AU2016201112B2 - Knuckle for a rail wagon coupling - Google Patents

Abstract

Embodiments relate to a knuckle for a rail car coupler, the knuckle comprising a body defining a hook portion and a connecting portion connected to the hook portion; wherein the connecting portion is configured to connect the knuckle to a head of the coupler, the connecting portion comprising a tongue portion to be received in the head, the tongue portion attaching to a remainder of the connecting portion by a neck that is narrowed, at least in part, relative to the tongue portion and relative to shoulder portions of the connecting portion that are adjacent the neck; wherein the connecting portion comprises a gusset extending from one of the shoulder portions to the neck. N N ~ ~ tt 4' N N N N N t~*-1 ~-'Nt4 ~N ~' N 'Nt 1 F'", 41 'N \.jf ~, f 1 N ~'ri N" 'N N1 'V 7 "'~N N' '-'ni A N A 'S '4 A' rN/N "t0 4 Figure 2

Description

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"Knuckle for a rail wagon coupling"

Cross-Reference to Related Applications

[0001] The present application claims priority from Australian Provisional Patent Application No 2015900685 filed on 26 February 2015, the content of which is incorporated herein by reference.

Technical Field

[0002] Embodiments generally relate to rail wagon couplings and in particular to knuckles for such rail wagon couplings.

Background

[0003] Rail car couplers are used to join rail cars also called ("wagons") together. Each rail car has a coupler on each end to connect to the coupler of the rail car to which it is to be joined. The coupler is responsible for transferring the buff (compressive) and draft (tensile) forces between wagons when the train accelerates or decelerates.

[0004] Draft forces can be responsible for fatigue failure of a coupler. Such fatigue can occur in the knuckle in areas that come under particular stress.

[0005] It is desired to address or ameliorate one or more shortcomings associated with prior coupler knuckles, or to at least provide a useful alternative thereto.

[0006] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0007] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

Summary

[0008] Some embodiments relate to a knuckle for a rail car coupler, the knuckle comprising:

a body defining a hook portion and a connecting portion connected to the hook portion;

wherein the connecting portion is configured to connect the knuckle to a head of the coupler, the connecting portion comprising a tongue portion to be received in the head, the tongue portion attaching to a remainder of the connecting portion by a neck that is narrowed, at least in part, relative to the tongue portion and relative to shoulder portions of the connecting portion that are adjacent the neck;

wherein the connecting portion comprises a gusset extending from one of the shoulder portions to the neck, such that the one shoulder portion, the neck and the tongue together define a recessed area, and the gusset partly defines an end wall of the recessed area.

[0009] The gusset may form part of the neck. A thickness of a part of the neck that includes the gusset may be between about 50% and about 65% of a thickness across the shoulder portions.

[0010] The gusset may be integrally formed with the neck and the one shoulder portion. The neck may have a contact face that, in use of the knuckle, can come into contact with a knuckle of another rail car coupler, wherein the gusset partly defines the contact face.

[0011] The gusset and the tongue together may define a valley region wherein the gusset and the tongue each define a valley wall, and the neck and the recess between the tongue and shoulder may each define the end openings of the valley. The gusset and the tongue define the valley region at one end of the neck, with the valley region extending at an angle to the recessed area. The valley region may be defined by an inner face of the gusset and an angled vertical wall of the tongue.

[0012] A maximum depth of the gusset may be between about 10% and about 20% of a depth of the neck, wherein this depth decreases in a direction toward the tongue. A thickness of or gusset may be between about 15% and about 30% of a thickness of the neck adjacent the gusset.

[0013] The gusset may comprise a ramped section adjacent the one shoulder.

[0014] Some embodiments relate to a rail car coupler comprising the knuckle described above. Some embodiments relate to a rail car comprising the rail car coupler.

Brief Description of Drawings

[0015] Embodiments are described in further detail below, by way of example, and with reference to the accompanying drawings, in which:

[0016] Figure 1 is a perspective view of an example coupler for a rail car;

[0017] Figure 2 is a perspective view of a knuckle for the railcar coupler;

[0018] Figure 3 is a further perspective view of the knuckle of Figure 2;

[0019] Figure 4 is a side view of one side of the knuckle of Figure 2;

[0020] Figure 5 is a side view of the knuckle of Figure 2, viewed from an opposite side to that shown in Figure 4; and

[0021] Figure 6 is aplan view of the knuckle of Figure 2.

Description of Embodiments

[0022] Embodiments described herein generally relate to rail car couplers and in particular to improved knuckles for use in such rail car couplers.

[0023] An example rail car coupler 100 is shown in Figure 1. The rail car coupler 100 has a coupler head 110, a knuckle 120 partly received in and connected to the coupler head 110, and a coupler shank 130 connected to and extending away from the coupler head 110 for connection to the rail car. The coupler head 110 and knuckle 120 are configured to engage with a similarly configured coupler head and knuckle of a rail car coupler 100 of an adjacent rail car.

[0024] Knuckle 120 is connected to the coupler head 110 by a pin 121 extending through a bore 213 (Figure 2) of the knuckle and by complimentary mating structures (not shown) of the coupler head 110 and the knuckle 120. The knuckle 120 can, when not held in a closed and locked position by a locking member 112, rotate to an open position in which the knuckle of an adjacent coupler 100 can be readily received in a mouth of the coupler head 110. When two couplers 100 are moved towards each other for engagement, an outer face of the knuckle 120 of each coupler 100 abuts and is pushed inwardly by a ramped inner face of the mouth of the coupler head 110, which rotates the knuckle 120 from the open position towards the closed position. In the closed position, the knuckles 120 of opposed couplers 100 are locked against longitudinal separation by more than a small amount by mutual hooking of the knuckles 120. Vertical movement of the hooked knuckles 120 can occur to some degree to allow for some height variation of the end of each rail car as it travels along the rail tracks.

[0025] The knuckle 120 comprises a tongue 211 (Figures 2 to 6) that is received in a cavity defined in one side of the coupler head 110. When the knuckle 120 is rotated to an open position, the tongue 211 projects at least partly out of the cavity and obstructs the path of a locking block 112 received in a central part of the coupler head 110. When the knuckle 120 is rotated to the closed position, the tongue 211 moves relative to the locking block 112 so that the tongue 211 no longer blocks the path of the locking block. The locking block 112 thus drops down adjacent a part of the tongue 211 and locks the tongue from rotation back to the open position. In order to then unlock the knuckle 124 rotation back to the open position, the locking block 112 must be manually or automatically withdrawn to a position in which movement of the tongue 211 is no longer prevented.

[0026] Referring now to Figures 2 to 6, the knuckle 120 is shown and described in further detail. The knuckle 120 has a body 210, which may be formed as a unitary body, defining a hook portion 212 and a tongue 211. The body 210 also defines a hollow bore or shaft 213 for receiving a coupler pin 121 to facilitate the knuckle 120 rotating between open and closed positions. The bore 213 is defined in a generally central portion of the body 210, while the tongue 211 projects away from the central portion in a first direction and the hooked portion 212 projects away from the central portion in another (somewhat opposite) direction.

[0027] The tongue 211 is coupled to the central portion of the body 210 by a neck portion 230 that is narrowed along part of its extent relative to the tongue portion and relative to adjacent shoulder portions 215a, 215b of the body 210. An outer wall 234 of the first shoulder portion 215a is adjacent and partly defines one side of a recessed area 232. This recessed area 232 partly defines an upper part of the neck 230 and separates part of the tongue 211 from the shoulder

215a. This recessed area 232 is sized and configured to receive part of the complimentary locking structures of the coupler head 110 when the knuckle 120 is in the closed (locked) position.

[0028] The hook portion 212 has a greater height (or vertical extent) than most of the rest of the body of the knuckle 120 and defines a convexly curved outer face 214 and a concavely curved inner face 216. The inner face 216 is where significant contact occurs with corresponding faces of the knuckle of an adjacent coupler 100.

[0029] Because of the configuration of the hook portion 212 and the tongue 211 in relation to the central portion of the main body 210, significant draft forces are exerted on the inner face 216 and transferred to more central parts of the main body 210, such as areas adjacent an inner face of the body 210 near where the bore or shaft 213 is formed. Additionally, significant strain and fatigue is experienced in sections of the neck 230.

[0030] As shown in Figures 2 to 6, the knuckle 120 includes a gusset portion 240, that may be in the form of a projecting ridge segment or member joining the neck 230 and one of the shoulders. This gusset portion 240 extends between the neck 230 and the first shoulder portion 215a and assists to strengthen the neck 230 on an inner side 238 thereof where greater stress is experienced by the knuckle 120 during use. The gusset portion 240 may be integrally formed as part of the body 210. The gusset portion 240 may resemble a ridge, buttress or brace extending from the shoulder 215a and a part of the central portion of the body 210 adjacent the first shoulder 215a. The gusset portion 240 defines a ramped surface 241 that may be flat or contoured to generally rise upward toward the shoulder 215a. The gusset 240 may extend away from the shoulder 215a towards the tongue 211 by a distance of about 15 to 50mm, possibly 30 to 45mm. This length allows the neck 230 to be strengthened and reinforced in an area of the knuckle 120 that is subjected to significant stress and fatigue under draft forces, while minimising stress concentration between the vertical inner wall 235 of the tongue and the gusset 240 as a result of draft forces. The ramped surface 241 may be at an angle from horizontal (where horizontal is generally parallel to a lower face 231 of the neck and tongue) of about 25 to degrees, optionally around 30 to 40 degrees, optionally around 33 to 37 degrees. This angle increases the stiffness of the knuckle 120 specifically through the neck 230. An angle greater than defined may increase stresses between the vertical inner wall 235 of the tongue and the gusset 240 as a result of draft forces, whereas an angle less than defined may not provide sufficient stiffness to the knuckle 120 and therefore may not appreciably reduce stresses on the neck 238 under draft.

[0031] The upper face of the ramped surface 243 may be flat. Where the top of the ramped section 243 meets the shoulder 215a a radius 244 may be around 10 mm but could be lower, for example around 3 mm. The gusset 240 also defines an inner face 242 that transitions downwardly from the ramped surface 241 and the upper surface 243 in to a lower surface of the recessed area 233. In some embodiments, the inner face 242 may be substantially vertical. In some embodiments, the inner face 242 may generally rise upward toward the upper face of the gusset 243 and may be at an angle from horizontal of about 30 to 85 degrees, optionally around to 80 degrees, optionally around 65 to 70 degrees. This angle reduces stresses on the neck 238 under draft while still allowing the knuckle 120 to connect with the coupler head 110.

[0032] Where the ramped section 241 and inner face 242 meet the coupler neck 238 and the lower surface of the recessed area 233 a radius 246 may be around 15 mm but could be lower, for example around 3 mm.

[0033] On an opposite side of the gusset portion 240 from the inner face 242 is an outer face of the gusset portion 240 that is generally continuous with an inner contact face 238 of the neck 230. The contact face 238 of the neck may come into contact with a knuckle of another rail car coupler when the coupler 100 is engaged with another such coupler 100. The gusset 240 thus defines an outer face that is substantially continuous with an adjacent face 238 of the neck portion 230.

[0034] The recessed area 232 is partially closed at one end by the gusset 240 and open at an opposite end at the other side of the neck 230. The recess 232 is defined by wall 234, a recess floor 233 (which is also an upper surface of the neck 230) and a vertical inner wall 235 of the tongue 211 that transitions down into the recessed area 232 from the upper face 211a. The vertical inner wall 235 transitions into the neck surface 238 via another vertical wall 251 that is adjacent the vertical wall 235 and the neck surface 238 and angled relative thereto. The angle (shown in Figure 6 as the dimension W) between the wall 251 and the side face 21lb of the tongue may be about 30 to 80 degrees, optionally around 45 to 65 degrees, optionally around 47 to 53 degrees. This angle W allows for the ramped surface 241 of the gusset 240 sufficient distance and angle to minimise neck stresses under draft while still allowing the coupler head 110 to connect with the vertical inner wall 235 completely.

[0035] The gusset 240 and the tongue 211 together may define a short valley region 245 wherein the gusset ramped surface 241 and the tongue vertical wall 251 each define a valley wall. The valley wall defined by the gusset ramped surface 241 may transition to the gusset inner face 242. One end of the valley 245 may be continuous with and open into the recessed area 232. The other end opening of the valley 245 may be defined by the neck 238 and the side face 21lb of the tongue. In some embodiments, the centreline of the valley region 245 may be at the angle W. In other embodiments, the angle of the centreline of the valley region 245 to the side face 21lb of the tongue may differ to the angle between the wall 251 and the side face 21lb of the tongue yet may remain within the range of values specified for W. Where the vertical wall 251 meets the floor of the valley region 245, a radius of curvature 252 may be around 10 mm but could be lower, for example around 3 mm.

[0036] In some embodiments, the thickness of the part of the neck 230 that includes the gusset 240 may be between about 50% and about 65% (optionally about 52% to about 63%, optionally about 56% to about 59%) of the thickness across the shoulder portions 215a and 215b. For example, the thickness across the shoulder portions 215a, 215b (shown in Figure 5 as the dimension Z, coinciding with the distance between the flat surfaces adjacent the bore apertures and the length of the bore or hollow shaft 213) may be about 160 to 170 millimetres, while the thickness of the part of the neck 230 that includes the gusset (shown in Figure 4 as Y) may be about 84 to about 104 millimetres. The part of the neck that does not include the gusset 240 is shown in Figure 5 as having a thickness X. The thickness X may be about 74 to 86 mm, for example. The gusset 240 may extend the thickness of the neck (on the end of the neck 230 where the gusset 240 is positioned) by an amount (Y-X) between about 2 millimetres and about millimetres, optionally between about 10 or 25 millimetres, optionally around 20 or 23 millimetres. This extension of the thickness of the neck 230 on the inner side of the neck 230 by the presence of the gusset 240 thus serves to strengthen and reinforce an area of the knuckle 120 that is subjected to significant stress and fatigue under draft forces. The maximum thickness of the neck (on the one end of the neck 230 where the gusset 240 is positioned) is limited by the geometry of the coupler head 110.

[0037] The (vertical) thickness of the neck 230 described above is the vertical dimension most easily seen in Figure 4 as the distance between the upper face 243 of the gusset 240 and the lower face 231 of the neck and tongue adjacent to the second shoulder portion 215b. In contrast, a depth of the gusset 240 as a proportion of the depth of the neck 230 across the inner face 238 to the outer face 239, at its thickest may be between about 10% and about 20% of the depth of the neck 230. This is most easily seen in Figure 6. In some embodiments, the depth of the gusset 240 defined by the gusset inner face 242 may vary at an angle to the side face 21lb of the tongue. In some embodiments, this angle may be equal to W, while in other embodiments, this angle may differ to the angle between the wall 251 and the side face 21lb of the tongue yet may remain within the range of values specified for W. In some embodiments, the maximum depth (or lateral thickness) of the gusset 240 may be between 5 and about 20 millimetres, optionally between about 13 and about 18 millimetres, optionally around 16 millimetres. The depth of the neck 230 between inner face 238 and outer face 239 may be approximately 100 to 110 millimetres at positions generally corresponding to a centre line of the recessed area 232.

[0038] As is also evident in Figure 6, the bore or hollow shaft 213 defined in the central part of the body 210 may not have a circular cross section. A centre 213a of the bore may not be positioned precisely in the middle of the central part of the body 210. For example, a minimum thickness of the body 210 between the bore 213 and a closest point to the outer surface of the body 210 may be between 80% and 90% of the minimum thickness between the bore 213 and the closest part of the inner surface of the main body. The main body may thus be relatively thicker in an area toward its concave inner curved surfaces that may experience greater stress due to draft forces.

[0039] The transition of the upper face 211a of the tongue 211 down into the recessed area 232 creates a pulling lug that, in use of the knuckle in the locked position in the coupler head, engages with a corresponding pulling surface of the coupler head when under draft load. By positioning the gusset portion 240 as an extension of the neck 230 along its inner wall, this provides greater structural strength across the neck 230 where it is adjacent the upper shoulder 215a. Such additional structural strength assists in transferring a draft force reaction from the pulling lug (defined by surfaces 235 and 211a) to the knuckle engagement face 216. The gusset portion 240 also serves to increase the cross sectional width of the neck 230 in a position that is subject to significant stress and fatigue. The cross sectional width of the neck (where the gusset 240 is present) is increased in the order of about 20%, which results in an increased load capacity of the knuckle and a greater fatigue limit. Testing has shown that peak stresses in the neck region where the gusset 240 is positioned are reduced in the order of 15% due to the presence of the gusset 240.

[0040] Additionally, the centre line of the knuckle neck is more centralised and aligned to the centre line of the knuckle shoulders, at least across the inner concave engagement face of the knuckle (including inner face 238). This results in a more symmetric transfer and distribution of load forces through the knuckle to the coupler, which can provide increased load capacity of the knuckle and increased life of the knuckle prior to fatigue failure.

[0041] Embodiments are described herein by way of example and not by limitation to those specific features or dimensions described herein. The described embodiments should be treated as being illustrated an exemplary rather than being limiting on the scope of the present disclosure.

Claims (13)

CLAIMS:

1. A knuckle for a rail car coupler, the knuckle comprising: a body defining a hook portion and a connecting portion connected to the hook portion; wherein the connecting portion is configured to connect the knuckle to a head of the coupler, the connecting portion comprising a tongue portion to be received in the head, the tongue portion attaching to a remainder of the connecting portion by a neck that is narrowed, at least in part, relative to the tongue portion and relative to shoulder portions of the connecting portion that are adjacent the neck; wherein the connecting portion comprises a gusset extending from one of the shoulder portions to the neck, and wherein the one shoulder portion, the neck and the tongue together define a recessed area, and the gusset partly defines an end wall of the recessed area.

2. The knuckle of claim 1, wherein the gusset forms part of the neck.

3. The knuckle of claim 2, wherein a thickness of a part of the neck that includes the gusset is between about 50% and about 65% of a thickness across the shoulder portions.

4. The knuckle of any one of the preceding claims, wherein the gusset and the tongue further define a valley region at one end of the neck, the valley region extending at an angle to the recessed area.

5. The knuckle of claim 4, wherein the valley region is defined by an inner face of the gusset and an angled vertical wall of the tongue.

6. The knuckle of any one of the preceding claims, wherein the neck has a contact face that, in use of the knuckle, can come into contact with a knuckle of another rail car coupler, wherein the gusset partly defines the contact face.

7. The knuckle of claim 6, wherein the gusset defines an outer face that is substantially continuous with an adjacent face of the neck.

8. The knuckle of any one of the preceding claims, wherein the gusset is integrally formed with the neck and the one shoulder portion.

9. The knuckle of any one of the preceding claims, wherein a depth of the gusset is between about 10% and about 20% of a depth of the neck.

10. The knuckle of any one of the preceding claims, wherein a thickness of the gusset is between about 10% and about 30% of a thickness of the neck adjacent the gusset.

11. The knuckle of any one of the preceding claims, wherein the gusset comprises a ramped section adjacent the one shoulder.

12. A rail car coupler comprising the knuckle of any one of the preceding claims.

13. A rail car comprising the rail car coupler of claim 12.