This invention relates to the field of discharge gate assemblies for railway hopper cars and, more particularly, to a discharge gate for a railway hopper car that may be assembled from stacked subunits and which provides improved sealing and glide systems.
Railroad hopper cars are used to transport bulk lading through railway systems. A railroad hopper car typically includes discharge gates located on the underside of the car for unloading the transported materials. Discharge gates typically include one or more sliding panels that may be selectively moved between open and closed positions to expose or cover an opening in the undercarriage of the car. Typically, an opening and closing drive mechanism shifts a panel between open and closed positions via a rack or racks fixed to the panel and an operating shaft. The operating shaft carries pinions which engage the racks. The operating shaft is rotated to move the panel in the desired direction. The car may be unloaded by sliding the panel to open the gate and allowing the lading to flow through the opening.
Often the materials transported comprise granular or particulate matter such as sugar, flour, grain, plastic pellets and cement. Conventional methods used to unload hopper cars include gravity discharge, vacuum discharge and pneumatic sled discharge, depending on the nature of the material transported.
During gravity discharge, lading falls from the car through a discharge opening in the gate by gravity. During vacuum discharge, lading falls from the car and through an opening in the gate into a closed vacuum chamber. Vacuum nozzles, in communication with the vacuum chamber, may project from the outer surface of the gate. A vacuum hose is connected to one or more of the vacuum nozzles and vacuum is applied to the hose. Air drawn from the car and through the gate carries lading into the vacuum chamber, through the vacuum nozzles and into the hose. During pneumatic sled discharge, a pneumatic sled is attached to the bottom of the discharge opening. The pneumatic sled includes screw type conveyors for discharging lading from the hopper car. Compressed air is blown into the discharge opening to pressurize the inside of the hopper car and separate compacted lading. The lading falls through the discharge opening and into the screw conveyors for removal.
In the case of high volume unloading, gravity discharge may be readily accomplished by simply opening the hopper car discharge gate and allowing the lading to flow downward through the gate. Gravity discharge is a common method of unloading used for materials such as unprocessed grains, feed, fertilizer, sand and soda ash. In the case of fine materials such as sugar, flour or cement, difficulties may be encountered during discharge due to significant quantities of the material becoming airborne. Such difficulties can lead to product contamination. In addition, fine materials may tend to accumulate on or within the elements of the discharge gate causing reduced outward flow of the lading, clogging of the discharge opening, and/or malfunction of the gate.
Unloaders may attach a boot to the bottom of a gravity discharge gate to feed lading to an enclosed screw conveyor. Attachment of a boot, however, is slow and awkward and the area of the gate where the boot attaches may not be sanitary. Therefore, many handlers of finished food products such as sugar and flour, and plastic pellet handlers, prefer vacuum unloading or discharge. Discharge of fine materials may accomplished using vacuum discharge methods which can increase material flow and reduce airborne particles in the work environment proximate to the gate. Vacuum discharge is particularly preferred where avoidance of contamination is important.
Difficulties in the prior art devices, however, persist relative to the seals formed between elements within the gate assembly, particularly between outer hopper or frame elements and sliding panels. Gaps between sealed components may be present as a result of dimensional variations in conventional multi-bend fabrication. In addition, surfaces for supporting the panels are prone to fouling due to build-up of transported matter, and wear due to friction caused by repetitive sliding of the panels over the support surfaces.
Various aspects of the hopper car discharge gate of the present invention include improved sealing and glide systems that provide for unimpeded flow of lading during discharge, a simplified method of assembly using multiple stacked frames that may be independently fabricated, a low-wear glide system that avoids damage to gate panels and other components due to friction, and an improved sealing system that protects lading from contaminants such as rain, dust and insect infestation and provides enhanced vacuum sealing for greater efficiency during vacuum discharge.
In one embodiment of the discharge gate a generally horizontally disposed gate panel is provided that is movable in opposite directions between an open position and a closed position. A frame structure defines a discharge opening for flow of material from the hopper car, and has first and second spaced side members presenting first and second edges respectively at the discharge opening extending generally in the directions of movement of the panel. Flexible seal strips on the side members extend along the respective edges and project into the discharge opening. Transversely spaced support surfaces for the panel are provided which underlie the seal strips. The panel is mounted on the support surfaces for movement between its opened and closed positions in sliding contact with the seal strips to thereby seal the discharge opening when the panel is closed and, when opened, provide for discharge of material through the opening without accumulation at the edges of the side members and the support surfaces.
In another embodiment a method is provided for controlling discharge of material from a hopper car, and comprises the steps of providing an upper, unitary hopper subassembly presenting an opening for downward flow of material thereinto, and a second, unitary gate subassembly beneath the upper subassembly in alignment with the opening. The second subassembly has a gate panel component movable between a closed position and an opened position permitting discharge of material therethrough. A third, unitary gate subassembly may also be utilized and is positioned beneath the second subassembly for receiving material discharged therefrom, and has a gate panel component movable between a closed position, when vacuum discharge is being utilized, and an open position permitting discharge of material by gravity flow through the open gates.
Other aspects of the present invention include the utilization of elongated glide elements to present the support surfaces for gate panels, and additional sealing components, such as wiper seals, to insure that when vacuum discharge is utilized the suction provided by vacuum apparatus at the unloading facility is effectively maintained within the hopper gate.
a is a partial, exploded view of the discharge gate.
b is a partial, simplified, exploded view of the discharge gate.
Referring now to the drawings, and initially in particular to
The upper frame sidewalls 106, 108, 110 and 112 have diverging angular sides 106b, 108b, 110b, 112b that extend upwardly from the inner edges 106a, 108a, 110a, 112a toward the upper portion of the frame. Typically, the upper portion of the frame is defined by a relatively flat, horizontal lip 106c, 108c, 110c and 112c extending from each sidewall. Each lip 106c, 108c, 110c and 112c may include a plurality of mounting holes 154 spaced along its perimeter. While the discharge gate 100 may be mounted directly to the undercarriage of the railroad car via these mounting holes 154, typically a separate interface (not shown) is used to allow for differences between the hole patterns in the discharge gate 100 and the various mounting structures that may be encountered on the car.
a is an exploded view of the gate 100 of
The lower frame is 120 is secured to the underside of the middle frame 118 and comprises sidewalls 142, 144, and 146. The lower panel 116 slides within the lower frame 120 and is typically supported principally by sidewalls 144 and 146 or by components associated with sidewalls 144 and 146. The lower discharge opening 140 may be sealed shut by positioning lower panel 116 in a closed position as shown in
When the lower panel 116 is in the closed position a sealed primary vacuum chamber 148 is formed (
As illustrated in
The middle frame 118 is positioned below, and is attached to, the upper frame 102. The middle frame 118 includes two transversely spaced, parallel sidewalls 136 and 138 that define a space below the discharge opening 104. In
The sidewalls 136 and 138 of the middle frame 118 include integral lower sidewalls 136b and 138b that extend inwardly at an angle from the ledges 136c and 138c. The lower sidewalls 136b and 138b terminate at inner edges 136a and 138a. In
A lower frame 120 may be positioned below and attached to the middle frame 118 in order to assemble a discharge gate 100 suitable for vacuum discharge. As illustrated in
The lower door panel 116 is positioned below the edges 136a and 138a and rests on support structures provided by the lower frame 120 that may comprise ledges 144a and 146a formed from, or projecting from, the lower frame sidewalls 144 and 146. Since the lower door panel 116 is not typically subject to weight exerted by lading during transport, as is upper door panel 114 which is used to close the opening in the railroad car, additional support for the lower door panel 116 is typically not required but may provided by a center rail (not shown).
From the forgoing, it may be appreciated that the sloping surfaces thereby provided by upper frame 102 and middle frame 118 allow material discharged from a railroad car to readily flow down the surfaces of the walls and through the upper and lower discharge openings 104 and 140.
As illustrated in
The stacked assembly method of construction whereby separate unitary bodies comprising the upper frame 102, middle frame 118 and lower frame 120 are assembled to construct a discharge gate, provides significant advantages both in the construction and in the operation and use of the assembled device. In the prior art, a discharge gate 200, as illustrated in diagrammatical form in
The discharge gate 100 is formed by stacking previously assembled gate components comprising the upper frame 102, middle frame 118 and lower frame 120. Each component, therefore, may be constructed with only one of the above criteria being critical to the final component dimensions. For example, when constructing the upper frame 102 the required distance between points 8a and 8b, as represented by arrow 8, may be maintained without the need for considering, or making adjustments based on, the distance between middle or lower frame ledges. As shown in
To maximize the efficiency of vacuum discharge, the discharge gate 100 may be provided with a system of seals to close gaps within the gate assembly, particularly gaps between stationary frame elements and moveable elements such as the upper and lower panels 114 and 116.
Flexible seal strips (see
In particular, as illustrated in
The seal strips extend along the associated sidewall edges and project partially into the proximate discharge openings 104 or 140 (
The bottom wall of the plenum 150 is formed by the lower panel 116. Therefore, when the lower panel 116 is fully opened the plenum 150 is open on the bottom for ready access for cleaning. In addition, when the lower panel 116 is fully opened a sanitary sealing surface is exposed (see seals 172a, 172b, 172c and 172d) for sealing a boot to the bottom of the gate 100.
As can be seen in
Additional vacuum air leakage can occur between the bottom surface of the upper door panel 114 and the top of the rear cross member. To seal this zone a seal 172f is affixed to the forward wall 150a of the rear cross member 150 so as to wipe against the bottom surface of the upper door panel 114 (see
It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims and allowable equivalents thereof.
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| Number | Date | Country | |
|---|---|---|---|
| 20050166788 A1 | Aug 2005 | US |