS. 5A and 5B, the tie plate distribution systems 400 having a first vehicle 101 moving on a rail 108 and a second vehicle 101 moving off the rail 108 are depicted. The vehicle 101 may be, without limitations a railcar, a rail truck, a road-rail vehicle, or an automobile (e.g., a sport utility vehicle (SUV)). The motion mechanism 111 of the vehicle 101 may include one or more of, without limitation, rubber wheels, rail wheels, flanged wheels, metal wheels, continuous tracks (e.g., metal link tracks, rubber tracks, single pin tracks, and double pin tracks), or a combination thereof. In some embodiments, the vehicle 101 may move along the path 109 (as illustrated in FIGS. 1 and 4) by moving on the rail 108 using rail wheels or other type of wheels or tracks allowing the vehicle 101 to move on the rail 108. In some embodiments, the vehicle 101 may move off the rail 108 using motion mechanism 111 in types allowing the vehicle 101 move on the off-rail surface.

Referring to FIG. 6, a tie plate distribution system 600 having one or more containment beds 613 and a conveyor 609 is depicted. The tie plate distribution system 600 includes a vehicle 601 having motion mechanisms 111 such as rail wheels, one or more containment beds 613 extending in a longitudinal direction of the vehicle 601, a path 631 extending longitudinally on the vehicle 601 and adjacent to the containment beds 613, a movable arm 403 disposed on the path 631, and a conveyor 609 extending along the vehicle 601 and within a reach of the movable arm 403.

The vehicle 601 may be a self-propelled vehicle and include engine or motor to propel the vehicle along the railroad track and for on-road usage. The vehicle 601 may be, without limitations, a railcar or a rail-truck.

The conveyor 609 may be, without limitations, a belt conveyor or a roller conveyor. The conveyor 609 may be indicative of a powered conveyor, a non-powered conveyor, or a combination. It should be noted that the term “conveyor” is utilized and is illustrative and not limiting to a traditional belt or roller conveyor but may be various forms of mover devices. For example, the term “conveyor” may be, but is not limited to, roller conveyors, chutes, gravity feeders, vibratory feeders, or any other device or mechanism capable of conveying the tie plates 105 from a first position to a second position. In some examples, a conveyor 609 may include multiple sections. For example, a first section of a conveyor 609 may be provided “upstream” from the movable arm 403, and may feed track material such as tie plates 105 to the movable arm 403. The movable arm 403 may place the track material on a second section of the conveyor 609. Another example of a conveyor 609 with multiple sections is illustrated in FIG. 6.

The one or more containment beds 613 are capable of containing a plurality of tie plates 105. The movable arm 403 is movable along the path 631 in the longitudinal direction. The path 631 may be referred to herein as a machine path. The containment beds 613 allow for placement and storage of tie plates 105, which are to be picked up by the movable arm 403 and deposited on the conveyor 609 for further movement onto the tie plate distribution system 600. In some embodiments, the one or more containment beds 613 may be, without limitations, one bed, two beds, three beds, four beds, or any number of beds. For example, as illustrated in FIG. 6, the number of containment beds 613 is two. The conveyor 609 and the path 631 may be formed between the two containment beds 613.

The movable arm 403 has a plurality of degrees of freedom and has a retaining mechanism 431 at an end of the movable arm 403, as disclosed further above (e.g., as illustrated in FIGS. 3A, 3B, and 4). In some embodiments, the movable arm 103 may include, without limitations, at least three movable joints. The movable arm 403 is capable of moving along the path 631 and obtaining one or more tie plates 105 from the one or more containment beds 613. The movable arm 403 can retain one or more of the plurality of tic plates 105 and deposit the tie plates 105 on the conveyor 609. In some embodiments, the tie plate distribution system 600 may further include a cart 639 that moves along the path 631. The movable arm 403 may be disposed in the cart 639. In some embodiments, the path 631 may be defined by a track 607. The track 607 may be disposed above the conveyor 609 and the cart 639 may move on the track 607.

In some embodiments, the tie plate distribution system 600 may include a vision system 603 and a controller 201 (e.g. as illustrated in FIG. 2). The vision system 603 may include a controller 201 and one or more vision sensors 208. The controller 201 may receive input from the vision system 603 and provide an output in the form of a trigger for movement of the movable arm 403 to obtain a tie plate 105. The controller 201 may operably move the cart 639 along the path 631, where the cart 639 may move adjacent to the containment beds 613.

Referring to FIG. 7, a flow diagram of illustrative steps for tie plate distribution is illustrated. At block 701, the method for tie plate distribution includes detecting, using a vision sensor 208 (e.g. as illustrated in FIGS. 1 and 2) coupled to a vehicle 101 (e.g. as illustrated in FIG. 1) or a movable arm 103 (e.g. as illustrated in FIG. 1), a target tie plate 155 (e.g. as illustrated in FIG. 1) along a path 109 (e.g., as illustrated in FIG. 1) comprising multiple ties 107 (e.g., as illustrated in FIG. 1) coupled to a rail 108 (e.g. as illustrated in FIG. 1), or detecting a target tie plate 155 in a container 115 (as illustrated in FIG. 1) or containment bed 613 (e.g. as illustrated in FIG. 6).

At block 702, the method for tie plate distribution includes lifting, using the movable arm 103, the target tie plate 155. In some embodiments, where the vehicle 101 includes a container 115 (e.g. as illustrated in FIG. 1), the method for tie plate distribution may further include, after lifting the target tie plate 155, detecting, using the vision sensor 208 (e.g. as illustrated in FIG. 1), a second target tie plate 105 (e.g. as illustrated in FIG. 1) along the path 109 (e.g. as illustrated in FIG. 1), placing, using the movable arm, the target tie plate in the container, and lifting, using the movable arm 103, the second target tie plate 105.

At block 703, the method for tie plate distribution includes detecting, using the vision sensor 208, an empty tie 407 (e.g. as illustrated in FIG. 4A) of the multiple ties 107 (e.g. as illustrated in FIG. 4A) missing at least a tie plate 105 thereon. At block 704, the method for tie plate distribution includes placing, using the movable arm 103, the target tie plate 155 onto or near the empty tie 407.

In some embodiments, the method for tie plate distribution further includes, before detecting the target tie plate 155, detecting, using the vision sensor 208, a second empty tie 407 of the multiple ties 107, lifting, using the movable arm 103, one tie plate 105 from the container 115, and placing, using the movable arm 103, the tie plate 105 onto the empty tie 407.

In some embodiments, the method for tie plate distribution further includes determining, using the vision sensor 208, that a stationary position is within reach of the movable arm 103, the stationary position comprising one or more tie plates 105, and transferring, using the movable arm, the one or more tie plates 105 from the stationary position to the container 115. This aspect of the method may be implemented separately from (e.g., without) block 704. This transferring may be in response to the stationary position being within reach of the movable arm 103.

In some embodiments, where the vehicle 101 includes a flipping station 117 (e.g. as illustrated in FIG. 1), the method for tie plate distribution further includes placing, using the movable arm 103, the target tie plate 155 in the flipping station 117 after determining that an orientation of the target tie plate 155 misaligns with a designated installation position of the target tie plate 155 on the empty tie 407, and adjusting, using the movable arm 103, the orientation of the target tie plate 155 to align with the designated installation position of the target tie plate 155 on the empty tie in the flipping station 117.

Referring to FIG. 8, a flow diagram of illustrative steps for collecting disqualified tie plates is illustrated. A disqualified tie plate refers to a tie plate that does not or can no longer fulfill its intended purpose due to a quality (such as its structural integrity, performance, time/life concerns of the tie plate, or compatibility with rails or ties). The disqualified tie plate may be, without limitations, a used tie plate, a spent tie plate, an improper-type tie plate, a damaged tie plate, or an extra tie plate. In some embodiments, the extra tie plate may refer to the surplus tie plates distributed to the empty tie than that the empty tie required. At block 801, the method for collecting used/spent tie plates includes detecting, using a vision sensor 208 (e.g. as illustrated in FIGS. 1 and 2) coupled to a vehicle 101 (e.g. as illustrated in FIG. 1) or a movable arm 103 (e.g. as illustrated in FIG. 1), a disqualified tie plate 105 (e.g. as illustrated in FIG. 1) along a path 109 (e.g., as illustrated in FIG. 1) comprising multiple ties 107 (e.g., as illustrated in FIG. 1) coupled to a rail 108 (e.g. as illustrated in FIG. 1). At block 802, the method for collecting used/spent tie plates includes lifting, using the movable arm 103, the used/spent tie plate 155. At block 803, the method for collecting used/spent tie plates includes placing, using the movable arm 103, the used/spent tie plate 155 in the container 115 of the vehicle 101.

It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modifications and variations come within the scope of the appended claims and their equivalents.

SYSTEMS AND METHODS FOR TIE PLATE DISTRIBUTION AND COLLECTION

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