Upgrade railcar holding systems for increased efficiency

Wheel grippers are mounted on the inside and outside of the rails to “grip” both sides of the wheel and hold railcars in place during the dumping cycle. These assemblies deliver accurate wagon control, which is important to improve time cycles, increase production capacity and provide a safe working environment. However, traditional railcar handling systems present a few inconveniences that contemporary systems can improve upon.

Wheel grippers are located in pits beneath the rail track, requiring deep excavation and significant civil work for installation. Traditional gripper pits present challenges for service access to provide inspections, check for wear and perform regular maintenance. Because of their subsurface location, wheel gripper pits are also gravitationally prone to moisture accumulation and flooding from rain and snow melt. These conditions may lead to premature wear of the gripper components, leading to early or more frequent replacement and increased operating costs.

Metso’s low-profile wheel gripper carries many advantages over traditional gripper assemblies.

Flexible application

Low-profile wheel grippers can be retrofitted to existing customer sites or implemented into new installations where lower gripping forces are required, such as where fewer railcars are processed.

Less space and less installation time

Metso’s low-profile wheel gripper has a significantly lower installation depth, requiring less civil work and downtime for installation, and occupying as little as 25 to 30 percent of the space of a traditional gripper pit. At brownfield sites, a precast concrete plinth can be placed in the existing excavation to reduce installation downtime. The reduced installation footprint also minimizes flooding risk with simpler drainage. Less pit flooding also leads to increased component reliability and service life.  

Maintenance accessibility

The low-profile wheel gripper system is designed for ease of maintenance and enhanced safety with operating cylinders located outside the track for greater part accessibility. The grippers are installed just below track level so they can be easily inspected and maintained from ground level.

Increased safety and efficiency

The low-profile grippers improve the dumping system’s operational safety and efficiency, removing the risk of uncontrolled railcar movement and eliminating the need for potentially hazardous manual operator interface. The system holds railcars in place so they can be easily and repeatedly located by a wagon positioning system to increase efficiency and plant throughput. The grippers also have a greater tolerance for inaccurate wagon positioning and accommodate a wide range of wagon sizes and wheelbases.

Increased sustainability

The wheel gripper’s low profile weighs nearly 35 percent less than a conventional assembly, allowing operators to reduce their carbon footprint with less manufacturing, material consumption and held inventory.