초록 ▼

An improved in-track welder eliminates conduction path force members and employs separate bridging current path conductors for DC welding of rail ends. The enhancement allows for an increased closure distance, thus improving cold-weather operations. An increased allowable distance between conduction

An improved in-track welder eliminates conduction path force members and employs separate bridging current path conductors for DC welding of rail ends. The enhancement allows for an increased closure distance, thus improving cold-weather operations. An increased allowable distance between conduction contacts allows for the incorporation of an internal shear member for more efficient finishing of welds. The force members may be optimized for strength rather than electrical properties, and are comprised of relatively small diameter alloy steel rods.

대표청구항 ▼

1. An improved in-track weld system for forge welding of rail segments together in place on a rail way, the improved in-track weld system comprising: a first set of two clamp arms pivotably connected at a first pivot point, and connected by a first hydraulic actuator, the first hydraulic actuator co

1. An improved in-track weld system for forge welding of rail segments together in place on a rail way, the improved in-track weld system comprising: a first set of two clamp arms pivotably connected at a first pivot point, and connected by a first hydraulic actuator, the first hydraulic actuator configured to actuate and cause the first set of two clamp arms to grasp a first rail segment;a second set of two clamp arms pivotably connected at a second pivot point, and connected by a second hydraulic actuator, the second hydraulic actuator configured to actuate and cause the second set of two clamp arms to grasp a second rail segment, the second rail segment to be substantially axially disposed with respect to the first rail segment;at least two hydraulically actuated force members linking the first set of two clamp arms clamping assembly and the second set of two clamp arms clamping assembly, wherein the force members are configured to provide a pulling force over a range of relative movement between the first set of clamp arms and the second set of clamp arms of greater than or equal to six inches, and with a maximum pulling force of 180 tons or greater; anda welding device configured to weld the first rail segment and second rail segment together. 2. The improved in-track weld system of claim 1, further comprising a weld circuit, separate from the force members, for applying a DC power differential across the first rail segment and the second rail segment, such that the weld circuit is closed when the first rail segment and the second rail segment are brought into contact, resulting in resistive heating of ends of the first rail segment and the second rail segment at a weld joint thereby enabling forging the rail ends together under the pulling force applied by the force members. 3. The improved in-track weld system according to claim 2, wherein the first hydraulic actuator has a primary axis that is substantially perpendicular to the first set of clamp arms attached thereto when the first hydraulic actuator is fully extended; and the second hydraulic actuator has a primary axis that is substantially perpendicular to the second set of two clamp arms attached thereto when the second hydraulic actuator is fully extended. 4. The improved in-track weld system according to claim 3, wherein each one of the first hydraulic actuator and the second hydraulic actuator has a cylinder and a rod, wherein the rod enters the cylinder at a cap end of the cylinder, and an opposite end of the rod supports a clevis connected to one clamp arm, and wherein the cap end of each cylinder includes a trunnion pivotably attached to another clamp arm. 5. The improved in-track weld system of claim 1, wherein each of the at least two hydraulically actuated force members is actuated via two in-line axially aligned hydraulically driven pistons. 6. The improved in-track weld system according to claim 5, wherein the force members are constructed of 4140 steel. 7. The improved in-track weld system according to claim 1, wherein a weld circuit includes a flexible member for allowing a stroke of the force members of greater than six inches. 8. The improved in-track weld system according to claim 7, wherein the flexible member comprises primarily flexible copper straps. 9. The improved in-track weld system according to claim 1, further comprising an internal shear assembly located between the first set of two clamp arms and the second set of two clamp arms, the internal shear assembly being operable to draw a shear member across a weld joint to remove a welding burr from the weld joint while the first and second sets of two clamp arms grasp the first and second rail segments. 10. The improved in-track weld system according to claim 9, wherein the internal shear assembly includes at least two actuators for drawing the shear member across the weld joint. 11. An improved in-track weld system for forge welding of rail segments together in place on a rail way, the improved in-track weld system comprising: at least two clamping assemblies, each clamping assembly comprising at least two clamp arms and a hydraulic actuator, such that a first clamping assembly is configured to clamp onto and causes grasping a first rail segment and a second clamping assembly is configured to clamp onto and causes grasping a second rail segment;at least two force members linking the first clamping assembly and the second clamping assembly, wherein the force members are operable to force the first rail segment and the second rail segment together; anda weld circuit included in a welding device configured to weld the first rail segment and the second rail segment together, separate from the force members, for applying a DC power differential across the first rail segment and the second rail segment, such that when the first rail segment and the second rail segment are brought into contact the weld circuit is closed, resulting in resistive heating of ends of the first rail segment and the second rail segment at a weld joint so that during operation of the weld system the ends are forged together under force applied by the force members. 12. The improved in-track weld system according to claim 11, wherein the force members are constructed of steel. 13. The improved in-track weld system according to claim 12, wherein the force members are constructed of 4140 steel. 14. The improved in-track weld system according to claim 11, wherein the weld circuit includes a flexible member for allowing a stroke of the force members of greater than six inches. 15. The improved in-track weld system according to claim 11, further comprising an internal shear member to remove a welding burr from the weld joint. 16. The improved in-track weld system according to claim 11, wherein the weld circuit includes a diode pack assembly having therein a transformer and one or more rectifying circuit elements. 17. The improved in-track weld system according to claim 16, wherein the diode pack outputs a low voltage DC power signal with an open-circuit voltage between about 5 and about 12 volts. 18. An on-track vehicle comprising: an in-track weld system for forge welding of rail segments together in place on a rail way, the improved in-track weld system comprising:at least two clamping assemblies, each clamping assembly comprising at least two clamp arms and a hydraulic actuator, such that a first clamping assembly is configured to clamp onto and causes grasping a first rail segment and a second clamping assembly is configured to clamp onto and causes grasping a second rail segment;at least two force members linking the first clamping assembly and the second clamping assembly, wherein the force members are operable to force the first rail segment and the second rail segment together; anda weld circuit included in a welding device configured to weld the first rail segment and the second rail segment together, the weld circuit separate from the force members, for applying a DC power differential across the first rail segment and the second rail segment, such that when the first rail segment and the second rail segment are brought into contact the weld circuit is closed, resulting in resistive heating of ends of the first rail segment and the second rail segment at a weld joint so that during operation of the weld system the ends are forged together under force applied by the force members;a generator within the vehicle for driving the weld circuit;an engine within the vehicle for driving the generator; and a hoist for placing the in-track weld system on a track to be welded. 19. The on-track vehicle according to claim 18, wherein the weld circuit includes a flexible member for allowing a stroke of the force members of greater than six inches. 20. The on-track vehicle according to claim 18, wherein the in-track weld system comprises a shear member that is operable to remove a welding burr from the weld joint while the at least two clamping assemblies are clamped.