WO2022221606A1 - Procédé de modification de wagons porte-rails à corps en aluminium, wagons porte-rails modifiés ainsi formés et accouplement par plaque d'assemblage de câble supérieur en aluminium utilisé dans ces derniers - Google Patents

Procédé de modification de wagons porte-rails à corps en aluminium, wagons porte-rails modifiés ainsi formés et accouplement par plaque d'assemblage de câble supérieur en aluminium utilisé dans ces derniers Download PDF

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Publication number
WO2022221606A1
WO2022221606A1 PCT/US2022/024932 US2022024932W WO2022221606A1 WO 2022221606 A1 WO2022221606 A1 WO 2022221606A1 US 2022024932 W US2022024932 W US 2022024932W WO 2022221606 A1 WO2022221606 A1 WO 2022221606A1
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WO
WIPO (PCT)
Prior art keywords
floor construction
hopper
railcar
car
modified
Prior art date
Application number
PCT/US2022/024932
Other languages
English (en)
Inventor
Michael H. Kress
Douglas M Jenkins
Gregory P. Josephson
Original Assignee
Jac Operations, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jac Operations, Inc. filed Critical Jac Operations, Inc.
Publication of WO2022221606A1 publication Critical patent/WO2022221606A1/fr
Priority to US18/380,329 priority Critical patent/US20240140496A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D7/00—Hopper cars
    • B61D7/02—Hopper cars with discharge openings in the bottoms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B61D17/10—Floors

Definitions

  • the present invention relates to railroad car modifications, and more particularly to a modification of aluminum body railcars and the modified railcars formed thereby.
  • Modification is Association of American Railroads (AAR) defined term (see Office Manual of the AAR Interchange Rules, rule 88(d)(2)) defined as a change to a car that alters capacity of car, or size of car type, or type of lading being hauled.
  • AAR Association of American Railroads
  • Rule 88(d)(2) Office Manual of the AAR Interchange Rules, rule 88(d)(2)
  • the repurposing or modification of the small cube covered hopper railcars in accordance with the invention will structurally alter the railcar in a manner that alters the capacity of the car, the size of the car, or operational characteristics of the car, or the general car type, or type of lading being hauled.
  • One aspect of the present invention is a top chord splice used in some of the modified railcars formed according to some of the methods of the present invention and this top chord splice can have separate application in the repair of aluminum top chords outside of modifications programs.
  • One aspect of the invention provides a method of modification of a railcar to form a modified railcar can be described as comprising the steps of i) Providing an existing aluminum body steel underframe donor railcar supported on a pair of trucks, such as shown in figures 1A and B and 2A and B; ii) Removing a donor car floor construction including either a) hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floors forming the hopper chutes of the hopper style donor railcar, or b) the floor sheets and tubs of the gondola style donor cars; iii) Forming a floor construction of the modified railcar which includes one of a) triple hopper independent transverse door floor construction, b) quad hopper independent transverse door floor construction, c) dual hopper independent longitudinal door floor construction, or d) flat bottom gondola floor construction, and iv) attaching the floor construction to the car to form the modified railcar.
  • Figure 1 is a schematic perspective view of an aluminum body steel underframe five hopper railcar acting as one type of donor car in a method of repurposing aluminum body railcars according to the present invention.
  • Figure 2 is schematic perspective view of an aluminum body steel underframe tub bottom gondola railcar acting as one type of donor car in a method of repurposing aluminum body railcars according to the present invention.
  • Figure 3 is a schematic perspective view of an existing prior art triple hopper independent transverse door floor construction intended to be mimicked by a floor construction in a method of repurposing aluminum body donor railcars according to one embodiment of the present invention.
  • Figure 4A is a schematic side elevational view of a triple hopper independent transverse door modified railcar according to one embodiment of the present invention.
  • Figure 4B is a side elevational view of a donor car of figure 1 with a central portion removed with an overlay of a floor construction to mimic an existing triple hopper independent transverse door railcar according to one embodiment of the present invention.
  • Figure 4C is a side elevational view of a donor car also illustrating a central portion to be removed.
  • Figure 5 is a schematic perspective view of an independent door system for a triple hopper independent transverse door modified railcar according to one embodiment of the present invention.
  • Figures 6A and B are schematic side elevational views of a triple hopper independent transverse door modified railcar and a side elevational view of a donor car of figure 1 with an overlay of a quad hopper independent door floor construction, respectively, according to another embodiment of the present invention.
  • Figures 7A, 7B and 7C are schematic perspective view, section view and top plan view, respectively of an existing prior art dual hopper independent longitudinal door floor construction intended to be mimicked by a floor construction in a method of repurposing Aluminum body railcars according to one embodiment of the present invention.
  • Figure 8A is a schematic side elevational view of a dual hopper independent longitudinal door modified railcar according to the present invention.
  • Figure 8B a side elevational view of a donor car of figure 1 with a central portion removed with an overlay of a floor construction to mimic the existing dual hopper independent longitudinal door railcar according to one embodiment of the present invention.
  • FIGURE 8C is a side elevational view of a donor car also illustrating a central portion to be removed.
  • Figures 9A-C is a schematic side elevational of a modified flat bottom gondola railcar, a side elevational view a floor construction to mimic the existing prior art flat bottom gondola railcar, and a side view of a donor car with an overlay of the floor construction to mimic the prior art flat bottom gondola railcar, respectively, according to one embodiment of the present invention.
  • Figure 10 is a schematic perspective section view of s flat bottom gondola modified railcar according to one embodiment of the present invention.
  • Figure 11 is a perspective view of a top chord splice casting for use with splicing the top chord in certain methods of the present invention.
  • Figure 12 is a cross-section elevation view of the top chord splice casting of figure 11.
  • Figures 13A and B are top and side sectional views of the top chord splice casting of figure 11 .
  • Figures 14 A and B are schematic perspective views of the insertion of the top chord splice casting of figure 11 into a top chord to be spliced.
  • Figures 15 A and 15B are side elevation and section views of a side sill splicing according to one embodiment of the present invention
  • FIG. 1 is a schematic perspective view of an aluminum body steel underframe five hopper railcar 10 acting as one type of donor car 10 in a method of repurposing aluminum body railcars according to the present invention.
  • This type of donor car 10 has been sold under the AUTOFLOODTM brand by Freightcar America.
  • the terms “railcar”, “car” and “rail car” are used interchangeably representing rolling rail stock.
  • Figure 2 show an aluminum body steel underframe tub bottom gondola railcar 10 acting as one type of donor car 10 in a method of repurposing aluminum body railcars 10 according to the present invention.
  • This very successful car type 10 was developed in the mid-1970s by Bethlehem Steel Corporation, as generally shown in U.S. Patent 4,361 ,097 which is incorporated herein by reference, and sold under the BETHGON® (I and II) brands. The modifications set forth herein will allow these cars 10 to have a longer extended productive life.
  • the donor cars 10of figures 1 and 2 can be categorized as 4000+ cubic foot capacity, Primarily Aluminum body with steel underframe design with an open top in a hopper or gondola style car type.
  • the method of modification of a railcar 10 to form a modified railcar 100 can be described as comprising the steps of i) Providing an existing aluminum body steel underframe donor railcar 10 supported on a pair of trucks 12, such as shown in figures 1 and 2; ii) Removing a donor car floor construction including either a) hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floors forming the hopper chutes of the hopper style donor railcar, or b) the floor sheets and tubs of the gondola style donor cars; iii) Forming a floor construction of the modified railcar 100 which includes one of a) triple hopper independent transverse door floor construction 110, b) quad hopper independent transverse door floor construction 120, c) dual hopper independent longitudinal door floor construction 130, or d) flat bottom gondola floor construction 140, and iv) attaching the floor construction to the car to form the modified railcar 100. Where the modified railcar 100 is a covered hopper car the method further includes the
  • the removing of the donor car 10 floor construction depends upon the donor car 10 type.
  • this includes removing the hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floors forming the hopper chutes.
  • this step entails the floor sheets and tubs of the gondola style donor cars 10 of figure 2.
  • a central portion 14 of the car 10 body is removed and the top chord 18 side walls and side sill 20 are spliced back together as discussed in detail below.
  • the removed material is scrapped.
  • the first modified railcar 100 of the present invention is a modified triple hopper independent transverse door railcar 100 with floor construction 110.
  • Figure 3 is a schematic perspective view of an existing prior art triple hopper independent transverse door floor construction 110’ intended to be mimicked with the floor construction 110 in a method of repurposing aluminum body donor railcars 10 to form the modified triple hopper independent transverse door railcar 100 according to one embodiment of the present invention.
  • the method includes forming a triple hopper independent transverse door floor construction 110 that mimics the arrangement or structure 110’ in figure 3 and is shown in Figures 4A and 4B.
  • Figures 4A and 4B are a schematic side elevational view of the triple hopper independent transverse door modified railcar, and a side elevational view of a donor car of figure 1 with a central portion removed with an overlay of a floor construction 110 to mimic the existing triple hopper independent transverse door railcar according to one embodiment of the present invention.
  • the modified railcar 100 will have a 31-11 1 ⁇ 2” truck center to truck center distance and the existing prior art triple hopper independent transverse door floor construction intended to be mimicked in this method has a 31-11 1 ⁇ 2” truck center to truck center distance.
  • This matching is achieved through a removals of an 8’-61/2” center section 14 as shown in figure 4C from the 40’-6” truck to truck length of the donor car 10.
  • the triple hoppers of the modified car 100 are independently operated to give greater flexibility to the discharge capabilities and the laden than may be carried.
  • the individual door systems 112 may be, for representative example, those disclosed in U.S. Patent 7,832,340 which is incorporated herein by reference.
  • the controls for the triple hopper doors may be push button actuation to operate the doors individually or all simultaneously.
  • Figure 5 is a schematic perspective view of an independent door system 112 for the triple hopper independent transverse door modified railcar according to this embodiment of the present invention.
  • Each door segment includes a pair of doors on opposed sides of the center sill which are connected through a door spreader.
  • the door operating system 112 is connected to the door spreader through an adjustable spreader fulcrum in which the sliding adjustment may add in a proper connection force or tension between the door operating system and the individual doors.
  • the main body of the individual pneumatic door operating system 112 can be completely preassembled.
  • the completed assembly 112 is mounted under the bottom surface of the railcar center sill and connected to the spreader fulcrum through a linkage arm.
  • the main body essentially consists of mounting side frame angles, one double acting pneumatic cylinder rotationally mounted in the side frame angles with a slotted cylinder nose clevis applied to the end of the cylinder shaft, one cylinder lever rotationally attached to the side frame angles and to the slotted nose clevis, at least one door spreader lever extending between the cylinder lever and the spreader fulcrum, a secondary lock mounted on the side frame angles at a position that can engage with the door structure when the doors are in a closed position, an indicator on the side frame angles that indicates the status of the secondary door lock, a cylinder fulcrum pin for rotationally mounting the cylinder to the side frame angles, a cylinder lever fulcrum pin for rotationally mounting the door spreader lever to the cylinder lever, and a door ful
  • the individual automatic door operating system 112 of the present invention can be activated by several different methods, examples of these are, air activated push buttons, electrically charged hot shoe or pads, mechanical linkages, and all known methods of activating the cars auxiliary air or way side air supply.
  • the particular activation and control system is up to the individual user. It is anticipated that multiple door operating cylinders of the modified railcar may be selected to be operated together by the control.
  • the linking of two or more door operating systems of the present invention do not make them less independent in that they can easily be designed for individual operation.
  • the independent door system 112 for the triple hopper independent transverse door modified railcar provides an effective efficient door operating system that can control the unloading by an individual hopper pocket (pair of doors), or all hoppers at once.
  • the present system eliminates injury associated with manual individual door actuators.
  • a double hopper door locking system is proposed, with the first being the cylinder and door lever’s over center position, and the second being the secondary locking.
  • the triple hopper independent transverse door floor construction 110 includes the three independent doors with two intervening partition floors.
  • the partition floors include apex brace elements extending to the donor car sidewall structure and two supporting gussets.
  • the triple hopper independent transverse door floor construction also includes lower hopper floor that is coupled to the end floor of the donor car.
  • the triple hopper independent transverse door floor construction 110 increases the slope of the hoppers to about 55-65 degrees (+/- 3 degrees).
  • the floor construction is preferably a stainless steel or a copper containing or copper bearing steel construction to inhibit corrosion. Copper containing or copper bearing steel references a copper content of the steel of at least 0.2% within the meaning of this application.
  • the present invention contemplates supplying a coating to the remaining interior of the donor car with a corrosion inhibiting coating (also called a lining).
  • This modified car may be an open hopper or a closed hopper with a roof.
  • the second modified railcar 100 family of the present invention is a modified quad hopper independent transverse door railcar 100. This design is similar to the original modification except that no splicing is required. Another hopper and independent door is added to the design.
  • Figures 6A and 6B are a schematic side elevational view of the triple hopper independent transverse door railcar 100 (for comparison), and a side elevational view of a donor car 10 of figure 1 with an overlay of the quad hopper independent door floor construction 120.
  • the doors and individual hoppers operate analogous to the triple hopper railcar, except the length is significantly longer as the length of the modified railcar 100 remains the same as the donor car 10 as there is no removed section.
  • This modified railcar 100 may be an open hopper design or a closed hopper design with a roof and an interior coating or liner may be added to the remaining donor car interior space forming parts.
  • the third family of modified railcar 100 of the present invention is a modified dual hopper independent longitudinal door railcar 100.
  • Figures 7A, 7B and 7C are schematic perspective view, section view and top plan view, respectively, of an existing prior art dual hopper independent longitudinal door floor construction 130’ intended to be mimicked by floor construction 130 in a method of repurposing aluminum body railcars 10 according to one embodiment of the present invention using a dual hopper independent longitudinal door floor construction 130.
  • Figures 8A is a schematic side elevational view of the dual hopper independent longitudinal door modified railcar 100.
  • Figure 8B is a side elevational view of a donor car 10 of figure 1 with a central portion 14 removed and with an overlay of a floor construction 130 to mimic the existing dual hopper independent longitudinal door railcar according to one embodiment of the present invention.
  • Figure 8C is a side elevational view of a donor car 10 illustrating the central portion 14 to be removed when forming the railcar 100 using the floor construction 130.
  • the modified railcar 100 will have a 31-11 1 ⁇ 2” truck center to truck center distance and the existing prior art triple hopper independent transverse door floor construction intended to be mimicked in this method has a 31-11 1 ⁇ 2” truck center to truck center distance.
  • the longitudinal doors of the floor construction 130 are analogous to the transverse doors above other than longitudinal orientation and individual door length. They offer independent operation as in the front two and back two doors can be independently operated. Independent operation is critical where a dump site can only take one hopper at a time such as due to size restrictions.
  • the dual hopper independent longitudinal door floor construction will form hopper chutes that are steeper than the donor cars as shown and may include use of corrosion inhibiting components.
  • the dual hopper independent longitudinal door floor construction 130 will couple to the sidewalls and end sheets of the donor car 10 to form the modified dual hopper independent longitudinal door railcar 100.
  • the dual hopper independent longitudinal door floor construction 130 may include a partition along the splice section of the modified car 100.
  • This modified railcar 100 may be an open hopper design or a closed hopper design with a roof.
  • An interior coating or liner may be added to the remaining donor car interior space forming parts.
  • FIG. 9A-C includes a schematic side elevational of a flat bottom gondola modified railcar 100, a side elevational view a floor construction 140 to mimic the existing prior art flat bottom gondola railcar and schematic side view of the donor car 10 with an overlay of the floor construction 140 to mimic the prior art flat bottom gondola railcar according to one embodiment of the present invention.
  • the flat bottom gondola modified railcar 100 is useful where the car 100 is to be unloaded in an as needed basis by a backhoe or the like, such as when the railcar 100 is being used to sequentially fill a series of dump trucks to carry the laden to a use site.
  • Figure 10 is a schematic perspective section view of the flat bottom gondola modified railcar 100 according to one embodiment of the present invention.
  • the flat bottom gondola floor construction 140 will couple to the sidewalls and to the bolster web of the donor car 10 to form the modified flat bottom gondola railcar 100 as outlined in figure 10.
  • the bolster web becomes part of the elements defining the interior laden carrying space in the modified railcar 100.
  • This modified railcar 100 will generally be an open hopper design as shown. It is possible, such as for light weight laden that is unloaded via a suction tube, that a roof design could be added.
  • Figures 11-13 illustrate a six fastener aluminum top chord splice casting 200 for use with splicing the top chord 18 in certain methods of the present invention, specifically those associated with the triple hopper transverse door and the dual hopper longitudinal door methodologies discussed above.
  • the six fastener aluminum top chord splice casting 200 will also have other application such as in repairs of damaged top chords 18.
  • the aluminum casting 200 is formed as a closed section with a reinforcing rib and boss members at bolt receiving holes.
  • the casting 200 is sized to fit within the top chord 18 in a close fitting relationship and has six reinforced fastener holes for bolts or the like.
  • the casting 200 is inserted in to one spliced top chord section 18 and bolted into place.
  • Appropriate bolt holes must be formed in the top chord section 18, generally by using the splice casting 200 as a guide.
  • the second top chord 18 is placed over the casting 200 and it too is bolted into place.
  • the splice can be completed with a weld.
  • the top chord splice casting 200 creates a reinforced splice joint that is generally stronger than the original top chord.
  • the top chord 18 can be removed and shortened and replaced or removed and replaced.
  • the top chord 18 is removed from only one half of the donor car 10 and the removed center section 14 and remains on a portion of the donor car 10 throughout the procedure and it is shortened to length and reattached to the modified car 100.
  • the splicing casting 200 discussed above is generally deemed more efficient than these alternatives.
  • Figures 15A and 15B illustrates the side sill 20 and sidewall splicing according to one embodiment of the present invention, specifically those associated with the dual hopper or tripple hopper modified railcars.
  • the key to the side sill 20 splice is the inclusion of a side sill reinforcing splice angle extending across the splice joint beneath the side sill and bolted to each side sill portion.
  • Angled patch plates 212 are bolted on either side of the splice joint as shown and coupled to the side sill 20.
  • a side stake 210 is placed over the sidewall splice connection and coupled to the patch plates 212. The abutting side sills 20 and side walls will be welded together prior to placement of the overlapping side stake 210.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Transportation (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Machines For Laying And Maintaining Railways (AREA)

Abstract

Un procédé de modification d'un wagon porte-rails pour former un wagon porte-rails modifié peut être décrit comme comprenant les étapes consistant i) à fournir un wagon porte-rails donneur à châssis en acier à corps en aluminium existant soutenu sur une paire de bogies ; ii) à retirer une construction de plancher de voiture donneuse comprenant soit a) des registres de vidange de trémie, et les plaques de fond extérieures, le plancher de trémie inférieur et les planchers de séparation formant les goulottes de trémie du wagon porte-rails donneur de type trémie, ou b) les tôles de plancher et les wagonnets des voitures donneuses de type wagon-tombereau ; iii) à former une construction de plancher du wagon porte-rails modifié qui comprend ia) une construction de plancher de porte transversale indépendante d'une triple trémie, ou b) une construction de plancher de porte transversale indépendante d'une quadruple trémie, ou, c) une construction de plancher de porte longitudinale indépendante d'une double trémie, ou d) une construction de plancher de wagon-tombereau inférieure plate, et iv) à fixer la construction de plancher sur la voiture pour former le wagon portes-rails modifié.
PCT/US2022/024932 2021-04-14 2022-04-14 Procédé de modification de wagons porte-rails à corps en aluminium, wagons porte-rails modifiés ainsi formés et accouplement par plaque d'assemblage de câble supérieur en aluminium utilisé dans ces derniers WO2022221606A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US18/380,329 US20240140496A1 (en) 2021-04-14 2023-10-16 Method of modifying aluminum body railcars, modified railcars formed thereby and aluminum top cord splice coupling used therein

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202163175046P 2021-04-14 2021-04-14
US63/175,046 2021-04-14

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US18/380,329 Continuation US20240140496A1 (en) 2021-04-14 2023-10-16 Method of modifying aluminum body railcars, modified railcars formed thereby and aluminum top cord splice coupling used therein

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WO2022221606A1 true WO2022221606A1 (fr) 2022-10-20

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PCT/US2022/024932 WO2022221606A1 (fr) 2021-04-14 2022-04-14 Procédé de modification de wagons porte-rails à corps en aluminium, wagons porte-rails modifiés ainsi formés et accouplement par plaque d'assemblage de câble supérieur en aluminium utilisé dans ces derniers

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5341747A (en) * 1991-11-21 1994-08-30 Trinity Industries, Inc. Railway gondola car
US6502518B1 (en) * 1999-07-13 2003-01-07 Jac Patent Company Converted multiple hopper rail car and method for making same
US20060207472A1 (en) * 2005-03-17 2006-09-21 Trn Business Trust Railway cars with combined material structures and method
US9272717B2 (en) * 2006-09-08 2016-03-01 National Steel Car Limited Rail road hopper car ridge fittings
US20210009169A1 (en) * 2018-03-30 2021-01-14 Jac Operations, Inc. Method and cast components for cold formed center sill rail car modification programs and railcars formed thereby

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5341747A (en) * 1991-11-21 1994-08-30 Trinity Industries, Inc. Railway gondola car
US6502518B1 (en) * 1999-07-13 2003-01-07 Jac Patent Company Converted multiple hopper rail car and method for making same
US20060207472A1 (en) * 2005-03-17 2006-09-21 Trn Business Trust Railway cars with combined material structures and method
US9272717B2 (en) * 2006-09-08 2016-03-01 National Steel Car Limited Rail road hopper car ridge fittings
US20210009169A1 (en) * 2018-03-30 2021-01-14 Jac Operations, Inc. Method and cast components for cold formed center sill rail car modification programs and railcars formed thereby

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