Description:TECHNICAL FIELD

The present disclosure relates to a wagon tippler. Particularly, but not exclusively, the present disclosure is directed towards a wagon tippler with enhanced endurance, wherein side beam of the wagon tippler is configured to accommodate side clamp cylinders without any notch on the side beam.
BACKGROUND
The mobility of goods drives contemporary commerce and economy. Wagon commodities have been the foundation of long-distance and bulk goods transit since the beginning of industry. At first appearance, the filling, transporting, and delivery steps in the transportation of bulk commodities may appear simple. However, in practice, each of these stages takes a long time and demands more labour. Modernizing bulk material handling is necessary in this situation to speed up delivery and enable effective product control. Bulk material unloading from wagons has traditionally been done by wagon tippler. They had played a crucial role in the transportation of cargo between inland and port facilities. The lower freight rates provided by the rail lines and the need for less labour are the key benefits of adopting wagon goods moving.
A wagon tippler is an unloading machine used to remove bulk materials from railroad wagons, such as coal, limestone, ore, etc. A wagon tippler is a component of the tippler system, which also includes an underground hoper, a feeder, wagon positioning equipment, and an underground hoper. In order to move bulk materials like coal, iron ore, lime, etc., they have a rail table on rotational support structures that can raise and tilt wagons to an angle of around 135º - 160º. These structures are utilized at various processing plants for power, steel, cement, and other materials like core, iron ore, and lime.
Conventional wagon tipplers, while effective for unloading bulk materials from railway wagons, can also present various challenges and limitations. Some common problems associated with conventional wagon tipplers include: Limited Unloading Speed, Mechanical Wear and Tear, Dust Emission, Energy Consumption, Limited Adaptability, High Maintenance Requirements, Bulk Material Spillage, Space Constraints etc. to name a few. However, mechanical wear and tear is a common issue in wagon tipplers. In the context of a wagon tippler, mechanical wear and tear refer to the deterioration of components and parts due to repetitive movements, loading, and other operational stresses. Some factors that contribute to the mechanical wear and tear include but not limited to frequent movements, contact surfaces, loading and unloading, environmental factors, lubrication and maintenance, material properties etc. The side beam of a wagon tippler is a critical structural component that can experience major mechanical wear and tear due to its role in supporting the side clamp cylinders and withstanding the forces generated during the unloading process. The side beam often fails due to numerous cracks. Wherein side beams with notches for accommodating side clamp cylinders face premature failure due to various reason. Such reasons include huge stress concentration at the all four top notches of side beam for mounting of side clamp cylinders, reduction in area at notches leading to high torsional stress and more angular deformation, transmission of force, developed in side beam, takes place vide line contact of welding joints etc. Further, different experimental modification had been conducted on the side beam by varying thickness of side beam, regular repair of the cracks and maintaining the same, changing material of construction, increasing the weight etc. However, none of the aforementioned solutions was successful in solving the mechanical wear and tear issue of the side beam.
In order to avoid such problems, there is a need for a wagon tippler with improved version of the side beam so as to avoid the problem the mechanical wear and tear during the usage of the wagon tippler, thereby enhancing life and endurance of the wagon tippler.
The present disclosure is directed to overcome one or more limitations stated above, and any other limitation associated with the prior arts.
SUMMARY
One or more shortcomings of the prior art are overcome, and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.
The present invention is directed to a wagon tippler for unloading bulk materials from railway wagons. The wagon tippler comprises a support structure configured to provide stability during operation, a tipping mechanism, and a side beam. The tipping mechanism is connected to the support structure and configured to raise and tilt a railway wagon for unloading bulk materials. The side beam is integrated into the support structure, wherein the side beam comprises a plurality of side clamp cylinders mounted therein for securing the railway wagon during tipping. Each of the plurality of side clamp cylinders comprises a hydraulic cylinder configured to apply clamping force to secure a railway wagon during tipping, and a piston rod extending from the hydraulic cylinder. The hydraulic cylinder extends and retracts based on the movement of the piston rod within the side beam to exert clamping force on the railway wagon.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and regarding the accompanying figures, in which:

Figure 1 illustrates a diagram representing various components of a vertical take-off and landing (VTOL) vehicle with tilt propellers, in accordance with an embodiment of the present disclosure; and
Figure 2 illustrates a perspective view of the VTOL vehicle with tilt propellers, in accordance with an embodiment of the present disclosure.
The figure depicts embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION
In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non- exclusive inclusion, such that a setup, device or process that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or process. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
Embodiments of the present disclosure provide a wagon tippler for unloading bulk materials from railway wagons. The wagon tippler comprises a support structure configured to provide stability during operation, a tipping mechanism, and a side beam. The tipping mechanism is connected to the support structure and configured to raise and tilt a railway wagon for unloading bulk materials. The side beam is integrated into the support structure, wherein the side beam comprises a plurality of side clamp cylinders mounted therein for securing the railway wagon during tipping. Each of the plurality of side clamp cylinders comprises a hydraulic cylinder configured to apply clamping force to secure a railway wagon during tipping, and a piston rod extending from the hydraulic cylinder. The hydraulic cylinder extends and retracts based on the movement of the piston rod within the side beam to exert clamping force on the railway wagon.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The following paragraphs describe the present disclosure with reference to Figures 1 – Figure 2. In the figures, Figure 1 is an exemplary embodiment of the present disclosure and illustrates various components of a wagon tippler. The side beam configuration of the wagon tippler aids in reducing stress concentration in localized areas of the side beam as there is no provision of notches.
However, it is understood by a person skilled in the art that the size and configuration of the wagon tippler may be variable in accordance with the requirement of the different types of installation environment. Any such variation/modification shall be construed to be within the scope of the present disclosure.
As illustrated in Figure 1, the wagon tippler comprises a support structure, a tipping mechanism, and a side beam.
The support structure is configured to provide stability during operation. The support structure of a wagon tippler is a foundational component that provides stability, strength, and integrity to the entire tippler system. The support structure is responsible for bearing the loads generated during the unloading process, as well as supporting various other components such as the tipping mechanism, side beam, and more. The support structure is usually anchored to a sturdy foundation, which ensures that the wagon tippler remains stable during operation. The foundation prevents vibrations and movements that could affect the accuracy and safety of the unloading process. The frame of the support structure is typically constructed from robust materials such as steel beams or other high-strength alloys. The frame's design considers the various forces and stresses acting on the tippler during tipping. The base frame provides a stable platform for the entire tippler apparatus. It often includes the components that anchor the tippler to the foundation, as well as support structures for the tipping mechanism. The column and beam structure provide vertical and horizontal support for the tippler. Columns support the weight of the tipping mechanism, wagons, and bulk materials, while beams distribute these loads to ensure uniform stress distribution. The support structure is engineered to distribute the loads and forces evenly to prevent localized stress concentrations that could lead to fatigue or failure over time. Some support structures incorporate vibration dampening technologies to absorb vibrations generated during tipping, reducing wear on components and enhancing operator comfort. The support structure features strong connections and welding points between beams and columns, ensuring the stability of the overall system. The design should allow for easy access to critical components for maintenance and inspection purposes.
Depending on the operational environment, the support structure may require additional protection against corrosion, moisture, and other environmental factors. The support structure should incorporate safety features such as emergency stops, safety barriers, and guards to protect operators and personnel working in the vicinity. The design of the support structure considers the maximum loads that the tippler will experience during operation. The support structure is engineered to handle these loads safely and reliably. The support structure is designed to seamlessly integrate with other components of the tippler, such as the tipping mechanism, side beam, and control systems.
The tipping mechanism of a wagon tippler is a fundamental component responsible for raising, tilting, and unloading bulk materials from railway wagons. It's a complex assembly of mechanical, hydraulic, pneumatic, and control systems that work together to facilitate controlled and efficient tipping. The tipping mechanism features pivot points that enable the controlled tilting motion of the wagon. These points are strategically located to allow smooth and stable movement. The drive system powers the tilting movement. It can be hydraulic, pneumatic, mechanical, or a combination, depending on the design and requirements. A drive system provides the necessary force to lift the weight of the wagon and its contents. The tipping mechanism includes a system to control the angle at which the wagon is tilted. Such control ensures that the unloading process is consistent and optimized for the type of material being unloaded. Some tipping mechanisms incorporate counterweights to balance the tipping process. These weights offset the weight of the wagon and the bulk material, making the tipping movement smoother and reducing the load on the drive system. In one embodiment, the tipping mechanism comprises pivot points, drive systems as one of hydraulic, pneumatic, or mechanical, and counterweights for balance.
Further, rails or rollers are often integrated into the tipping mechanism to guide the movement of the wagon wheels during tilting. These components ensure that the wagon moves along a controlled path. The tipping mechanism is further equipped with safety features to prevent accidents. Emergency stops, overload sensors, and position locks ensure the safety of operators and equipment during the tilting process. A control system oversees the entire tipping process. The control system receives inputs from sensors, monitors the angle and position of the wagon, and controls the drive system accordingly. A set of limit switches are used to accurately determine the starting and ending positions of the tipping process. The limit switches ensure that the wagon tilts to the correct angle and returns to its initial position accurately. One or more operators initiate and monitor the tipping process by using respective control panel that provides a user interface to control the speed, angle, and timing of the tilting operation. Some tipping mechanisms incorporate safety barriers or enclosures to protect personnel from moving parts and potential hazards during operation. Tipping mechanisms are designed with emergency procedures in mind. If a malfunction occurs, there are protocols to stop the operation and prevent accidents. Advanced tipping mechanisms can include automation features for seamless integration into larger material handling systems. These features can enable remote control and real-time monitoring.
As illustrated in Figure 2, the side beam (122) of a wagon tippler is a structural component that plays a crucial role in supporting the side clamp cylinders and providing stability during the unloading process. The side beam (122) comprises a plurality of side clamp cylinders (118, 120) mounted therein for securing the railway wagon during tipping, and a plurality of bracket assemblies (108, 116), wherein one side clamp cylinder is rigidly mounted on one bracket assembly. The side beam (122) is typically integrated into the support structure of the wagon tippler and is designed to accommodate the movement and force exerted by the side clamp cylinders that secure the railway wagons during tipping. The main function of the side beam (122) is to house the side clamp cylinders, which are hydraulic or pneumatic components responsible for clamping the railway wagons securely in place during the tipping process. The side beam features openings strategically positioned to accommodate the movement of the side clamp cylinders. These openings allow the side clamp cylinders to extend and retract smoothly as they apply clamping pressure to the wagon.
The side beam is typically made from durable and robust materials such as steel or other high-strength alloys. The material is chosen to withstand the forces, stresses, and wear associated with the clamping and tipping actions. To maintain structural integrity and minimize stress concentrations, reinforcements might be incorporated into the side beam's configuration. These reinforcements could include bracing members, additional material layers, or other strengthening elements. The side beam is reinforced with strategically positioned bracing members, wherein the bracing members enhance the structural integrity of the side beam to withstand the forces exerted by the hydraulic cylinder. In one embodiment, the side beam (122) is a rectangular housing encompassed by a top plate (102), a bottom plate (110), a front plate and a back plate, wherein each of top side and bottom side of both the top plate and the bottom plate is secured with a splice plate (104, 106, 112, 114) by means of high strength tensile bolts in order to increase load bearing capacity of the top plate (102) and the bottom plate (110). The front plate of the side beam is having a plurality of openings (124) for making the side clamp cylinders (118, 120) operational while clamping a wagon to be tippled, wherein one opening corresponds to one side clamp cylinder.
Each of the plurality of bracket assemblies (108, 116) is secured only with the splice plate (106) attached to the bottom side of the top plate (110) or with the splice plate (114) attached to the bottom side of the bottom plate (110). Further, each of the bracket assemblies (108, 116) is a closed housing having a wide area at top for being mechanically secured with the respective splice plate, wherein the wide area of mechanical attachment aids in distributing the load as transmitted from respective side clamp cylinder towards the top plate or the bottom plate via the splice plates.
The surfaces within the openings are smooth and properly finished to allow the side clamp cylinders to move without friction or binding. Such movement ensures reliable and efficient operation. The side beam is protected against corrosion, as exposure to environmental factors like moisture, dust, and chemicals can degrade the material over time. Protective coatings or treatments can help enhance the side beam's longevity. The configuration of the side beam is considered even distribution of loads and forces during the tipping process. Such configuration ensures that the wagon remains stable and the side clamp cylinders exert uniform pressure. Further, configuring the side beam with considerations for ease of inspection, maintenance, and potential replacement of components can minimize downtime and maintenance costs.
Each of the plurality of side clamp cylinders comprises a hydraulic cylinder configured to apply clamping force to secure a railway wagon during tipping; and a piston rod extending from the hydraulic cylinder. The hydraulic cylinder extends and retracts based on the movement of the piston rod within the side beam to exert clamping force on the railway wagon. Each of the side clamp cylinders is strategically positioned to maintain the structural integrity of the side beam
The wagon tippler further comprising a smooth sliding mechanism between the hydraulic cylinder and the side beam, ensuring reduced friction and wear during the extension and retraction of the hydraulic cylinder.
The wagon tippler comprises a protective shield positioned over each of the hydraulic cylinders of the side beam, the shield preventing the ingress of contaminants that could affect the operation and longevity of the hydraulic cylinder.
Advantages of the present disclosure:
The present disclosure provides a wagon tippler with a side beam that applies symmetrical torsional stress and results in same angular deformation as there is no cross-section reduction (area) throughout the side beam.
The side beam of the wagon tippler can take more bending moment due to increase in section modulus (moment of inertia) at the location of the hydraulic cylinders.
The hydraulic cylinders are mounted by splice plate and bracket arrangement due to which load transmitted through cylinders are distributed uniformly on top plate.
Further, axial load transmitted through the hydraulic cylinders are now transmitted to bracket assembly and from bracket assembly it goes to top plate, wherein the bracket assembly and the top plate are connected by high strength tensile bolts so in case of huge load bolts will get fail first in place of the top plate.
In the detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The description is, therefore, not to be taken in a limiting sense.
Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the 3 claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.
In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

, Claims:1. A wagon tippler for unloading bulk materials from railway wagons, the wagon tippler comprising:
a support structure configured to provide stability during operation;
a tipping mechanism connected to the support structure, configured to raise and tilt a railway wagon for unloading bulk materials;
a side beam integrated into the support structure, wherein the side beam comprises a plurality of side clamp cylinders mounted therein for securing the railway wagon during tipping, and a plurality of bracket assemblies, wherein one side clamp cylinder is rigidly mounted on one bracket assembly.
2. The wagon tippler as claimed in claim 1, wherein the tipping mechanism comprises pivot points, drive systems as one of hydraulic, pneumatic, or mechanical, and counterweights for balance.
3. The wagon tippler as claimed in claim 1, wherein the side beam is a rectangular housing encompassed by a top plate, a bottom plate, a front plate and a back plate, wherein each of top side and bottom side of both the top plate and the bottom plate is secured with a splice plate by means of high strength tensile bolts in order to increase load bearing capacity of the top plate and the bottom plate.
4. The wagon tippler as claimed in claim 2, wherein the front plate of the side beam is having a plurality of openings for making the side clamp cylinders operational while clamping a wagon to be tippled, wherein one opening corresponds to one side clamp cylinder.
5. The wagon tippler as claimed in claim 1, wherein each of the plurality of bracket assemblies is secured only with the splice plate attached to the bottom side of the top plate or with the splice plate attached to the bottom side of the bottom plate.
6. The wagon tippler as claimed in claim 1, wherein each of the bracket assemblies is a closed housing having a wide area at top for being mechanically secured with the respective splice plate, wherein the wide area of mechanical attachment aids in distributing the load as transmitted from respective side clamp cylinder towards the top plate or the bottom plate via the splice plates.
7. The wagon tippler as claimed in claim 1, wherein each of the plurality of side clamp cylinders comprises:
a hydraulic cylinder configured to apply clamping force to secure a railway wagon during tipping;
a piston rod extending from the hydraulic cylinder;
wherein the hydraulic cylinder extends and retracts based on the movement of the piston rod within the side beam to exert clamping force on the railway wagon.
8. The wagon tippler as claimed in claim 1, wherein the wagon tippler further comprising a smooth sliding mechanism between the hydraulic cylinder and the side beam, ensuring reduced friction and wear during the extension and retraction of the hydraulic cylinder.
9. The wagon tippler as claimed in claim 1, wherein the side beam is reinforced with strategically positioned bracing members, the bracing members enhancing the structural integrity of the side beam to withstand the forces exerted by the hydraulic cylinder.
10. The wagon tippler apparatus of claim 1, wherein each of the side clamp cylinders is strategically positioned to maintain the structural integrity of the side beam.