Patent Application
20210347392
This disclosure relates generally to configuring an autorack car.
Autorack cars are a type of railcar configured to store and transport automobiles and/or vehicles (e.g., cars, trucks, motorcycles, etc.). Existing autorack cars may be configured with one deck, (Uni-level), two decks, (Bi-level), or three decks, (Tri-level). Deck heights determine the maximum height of auto vehicles the autorack deck can transport. Deck heights are generally set and not moved due to difficulty and expense. Deck adjustments may be performed at a distant facility, which requires scheduling and having the autorack car out of service for the duration of the conversion. These adjustments may increase the expense to the shipper and limits the flexibility of the shipper to manage loading efficiency. These adjustments may also require careful scheduling of autorack cars with the correct deck heights to accommodate a given shipment. Further, in order for an autorack car to be compatible with other autorack cars, the decks may have to be located in certain positions or within some tolerance (e.g. plus or minus 3 inches) of the other autorack cars.
This disclosure contemplates an unconventional coupler that assists in adjusting the height of a deck in an autorack car. The coupler allows the deck to couple to an adjustment mechanism (e.g., a ball screw) that can adjust the height of the deck. When the deck is repositioned, the coupler allows the deck to decouple from the adjustment mechanism. In certain embodiments, by using this unconventional coupler, no tools are needed to connect or disconnect the coupler and/or the deck. Additionally, no parts are removed or added while using the coupler, which could otherwise result in parts being misplaced or lost. Furthermore, the coupler can be connected and disconnected within seconds and prevents users from connecting or disconnecting incorrectly or partially. Moreover, the connected or disconnected status can be visually verified with a glance. Various embodiments are described below.
According to an embodiment, an apparatus includes a latch, a travelling nut, and a collar. The latch couples to a deck of an autorack car. The latch includes a body coupled to a hinge such that the body may rotate about the hinge from a first position to a second position. The latch further includes a headpiece coupled to the body. The headpiece may or may not include a key. The travelling nut engages a ball screw. The travelling nut rotates with the ball screw when the body is in the first position. The body exerts a force on the travelling nut when the body is in the second position. The travelling nut and the latch adjust a height of the deck in the autorack car when the body is in the second position and when the ball screw is turned. The collar includes a slot and encircles the latch when the body is in the second position. The slot and the key are configured such that the collar may be lifted above the latch when the slot is aligned with the key.
According to another embodiment, a method includes rotating a latch from a first position to a second position such that a body of the latch exerts a force on a travelling nut and aligning a slot in a collar with a key of a headpiece of the latch. The headpiece is coupled to the body. The method also includes lowering the collar such that it prevents the latch from rotating from the second position to the first position and rotating a ball screw such that the travelling nut and the latch adjust a height of a deck in an autorack car.
Certain embodiments provide one or more technical advantages. For example, an embodiment includes an unconventional coupler that allows a deck in an autorack car to be repositioned without the need for tools. As another example, an embodiment includes a coupler that allows a deck in an autorack car to be repositioned without having to remove the deck from the autorack car. In some embodiments, a coupler allows for decks in an autorack car to be repositioned independently of one another. Certain embodiments may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and claims included herein.
For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
Autorack cars are a type of railcar used to store and transport vehicles (e.g., cars, trucks, motorcycles, etc.).
In existing autorack cars, once the decks are positioned in the autorack car, the decks may be difficult to remove and/or adjust. Furthermore, it may also be difficult to adjust a height of the existing autorack cars. This disclosure contemplates an unconventional coupler that allows for decks in an autorack car to couple and uncouple from an adjustment mechanism (e.g., a ball screw). The coupler is used to couple the deck to the adjustment mechanism when the deck needs to be repositioned. After the deck is repositioned, the coupler can be used to uncouple the deck from the adjustment mechanism. By using the coupler, it may not be necessary to use tools to reposition the decks in an autorack car in certain embodiment. In some embodiments, the coupler may allow decks to be repositioned independently of one another and/or without removing the decks from the autorack car. Additionally, no parts are removed or added while connecting and disconnecting the coupler, which could otherwise result in parts being misplaced or lost. Furthermore, the coupler can be connected and disconnected within seconds and prevents users from connecting or disconnecting incorrectly or partially. Moreover, the connected or disconnected status can be visually verified with a glance.
Disclosed herein is an unconventional coupler for configuring decks in an autorack car 100. An autorack car 100 may be configured or reconfigured for different vehicles by adjusting the vertical position of decks within the autorack car 100.
In one embodiment, the vertical position of decks in an autorack car 100 may be adjusted without disassembling portions of the autorack car 100. Each deck may be raised or lowered within the autorack car 100 to accommodate a variety of load combinations. The ability to adjust the vertical position of decks in an autorack car 100 may permit a shipper to easily adjust deck heights to maximize loading efficiency without having to move the autorack car 100 into a maintenance shop, and may provide a means to adjust deck heights to match that of an adjacent autorack car 100 making autorack cars 100 with this design compatible.
A vertical position of deck 102A may be adjusted using similar processes to adjust a vertical position of deck 102B or 102C in particular embodiments. In some embodiments, deck 102A is a floor of autorack car 100 and a vertical position of deck 102A cannot be adjusted. In some embodiments, a vertical position of deck 102A can be adjusted.
In one embodiment, the adjustment system may be a Ball screw system that includes Ball screws 104 (or ACME thread in certain embodiments), Ball screw actuators 106, a coupler 108, and a controller 110. A Ball screw actuator 106 may be attached to the roof section of the autorack car 100 and may be controlled by controller 110. The controller 110 is operably coupled to the Ball screw actuator 106, and is configured to communicate electrical signals for positioning decks 102B and 102C. The Ball screw 104 is operably coupled to the Ball screw actuator 106 and configured to be rotated by the Ball screw actuator 106 through a gear reduction mechanism and an electric motor or any other rotational system. The coupler 108 may be operably coupled to deck 102B or 102C and Ball screw 104 and configured to move along the Ball screw 104 when the Ball screw 104 is turned. The direction of travel of the coupler 108 depends upon the direction the Ball screw 104 is turned. Using the Ball screw 104 and coupler 108, the deck 102B and 102C can be moved anywhere along the Ball screw 104. The position of the deck 102B or 102C may only be limited by the length of the Ball screw 104 and the clearances within the autorack car 100. This disclosure contemplates coupler 108 being located above, below, or both above and below a deck 102.
Deck 102B or 102C may be held in position by a brake on the Ball screw 104 and/or a locking system between the deck 102B or 102C and the side structure of the autorack car 100. Multiple Ball screw systems may be used to provide enough lifting capacity, redundancy, and to maintain the deck level during movement. In one embodiment, the deck 102B or 102C may be comprised of multiple sections that can be moved individually or in unison (e.g., a vertical position of one portion of deck 102B or 102C may be adjusted independently of a vertical position of another portion of deck 102B or 102C). The Ball screw system may be configured to reposition a deck 102B or 102C while the deck 102B or 102C is unloaded or loaded, for example, with a vehicle. A Ball screw system may include any number of Ball screws 104 and couplers 108. For example, in one embodiment each deck 102B or 102C may be configured to couple with four Ball screws 104 and four couplers 108 with a Ball screw 104 and a coupler 108 at each corner of the deck 102B or 102C. In another embodiment, each deck 102B or 102C may be configured to couple with six Ball screws 104 and six couplers 108 with a Ball screw 104 and a coupler 108 at each corner of the deck 102B or 102C and a pair of Ball screws 104 and couplers 108 supporting a mid-portion of the deck 102B or 102C. The Ball screws 104 and couplers 108 may be positioned anywhere along the deck and any suitable configuration of Ball screws 104 and couplers 108 may be employed as would be appreciated by one of ordinary skill in the art upon viewing this disclosure. Although the illustrated example shows couplers 108 positioned above decks 102, couplers 108 may also be positioned below decks 102.
In order to move autorack decks vertically inside the railcar, some form of attachment (e.g., a coupler) between the decks and the ball screw system should be employed. To move both decks independently from each other, a coupler may attach to the deck being moved and a coupler may be detached from the deck not being moved. Further, to reduce the time used to adjust decks, the coupler may be attached and/or detached quickly and easily.
This disclosure contemplates a coupler 108 that allow for easy adjustment of deck 102B or 102C. For example, coupler 108 allows adjustment of deck 102B or 102C without using tools. As another example, coupler 108 allows adjustment of deck 102B or 102C without having to remove deck 102B or 102C from the autorack car. In certain embodiments, coupler 108 allows adjustment of deck 102B or 102C without using fasteners or pins. Additionally, coupler 108 protects components of coupler 108 from theft or loss. Furthermore, coupler 108 allows for independent adjustment of different decks in a railcar and prevents users from connecting and disconnecting the coupler 108 incorrectly or partially. This disclosure contemplates any number of decks of a railcar using coupler 108 to allow for vertical adjustment of the decks. Designs and uses for coupler 108 will be described using
Coupler 108 includes a collar 210 and one or more latches 215. When coupler 108 is detached from ball screw 104 and/or travelling nut 220, ball screw 104 can rotate without moving deck 102 (e.g., because travelling nut 220 rotates with ball screw 104 instead of moving upwards or downwards on ball screw 104). Travelling nut 220 is stored slightly above (and/or below) deck 102 and due to friction between travelling nut 220 and ball screw 104, when ball screw 104 is turned, travelling nut 220 spins with ball screw 104 and no vertical motion of travelling nut 220 takes place. Latches 215 and collar 210 are stored below (and/or above) travelling nut 220.
Latches 215 include a headpiece 218, a body 235, and a hinge 240. Headpiece may be coupled to body 235, and body 235 may be coupled to deck 102 via hinge 240. Headpiece 218 may be transverse to body 235 and may be coupled to a top end of body 235 while hinge 240 is coupled to body 235 near a bottom end of body 235. Hinge 240 may allow for headpiece 218 and body 235 to rotate outward around hinge 240 from a vertical position (as shown in
Collar 210 encircles latches 215 when latches 215 are in the vertical position and prevent latches 215 from rotating outwards to the unlocked position. Collar 210 may be lifted above latches 215 so that latches 215 may rotate outward to the unlocked position. Collar 210 may also be rotated. In this manner, collar 210 may lock and/or unlock latches 215. Collar 210 may be any suitable shape such as circular, rectangular, triangular, etc.
Latches 215 may include one or more keys 225. As shown in
When latches 215 are in the vertical, locked position, body 235 of each latch 215 exerts a force transverse to body 235 to travelling nut 220. These forces are opposite each other and they prevent or hinder travelling nut 220 from rotating. Additionally, travelling nut 220 exerts a vertical force on headpieces 218 to support latches 215, coupler 108, and/or deck 102. As a result, when ball screw 104 is turned, travelling nut 220 does not turn and instead moves vertically on ball screw 104, which causes coupler 108 and deck 102 to move vertically as well. In this manner, the height of deck 102 can be adjusted in autorack car 100.
When latches 215 are in the horizontal, unlocked position, body 235 of each latch 215 does not exert a force on travelling nut 220. As a result, travelling nut 220 is allowed to rotate with ball screw 104, and rotation of ball screw 104 does not cause travelling nut 220 to translate vertically on ball screw 104.
As an example operation, when it is desired to move deck 102 vertically, collar 210 is lifted. In order to do so, slots 230 in the collar are aligned with keys 225 in each headpiece 218 in order for collar 210 to go past latches 215. Collar 210 is lifted above travelling nut 220 and both latches 215 are rotated outwards to the unlocked position. While holding travelling nut 220, ball screw 104 is turned in a direction that causes nut 220 to move towards deck 102 and coupler 108. This motion is continued until nut 220 contacts deck 102 and/or coupler 102, and then ball screw 104 motion is stopped. Nut 220 may then be turned by hand to align the nut 220 to latches 215. Latches 215 are then rotated up towards the locked position to engage ball screw 104 and/or travelling nut 220. Collar 210 is turned to align slots 230 of collar 210 with keys 225 of headpieces 218, and then collar 210 is lowered over latches 215 to rest on deck 102. This process is repeated for all ball screw-to-deck attachments for the portion of deck 102 that is desired to move.
Deck 102 is then uncoupled from the autorack car. Ball screws 104 are then rotated to move deck 102 in the desired direction. Deck 102 is then coupled back to the autorack car. Then, collar 210 may be lifted and latches 215 may be moved to the unlocked position to disengage coupler 108 from ball screw 104 and/or travelling nut 220. Specifically, collar 210 is lifted over latches 215 by aligning slots 230 with keys 215 on headpieces 218 of latches 215. This allows latches 215 to be rotated away from ball screw 104 to the unlocked position. Holding on to travelling nut 220, ball screw 104 is rotated in the direction that moves nut 220 above (and/or below) deck 102 and/or coupler 108. Latches 215 are rotated to the vertical position and collar 210 is lowered over latches 215 to the stored position. This process is repeated for all ball screw-to-deck attachments.
In certain embodiments, by using coupler 108, it may not be necessary to use tools to reposition deck 102 in the railcar 100. In some embodiments, coupler 108 allows deck 102 to be repositioned independent of other decks 102 in railcar 100. Furthermore, in some embodiments, collar 210 may prevent or hinder theft or loss of certain components of coupler 108 by making it more difficult to remove these components when collar 210 is resting on deck 102. Moreover, the design of coupler 108 prevents a user from connecting and/or disconnecting coupler 108 incorrectly or partially.
This disclosure contemplates any number of travelling nuts 220 in any position relative to deck 102. For example, two travelling nuts 220 may be used at a particular position of deck 102, one above and one below the deck 102, to capture the deck 102 for movement.
Modifications, additions, or omissions may be made to the systems and apparatuses described herein without departing from the scope of the disclosure. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. Additionally, operations of the systems and apparatuses may be performed using any suitable logic comprising software, hardware, and/or other logic. As used in this document, “each” refers to each member of a set or each member of a subset of a set.
Modifications, additions, or omissions may be made to method 300 depicted in
Although the present disclosure includes several embodiments, a myriad of changes, variations, alterations, transformations, and modifications may be suggested to one skilled in the art, and it is intended that the present disclosure encompass such changes, variations, alterations, transformations, and modifications as fall within the scope of the appended claims.
While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods might be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.
In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.
To aid the Patent Office, and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants note that they do not intend any of the appended claims to invoke 35 U.S.C. § 112(f) as it exists on the date of filing hereof unless the words “means for” or “step for” are explicitly used in the particular claim.
