The present invention is related to an actuating mechanism of automatic sliding doors on railroad hopper cars.
This background is provided merely to assist with understanding the invention and its application and uses, and may not constitute prior art.
A hopper car or hopper wagon is a type of railroad freight car used to transport loose bulk commodities such as coal, ore, grain, and track ballast. Hopper cars can include covered hopper cars, which are equipped with a roof, and open hopper cars, which do not have a roof. Covered hopper cars are used for bulk cargo such as grain, sugar, and fertilizer that must be protected from exposure to the weather. Open hopper cars are used for commodities such as coal, which can suffer exposure with less detrimental effect to the cargo.
In addition to top hopper covers, hopper cars have doors or gates on the bottom for material discharge and unloading. For example, gravity-based bottom gates consists of a sliding metal plate at the bottom of each hopper, and such sliding doors can be opened and closed to allow materials to flow out by means of gravity. Conventionally there have been various methods of operating bottom sliding doors on railroad hopper cars. For example, a bar can be used to manually open the doors, but this is labor intensive, difficult, dirty, and subjects the operator to potential back injuries. Another method uses an air-powered wrench to open the sliding door. This too may cause back injuries to the operator. Yet another method uses an air-powered wrench that follows along the side of the hopper car as it is moving over a receiving bin. All of these methods are time-consuming and complex to operate.
Therefore, there is an unsolved need for methods and systems which can replace existing traditional methods to simplify the operation of bottom hopper doors, making the opening and closing of hopper doors less time consuming and less likely to cause injuries to operators. It is against this background that the present invention was developed.
The brief summary is intended to provide a broad overview of the invention and its illustrative embodiments, applications and uses, and is not intended to be read as limiting the scope of the invention or this disclosure.
In one aspect, one embodiment of the present invention is an apparatus for a sliding door actuating mechanism on a hopper car. The apparatus includes a cylinder, having a first cap end and a second rod end, where the first cap end of the cylinder is mounted on the hopper car; an actuating reinforcer, where a first end of the actuating reinforcer is coupled to a clevis on the second rod end of the cylinder; a main shaft, coupled to a second end of the actuating reinforcer; an operating lever, where a first end of the operating lever is coupled to the main shaft; a connecting link, where a first end of the connecting link is coupled to a second end of the operating lever; and a door pan fulcrum, coupled to a second end of the connecting link.
In some embodiments, the main shaft is rotatably coupled to the second end of the actuating reinforcer. In some embodiments, the first end of the operating lever is rotatably coupled to the main shaft.
In some embodiments, the apparatus further includes a shaft reinforcer, coupled with an end of the main shaft.
In some embodiments, the apparatus further includes at least two longitudinal mechanism support components, where each longitudinal mechanism support component has two given ends, where at least one of the two given ends is attached to a hopper wall of the hopper car, where the main shaft is placed along a transverse axis of the hopper car, and where the main shaft is mounted onto the at least two longitudinal mechanism support components.
In some embodiments, the door pan fulcrum is coupled to a door of the hopper car. In some embodiments, the door is a bottom sliding door.
In a second aspect, one embodiment of the present invention is a hopper car. The hopper car includes a hopper car body having a hopper and an apparatus for a sliding door actuating mechanism. The apparatus includes a cylinder, having a first cap end and a second rod end, where the first cap end of the cylinder is mounted on the hopper car; an actuating reinforcer, where a first end of the actuating reinforcer is coupled to a clevis on the second rod end of the cylinder; a main shaft, coupled to a second end of the actuating reinforcer; an operating lever, where a first end of the operating lever is coupled to the main shaft; a connecting link, where a first end of the connecting link is coupled to a second end of the operating lever; and a door pan fulcrum, coupled to a second end of the connecting link.
In some embodiments, the main shaft is rotatably coupled to the second end of the actuating reinforcer. In some embodiments, the first end of the operating lever is rotatably coupled to the main shaft.
In some embodiments, the hopper car further includes a shaft reinforcer, coupled with an end of the main shaft.
In some embodiments, the hopper car further includes at least two longitudinal mechanism support components, where each longitudinal mechanism support component has two given ends, where at least one of the two given ends is attached to a hopper wall of the hopper car, where the main shaft is placed along a transverse axis of the hopper car, and where the main shaft is mounted onto the at least two longitudinal mechanism support components.
In some embodiments, the door pan fulcrum is coupled to a door of the hopper. In some embodiments, the door is a bottom sliding door.
Other embodiments of the present invention include the methods and modes of operation of the systems and devices describes herein. Yet other embodiments will become apparent from reading the detailed description and accompanying drawings.
Embodiments of the present invention described herein are exemplary, and not restrictive. Embodiments will now be described, by way of examples, with reference to the accompanying drawings. In these drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like reference character. For purposes of clarity, not every component is labeled in every drawing. The drawings are not necessarily drawn to scale, and any exemplary dimensions are provided for illustrative purpose only, with emphasis instead being placed on illustrating various aspects of the techniques and devices described herein.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details. In other instances, structures, devices, activities, and methods are shown using schematics, use cases, and/or flow diagrams in order to avoid obscuring the invention. Although the following description contains many specifics for the purposes of illustration, anyone skilled in the art will appreciate that many variations and/or alterations to suggested details are within the scope of the present invention. Similarly, although many of the features of the present invention are described in terms of each other, or in conjunction with each other, one skilled in the art will appreciate that many of these features can be provided independently of other features. Accordingly, this description of the invention is set forth without any loss of generality to, and without imposing limitations upon, the invention. Furthermore, in the descriptions and in the claims which follow, the use of such words as “left”, “right”, “clockwise”, “counterclockwise”, “distal”, “proximal”, “forward”, “outward”, “rearward”, “vertical”, “horizontal”, and the like is in conjunction with the drawings for purposes of clarity.
As noted, a hopper car or hopper wagon is a type of railroad freight car used to transport loose bulk commodities. Hopper cars can have top covers and hatch doors for material intake, as well as bottom doors or gates for material discharge and unloading. For example, gravity-based bottom gates consists of a sliding metal plate at the bottom of each hopper, and such sliding doors can be opened and closed to allow materials to flow out by means of gravity. Conventionally there have been various methods of operating bottom sliding doors on railroad hopper cars. For example, a bar can be used to manually open the doors, but this is labor intensive, difficult, dirty, and subjects the operator to potential back injuries. Another method uses an air-powered wrench to open the sliding door. This too may cause back injuries to the operator. Yet another method uses an air-powered wrench that follows along the side of the hopper car as it is moving over a receiving bin. All of these methods are time-consuming and complex to operate.
For example, U.S. Patent Publication No. 2020/0317231 entitled “Open top hopper railcar with lading shedding top chord and corner cap and integrated door operating controls with manual override”, discloses an automatic door operating system to open and/or close railroad hopper car doors. U.S. Pat. No. 10,668,933 entitled “Actuating system for transverse doors of railroad hopper car”, discloses a door operating mechanism to control opening and closing of hopper doors. U.S. Pat. No. 7,832,340 entitled “Hopper railcar with automatic individual door system”, discloses an automatic individual door system to open a rotating discharge door of a hopper railcar. U.S. Pat. No. 10,648,217 entitled “Railroad hopper car body fittings”, discloses a means to change the position of railroad hopper's door from open to close and vice-versa. Canadian Patent No. 2,810,131 entitled “Railroad hopper car and door mechanism therefor”, discloses a mechanism to open and close doors of hopper car.
However, none of the references above disclose the same structural components as those of the disclosed invention. The structures in the above references are bulkier in overall size whereas the size of the overall unit of the present invention is compact and simple in design. Further, the present disclosure is directed to a sliding discharge door which may be used in connection with a hopper car, different from the above cited references. The disclosed invention replaces traditional methods and systems, and makes the operation of the opening and closing of bottom discharge doors easier, safer, and less time consuming.
Broadly, embodiments of the present invention relate to an automatic sliding door actuating and operating systems and methods for use, for example, with vehicles such as hopper cars. An exemplary sliding door actuating mechanism may include a cylinder such as an air cylinder or a hydraulic cylinder, with one end mounted to the hopper car body by a rear cylinder mount. In some embodiments, a gas-filled cylinder may be less prone to leakage and therefore more easily implemented in the context of hopper cars; however, it is understood that the disclosure is not limited to gas-filled cylinders. A rod clevis of the cylinder may be coupled to an actuating reinforcer on one end of the actuating reinforcer, while another end of the actuating reinforcer may be mounted or fixed to a rotating main shaft that also connects to a proximal end of an operating lever.
In some embodiments, the main shaft may serve multiple sets of the actuating mechanism. In some embodiments, the clevis may include a U-shaped or hook-shaped fastening device with two holes that hold a pin in place, and may be part of a fastener assembly to provide a means of allowing rotation in some axes while restricting rotation in others.
When the piston rod of the cylinder extends forward, the actuating reinforcer coupled to it may rotate around the main shaft, causing the main shaft coupled to the actuating reinforcer to also rotate or pivot around the main shaft at its proximal end. The operating lever may be coupled at a distal end to a connecting link, while the connecting link may further connect a door pan fulcrum mounted to a sliding discharge door. The connecting link moves in response to the pivoting of the operating lever, and this movement of the connecting link may cause the door pan fulcrum to move in a sliding motion, causing the door to slide open. In the same manner, when the piston rod of the cylinder reverts back to its initial position, the parts of the actuating mechanism or device work together and the door slides close.
As the present system may utilize an actuating cylinder such as an air cylinder or any suitable cylinder for its operation, any single and/or multiple doors of a hopper car may be opened one at a time, at the same time, or in successive instances of time, based on the size of bins where the commodity is being dumped. The system may be installed on existing cars using existing gates that are already on the hopper cars, and existing receiving bins do not need to be changed either.
Other non-limiting advantages of the disclosed systems and methods include increasing the safety of operation for operators, reducing the amount of time-consuming operations, and increasing the efficiency and speed of opening and closing of the sliding doors of the hopper cars. The reduction in the operating time of the doors allows for quicker turn-around of the hopper cars during normal transport operations. Moreover, the system can be set to dump in motion for a customer that has larger receiving bins. This process can be performed, for example, by using a sparkless pickup shoe.
As shown in the zoomed-in view 105, in this embodiment, a sliding door actuating mechanism may be installed in-between hoppers to actuate, or open and close one or more bottom discharge doors that are mounted through a door pan fulcrum. In other embodiments, such sliding door actuating mechanisms may be used to operate sliding doors on top of hoppers, in other types of bins, storage devices, transportation vehicles, and the like. That is, while embodiments of the present invention are described in connection with a hopper car, it is understood that the disclosed system and method can be used in connection with a variety of vehicles and/or stationary structures that use a sliding door.
In this embodiment, the system may use a mechanical actuator such as a cylinder 155 to provide a unidirectional force to operate a sliding door attached to a door pan fulcrum 140. Cylinder 155 may be fluid-powered. For example, it may be pneumatic and powered by a compressed gas such as air, or maybe hydraulic and powered by a hydraulic fluid, such as water or oil. Cylinder 155 may be of any appropriate type. For example, it may be double-acting or single acting, may be tie-rod or welded, may have double rod-ends, may be telescopic, and may have multiple pistons. Cylinder 155 may have a cap end and a rod end, with its cap end mounted to the hopper car using any suitable means such as rear cylinder mount 170. In
On application of a fluid such as compressed air into cylinder 155, a piston rod 157 of the cylinder 155 extends forward (e.g., in the upper left direction in
As actuating reinforcer 160 rotates or pivots around main shaft 150, main shaft 150 may also rotate (e.g., counter-clockwise around its axis in
Similarly, the disclosed system allows for the closing of sliding door 142. In particular, with sliding door 142 mounted with door pan fulcrum 140, a combined effect of all the components connected between rod clevis 159 of cylinder 155 and door pan fulcrum 140 may cause door 142 to move (e.g., to the left in
Similar additional components are shown in
Similarly, main shaft 180 may be coupled to a separate, second actuating reinforcer 164 that operates independently from the first actuating reinforcer 160 using a second cylinder, to open or close one or more sliding discharge doors (not shown in
In some embodiments, main shafts 150 and 180 may be coupled through one or more gears, such that a single cylinder and a single actuating reinforcer may drive all of the operating levers shown in
Furthermore, in this illustrative example, there are two mechanism support angles or mechanism support components 190 and 194 that are positioned along a longitudinal direction of the hopper car. The two ends of these longitudinal components may be mounted or welded to hopper walls directly, thus enabling the installation of the sliding door actuating mechanism onto existing hopper cars. On the other hand, main shafts 150 and 180 are positioned along a transverse direction or transverse axis of the hopper car, and each mounted onto or supported by the longitudinal mechanism support components 190 and 192. In some embodiments, bearings may be used to allow a main shaft to rotate without much friction from the mechanism support components. In some embodiments, depending on the lengths and weights of the main shafts, additional mechanism support components may be used, for example in between operating levers 126 and 128.
Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that the various modification and changes can be made to these embodiments without departing from the broader scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than in a restrictive sense. It will also be apparent to the skilled artisan that the embodiments described above are specific examples of a single broader invention which may have greater scope than any of the singular descriptions taught. There may be many alterations made in the descriptions without departing from the scope of the present invention.
Filing Document | Filing Date | Country | Kind |
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PCT/US21/60231 | 11/21/2021 | WO |
Number | Date | Country | |
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63116869 | Nov 2020 | US |