Portable Weld Milling Machine Apparatus and Methods of Using the Same

Abstract

A portable rail weld milling machine apparatus comprises a metal frame that incorporates a motor with a rotary carbide tool that is able to lock to a rail or rails for stability. The apparatus houses the required guides and motors to maneuver the tool on a plurality of axes with computer numerical control (“CNC”). The CNC programming is able to control the carbide tool such that the welded rail can be milled to proper profile on the entire running surface, including the top, the field side, and the gauge side of the ball of the rail.

We claim: 
     
         1 . An apparatus for milling a weld on a rail comprising:
 a frame comprising a first clamp extending from the frame and configured for clamping the frame to a first rail; and   a milling head connected to a motor wherein the motor is configured to drive the milling head, the milling head connected to a first linear guide, the linear guide connected to the frame.   
     
     
         2 . The apparatus of  claim 1  wherein the milling head extends from the motor, and the motor is attached to the linear guide. 
     
     
         3 . The apparatus of  claim 1  wherein the milling head is connected to a second linear guide 
     
     
         4 . The apparatus of  claim 3  wherein the first linear guide is configured to move the milling head in a direction lateral to the rail and the second linear guide is configured to move the milling head in a direction longitudinal to the rail. 
     
     
         5 . The apparatus of  claim 3  wherein the first linear guide is configured to move the milling head in a direction lateral to the rail and the second linear guide is configured to move the milling head vertically. 
     
     
         6 . The apparatus of  claim 3  wherein the first linear guide is configured to move the milling head in a direction longitudinal to the rail and the second linear guide is configured to move the milling head vertically. 
     
     
         7 . The apparatus of  claim 3  wherein the milling head is connected to a third linear guide. 
     
     
         8 . The apparatus of  claim 5  wherein the first linear guide is configured to move the milling head in a direction lateral to the rail, the second linear guide is configured to move the milling head in a direction longitudinal to the rail, and the third linear guide is configured to move the milling head vertically. 
     
     
         9 . The apparatus of  claim 1  wherein the milling head is rotatably connected to the first linear guide and configured to be disposed between a vertical position and a horizontal position. 
     
     
         10 . The apparatus of  claim 1  further comprising:
 an arm extending from the frame; and 
 a second clamp extending from the terminal end of the arm, configured to clamp to a second rail running parallel to the first rail. 
 
     
     
         11 . A system for milling a weld on a rail comprising:
 a milling apparatus comprising a frame comprising a first clamp extending from the frame and configured for clamping the frame to a first rail, and a milling head connected to a motor wherein the motor is configured to drive the milling head, the milling head connected to a first linear guide, the linear guide connected to the frame; and   a first rail having a weld thereon, wherein the first clamp is clamped to the first rail, and the milling head is positioned over an area of the first rail to be milled.   
     
     
         12 . The system of  claim 11  wherein the first rail comprises a first rail section and a second rail section and a butt-weld between the first rail section and the second rail section. 
     
     
         13 . The system of  claim 11  wherein the weld is disposed on a top surface of the rail. 
     
     
         14 . The system of  claim 11  wherein the milling head moves in three-dimensions. 
     
     
         15 . The system of  claim 11  further comprising:
 an arm extending from the frame having a second clamp on a terminal end thereof, wherein the second clamp is clamped to a second rail running parallel to the first rail. 
 
     
     
         16 . A method of milling a weld on a rail comprising the steps of:
 providing a milling apparatus comprising a frame comprising a first clamp extending from the frame and configured for clamping the frame to a first rail, and a milling head connected to a motor wherein the motor is configured to drive the milling head, the milling head connected to a first linear guide, the linear guide connected to the frame;   providing a first rail having a weld thereon;   positioning the frame over the rail;   claiming the first clamp to the first rail;   positioning the milling head over an area of the first rail to be milled; and   milling the area of the first rail including the weld.   
     
     
         17 . The method of  claim 16  wherein the first rail comprises a first rail section and a second rail section and a butt-weld between the first rail section and the second rail section. 
     
     
         18 . The method of  claim 16  wherein the weld is disposed on a top surface of the rail. 
     
     
         19 . The method of  claim 16  further comprising:
 moving the milling head in three dimensions when milling the area of the first rail including the weld. 
 
     
     
         20 . The method of  claim 16  wherein the frame comprises an arm extending from the frame having a second clamp on a terminal end thereof, further comprising the steps of:
 providing a second rail running parallel to the first rail; and 
 clamping wherein the second clamp to a second rail.