Systems and methods for tie plate distribution and collection

Abstract

The embodiments are directed to tie plate distribution systems and methods including a vehicle including 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 including 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 tie plate thereon. The movable arm is configured to lift the target tie plate and place the target tie plate in association with the empty tie.

1 . A tie plate distribution system, comprising:
 a vehicle comprising a motion mechanism and a floor;   a movable arm positioned on the vehicle, wherein the movable arm has a plurality of degrees of freedom and has a retaining mechanism at an end of the movable arm;   a vision sensor positioned on the vehicle or the movable arm;   wherein:
 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 tie plate thereon; and 
 the movable arm is configured to:
 lift the target tie plate; and 
 place the target tie plate in association with the empty tie. 
 
   
     
     
         2 . The tie plate distribution system of  claim 1 , wherein the retaining mechanism comprises one of a magnet, an electromagnet, a permanent magnet, or a combination thereof. 
     
     
         3 . The tie plate distribution system of  claim 1 , wherein the retaining mechanism is an impactive end effector, an ingressive end effector, an astrictive end effector, or a contigutive end effector. 
     
     
         4 . The tie plate distribution system of  claim 1 , wherein the movable arm further comprises a base, a shoulder joint, an elbow, and a wrist joint, wherein:
 the base is 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, and   a second end of the elbow is pivotally coupled to the retaining mechanism with the wrist joint.   
     
     
         5 . The tie plate distribution system of  claim 1 , the motion mechanism comprising a selection of rubber wheels, rail wheels, continuous tracks, or a combination thereof, wherein the vehicle is operable to move along the path adjacent to a rail or move on the rail along the path. 
     
     
         6 . The tie plate distribution system of  claim 1 , wherein the vision sensor is one or more of a proximity sensor, a camera, a light detection and ranging (LIDAR) sensor, a thermal image sensor, an infrared sensor, or an ultrasonic sensor. 
     
     
         7 . The tie plate distribution system of  claim 1 , wherein the vehicle further comprises a container configured to store one or more tie plates. 
     
     
         8 . The tie plate distribution system of  claim 7 , wherein the movable arm is configured to place a stored tie plate from the container on the empty tie or deposit the target tie plate into the container. 
     
     
         9 . The tie plate distribution system of  claim 7 , wherein the movable arm is configured to transfer the one or more tie plates from a stationary position along the path to the container. 
     
     
         10 . The tie plate distribution system of  claim 1 , wherein the vehicle further comprises 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. 
     
     
         11 . A method for tie plate distribution, comprising:
 detecting, using a vision sensor associated with a vehicle or a movable arm, a target tie plate, wherein the vehicle or the movable arm is operable to move along a path comprising multiple ties and one or more rails;   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 target tie plate; and   placing, using the movable arm, the target tie plate onto or in proximity to the empty tie.   
     
     
         12 . The method of  claim 11 , wherein the target tie plate is disposed along the path and the method further comprises:
 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.   
     
     
         13 . The method of  claim 11 , wherein the target tie plate is disposed in a container of the vehicle. 
     
     
         14 . The method of  claim 11 , wherein the target tie plate is disposed in a stationary position, the stationary position comprising one or more tie plates, and the method further comprises:
 determining, using the vision sensor, that the stationary position is 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.   
     
     
         15 . The method of  claim 11 , further comprising:
 placing, using the movable arm, the target tie plate in a flipping station of the vehicle 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.   
     
     
         16 . The method of  claim 11 , wherein the target tie plate is disposed between a tie of the multiple ties and a replacement rail. 
     
     
         17 . A tie plate distribution system, comprising:
 a vehicle having rail wheels;   one or more containment beds capable of containing a plurality of tie plates;   a machine path extending longitudinally on the vehicle and adjacent to the one or more containment beds;   a movable arm disposed on the machine path, the movable arm movable along the machine path;   said movable arm having a plurality of degrees of freedom and having a retaining mechanism at an end of the movable arm;   a conveyor extending along the vehicle and within a reach of the movable arm; and   wherein the movable arm is capable of moving along the machine path and obtaining a tie plate, and wherein the movable arm is configured to retain the tie plate and deposit the tie plate on the conveyor.   
     
     
         18 . The tie plate distribution system of  claim 17 , the machine path defined by a track. 
     
     
         19 . The tie plate distribution system of  claim 18 , the track disposed above the conveyor. 
     
     
         20 . The tie plate distribution system of  claim 17 , further comprising a cart that is capable of moving along the machine path, the movable arm disposed in the cart. 
     
     
         21 . The tie plate distribution system of  claim 17 , the conveyor comprising one or more belt conveyors, one or more roller conveyors, or a combination thereof. 
     
     
         22 . The tie plate distribution system of  claim 17 , the one or more containment beds being two containment beds. 
     
     
         23 . The tie plate distribution system of  claim 22 , the conveyor and the machine path formed between the two containment beds. 
     
     
         24 . The tie plate distribution system of  claim 17 , further comprising a vision system. 
     
     
         25 . The tie plate distribution system of  claim 24 , further comprising a controller configured to receive input from the vision system. 
     
     
         26 . The tie plate distribution system of  claim 25 , the controller configured to provide an output to trigger movement of the movable arm to obtain the tie plate. 
     
     
         27 . The tie plate distribution system of  claim 26 , the controller configured to cause a cart associated with the movable arm to move along the machine path. 
     
     
         28 . The tie plate distribution system of  claim 27 , the cart movable adjacent to the one or more containment beds. 
     
     
         29 . The tie plate distribution system of  claim 17 , the vehicle being a railcar or a rail-truck. 
     
     
         30 . The tie plate distribution system of  claim 17 , the conveyor having a first part and a second part, the movable arm being configured to obtain the tie plate from the first part and place the tie plate on the second part.