WO2013090985A1

WO2013090985A1 - Rail forming apparatus

Info

Publication number: WO2013090985A1
Application number: PCT/AU2012/001539
Authority: WO
Inventors: Danny Klein; Gordon STOREY
Original assignee: Klein Group Ltd
Priority date: 2011-12-23
Filing date: 2012-12-14
Publication date: 2013-06-27

Abstract

An apparatus for forming at least one helical groove in a rail is disclosed. The apparatus has a groove forming portion and means for causing the rail to be conveyed and rotated relative to the groove forming portion such that the helical groove(s) is(are) formed in the rail as the rail is conveyed and rotated relative to the groove forming portion.

Description

RAIL FORMING APPARATUS

TECHNICAL FIELD

[0001] The present invention relates to an apparatus for forming one or more helical grooves in a rail.

BACKGROUND

[0002] Rails have been provided with one or more helical grooves extending around the outer surface of the rail and along at least part of the length of the rail, giving the rail a "twisted" appearance. One such rail is described in Australian Innovation Patent No. 2009100535 the contents of which are hereby incorporated by reference. Examples of such rails with a twisted appearance are also shown in Figures 1 and 2. Note that the example rails in Figures 1 and 2 have a twisted appearance, but the surface profile/shape of the rails (which is what gives the rails the twisted appearance) is not created by twisting the rail. Rather, the twisted appearance is due to one or more helical grooves extending around the outer surface of the rail.

[0003] The production of such rails has previously been a slow and laborious process, and the ability to supply the rails to customers has been limited by the relatively slow rate at which the rails can be fabricated.

[0004] Thus, it is considered desirable to provide a rail forming apparatus that allows rails with a twisted appearance (or rails with one or more helical grooves therein) to be produced more easily and/or at an increased rate.

[0005] It is to be clearly understood that mere reference herein to previous or existing products, practices, publications or other information, or to any associated problems or issues, does not constitute an acknowledgement or admission that any of those things, individually or in any combination, are admissible prior art or formed part of the common general knowledge of those skilled in the field.

[0006] Throughout this specification, the term "comprising" and its grammatical equivalents shall be taken to have an inclusive meaning unless the context of use indicates otherwise.

SUMMARY OF THE INVENTION

[0007] In one form, the invention relates broadly to an apparatus for forming at least one helical groove in a rail, the apparatus comprising a groove forming portion and means for causing the rail to be conveyed and rotated relative to the groove forming portion such that the helical groove(s) is(are) formed in the rail as the rail is conveyed and rotated relative to the l groove forming portion.

[0008] Rails, in which one or more helical grooves are formed using the apparatus may be of any initial shape, although it is envisaged that the rails will generally have an initially straight cylindrical shape. In other words, before the groove is formed in the rail, the rail (i.e. the "blank" rail) may resemble a straight cylindrical pipe (if the rail is hollow) or a straight solid cylindrical rod (if the rail is not hollow). The "blank" rail could of course also have a range of other initial cross-sectional shapes (although this may be rare), and could also potentially be curved rather than straight along its length.

[0009] The rail may also be made of any suitable material. In many embodiments of the invention, it is expected that the rail will be made of metal such as aluminium, copper, brass, steel (including stainless steel, mild steel or steel having a surface coating such as galvanized steel) or the like. Other, metal and non-metal materials are also possible. The material will depend on the particular application in which the rail is ultimately intended to be used.

[0010] In some embodiments, the apparatus may be provided with guide means, or one or more guides, for guiding the rail into, through, over, off (etc) different parts or portions of the apparatus. That is, the guide(s) or guide means may guide the rail relative to (parts or portions of) the apparatus. The guide(s) or guide means could take any form suitable for achieving the intended guiding function.

[0011] The invention, as described in broad terms above, relates to an apparatus for forming at least one helical groove in a rail. The apparatus could be a single apparatus such as, for example, a standalone machine or piece of equipment. Alternatively, multiple separate components, assemblies, pieces of equipment, mechanisms, etc may be assembled so as to together form and/or operate as the apparatus. Thus, the apparatus may comprise multiple parts.

[0012] The term "groove" herein refers to and covers, at least, any contour or other feature of shape associated with the rail's surface which deviates from the shape the rail's surface has before the groove is formed in the rail. Often, the groove will be formed by pressing or indenting into, or cutting or digging into, the surface of the rail. However, the groove could also be, for example, formed by applying pressure to the surface of the rail to "force up" or otherwise create raised portions and the region between said raised portions may define the groove. Other examples are also possible.

[0013] The invention operates to form at least one helical groove in a rail. Therefore, without limiting anything in the previous paragraph, the groove formed by the apparatus will be a feature of shape which is helical or which is (in a manner of speaking) "wound along" at least a portion of the length of the rail. The helical groove need not be a regular or unchanging helix. Thus, the pitch of the helix, or the number of turns per unit length, etc, may change along the length of the groove/rail. The helix could therefore be an irregular helix.

[0014] The groove forming portion of the apparatus could take a wide range of possible configurations. In fact, the groove forming portion could potentially take any configuration suitable for forming the one or more grooves in the rail as the rail is conveyed and rotated relative to it. In certain embodiments of the invention, the groove forming portion may comprise or include one or more rollers. The rollers may be operable to press against, and press into, the surface (the outer surface) of the rail to create the groove(s). Other configurations are also possible. For example, in other embodiments, the groove forming portion could comprise or incorporate one or more cutting implements operable to cut or dig into the surface of the rail to create the groove(s). In another example, the groove forming portion could operate to at least partially melt or soften the outer surface of the rail (preferably in a controlled manner) to enable formation of the groove (this possibility might be more suitable to rails made from particular materials such as, for example, polymers). There are also a range of other possibilities.

[0015] The invention will be discussed hereinafter with reference to embodiments where the groove forming portion comprises one or more rollers and also where the rail is made from metal such as, for example, steel. However, it is to be clearly understood that this is simply for ease of explanation. No limitation whatsoever is to be implied from this.

[0016] In some embodiments, a single roller may be provided to create the, or each, groove in the rail. Alternatively, multiple rollers may together create a single groove, and if multiple grooves are to be formed in the rail, multiple such sets of rollers could be provided to each create a separate groove. Different combinations of single and multiple rollers might also be used. For example, a single roller might be provided to create a narrow groove whereas multiple rollers could potentially be used to, say, create a wider groove. The rollers could also be provided with different edge shapes. For example, rollers with a sharp edge (e.g. where the edge of the roller is shaped like a "^Λ") could be used to create a sharply indented (e.g. "V" shaped) or sharply angled groove. Alternatively, rollers with a more rounded or flat edge might be used, for example, to create grooves with a more rounded or flat profile. Rollers could also be made from different materials. For instance, rollers made from a slightly softer or more resilient material may deform slightly more when pressed against the surface of the rail and may perhaps therefore create a shallower, wider groove (as compared to a groove created by a similarly shaped roller made from a harder or less resilient material).

[0017] At least one roller may be movable to allow initial insertion or positioning of the rail (i.e. to allow the rail to be moved into position before operation of the apparatus is commenced to form the helical groove(s)). For instance, one or more rollers could be removable, or retractable, or pivotable so as to initially move out of the way of the rail, etc. In any case, after the rail is inserted or correctly positioned, the said roller(s) may then be moved into position to press against, and indent into, the rail so that formation of the groove(s) commences when operation of the apparatus is commenced. Where multiple rollers are provided, the pressure created when the movable roller(s) is/are moved into position to press against the rail may cause (or help to cause) the other roller(s) to press against, and indent into, the rail. Thus, the rail in these embodiments may be, in effect, squeezed between multiple rollers.

[00181 The rollers may be adjustable in a range of different ways. For example, the rollers may be adjusted to press harder against the surface of the rail (and therefore indent further into the surface of the rail), or vice versa. This may result in grooves which are deeper, or shallower, respectively. The orientation of a roller could also be adjusted to alter the shape or profile of the groove formed thereby. Where multiple rollers are provided, different rollers may be adjusted differently to create grooves of different depths, or different profiles, etc, in a single rail.

[0019] In embodiments which comprise rollers, one or more of the rollers may be provided with indicia thereon, such that, as the roller is brought progressively into contact with the rail, the indicia is transferred to the rail as part of the groove formed therein. Any suitable indicia may be provided, such as, but not limited to, details of the manufacturer (name, contact details etc), details of the formed product (part numbers, information regarding the material from which the rail is formed etc), details of the customer (name, logo etc) or any suitable message or pattern or decoration that the manufacturer or customer wishes to have "stamped" or imprinted on the rail. In this way, a degree of customization of the rail formed by the apparatus is possible.

[0020] The apparatus also has means for causing the rail to be conveyed and rotated relative to the groove forming portion (recall that the rollers described above are not necessarily the only possible configuration of the groove forming portion - other configurations are also possible). The said means may function such that the helical groove(s) is(are) formed in the rail as the rail is conveyed and rotated relative to the groove forming portion. For example, where the groove forming portion comprises one or more rollers (as described above), as the rail is conveyed and rotated, the rail may thus be pulled passed or through the one or more rollers which press into the surface of the rail thus creating the indented helical groove(s) as the rail passes.

[0021] Any suitable means for causing the rail to be conveyed and rotated relative to the groove forming portion could potentially be used. A single means or mechanisms may perform both functions (conveying and rotating the rail). Alternatively, one means or mechanism may be provided for conveying the rail and another separate means or mechanisms may be provided for rotating the rail.

[0022] The means for causing the rail to be conveyed and rotated could comprise one or more rollers. In some embodiments, these could be the same rollers as the rollers described above which function to create the groove(s). Alternatively, the rollers which function to convey and/or rotate the rail could be separate from the rollers which create the groove(s) (e.g. separate "stator" type rollers). In either case, if rollers are used to convey and rotate the rail (or to perform one of these functions), those rollers may be driven to rotate so that when they come into contact with the rail their rotation is transmitted by the contact to cause longitudinal and/or rotational motion of the rail (longitudinal movement of the rail being movement of the rail in the direction of the rail's longitudinal axis, and rotational motion being rotation of the rail about that axis).

[0023] Alternative arrangements or means may also be provided for causing the rail to be conveyed and rotated. For instance, in relation to the means for rotating the rail, the mechanism which performs this function may grip the rail (generally, but not necessarily, by gripping the rail at one end) and turn, thus rotating the rail. A wide range of different mechanisms may be used to grip the rail, for example, jaws, teeth, clamps, etc, although it is envisaged that in many embodiments a chuck may be used to grip one end of the rail. The chuck may be rotatable to thereby rotate the gripped rail. In other words, in these embodiments, the rail may be gripped at one end and turned by the chuck in much the same way (albeit on a larger scale) to the way a drill bit is gripped and turned by the chuck of a drill.

[0024] Furthermore, in embodiments such as those described in the previous paragraph, the chuck may be configured to (or it may have an associated mechanism which is operable to) not only grip and rotate the rail, but to also move laterally (longitudinally) relative to the groove forming portion of the apparatus. Thus, when the rail is gripped by the chuck, the lateral movement of the chuck may result in the rail being conveyed longitudinally relative to the groove forming portion of the apparatus. (The longitudinal movement of the rail may also result in the chuck being conveyed relative to the group forming portion.) The chuck (or the chuck with its associated mechanism) may therefore function to convey the rail, or allow the rail to be conveyed, as well as rotating the rail.

[0025] In some embodiments, in the operation of the apparatus, the chuck may move towards the groove forming portion, for example, pushing the rail through/past the rollers (in embodiments where the groove(s) are formed by rollers). Alternatively, the chuck may move away from the groove forming portion to, for example, pull/draw the rail through/past the rollers. In further embodiments, the chuck may be driven to rotate (thereby rotating the rail), and as the rail rotates while in contact with the groove forming portion, that contact may impose longitudinal forces on the rail thereby conveying rail (and the chuck).

[0026] The angular speed with which the rail is rotated relative to the groove forming portion (e.g. rollers etc) may be varied/controlled (in some embodiments) in order to adjust the helical shape/configuration of the groove(s) formed. For instance, assuming the rail is conveyed (longitudinally) relative to the groove forming portion at a given set linear speed, rotating the rail at a lower angular speed (in embodiments where this is possible) will generally result in fewer "winds" of each helical groove per unit length of rail, and vice versa. Similarly, the linear speed with which the rail is conveyed relative to the_x groove forming portion may (in some embodiments) be varied/controlled to adjust the helical shape of the groove(s) formed. In this case, assuming the rail is rotated at a given set angular speed, moving the rail through/past the groove forming portion more slowly (again, where this is possible) will generally result in a greater number of "winds" of each helical groove per unit length of rail, and vice versa. The linear speed with which the rail is conveyed and the angular speed with which the rail is rotated may (in some embodiments) be adjusted together or in combination to control the helical shape/configuration of the groove(s) formed.

[0027J The chuck or other mechanism(s) for conveying and/or rotating the rail may be driven or powered in any suitable way. For example, it/they may be electrically powered, pneumatically powered, hydraulically powered, etc. Such mechanisms and arrangements will be familiar to those skilled in the art and therefore need not be described in detail.

[0028] In another form, the invention relates broadly to a method of forming one or more helical grooves in a rail, the method involving (or including) causing the rail to be conveyed and rotated relative to a groove forming portion of an apparatus such that the helical groove(s) is(are) formed in the rail as the rail is conveyed and rotated relative to the apparatus' groove forming portion.

[0029] In a more particular form, the invention relates to a method of forming one or more helical grooves in a rail using an apparatus (such as, for example, an apparatus as described above), the method involving gripping one end of the rail, rotating the rail by the gripped end relative to the groove forming portion of the apparatus, the rail also being conveyed relative to the groove forming portion, so that the helical groove(s) is(are) formed as the rail is conveyed and rotated relative to the groove forming portion.

[0030] Any of the features described herein in relation to any one or more forms or aspects of the invention can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0032] Figures 1 and 2 (referred to in the Background section) each show a portion of a rail

- which has been provided with helical grooves extending around the outer surface of the rail giving the rail a "twisted" appearance;

[0033] Figure 3 is a perspective schematic illustration of a rail forming apparatus according to an embodiment of the present invention;

[0034] Figure 4 is a side-on schematic illustration of the groove forming portion of the apparatus in Figure 3;

[0035] Figure 5 is a front-on schematic illustration of the groove forming portion of the apparatus in Figure 3;

[0036] Figure 6 is a perspective view of the groove forming portion of an apparatus in an embodiment similar to the embodiment in Figure 3;

[0037] Figure 7 is a view of the rear of the groove forming portion in Figure 6;

[0038] Figure 8 is a side-on view of the chuck used in the embodiment in Figures 6 and

[0039] Figure 9 is a front-on view of the chuck in Figure 8;

[0040] Figure 10 is a close-up view of the rollers shown in Figure 6;

[0041] Figure 11 is a close-up view of one of the lower two rollers in Figures 6 and 10;

[0042] Figure 12 is a close-up view of the upper roller in Figure 6 and the piston mechanism which enables it to move;

[0043] Figure 13 is a view of the chuck track along which the chuck in Figures 8 and 9 moves; and

[0044] Figure 14 is a view of the stand on which the rails are stored prior to passing through the apparatus.

DETAILED DESCRIPTION OF THE DRAWINGS

[0045] As mentioned above, Figure 3 is a perspective schematic illustration of a rail forming apparatus according to an embodiment of the present invention. The apparatus is made up of four main parts, namely the groove forming portion 10, the rail stand 20, the chuck 30 and the chuck track 40. Each of these will be discussed below.

[0046] Referring first to the rail stand 20, this is a stand or rack on which one or more "blank" rails are stored or positioned before being fed through the groove forming portion 10 to have the helical grooves formed therein. It should be noted that Figure 3 is only a schematic illustration. Therefore, the rail stand 20 is also only shown schematically in Figure 3. The actual configuration and appearance of the rail stand 20 will therefore often differ from that shown in Figure 3. For example, an alternative configuration of the rail stand 20 is shown in Figure 14. Note that in Figure 14 the stand 20 includes a number of conveyor-rollers, several of which are actually shown disconnected and resting on the end of the stand. When properly assembled, the conveyor rollers are positioned at spaced locations along the stand and help to enable rails to move (roll) along the stand as they are fed into and through the groove forming portion 10.

[0047] Referring next to the groove forming portion 10, this part of the apparatus will also be described further below. However, for present purposes, it should be noted that the groove forming portion 10 comprises a main upstanding body 1 1 and a base 12. The body 11 and base 12 are supported on a stand 50 as shown in Figure 3 so that the base is positioned at approximately the same level at the top of the rail stand 20. The height of the stand 50 may of course be varied to suit. The groove forming portion 10 also has a central hole 13 extending through the full thickness of the body 11. The body 11 further incorporates roller mounting guides 14 for assisting in mounting rollers to the body (the rollers themselves are not shown in Figure 3). The body 11 further incorporates a piston arrangement (designated by reference numeral 15 in Figures 3-5) for allowing one of the rollers (the top vertical roller) to be moved to allow insertion of the rail. This will be explained further below.

[0048] As shown in Figure 3, the chuck 30 is mounted to the chuck track 40. The chuck 30 is able to move back and forth along the track 40. The actual configuration and appearance of the chuck 30 and track 40 will often differ from that shown in Figure 3. For example, an alternative configuration of the chuck 30 is shown in Figures 8 and 9, and an alternative configuration of the track 40 is shown in Figure 13. These alternative configurations will be discussed in further detail below.

[0049] The chuck 30 incorporates a chuck head 31. The chuck head 31 is the part which grips the end of the rail. The chuck head 31 also rotates relative to the rest of the chuck to thereby rotate the rail. The rotation of the chuck head 31 is driven by hydraulic actuators (not shown).

[0050] The overall operation of the apparatus may be described in summary terms as follows. A blank rail is initially fed from the rail stand 20 and through the hole 13 in the body 11 so that the end of the rail protrudes slightly out through the hole 13 on the chuck side of the body 11. (To allow insertion of the rail in this way, the upper vertical roller must also be raised, but this will be described further below.) The chuck 30 is then moved along the track 40 towards the body 11 so that the end of the rail which protrudes through the hole 13 can be received and gripped (clamped) by the chuck head 31. (The upper roller must also be lowered again so that the rail is squeezed hard between the three rollers as it passes out of the hole 13.) Thereafter, operation of the apparatus can commence.

[0051] When the apparatus is operated, the chuck head 31 rotates relative to the rest of the chuck, and the end of the rail is gripped by the chuck head 31. Therefore, the rail is rotated by the rotating chuck head 31. Furthermore, the rail is squeezed hard between the three rollers which are positioned near the exit of the hole 3. There are two effects of this. Firstly, because of the angle at which the rollers engage the rail, as the rail rotates, the rollers impose a longitudinal force on the rail and this is what conveys the rail and the chuck 30. Secondly, the rollers actually press sufficiently hard against the rail such that they press/indent into the surface of the rail. The three rollers therefore each create an indented helical groove in the rail as the rail is conveyed and rotated through hole 13 and through/between the rollers.

[0052] After the full length (or the desired length) of the rail has passed through the groove forming portion 10, the rail (with the helical groove(s) then formed therein) can be removed (if it has not already passed all the way through -removing the rail would again involve lifting the top roller) and the process can be repeated starting with a new blank rail. It has been found through testing that, using the machine the parts of which are illustrated in Figures 6-14, rails can be produced with helical grooves at a rate of up to 200 meters of rail per hour.

[0053] Turning next to Figures 4, 5 and 6, these Figures illustrate the rollers in a similar embodiment to Figure 3 (recall that the rollers are not shown in Figure 3). Each of the rollers is part of a roller assembly. Each one of the roller assemblies is positioned generally between one of the sets of roller guides 14 (the roller guides 14 are shown in Figure 3 as well as in Figures 4-6). When the roller assemblies are mounted to the body 11 , the respective rollers are oriented (i.e. they point) generally towards the axis extending through the centre of the hole 13 (although note that the exact position and orientation of the respective rollers can be adjusted in a number of ways, as discussed further below).

[0054] Each of the roller assemblies comprises a roller frame 141 , and each frame 141 supports a roller 142. The configuration and mounting of the upper vertical roller assembly is slightly different to the configuration and mounting of the two lower roller assemblies (for reasons that will become apparent). The two lower roller assemblies will therefore be described separately from the vertical roller assembly.

[0055] Referring initially to the two lower roller assemblies (which are best illustrated in Figures 10 and 11), it will be seen that the frame 141 of each of these assemblies comprises a base plate 143, a roller plate 144 and a web 145 (the web 145 is primarily for reinforcing). The base plate 143 in each case has four holes therein which allow the frame 141 to be bolted to the body 11 as shown. Note that the holes in each base plate 143 are elongated or made slightly larger than would be necessary to receive the bolts (this can be seen in Figures 10 and 11). This allows fine adjustment of the position at which the frame 141 is bolted to the body 11 (i.e. the bolts can be loosened allowing the frame 141 to be shifted slightly relative to the body 11 before re-tightening the bolts). This in turn allows adjustment of the position of the roller 142 relative to the body 11 and the hole 13 etc (see below).

[0056] The roller plate 144 in the frame 141 of each of the roller assemblies is the plate to which the roller is mounted. As shown in Figure 10, the roller in each case actually comprises a roller wheel 142 which is supported for rotation between two struts 146. The struts 146 are in turn attached to a disc 147, and it is the disc 147 which is bolted to the roller plate 144. Note that the holes in the disc 147 which receive the bolts have a slightly arcuate shape, and this allows the orientation (i.e. angle) at which the disc 147 is bolted to the roller plate 144 to be finely adjusted. In other words, the orientation (angle) of the disc 147 (and hence the roller 142) relative to the roller plate 144 can be adjusted by loosening the bolts and twisting the disc 147 relative to the roller plate 144 before re-tightening the bolts.

[0057] Turning now to the roller assembly for the upper vertical roller, the frame for this assembly is designated 141^* (to distinguish it from the frames 141 of the other two roller assemblies). The frame 141 ' is mostly the same as the frame 141 of other two roller assemblies (described above). That is, the frame 141' of the upper vertical roller assembly comprises a base plate 143', a roller plate 144' and a web 145' (the web 145' again is for reinforcing). However, unlike the frames 141 of the other two rollers, the frame 141' of the upper roller assembly also has a back plate 148'. The purpose of the back plate 148' will be described below. Another difference between the frame 141' for the upper vertical roller and the frames of the other two rollers is that, the frame 141' for the upper vertical roller is not bolted to the body 11. On the contrary, the frame 141" for the upper vertical roller is moveable up and down between the guides 14.

[0058] The reason the upper vertical roller frame is movable is to allow initial insertion of the rail. If the upper vertical roller frame were not movable (or at least if one of the rollers were not somehow movable out of the way to allow initial rail insertion) it would be necessary for the rail to be forced through between the rollers when initially inserting the rail through the hole 13. This would be difficult or impossible, and might also cause significant damage to the rail, the apparatus, or both. Accordingly, in this embodiment, the frame 141' of the upper vertical roller is able to move vertically upwards out of the way to allow the rail to be initially inserted through the hole 13. The roller can then be brought back down (after the rail has been inserted) so that the rail becomes squeezed forcefully between the three rollers.

[0059] The frame 4 of the upper vertical roller is moved up and down (as described in the previous paragraph) by a piston arrangement. The piston arrangement is shown only schematically in Figures 3-5 where it is designated by reference numeral 15. However, a slightly alternative piston arrangement is shown more clearly in Figures 6 and 12 and is designated by reference numeral 150. The piston arrangement 150 shown in Figures 6 and 12 comprises an upper (cylindrical) housing 151 , a drive rod 152 projecting down from the housing 151 , and is hydraulically powered. The nozzle or valve 153 shown facilitates attachment of a hydraulic hose or line for supplying hydraulic pressure. A piston (not shown) inside the housing

151 is connected to the upper end of the drive rod 152. The lower end of the drive rod attaches to the back plate 148' thereby linking the frame 141' of a vertical upper roller assembly to the piston arrangement 150.

[0060] When it is necessary to insert a new blank rail through the hole 13 in the body 11 , the piston arrangement 150 is hydraulically operated causing the piston inside the housing 151 to move upwards. Because the upper end of the drive rod 152 is connected to the piston, this therefore causes the drive rod to move upwards. And, because the lower end of the drive rod

152 is connected to the back plate 148' of the upper roller frame 141', the upper roller frame 141' is also moved upwards. This therefore allows the end of the new blank rail to be inserted through the hole 13 and positioned on or just above the lower two rollers. Once the new blank rail is positioned in this way, the piston arrangement can again be hydraulically operated causing the piston inside the housing 151 to move downward. This in turn drives the drive rod 152 and the roller frame 141' back downwards thereby causing the end of the new blank rail to become forcefully squeezed between the three rollers.

[0061] Next, the chuck will be described. As explained above with reference to Figure 3, when the apparatus is operated, the chuck head 31 rotates relative to the rest of the chuck, and this (due to the engagement of the rollers with the rail) causes the rail and the entire chuck 30 to move away from the body 11 (along the track 40), and the helical grooves are formed as the rail passes through the rollers 142.

[0062] Figures 8 and 9 illustrate the chuck 30 and chuck head 31 used in the embodiment of Figures 6 and 7. As can be seen from Figures 8 and 9, the chuck head 31 resembles an oversized drill chuck, and operates in much the same way. Specifically, the chuck head 31 comprises three gripping members 32. The gripping members 32 are spaced evenly around the chuck head 31, and they can be moved radially in and out to clamp and release (respectively) the end of the rail. In order to move the gripping members 32 in and out, a tool can be inserted and turned (one way and the other, respectively) in one of the spckets 33. This is much the same as the chuck of a conventional drill.

[0063] The chuck head 31 rotates relative to the rest of the chuck 30. The rotational movement of the chuck head 31 is hydraulically driven. The hydraulic pressure that drives this can be supplied by a hydraulic hose or tube which connects to the valve 34. The hydraulic actuator/motor used to turn the chuck head 31 is not visible in the Figures, however the general operation of hydraulic actuator/motors will be understood by those skilled in the art and therefore need not be described.

[0064] The chuck 30 is also configured to move along the chuck track 40·. It should be noted that the chuck track 40 is only represented schematically in Figure 3. The actual configuration and appearance of the chuck track 40 will therefore often differ from that shown in Figure 3. For example, the chuck 30 illustrated in Figures 8 and 9 is, in fact, configured to move along the chuck track 40 illustrated in Figure 13. The track 40 in Figure 13 comprises a pair of long cylindrical tracks 41 supported on a reinforced substructure.

[0065] The chuck 30 has four main runners 35 which are rotatably mounted to the body of the chuck 30. The runners 35 are shaped (curved) and positioned to allow the chuck 32 rest on, and roll back and forth along, the cylindrical tracks 41 of track 40. The chuck 30 also has four smaller stabilisers 36 (each one rotatably mounted beneath one of the runners 35). The stabilisers 36 can operate to secure and stabilise the chuck 30 on the track (e.g. as shown in Figure 3).

[0066] The operation of the apparatus and its various parts and components may be controlled in any suitable way. For example, manually operated levers or switches etc may be provided to control the various hydraulically, electrically (etc) driven parts of the apparatus. Alternatively, electronic or computerised controls may be provided. The electronic or computerised controls could have, for example, a control terminal from which an operator can control the apparatus and its various functions. The electronic or computerised controls may also provide/allow at least some degree of automation so that at least some functions of the apparatus are (or can be) performed automatically without requiring manual initiation and/or control by the operator, etc. In any case, the way in which the various functions performed by the apparatus are initiated by a user/operator, and the way in which the apparatus is controlled, is not narrowly critical to the invention.

[0067] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises a preferred form of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims

1. An apparatus for forming at least one helical groove in a rail, the apparatus comprising a groove forming portion and means for causing the rail to be conveyed and rotated relative to the groove forming portion such that at least one helical groove is formed in the rail as the rail is conveyed and rotated relative to the groove forming portion.

2. An apparatus as claimed in claim 1 further including one or more guides for guiding the rail into and/or through and/or over and/or off different parts or portions of the apparatus, or for otherwise guiding the rail relative to one or more parts or portions of the apparatus.

3. An apparatus as claimed in any one of the preceding claims wherein the means for causing the rail to be conveyed and rotated relative to the groove forming portion includes means for rotating the rail relative to the groove forming portion while the rail is in contact with the groove forming portion, whereby that contact imposes a longitudinal force on the rail thereby conveying the rail.

4. An apparatus as claimed in any one of the preceding claims wherein the groove forming portion includes one or more rollers operable to press against and/or press into the surface of the rail to create the one or more grooves.

5. An apparatus as claimed in claim 4 wherein a single roller is provided to create each groove in the rail.

6. An apparatus as claimed in claim 4 or 5 wherein- at least one roller is movable or removable to allow positioning of the rail relative to the groove forming portion and/or removal of the rail from the groove forming portion.

7. An apparatus as claimed in claim 6 comprising a plurality of rollers for forming a plurality of grooves in the rail, wherein when the rail is correctly positioned relative to the groove forming portion, each of the rollers which is movable or removable can be moved into position to press against the rail, and the pressure created when the movable roller(s) is/are moved into position to press against the rail causes other roller(s) to press against the rail as well.

8. An apparatus as claimed in any one of claims 4-7 wherein one or more rollers are adjustable to press harder, or less hard, against the surface of the rail, and/or to alter the roller orientation.

9. An apparatus as claimed in any one of claims 4-8 wherein the means for causing the rail to be conveyed and rotated relative to the groove forming portion includes means for rotating the rail relative to the groove forming portion while the rail is in contact with the one or more rollers, whereby the contact between the rail and the one or more rollers imposes a longitudinal force on the rail thereby conveying the rail.

10. An apparatus as claimed in claim 9, wherein the means for rotating the rail relative to the groove forming portion comprises a mechanism which can grip the rail and rotate while gripping the rail to thereby rotate the rail.

11. An apparatus as claimed in claim 10, wherein the said mechanism comprises a rotatably driven chuck, whereby the chuck is also operable to be conveyed as the rail is conveyed.

12. An apparatus as claimed in any one of claims 4-11 wherein the apparatus includes a body, the body having a hole therein which the rail can rotate within and pass through, wherein the one or more rollers are mounted relative to the body such that the rollers contact the rail and create the one or more helical grooves in the rail as the rail is conveyed and rotated relative to the hole.

13. An apparatus as claimed in claim 6, or as claimed in any one of claims 7-12 when read as dependent upon at least claim 6, comprising one or more said movable rollers and wherein a hydraulically operated piston is provided for moving each movable roller between a retracted position in which the said roller does not engage the rail and an extended position in which the said roller engages the rail.

14. An apparatus as claimed in any one of the preceding claims including a rail stand on which one or more rails can be stored or positioned before being caused to be conveyed and rotated relative to the groove forming portion.

15. A method for forming one or more helical grooves in a rail, the method including causing the rail to be conveyed and rotated relative to a groove forming portion of an apparatus such that one or more helical grooves are formed in the rail as the rail is conveyed and rotated relative to the apparatus' groove forming portion.

16. A method for forming one or more helical grooves in a rail using an apparatus, the method involving gripping one end of the rail, rotating the rail by the gripped end relative to a groove forming portion of the apparatus, the rail also being conveyed relative to the groove forming portion, so that the one or more helical grooves are formed as the rail is conveyed and rotated relative to the groove forming portion.

17. A method as claimed in claim 15 or 16 wherein the apparatus comprises an apparatus as claimed in any one of claims 1-14.

18. A method for forming one or more helical grooves in a rail using an apparatus as claimed in claim 14 with claim 14 read as dependent upon at least claims 13, 12, 11 and 6, the method comprising moving at least one movable roller to its retracted position, feeding a rail from the rail stand through the hole in the body so that the end of the rail protrudes through the hole, moving the at least one movable rolter to the extended position, gripping the end of the rail with the rotatable chuck, rotating the chuck thereby rotating the rail wherein,. ecause of the angle at which the rollers engage the rail, as the rail rotates the rollers impose a longitudinal force on the rail conveying the rail, and the rollers create helical grooves in the rail as the rail is conveyed and rotated.

19. A rail having at least one helical groove, wherein the at least one helical groove is formed using an apparatus as claimed in any one of claims 1-14.

20. A rail having at least one helical groove, wherein the at least one helical groove is formed using a method as claimed in any one of claims 15-18.