Automated Geometry and Crowning Apparatus for Use of Mobile Electric Flash-Butt Welding of Railroad Rails and Rail Inserts

Abstract

A Mobile Electric Flash-Butt (EFB) Welding apparatus that incorporates an automated geometry system which creates field/mobile EFB welds with proper vertical alignment, within a definable distance. The system has a first pair of adjustable reference points on a left side of a mobile welding apparatus. The system has a second pair of adjustable reference points on the right side of the welding apparatus. The system has a first lifting mechanism positioned between the first pair of adjustable reference points and a second lifting mechanism positioned between the second pair of adjustable reference points. The welding line is positioned between the first and second pair of adjustable reference points and is the location of the weld. The system allows for comparatively shorter inserts than previously utilized.

What is claimed is: 
     
         1 . A system for a welding apparatus, said system comprising:
 a mobile welding apparatus comprising a left side and a right side;   a first pair of adjustable reference points on said left side;   a first lifting mechanism positioned between said first pair of adjustable reference points;   a second pair of adjustable reference points on said right side;   a second lifting mechanism positioned between said second pair of adjustable reference points;   a welding line positioned between said first pair and said second pair of adjustable reference points;   wherein each adjustable reference point is independently adjustable;   a first rail and a second rail, wherein said first rail is positioned between said first pair of adjustable reference points on the left side, and wherein said second rail is positioned between said second pair of adjustable reference points on the right side;   wherein said first rail is manufactured to match a removed insert.   
     
     
         2 . The system of  claim 1  wherein said first rail comprises an insulated joint. 
     
     
         3 . The system of  claim 1  wherein said first rail is milled to match a head loss of a worn rail section. 
     
     
         4 . The system of  claim 1  wherein said first rail insert comprises a rail head. 
     
     
         5 . The system of  claim 1  wherein said first rail is a new rail. 
     
     
         6 . The system of  claim 1  wherein said first rail is a used rail. 
     
     
         7 . The system of  claim 1  wherein said first rail comprises a rail head shape, and wherein said rail head shape is milled to resemble a worn rail. 
     
     
         8 . The system of  claim 1  wherein said first rail is milled in a series of horizontal and vertical increments to match a profile of a worn rail. 
     
     
         9 . A method of replacing a worn rail insert, said method comprising the steps of:
 a) removing said worn rail section, wherein said worn rail section comprises a head loss;   b) manufacturing a rail insert to match said head loss of said worn rail section.   
     
     
         10 . The method of  claim 9  wherein said manufacturing step comprises reducing head loss in said rail insert in approximately 1/16″ increments. 
     
     
         11 . The method of  claim 9  wherein rail insert has a length of between about 10 feet to about 20 feet. 
     
     
         12 . The method of  claim 9  wherein said rail insert has a first end section which is unworn and which tapper milled down to the largest head loss on a second end section. 
     
     
         13 . The method of  claim 9  wherein said rail insert is manufactured from a new piece of rail and is milled down in a series of increments to match the corresponding worn rail section. 
     
     
         14 . The method of  claim 9  wherein said rail insert is manufactured from a new piece of rail and is milled down in a series of increments and horizontal increments to match the corresponding worn rail section with non-typical profile. 
     
     
         15 . The method of  claim 9  wherein said rail insert is elongated to a 4′-7′ length. 
     
     
         16 . The method of  claim 9  wherein said rail insert is drilled on one end. 
     
     
         17 . The method of  claim 9  wherein said rail insert is utilized to make a mechanical joint on one end, to create a non-conductive section in track.