The present invention relates to railroad freight cars including wells for carrying intermodal freight containers, and relates particularly to shortening existing container well cars to carry containers of a shorter length.
Many railroad freight cars were built over a period of several years, beginning in the 1980's, to be able to carry containers 48 feet long, as well as containers of the international standard 40-foot length, in container wells defined between deep side sills of the car bodies. Cars of this type are disclosed in U.S. Pat. No. 5,170,718, for example. Many of such 48-foot well cars were built as multi-unit cars, each usually having five container-well car units permanently coupled together. Recently, longer containers such as nominal 53-foot containers have largely replaced 48-foot containers. Since 48-foot well cars cannot accept the 53-foot containers, the cars with 48-foot wells began to be used largely for carrying 40-foot containers. Because of their greater length and weight, such cars are less efficient and more costly to use to carry 40-foot containers, and so owners of the cars have shortened many cars so that the container wells can still carry 40-foot containers, but don't have the extra eight-foot well length. The weight of material removed from the car bodies can be replaced by freight-earning lading without exceeding gross weight limitations. Also, more of the shortened cars can be included in a freight train without exceeding train length limitations.
It has been discovered that in many shortened container-well car units joints interconnecting the side sills and container corner support structures with the body bolsters and adjacent end portions of the car unites showed signs of failures and inability to sustain the loads resulting from carrying the lading for which the car units had been designed. Subsequent investigation revealed that gaps had remained unexpectedly unwelded between certain parts during the process of rejoining the ends of the well car units to shortened side sills, and a critical portion of the intended welded interconnection between end portions of the car units and the adjacent container well structures had not been able to be accomplished properly.
What is needed, then, is a joint structure and a method for shortening container-well units of railroad freight cars to result in strong, long-lasting, dependable, shortened container-well car units capable of carrying the full weight of lading for which the cars were originally designed, over a further lifetime of several years.
The present disclosure provides an answer to the aforementioned need for an improved structure and method for shortening container-carrying well cars to carry standard 40-foot cargo containers.
According to one aspect of the disclosure, a method for converting well car units is disclosed in which preexisting container support assemblies are removed from container well car side sills; a bottom chord of each side sill is disconnected from the side sill web plate; longitudinally extending sections of the top chord and web plate are removed from each side sill near an end of an extra-long container well car unit; an end portion of the car unit is moved into a new position closer to a longitudinally central remaining portion of the body of the car unit; the top chord and web plate portions are reconnected as shortened; the bottom chord is connected to the moved portion of the side sill web plate of the end portion of the car unit; a container corner support assembly including a transverse gusset plate is attached to the side sill at the end of the shortened container well; and a connecting plate is welded to a longitudinally outboard face of the transverse gusset plate and to an inboard face of a closure plate of a connecting portion of the end portion of the car unit, completing a pathway for transfer of forces between the container corner support assembly and a body bolster.
In accordance with one aspect of the disclosure, a joint structure includes structure interconnecting a side sill and a container corner support assembly of a container well car unit with a connecting assembly extending between a body bolster and the container corner support assembly, in which the connecting assembly includes a closure plate spaced inboard from an extension of a side sill web plate and connected to the extension of the side sill web plate by a transversely extending vertical support plate, and a connecting member is welded to the closure plate and to a transverse gusset plate that is part of the container corner support assembly.
In one embodiment a spacer member is located between the transverse gusset plate and the transverse vertical support plate and helps to shape a weld joint between those plates.
In one embodiment a connector plate lies alongside the closure plate and has a serpentine margin providing a long weld connection to the closure plate, while a vertical margin of the connector plate is welded to the transverse gusset plate so that the connector plate interconnects the closure plate with the transverse gusset plate across a gap between the transverse gusset plate and the vertical support plate of the connecting assembly.
The foregoing and other features of the invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.
Referring now to the drawings which form a part of the disclosure herein, in
The multi-unit car 20 is shown laden with a pair of nominal 40-foot intermodal freight containers 34 and 36 carried in a container well of each car unit 22, 28. A lower tier container 34 is held within the each container well, and the upper 40-foot container 36 is stacked upon and locked to the lower container 34 in each container well. A respective container well is defined between the opposite side sills 38 of the end unit 22 and between the opposite side sills 40 of the intermediate unit 28. The container well of each well car unit 22, 28 receives the lower container 34 with room to spare at each end of the container 34, as shown in
For the economic reasons explained above, it is desirable to convert such a multi-unit car 20 to a shorter configuration in which the container wells are still capable of carrying the 40-foot containers 34 and 36, but can no longer receive 48-foot containers 42. Accordingly, the multi-unit car 20 shown in
The side sills 38 of the end unit 22 are interconnected by a transversely extending body bolster 46 at the coupler end 24 and by a transversely extending body bolster 48 at the intermediate end 26. A respective body bolster 48 interconnects the side sills 40 of each intermediate unit 28 at each of its intermediate ends 30.
Referring next to
A large reinforcing plate 56 and a doubler plate 58 extend vertically along the inboard, or container well, side of the side sill 38, between the body bolster 48 and a container support assembly 60 welded to the side sill 38. Attachment of the container support assembly 60 includes a bridge plate 62 welded to the top chord 50 and a reinforcing member 64 extending along a portion of the inboard face of the web plate 52.
A truss assembly 66 extends horizontally between the two side sills 38 at the bottom of the container wells, and extends longitudinally to the end of the container well, adjacent the body bolster 48. A gusset 68, shown only in edge view in
To prepare for shortening the container well, as shown in
With the intermediate end 26 of the car unit, including the body bolster 48, supported on a suitable dolly that can be moved longitudinally with respect to the central portion of the body of the container car end unit 22, a portion of 67 the web plate 52 approximately four feet long is removed, and thereafter, or at the same time, a corresponding portion of the top chord 50 is removed, leaving the portion of the car shown in
The portion 70 of the side sill 38 that is left connected with the body bolster 48 includes a portion of the web plate 52 whose upper portion extends longitudinally alongside the respective end of the body bolster and whose lower portion is cut diagonally to form the laterally outer portion of a triangular connecting part 72. Spaced laterally inboard from the web plate 52 by a small distance that may vary from about two inches to about four inches is a vertical longitudinally extending closure plate 74 that is attached to the body bolster 48. Transverse structural members including a generally vertical and transverse support plate 76 interconnect the closure plate 74 with the side sill web plate 52 in the triangular connecting assembly 72. The remaining portion of the doubler plate 58 overlies and is securely fastened to the closure plate 74. In preparing to shorten the well unit, when the reinforcing plate 56 is removed, the transverse generally vertical support plate 76 is exposed and the closure plate 74 is trimmed along the exposed face of the vertical support plate 76. The doubler plate 58 is also cut back to be flush with the exposed longitudinally inboard face of the transverse vertical support plate 76.
Carried on a suitable wheeled dolly, for example, or otherwise movably supported, the body bolster 48 and the attached connecting parts 72 and the end portion 70 of the side sill, including its top chord 50 and side plate 52, are moved longitudinally with respect to the remaining longitudinally central portion 77 of the body of the end unit 22, and the corresponding portions of the top chord 50 and side sill web plate 52 are aligned with each other, with a small gap 78 left for properly welding the corresponding parts together. A series of slots 80 are formed through the side sill web member 52 to be used to weld a container corner support assembly 81 into place within the shortened container well.
As shown in
In interconnecting the end portion 70 of the side sill 38 with the longitudinally central portion 77 of the side sill 38, as shown in
The bottom chord 54 is welded to the lower margin of the side sill web plate 52 in the end portion 70 of the side sill, and the excess portion of the bottom chord 54 is cut off, as may be seen in
The longitudinally inboard margin 98 of the support bracket 86 is welded to the laterally inner face of the side sill web plate 52, and the outer margin surface 100 of the transverse gusset plate 88 is welded to the side sill web plate 52 by use of the slots 80 shown in
The size of the gap 96 may be determined fairly accurately in its upper portion, leaving space for a slot weld between the transverse gusset plate 88 and the doubler plate 58 and the adjacent portion of the vertical support plate 76. However, because the location of the vertical support plate member 76 as originally installed was not critical when the car unit was built to include a 48-foot container well, the lower portion of the gap 96 may not be of the same width, as a result of the original construction of the container well unit 22 that is being shortened. Nevertheless, a strong and durable welded interconnection between the transverse gusset plate 88 of the container corner support assembly 81 and the triangular connecting assembly 72 of the intermediate end 26 is critical, so that the forces to which the container corner support assembly 80 is exposed can be carried efficiently to the body bolster 48. In forming such a connection a spacer plate 106 of suitable thickness, such as 0.5 or 0.375 inch, is tacked in place between the vertical transverse gusset plate 88 and the generally coplanar surfaces of the margins of the doubler plate 58 and the cover plate 74, and the inboard face of vertical support plate 76, as shown in
A reinforcing connector bar 110 of ample thickness, at least equal or greater than the thickness of the closure plate 74, is placed alongside and welded to the face of the closure plate 74 to bridge the lower portion of the gap 96. A margin of the reinforcing connector bar 110 is located adjacent and welded securely to the longitudinally outboard face of the transverse vertical gusset plate 88, connecting the lower part of the gusset plate 88 to the connecting assembly 72.
To complete the installation of the container support assembly a reinforcing cover plate 112 is welded to the top chord 50, the longitudinally inboard face 90 of the gusset plate 88 and the support bracket 86, covering the opening that was previously available at the top of the support bracket 86 to allow the filler piece 102 to be installed. The cover plate 112 connects the support bracket 86 to the top chord 50. A connecting piece 114 is welded in place to bridge the remaining space between the top chord 50 and the top of the support bracket 86, and an attachment bracket 116 is welded to the support bracket 86 and the laterally inward face of the side sill web plate 52.
While only one side of the container well at the intermediate end 26 has been shown and described, the operation is similar on the opposite side sill 38 and thus need not be described in detail. Also, the shortening of the container well at the intermediate end portion 30 of each intermediate unit 28 is performed substantially similarly to the shortening of the container well at the intermediate end 26 of the end unit 22 as just described, and thus need not be discussed in detail.
The coupler end 24 of the end container well unit 22 of the multi-unit car 20 is prepared for shortening the container well by a procedure generally similar to that described above with respect to the intermediate end 26. A container support assembly 120 and associated connecting parts 122 and 124 are scarfed free from the side sill 38. Generally triangular gussets 126 and 128 are scarfed free from the top chord 50 and bottom chord 54, respectively, and a pipe-like piece 129 is cut back flush. The bottom chord 54 is scarfed free from the side sill web plate 52, and the top chord 50 and side sill web plate 52 are shortened by removal of a section such as that indicated by broken lines 130 and 132 in
As shown in
Similar to the intermediate end triangular connecting part 72, the longer connecting assembly 134 between the side sill 38 and the body bolster 46 at the coupler end 24 of the container well car unit 22 includes continuations of the top chord 50 and the side sill web plate 52 of the side sill 38. Spaced laterally inward from the web plate 52 with its upper portion at a distance about equal to the lateral width of the top chord 50 is a flat closure plate 144. A structural spacer member 146 extends along a diagonally sloping bottom portion of the connecting assembly 134, and a horizontal structural spacer member 148 extends for the length of the connecting assembly 134, connecting the closure plate 144 with the lower portion of the side sill web plate 52, in a lower portion of the connecting assembly 134. Also, as in the triangular connecting assembly 72, a transverse vertical support plate 150 extends from the top chord 50 to the bottom of the connecting assembly 134, joining the side sill web plate 52 with the closure plate 144 in the same manner as does the vertical support plate 76 at the intermediate end 26. As shown also in
A gap 154, similar to the gap 96, extends vertically, between the longitudinally outboard face of the transverse gusset plate 88 of the container corner support assembly 140 and the aligned longitudinally inboard margins of the closure plate 144 and upper closure plate 152 and the longitudinally inboard face of the transverse vertical support plate 150.
In order to provide the required strong durable connection between the container corner support assembly 140 and the connecting assembly 134, a short upper connector plate 156 has an inboard margin securely welded to the longitudinally outboard face of the gusset plate 88 of the container support assembly 140 and lies closely alongside and is welded to a laterally inboard face of the upper closure plate 152, bridging the gap 154 as shown in
A reinforcing connector plate 160, also shown separately in a larger view in
As in the intermediate end 26 described above the lower margin of the gusset plate 88 is securely welded to the bottom chord member 54, and the outer margin is welded to the side sill web plate 52 through slots similar to the slots 80 shown in
A reinforcing cover plate 172, similar to the cover plate 112 shown in
After reconnection of the shortened side sills 38 and installation of the container support assemblies 81 and 140, container locator cones 180 and support pads 182 may be installed on the container support feet 82, as shown best in
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.