Multiple batch system and method for loading railcars of a wide range of capacities and designs

• US 20080000699A1
• Filed: 07/03/2006
• Published: 01/03/2008
• Est. Priority Date: 07/03/2006
• Status: Active Grant

• Current Assignee: DONNA F. WALKER AND HAROLD A. WALKER JOINTLY WITH RIGHT OF SURVIVORSHIP, Purvis Industries, LLC
• Original Assignee: DONNA F. WALKER AND HAROLD A. WALKER JOINTLY WITH RIGHT OF SURVIVORSHIP
• Inventors: Walker, Harold A.
• Granted Patent: US 7,411,136 B2
• Time in Patent Office: Days
• US Class Current: 177/60
• CPC Class Codes: G01G 13/24 Weighing mechanism control arrangements for automatic feed or discharge

Abstract

Multiple-batch train loading systems and methods, for example for loading coal, which are capable of accommodating railcars of a wide range of capacities and designs. Each railcar is loaded with at least a relatively large initial weighed batch having a weight at least approximately equal to the maximum available capacity of a weigh bin, and a relatively small final weighted batch. The initial weighted batch and the final weighed batch are both made up with precision. If required, one or more intermediate weighed batches are loaded into the railcar. The intermediate batches, if required, are made up rapidly, but not necessarily with precision.

Claims

1. A multiple-batch method capable of accommodating railcars of a wide range of capacities and designs for loading a moving railcar from front to back with a car target weight of particulate material employing a train loading system including a surge bin, a weigh bin having a maximum available capacity as well as a maximum target capacity for a non-precision-charged batch positioned below the surge bin, the maximum target capacity for a non-precision-charged batch being less than the maximum available capacity, a controlled and staged charging gate for selectively charging both precision-charged and non-precision-charged batches of particulate material from the surge bin into the weigh bin, and a controlled discharge gate for discharging particulate material from the weigh bin through a loading chute into the railcar, said method comprising the steps of:

at least initially calculating the number and individual target weights of batches in order to load the railcar to the car target weight based on an initial weighed batch having a weight at least approximately equal to the maximum available capacity of the weigh bin, a final weighed batch sized no larger than the amount of particulate material that can be precision-charged into the weigh bin in the time it takes to completely empty the loading chute, and zero or more intermediate weighed batches sized no larger than the maximum target capacity of the weigh bin for a non-precision-charged batch;

as the railcar approaches the loading chute, precision-charging the weigh bin with the initial weighed batch of material, and then discharging the initial batch from the weigh bin through the loading chute into the railcar;

if one or more intermediate weighed batches are required, while material from a previous batch is flowing from the loading chute into the railcar, non-precision-charging the weigh bin with each intermediate batch of material, and then discharging each intermediate batch from the weigh bin through the loading chute into the railcar; and

while material from a previous batch is flowing from the loading chute into the railcar, precision-charging the weigh bin with the final weighed batch, the weight of the final weighed batch being what is required to reach the car target weight after the initial and any intermediate weighed batches are weighed and loaded into the railcar, and then discharging the final batch from the weigh bin through the loading chute into the railcar.

2. The method of claim 1, which further comprises, in the event one or more intermediate weighed batches are required, after the weigh bin has been charged with each intermediate weighed batch, re-calculating the number and individual target weights of any additional intermediate batches that may be required, as well as the target weight of the final weighed batch.

3. A train loading system for loading successive railcars of a moving train with respective car target weights of particulate material, said system capable of accommodating railcars of a wide range of capacities and designs, and said system comprising:

a surge bin;

a weigh bin positioned below said surge bin, said weigh bin having a maximum available capacity as well as a maximum target capacity for a non-precision-charged batch, the maximum target capacity for a non-precision-charged batch being less than the maximum available capacity, and at least one transducer connected to said weigh bin for measuring the weight of said weigh bin and particulate material contained therein, said at least one transducer having a weighing transducer output;

a controlled and staged charging gate with selective opening sizes for selectively charging both precision-charged and non-precision-charged batches of particulate material from said surge bin into said weigh bin;

a loading chute positioned below said weigh bin for conveying particulate material from said weigh bin into the railcars;

a controlled discharge gate for discharging particulate material from said weigh bin; and

a controller connected to said transducer output for determining the weight of said weigh bin and particulate material contained therein, connected to said charging gate for controlling the charging of said weigh bin, and connected to said discharge gate for controlling discharging from said weigh bin, said controller operable,

to at least initially calculate the number and individual target weights of batches in order to load the railcar to the car target weight based on an initial weighed batch having a weight at least approximately equal to the maximum available capacity of said weigh bin, a final weighed batch sized no larger than the amount of particulate material that can be precision-charged into said weigh bin in the time it takes to completely empty said loading chute, and zero or more intermediate weighed batches sized no larger than the maximum target capacity of said weigh bin for a non-precision-charged batch,

as an individual railcar approaches said loading chute, to open said charging gate and then close said charging gate in stages, while monitoring said weighing transducer output, so as to precision-charge said weigh bin with the initial weighed batch of material,

to open said discharge gate, and then to close said discharge gate when said weigh bin is empty, so as to discharge the initial batch from said weigh bin through said loading chute into the railcar,

if one or more intermediate weighed batches are required, while material from a previous batch is flowing from said loading chute into the railcar, to open said charging gate, while monitoring said weighing transducer output, so as to non-precision-charge said weigh bin with each intermediate batch of material, to open said discharge gate, and then to close said discharge gate when said weigh bin is empty, so as to discharge each intermediate batch from said weigh bin through said loading chute into the railcar,

while material from a previous batch is flowing from said loading chute into the railcar, to open said charging gate and then close said charging gate in stages, while monitoring said weighing transducer output, so as to precision-charge said weigh bin with the final weighed batch, the weight of the final weighed batch being what is required to reach the car target weight after the initial and any intermediate weighed batches are weighed and loaded into the railcar, and

to open said discharge gate, and then to close said discharge gate when said weigh bin is empty so as to discharge the final batch from said weigh bin through said loading chute into the railcar.

4. The train loading system of claim 3, wherein said controller is further operable, in the event one or more intermediate weighed batches are required, after said weigh bin has been charged with each intermediate weighed batch, to re-calculate the number and individual target weights of any additional intermediate batches that may be required, as well as the target weight of the final weighed batch.