Note: Descriptions are shown in the official language in which they were submitted.
RAILCAR TRUCK ROLLER BEARING ADAPTER-PAD SYSTEMS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional
Patent
Application No. 62/440,704 filed on December 30, 2016 and U.S. Non-Provisional
Patent Application No. 15/856,221 filed on December 28, 2017. This patent
application is also related to pending U.S. Patent
Application No. 15/378,472 filed December 14, 2016, which is related to
U.S. Patent Application No. 15/152,860 (now U.S. Patent No.
9637143) filed May 12, 2016, and which claims the benefit of U.S. Provisional
Patent
Application No. 62/161,139 filed May 13, 2015. U.S. Patent Application No.
15/152,860 is also related to U.S. Patent Application No.
14/585,569 filed December 30, 2014 (now U.S. Patent No. 9,434,393), which
claims
the benefit of United States Provisional Application Serial Nos. 61/921,961
and
62/065,438, filed December 30, 2013 and October 17, 2014 respectively. U.S.
Patent Application No. 15/152,860 is also related to U.S. Patent
Application No. 14/561,897 filed December 5, 2014, U.S. Patent Application
No.14/562,005 filed December 5,2014, and U.S. Patent Application No.14/562,082
filed December 5, 2014, which, in turn, each claim the benefit of United
Stales
Provisional Application Serial Nos. 61/921,961 and 62/065,438, filed December
30,
2013 and October 17, 2014 respectively.
TECHNICAL FIELD
[0002] The present disclosure relates to railcar trucks, and more
particularly to
roller bearing adapter and adapter-pad systems that can improve stiffness,
damping,
and displacement characteristics to satisfy both curving and high speed
performance
of a three-piece railcar truck.
BACKGROUND
[0003] The conventional railway freight car truck in use in North America
for many
decades has been the three-piece truck, comprising a pair of parallel side
frames
connected by a transversely mounted bolster. The bolster is supported on the
side
frames by spring groups consisting of a number of individual coil springs. The
wheelsets of the truck are received in bearing adapters placed in leading and
trailing
pedestal jaws in the side frames, so that axles of the wheelsets are parallel
in a
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transverse or lateral position relative to the two rails. The railway car is
mounted on
the center plate of the bolster, which allows the truck to rotate with respect
to the car.
The spring groups and side frame to bolster clearance stops permit the side
frames
to move somewhat with respect to the bolster, about the longitudinal, vertical
and
transverse or lateral axes.
[0004] It has long been desired to improve the performance of the three-
piece
truck. Resistance to lateral and longitudinal loads and truck performance can
be
characterized in terms of one or more of the following well-known phenomena.
[0005] "Parallelogramming" occurs when one side frame moves forward
longitudinally with respect to the other, such that the leading and trailing
wheel sets
remain parallel to each other but they are not perpendicular to the rails, as
may
happen when a railway car truck encounters a curve. This
action of
parallelogramming side frames is also referred to as truck warp.
[0006] "Hunting" describes an oscillating sinusoidal longitudinal and
lateral
movement of the wheelsets that causes the railcar body to move side-to-side.
This
sinusoidal movement is the harmonic oscillation caused by the tapered profile
of the
wheelset. While the tapered profile promotes natural oscillation of the
wheelset, it is
also the primary feature that allows the wheelsets to develop a rolling radius
difference and negotiate curves. Hunting may be dangerous when the
oscillations
attain a resonant frequency. Hunting is more likely to occur when there is a
lack of
proper alignment in the truck as manufactured, or developed over time through
various operating conditions such as wear of the truck components. Hunting is
also
more likely to occur when the railcar is operated at higher speeds. The speed
at
which hunting is observed to occur is referred to as the "hunting threshold."
[0007] Several approaches have been tried to improve the stability of the
standard three-piece truck to prevent parallelogramming and hunting, while at
the
same time ensuring that the truck is able to develop the appropriate geometry
to
accommodate the different distances traveled by the wheels on the inside and
outside of a turn, respectively. Additional improvement is desired, both to
meet truck
hunting requirements as well as to simultaneously improve stiffness, damping,
and
displacement characteristics that yield good high speed and curving
performance.
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BRIEF SUMMARY OF THE INVENTION
[0008] This Summary provides an introduction to some general concepts
relating
to this invention in a simplified form that are further described below in the
Detailed
Description.
[0009] Aspects of the disclosure herein relate to railcar trucks, roller
bear
adapters and adapter pads.
[0010] In one example the disclosure provides a roller bearing adapter pad
configured for use with a three-piece truck having AAR standard geometry the
adapter pad configured to engage a side frame pedestal roof. The roller
bearing
adapter pad may include a continuous top plate having a central portion, first
and
second upturned regions projecting upwardly from opposite edges of the central
portion, a first lateral flange projecting outwardly from the first upturned
region, the
first lateral flange having a first lateral edge, and a second lateral flange
projecting
outwardly from the second upturned region, the second lateral flange having a
second lateral edge, the continuous top plate having first and second
longitudinal
edges; a continuous bottom plate having a central portion, first and second
upturned
regions projecting upwardly from opposite edges of the central portion, a
first lateral
flange projecting outwardly from the first upturned region, the first lateral
flange
having a first lateral edge, and a second lateral flange projecting outwardly
from the
second upturned region, the second lateral flange having a second lateral
edge, the
continuous bottom plate having first and second longitudinal edges; an
elastomeric
member disposed between the top and bottom plate. The first lateral edge of
the top
plate and the second lateral edge of the top plate may define a inward curving
or
inward angled edge from an outer surface of the top plate to an inner surface
of the
top plate in a side view, and the first lateral edge of the bottom plate and
the second
lateral edge of the bottom plate define a inward curving or inward angled edge
from
an outer surface of the bottom plate to an inner surface of the bottom plate
in a side
view. The first longitudinal edge of the top plate and the second longitudinal
edge of
the top plate define a inward curving or inward angled edge from an outer
surface of
the top plate to an inner surface of the top plate in a side view, and the
first
longitudinal edge of the bottom plate and the second longitudinal edge of the
bottom
plate define a inward curving or inward angled edge from an outer surface of
the
bottom plate to an inner surface of the bottom plate in a side view. The first
lateral
edge of the top plate and the second lateral edge of the top plate include
curved
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portions from a top view, and the first lateral edge of the bottom plate and
the second
lateral edge of the bottom plate include curved portions from a top view. The
elastomeric member extends laterally outward beyond the first and second
lateral
edges of the top and bottom plates; and the elastomeric member extends
longitudinally outward beyond the first and second longitudinal edges of the
top and
bottom plates.
[0011] The first lateral edge of the top plate and the second lateral edge
of the top
plate may include a continuous radius in a top view measured from a vertical
axis at
a center point of the central portion of the top plate, and the first lateral
edge of the
bottom plate and the second lateral edge of the bottom plate include a
continuous
radius in a top view measured from a vertical axis at a center point of the
central
portion of the bottom plate.
[0012] The elastomeric member may extend laterally outward beyond the first
and second lateral edges of the top and bottom plates by at least 0.05 inches,
and
the elastomeric member may extend longitudinally outward beyond the first and
second longitudinal edges of the top and bottom plates by at least 0.05
inches. The
elastomeric member disposed between the central portions of the top and bottom
plates may have substantially uniform thickness.
[0013] In another example, a roller bearing adapter pad system configured
for
use with a three-piece truck having AAR standard geometry is disclosed. The
roller
bearing adapter pad system may include a roller bearing adapter configured to
engage a roller bearing, the roller bearing adapter comprising: a crowned top
surface; a bottom surface configured to engage a roller bearing; and first and
second
vertical shoulders that project upwardly from opposite lateral edges of the
top
surface. The roller bearing adapter pad system may also include an adapter pad
engaged with the roller bearing adapter and configured to engage a side frame
pedestal roof. The adapter pad may include a continuous top plate having a
central
portion, first and second upturned regions projecting upwardly from opposite
edges
of the central portion, a first lateral flange projecting outwardly from the
first upturned
region, the first lateral flange having a first lateral edge, and a second
lateral flange
projecting outwardly from the second upturned region, the second lateral
flange
having a second lateral edge, the continuous top plate having first and second
longitudinal edges; a continuous bottom plate having a central portion, first
and
second upturned regions projecting upwardly from opposite edges of the central
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portion, a first lateral flange projecting outwardly from the first upturned
region, the
first lateral flange having a first lateral edge, and a second lateral flange
projecting
outwardly from the second upturned region, the second lateral flange having a
second lateral edge, the continuous bottom plate having first and second
longitudinal
edges; and an elastomeric member disposed between the top and bottom plate.
The first and second laterally projecting flanges of the top plate and the
bottom plate
are entirely disposed above the vertical shoulders of the roller bearing
adapter.
[0014] The first lateral edge of the top plate and the second lateral edge
of the top
plate may include curved portions from a top view, and the first lateral edge
of the
bottom plate and the second lateral edge of the bottom plate include curved
portions
from a top view. The first lateral edge of the top plate and the second
lateral edge of
the top plate may also include a continuous radius in a top view measured from
a
vertical axis at a center point of the central portion of the top plate, and
the first
lateral edge of the bottom plate and the second lateral edge of the bottom
plate may
also include a continuous radius in a top view measured from a vertical axis
at a
center point of the central portion of the bottom plate.
[0015] The first lateral edge of the top plate and the second lateral edge
of the top
plate define a inward curving or inward angled edge from an outer surface of
the top
plate to an inner surface of the top plate in a side view, and the first
lateral edge of
the bottom plate and the second lateral edge of the bottom plate define a
inward
curving or inward angled edge from an outer surface of the bottom plate to an
inner
surface of the bottom plate in a side view.
[0016] The first longitudinal edge of the top plate and the second
longitudinal
edge of the top plate define a inward curving or inward angled edge from an
outer
surface of the top plate to an inner surface of the top plate in a side view,
and the
first longitudinal edge of the bottom plate and the second longitudinal edge
of the
bottom plate define a inward curving or inward angled edge from an outer
surface of
the bottom plate to an inner surface of the bottom plate in a side view.
[0017] The elastomeric member may extend laterally outward beyond the first
and second lateral edges of the top and bottom plates; and the elastomeric
member
may extend longitudinally outward beyond the first and second longitudinal
edges of
the top and bottom plates.
[0018] The highest strain values may occur inward of the outer edges of the
elastomeric member when the top plate is displaced 0.234 inches laterally
relative to
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the bottom plate. The combined top plate, bottom plate, and elastomeric member
of
the adapter pad provide a strain that is less than 80% when the top plate is
displaced
0.234 inches laterally relative to the bottom plate. The combined top plate,
bottom
plate, and elastomeric member of the adapter pad provide a strain that is less
than
90% when the top plate is displaced 0.234 inches laterally relative to the
bottom
plate.
[0019] The highest strain values occur inward of the outer edges of the
elastomeric member when the top plate is displaced 0.139 inches longitudinally
relative to the bottom plate. The combined top plate, bottom plate, and
elastomeric
member of the adapter pad provide a strain that is less than 80% when the top
plate
is displaced 0.139 inches longitudinally relative to the bottom plate. The
combined
top plate, bottom plate, and elastomeric member of the adapter pad provide a
strain
that is less than 90% when the top plate is displaced 0.139 inches
longitudinally
relative to the bottom plate.
[0020] The thickness of portions of the elastomeric members disposed
between
the first and second lateral flanges of the top and bottom plates are precom
pressed
from a static state.
[0021] The roller bearing adapter pad system may also include a first
compression shim disposed between the first lateral flange of the bottom plate
and
the first vertical shoulder of the roller bearing adapter; and a second
compression
shim disposed between the second lateral flange of the bottom plate and the
second
vertical shoulder of the roller bearing adapter.
[0022] A portion of the elastomeric member disposed between the central
portions of the top and bottom plates may have a substantially uniform
thickness.
[0023] In another example the disclosure provides, a roller bearing adapter
pad
configured for use with a three-piece truck having AAR standard geometry the
adapter pad configured to engage a side frame pedestal roof. The adapter pad
may
include a continuous top plate having a central portion, first and second
upturned
regions projecting upwardly from opposite edges of the central portion, a
first lateral
flange projecting outwardly from the first upturned region, the first lateral
flange
having a first lateral edge, and a second lateral flange projecting outwardly
from the
second upturned region, the second lateral flange having a second lateral
edge, the
continuous top plate having first and second longitudinal edges; a continuous
bottom
plate having a central portion, first and second upturned regions projecting
upwardly
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from opposite edges of the central portion, a first lateral flange projecting
outwardly
from the first upturned region, the first lateral flange having a first
lateral edge, and a
second lateral flange projecting outwardly from the second upturned region,
the
second lateral flange having a second lateral edge, the continuous bottom
plate
having first and second longitudinal edges; and an elastomeric member disposed
between the top and bottom plate. The first lateral edge of the top plate and
the
second lateral edge of the top plate define a inward curving or inward angled
edge
from an outer surface of the top plate to an inner surface of the top plate in
a side
view, and the first lateral edge of the bottom plate and the second lateral
edge of the
bottom plate define a inward curving or inward angled edge from an outer
surface of
the bottom plate to an inner surface of the bottom plate in a side view; and
the first
longitudinal edge of the top plate and the second longitudinal edge of the top
plate
define a inward curving or inward angled edge from an outer surface of the top
plate
to an inner surface of the top plate in a side view, and the first
longitudinal edge of
the bottom plate and the second longitudinal edge of the bottom plate define a
inward curving or inward angled edge from an outer surface of the bottom plate
to an
inner surface of the bottom plate in a side view. The adapter pad may also
include a
first compression shim disposed below the first lateral flange of the bottom
plate; and
a second compression shim disposed below the second lateral flange of the
bottom
plate.
[0024] The first lateral edge of the top plate and the second lateral edge
of the top
plate may include curved portions from a top view, and the first lateral edge
of the
bottom plate and the second lateral edge of the bottom plate may include
curved
portions from a top view.
[0025] The first lateral edge of the top plate and the second lateral edge
of the top
plate include a continuous radius in a top view measured from a vertical axis
at a
center point of the central portion of the top plate, and the first lateral
edge of the
bottom plate and the second lateral edge of the bottom plate include a
continuous
radius in a top view measured from a vertical axis at a center point of the
central
portion of the bottom plate. Any point on the lateral edge, when the top plate
is
rotated up to 41 milliradians from the neutral position relative to the bottom
plate,
may have a linear displacement less than or equal to 0.234,
[0026] The elastomeric member may extend laterally outward beyond the first
and second lateral edges of the top and bottom plates and, the elastomeric
member
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extends longitudinally outward beyond the first and second longitudinal edges
of the
top and bottom plates.
[0027] The thickness of portions of the elastomeric members disposed
between
the first and second lateral flanges of the top and bottom plates may be
precompressed from a static state.
[0028] The elastomeric member disposed between the central portions of the
top
and bottom plates may have a substantially uniform thickness.
[0029] The adapter pad may have an overall longitudinal length of about 6.5
inches to about 8.5 inches, and the adapter pad may have an overall lateral
length of
about 9 inches to about 11 inches.
[0030] The elastomeric member may have a hardness between 65-80 Shore A
durometer.
[0031] In another example, the disclosure provides a roller bearing adapter
pad
system configured for use with a three-piece truck having AAR standard
geometry.
The roller bearing adapter pad system may include a roller bearing adapter
configured to engage a roller bearing, the roller bearing adapter having a top
surface; and a bottom surface configured to engage a roller bearing. The
roller
bearing adapter pad system may also include an adapter pad engaged with the
roller
bearing adapter and configured to engage a side frame pedestal roof. The
adapter
pad may include a top plate; a bottom plate; and an elastomeric member
disposed
between the top and bottom plate. The combined top plate, bottom plate, and
elastomeric member may provide a longitudinal stiffness of at least 45,000
pounds
per inch through a longitudinal displacement of the top plate relative to the
bottom
plate of up to 0.139 inches from a central position, a lateral stiffness of at
least
45,000 pounds per inch through a lateral displacement of the top plate
relative to the
bottom plate of up to 0.234 inches from the central position, and a rotational
stiffness
of at least 250,000 pound *inches per radian of rotation through a rotational
displacement of the top plate relative to the bottom plate of up to 41
milliradians from
the central position when a vertical load of 35,000 pounds is applied to the
central
portions of the adapter pad. The roller bearing adapter may also include a
first
compression shim disposed below the first lateral flange of the bottom plate;
and a
second compression shim disposed below the second lateral flange of the bottom
plate.
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[0032] The highest strain values occur inward of the outer edges of the
elastomeric member when the top plate is displaced 0.234 inches laterally
relative to
the bottom plate. The combined top plate, bottom plate, and elastomeric member
of
the adapter pad provide a strain that is less than 90% when the top plate is
displaced
0.234 inches laterally relative to the bottom plate.
[0033] The highest strain values occur inward of the outer edges of the
elastomeric member when the top plate is displaced 0.139 inches longitudinally
relative to the bottom plate. The combined top plate, bottom plate, and
elastomeric
member of the adapter pad provide a strain that is less than 90% when the top
plate
is displaced 0.139 inches longitudinally relative to the bottom plate.
[0034] The portion of the elastomeric member disposed between the central
portions of the top and bottom plates may have a substantially uniform
thickness.
[0035] In another example, a roller bearing adapter pad system configured
for
use with a three-piece truck having AAR standard geometry is disclosed. The
roller
bearing adapter pad system includes a roller bearing adapter configured to
engage a
roller bearing, the roller bearing adapter comprising: a top surface; a bottom
surface
configured to engage a roller bearing; first and second vertical shoulders
that project
upwardly from opposite lateral edges of the top surface; an adapter pad
engaged
with the roller bearing adapter and configured to engage a side frame pedestal
roof,
the adapter pad comprising: a continuous top plate having a central portion,
first and
second upturned regions projecting upwardly from opposite edges of the central
portion, a first lateral flange projecting outwardly from the first upturned
region, and a
second lateral flange projecting outwardly from the second upturned region; a
continuous bottom plate having a central portion, and first and second
upturned
regions projecting upwardly from opposite edges of the central portion, a
central
elastomeric member disposed between the central portion of the top and bottom
plates; a bushing system, the bushing system comprising: a shaft; and a
bushing.
The first and second laterally projecting flanges of the top plate are
disposed above
the vertical shoulders of the roller bearing adapter.
[0036] The bushing system may further comprise elastomeric material
disposed
between the bushing and the shaft. The elastomeric material may occupy
substantially all the area between the bushing and the shaft.
[0037] The bushing may be engaged with the first lateral flange of the top
plate
and the shaft may be engaged with the roller bearing adapter. The bushing may
be
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integrally formed with the first lateral flange of the top plate and the shaft
may be
integrally formed with the roller bearing adapter.
[0038] The shaft may be engaged with the first lateral flange of the top
plate and
the bushing may be engaged with the roller bearing adapter. The shaft may be
integrally formed the first lateral flange of the top plate and the bushing
may be
integrally formed with the roller bearing adapter.
[0039] The bushing may have generally cylindrical cross-sectional shape.
The
shaft may have a generally cylindrical cross-sectional shape.
[0040] The bushing system may include four bushing systems and each bushing
system may include a bushing and a shaft.
[0041] The combined top plate, bottom plate, elastomeric member, and
bushing
system may provide a longitudinal stiffness of at least 45,000 pounds per inch
through a longitudinal displacement of the top plate relative to the bottom
plate of up
to 0.139 inches from a central position, a lateral stiffness of at least
45,000 pounds
per inch through a lateral displacement of the top plate relative to the
bottom plate of
up to 0.279 inches from the central position, and a rotational stiffness of at
least
250,000 pound *inches per radian of rotation through a rotational displacement
of
the top plate relative to the bottom plate of up to 52.4 milliradians from the
central
position when a vertical load of 35,000 pounds is applied to the central
portion of the
adapter pad.
[0042] The roller bearing adapter may have a height of the adapter pad at a
central portion is about 1.15 inches to about 1.8 inches. And the height of
the
adapter pad at the central portion may be about 1.5 inches.
[0043] In another example, a roller bearing adapter pad system configured
for
use with a three-piece truck is disclosed. The roller bearing adapter pad
system
includes a roller bearing adapter configured to engage a roller bearing, the
roller
bearing adapter comprising: a top surface; a bottom surface configured to
engage a
roller bearing; an adapter pad engaged with the roller bearing adapter and
configured to engage a side frame pedestal roof, the adapter pad comprising: a
top
plate; a bottom plate; an elastomeric member disposed between the top and
bottom
plates; a bushing system, the bushing system comprising: a shaft; a bushing;
and
elastomeric material disposed between the bushing and the shaft.
[0044] The bushing may be engaged with the top plate. The shaft may be
engaged with the top plate.
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[0045] The bushing system may comprise four bushing systems and each
bushing system may comprise a bushing and a shaft.
[0046] The height of the adapter pad at a central portion may be about 1.5
inches.
[0047] In another example, a roller bearing adapter pad system configured
for
use with a three-piece truck is disclosed. The roller bearing adapter pad
system
include a roller bearing adapter pad configured to engage a roller bearing
adapter
and configured to engage a side frame pedestal roof, the adapter pad
comprising: a
top plate; a bottom plate; an elastomeric member disposed between the top and
bottom plates; a bushing system, the bushing system comprising: a shaft; a
bushing.
The combined top plate, bottom plate, elastomeric member, and bushing system
provide a longitudinal stiffness of at least 45,000 pounds per inch through a
longitudinal displacement of the top plate relative to the bottom plate of up
to 0.139
inches from a central position, a lateral stiffness of at least 45,000 pounds
per inch
through a lateral displacement of the top plate relative to the bottom plate
of up to
0.279 inches from the central position, and a rotational stiffness of at least
250,000
pound *inches per radian of rotation through a rotational displacement of the
top
plate relative to the bottom plate of up to 52.4 milliradians from the central
position
when a vertical load of 35,000 pounds is applied to a central portion of the
adapter
pad.
[0048] The bushing may be engaged with the top plate, or the shaft may be
engaged with the top plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] Figure 1A is a perspective view of a standard 3-piece truck.
[0050] Figure 1B is an exploded view of a standard 3-piece truck.
[0051] Figure 2 is a perspective view of a roller bearing adapter and
adapter pad
according to aspects of the disclosure.
[0052] Figure 3 is a cross-sectional view of roller bearing adapter,
adapter pad,
and a side frame according to aspects of the disclosure.
[0053] Figure 3A is a detail view of a portion of Figure 3.
[0054] Figure 3B is a detail view of a portion of Figure 3.
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[0055] Figure 4 is a perspective view of a roller bearing adapter according
to
aspects of the disclosure.
[0056] Figures 5A-5D are perspective views of roller bearing adapters
according
to aspects of the disclosure.
[0057] Figure 6 is a cross-sectional view of the roller bearing adapter of
Figure 4
taken along a centerline.
[0058] Figure 7 is a top view of the roller bearing adapter of Figure 4.
[0059] Figure 8 is a side view of the roller bearing adapter of Figure 4.
[0060] Figure 9 is a front view of the roller bearing adapter of Figure 4.
[0061] Figure 10 is a cross-sectional view taken along line A-A of Figure
8.
[0062] Figure 11 is a top view of an adapter pad according to aspects of
the
disclosure.
[0063] Figure 11A is a cross-sectional view taken along line A-A of Figure
11.
[0064] Figure 11B is a cross-sectional view taken along line B-B of Figure
11.
[0065] Figure 110 is a detail view of detail G of Figure 11.
[0066] Figure 12 is a side view of a bottom plate of an adapter pad
according to
aspects of the disclosure.
[0067] Figure 13A is a top view of an adapter pad according to aspects of
the
disclosure.
[0068] Figure 13B is a cross-sectional view taken along the longitudinal
line of
Figure 13A.
[0069] Figure 130 is a section view along the longitudinal center
centerline of an
adapter pad and a portion of a roller bearing adapter according to aspects of
the
disclosure.
[0070] Figure 130 is a perspective view of an adapter pad according to
aspects
of the disclosure with all elastomeric material removed including a ground
strap.
[0071] Figure 13E is a perspective view of an adapter pad according to
aspects of
the disclosure including a ground strap.
[0072] Figure 14 is an exemplary graph depicting adapter pad lateral force
vs.
displacement according to aspects of the disclosure.
[0073] Figure 15 is an exemplary graph depicting temperature vs. time
during
loading of an adapter pad according to aspects of the disclosure.
[0074] Figure 16A is a top view of an adapter pad without the top plate
according
to aspects of the disclosure.
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[0075] Figure 16B is cross-sectional view of adapter pad according to
aspects of
the disclosure.
[0076] Figure 17A is a top view of an adapter pad according to aspects of
the
disclosure.
[0077] Figure 17B is a top view of the adapter pad of Figure 17A depicting
longitudinal displacement.
[0078] Figure 17C is a top view of the adapter pad of Figure 17A depicting
lateral
displacement.
[0079] Figure 17D is a top view of the adapter pad of Figure 17A depicting
rotational displacement.
[0080] Figure 18 is a depiction of a method of manufacturing an adapter pad
according to aspects of the disclosure.
[0081] Figure 19 is a perspective view of an elastomeric member of an
adapter
pad according to aspects of the disclosure.
[0082] Figure 20A-C are vertical sectional views of a portion of an adapter
pad
according to aspects of the disclosure showing various geometries for the
plurality of
gaps, with the adapter pad in an unloaded configuration.
[0083] Figure 21A-C are each views of the respective Figures 20a-20c
schematically showing the geometry of the gaps altered when load is applied to
the
adapter pad.
[0084] Figure 22 is a sectional view of a portion of an adapter pad
according to
aspects of the disclosure, showing a representative alignment of the plurality
of gaps
within the elastomeric portion.
[0085] Figure 23 is a sectional view of a portion of the adapter pad
according to
aspects of the disclosure showing a plurality of gaps extending only a partial
thickness of the elastomeric layer.
[0086] Figure 24 is a depiction of a method of manufacturing an adapter pad
according to aspects of the disclosure.
[0087] Figure 25 is a depiction of a method of manufacturing an adapter pad
according to aspects of the disclosure.
[0088] Figures 25A-25I are perspective views of adapter pads according to
aspects of the disclosure.
[0089] Figure 26 is a depiction of a method of manufacturing an adapter pad
according to aspects of the disclosure.
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[0090] Figure 27 is an exemplary graph depicting testing of an adapter pad
according to aspects of the disclosure.
[0091] Figure 28 is a perspective view of an adapter pad according to
aspects of
the disclosure.
[0092] Figure 29A is a top view of the adapter pad of Figure 28.
[0093] Figure 29B is a top view of the adapter pad of Figure 28 showing the
plates in dotted lines.
[0094] Figure 30 is a cross-sectional view taken along line A-A of Figure
29.
[0095] Figure 31 is a detail view of a portion of Figure 30.
[0096] Figure 31A is a detail view of another embodiment of a portion of an
adapter pad similar to Figure 31.
[0097] Figure 31B is a detail view of another embodiment of a portion of an
adapter pad similar to Figure 31.
[0098] Figure 32 is a cross-sectional view taken along line B-B of Figure
30.
[0099] Figure 33 is a detail view of a portion of Figure 32.
[00100] Figure 33A is a detail view of another embodiment of a portion of
an
adapter pad similar to Figure 33.
[00101] Figure 33B is a detail view of another embodiment of a portion of
an
adapter pad similar to Figure 33.
[00102] Figure 34A is a screen shot of finite element analysis simulation
results
from a computer showing strain within the elastomeric portion when the top
plate is
displaced laterally relative to the bottom plate according to aspects of this
disclosure.
[00103] Figure 34B is a screen shot of a portion of the finite element
analysis
simulation results of Figure 34B.
[00104] Figure 35A is a screen shot of finite element analysis simulation
results
from a computer showing strain within the elastomeric portion when the top
plate is
displaced longitudinally relative to the bottom plate according to aspects of
this
disclosure.
[00105] Figure 35B is a screen shot of a portion of the finite element
analysis
simulation results of Figure 35B.
[00106] Figure 36A is a perspective view of an adapter pad and roller
bearing
adapter according to aspects of the disclosure.
[00107] Figure 36B is a side view of an adapter pad and roller bearing
adapter
according to aspects of the disclosure.
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[00108] Figure 36C is a top view of the adapter pad and roller bearing
adapter
of Figure 36A.
[00109] Figure 36D is a cross-sectional view of the adapter pad and roller
bearing adapter of Figure 360 taken along the line A¨A.
[00110] Figure 36E is a front view of the adapter pad and roller bearing
adapter
of Figure 36A.
[00111] Figure 37 is a perspective view of an adapter pad according to
aspects
of the disclosure.
[00112] Figure 38 is a top view of the adapter pad of Figure 37.
[00113] Figure 39 is a bottom view of the adapter pad of Figure 37.
[00114] Figure 40 is a front view of the adapter pad of Figure 37.
[00115] Figure 41 is a back view of the adapter pad of Figure 37.
[00116] Figure 42 is a side view of the adapter pad of Figure 37.
[00117] Figure 43 is a side view of the adapter pad of Figure 37.
[00118] Figure 44 is a perspective view of an adapter according to aspects
of
the disclosure.
[00119] Figure 45 is a front view of the adapter pad of Figure 44.
[00120] Figure 46 is a side view of the adapter pad of Figure 44.
[00121] Figure 47 is a back view of the adapter pad of Figure 44.
[00122] Figure 48 is a side view of the adapter pad of Figure 44.
[00123] Figure 49 is a top view of the adapter pad of Figure 44.
[00124] Figure 50 is a bottom view of the adapter pad of Figure 44.
[00125] Figure 51A is a perspective view of an adapter pad and roller
bearing
adapter according to aspects of the disclosure
[00126] Figure 51B is a cross-sectional view of the adapter pad and roller
bearing adapter of Figure 51A.
[00127] Figure 52A is a perspective cross-sectional view of a bushing
system
according to aspects of the disclosure.
[00128] Figure 52A is a perspective cross-sectional view of a bushing
system
according to aspects of the disclosure.
[00129] Figure 52B is a side cross-sectional view of the bushing system of
Figure 52A.
[00130] Figure 520 is a perspective cross-sectional view of a bushing
system
according to aspects of the disclosure.
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DETAILED DESCRIPTION
[00131] In the following description of various example structures
according to
the invention, reference is made to the accompanying drawings, which form a
part
hereof, and in which are shown by way of illustration various example devices,
systems, and environments in which aspects of the invention may be practiced.
It is
to be understood that other specific arrangements of parts, example devices,
systems, and environments may be utilized and structural and functional
modifications may be made without departing from the scope of the present
invention. Also, while the terms "top," "bottom," "front," "back," "side,"
"rear," and the
like may be used in this specification to describe various example features
and
elements of the invention, these terms are used herein as a matter of
convenience,
e.g., based on the example orientations shown in the figures or the
orientation during
typical use. Additionally, the term "plurality," as used herein, indicates any
number
greater than one, either disjunctively or conjunctively, as necessary, up to
an infinite
number. Nothing in this specification should be construed as requiring a
specific
three dimensional orientation of structures in order to fall within the scope
of this
invention. Also, the reader is advised that the attached drawings are not
necessarily
drawn to scale.
[00132] In general, aspects of this invention relate to a railcar truck,
and railcar
truck roller bearing adapters and adapter pads. According to various aspects
and
embodiments, the railcar truck and the railcar truck roller bearing adapters
and
adapter pads may be formed of one or more of a variety of materials, such as
metals
(including metal alloys), polymers, and composites, and may be formed in one
of a
variety of configurations, without departing from the scope of the invention.
It is
understood that the railcar truck roller bearing adapters and adapter pads may
contain components made of several different materials. Additionally, the
components may be formed by various forming methods. For example, metal
components, may be formed by forging, molding, casting, stamping, machining,
and/or other known techniques. Additionally, polymer components, such as
elastomers, can be manufactured by polymer processing techniques, such as
various molding and casting techniques and/or other known techniques.
[00133] The various figures in this application illustrate examples of
railcar
trucks, railcar truck roller bearing adapters, and adapter pads according to
this
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invention. When the same reference number appears in more than one drawing,
that reference number is used consistently in this specification and the
drawings
refer to the same or similar parts throughout.
[00134] As shown in Figures 1A and 1B, a typical railroad freight car truck
includes an assembly made up of two wheel sets 1 each including two wheels 2,
two
side frames 4, one bolster 6, two spring groups 8, a friction damping system,
and
four adapters 10. Figures lA and 1B depict an example truck assembly.
[00135] The side frames 4 are arranged longitudinally, e.g., in the
direction of
the rails upon which the truck sits. The bolster 6 is aligned transversely or
laterally
with respect to the side frames 4 and extends through the middle of each side
frame
4.
[00136] The bolster bowl 12 is the round section of the bolster 6 that
includes a
rim that protrudes upward. The body centerplate of the car body rests in the
bolster
bowl 12 and acts as a rotation point for the truck and car body. It is at this
interface
that the majority of the vertical load of the freight car is reacted. Usually,
the bolster
bowl 12 is equipped with wear plates or a wear liner so that the bolster
casting 6 is
prevented from wear during the service life of the freight car. Also on the
top surface
of the bolster 6 and located 25 inches off the centerline are the side
bearings 14,
which can help stabilize the car body and can provide some prevention of truck
hunting if they are of the constant contact type. The side bearings 14 shown
in
Figure 1B are not of the constant contact type but rather consist of rollers
and a
cage.
[00137] The bolster 6 rests on top of spring groups 8 that are supported
underneath by the spring seat of the side frames. Additional springs, often
called
snubber or side springs 17, can also be part of the spring group and rest on
the
spring seat extending upward to the bottom of friction wedges 16 that can be
part of
the friction damping system.
[00138] The friction wedges 16 can be located in pockets at the end of and
to
each side of the bolster 6. The friction wedge pockets of the bolster can be
angled,
typically at an angle of about 60 from horizontal matching the angle surface
of the
friction wedges. The opposite face of a friction wedge 16 is typically
vertical and
contacts what is called the column face of the side frame. The spring force of
the
snubber springs 17 pushes the friction wedge 16 against the angled surface of
the
17
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bolster friction wedge pocket which creates a reaction force against the
vertical
column face of the side frame.
[00139] As the bolster 6 moves up and down under the load from the freight
car
resting on the truck, the sliding of the friction wedge 16 against the column
face can
create column friction damping. This damping can provide for a dissipation of
energy that prevents the freight car from developing undesired
vibrations/oscillations
when moving in railroad service. It is also these forces acting between the
bolster 6
and side frame 4 through the friction wedges 16 that seeks to prevent the
truck from
taking on a parallelogram geometry when under operation. Hard stops, such as
the
gibs and rotation stops, help prevent trucks from taking on an extreme
parallel
shape. This resistance to parallelogramming is often called warp stiffness.
[00140] As shown in Figures 1A and 1B, the wheel sets 1 of the truck
assembly
consist of two wheels 2, an axle 3, and two roller bearings 5. The wheels are
press
fit onto the raised wheel seats of the axle. The journal of the axles extend
outboard
of the wheels and provide the mounting surface for the roller bearings 5. The
roller
bearings 5 are press fit onto the axle journals. The interface between the
roller
bearings 5 and the side frames 4 can consist of a bearing adapter 7. Typically
railroad freight car trucks have been equipped with metal adapters that are
precisely
machined to fit on the roller bearings rather tightly while providing a looser
fit to the
steel side frame pedestals which envelope the interface between the roller
bearings
and the side frames. This interface provides a small movement between the
wheel
sets and the side frames which is controlled by the vertical load that exists
from the
freight car and the frictional forces that exist between the sliding metallic
surface on
top of the adapter, referred to as the adapter crown, and the bottom of the
steel
pedestal roof which is usually equipped with a steel wear plate.
[00141] Because the vertical load varies with the lading weight contained
in the
freight car and with the rocking motion of the freight car on the truck, the
frictional
forces at the metal adapter crown and steel pedestal roof wear plate can vary
considerably and are not controlled in the typical truck. This metal to metal
connection requires large wheelset forces to force sliding at the interfacing
surface
due to the stick-slip nature of metal sliding connections. More recent truck
designs,
such as those trucks qualified under the American Association of Railroads
("AAR")
M-976 specification, now include an adapter pad at the interface between the
steel
adapter and the pedestal roof.
18
[00142] Some adapter pad systems have been successful in lowering wheelset
forces during railcar curving by allowing low stiffness compliance between the
side
frame and axle. This added compliance created by the adapter pad also reduces
the
force it takes to pull or push a railcar through a curve as required in the M-
976
specification. Adversely, these designs
have lowered the speed at which the car resonates during tangential track
travel,
otherwise described as lowering the hunting speeds of the cars. Lowering the
hunting speed is a disadvantage because it limits the operating speeds of the
trains
and increases the risk of derailing cars or damaging track. Other designs
utilize
premium side frame squaring devices such as transoms, frame bracing, steering
arms, spring planks, yaw dampers, cross bracing, or additional friction wedges
to
improve the hunting performance. These systems, generally referred to as
premium
truck technology, typically increase the wheelset forces and therefore the
pulling
resistance during curving. In addition to increasing curve resistance, these
designs
have traditionally increased truck maintenance costs due to the added wear
components and system complexity.
[00143] Adapter pad system embodiments described herein can meet the
curving performance criteria set forth in M-976, without decreasing the
critical
hunting threshold. The adapter pad systems described herein also do not
require
any additional side frame squaring devices, such as transoms, frame bracing,
steering arms, spring planks, yaw dampers, cross bracing, or additional
friction
wedges, to be added to a standard 3-piece truck. The resulting truck system
described herein can improve the life of the wheelsets, maintain a high
hunting
threshold, improve the durability of the pad system, and minimize wear and
forces
exerted on the rails.
[00144] By way of background, there are many different rail car types and
services native to the North American Rail Industry which require different
truck
sizes. Cars designed for 70 ton service have a Gross Rail Load of 220,000
lbs., and
commonly use 28 inch or 33 inch wheels with 6 inch x 11 inch bearings. Cars
designed for 100 ton service have a Gross Rail Load of 263,000 lbs., and
commonly
use 36 inch wheels with 6.5 inch x 12 inch bearings. Cars designed for 110 ton
service have a Gross Rail Load of 286,000 lbs. and must meet the performance
specification M-976 as mentioned above. These 110 ton cars typically use 36
inch
wheels with 6.5 inch x 9 inch bearings. The final car type typical to North
America is
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designed for 125 ton service and has a Gross Rail Load of 315,000 lbs. This
car
type typically uses 38 inch wheels with 7 inch x 12 inch bearings. The other
truck
sizes ¨70 ton, 100 ton, and 125 ton are not subject to the same strict
performance
standard, and thus have not required the use of pads to date.
[00145] The roller bearing adapter and matching adapter pad are the focus
of
this application. Embodiments of the disclosed adapter and matching adapter
pad
system can be used with cars designed for 110 ton service and can be scalable
for
use with and improve the performance of trucks for all car capacities
(including 70
ton, 100 ton, 110 ton, and 125 ton), including those trucks that do not
require
compliance with the M-976 standard.
[00146] One embodiment of the adapter pad system 198 is shown in at least
Figures 2 and 3. The adapter pad system 198 may comprise a roller bearing
adapter 199 and an adapter pad 200 configured to be disposed between a
wheelset
roller bearing or roller bearing 5 and a side frame pedestal roof 152 of a
three-piece
railcar truck. The side frame can include first and second outer sides 154,
156. The
adapter pad 200 also includes an elastomeric member 360 that supports the
vertical
load and allows for low force longitudinal, lateral, and rotational motion of
the top
plate 220 (engaged with the side frame) relative to the bottom plate 240
(engaged
with the roller bearing adapter) as compared to a traditional steel-steel
sliding
adapter system.
[00147] In some embodiments, as shown in at least Figures 2-3, the adapter
pad system 198, when installed within a truck system is compressed with a
constant
vertical load, due to the weight of the railcar and truck components that are
carried
by the adapter pad 200 and ultimately transferred to the track through the
wheel
sets. While the vertical load that is imparted upon the central portion of the
adapter
pad 200 naturally varies with the different loading of the railcar, it has
been assumed
that a vertical load can be about 35,000 pounds per adapter pad for about a
corresponding 286,000 gross rail load car.
[00148] It has been determined through testing that the performance of the
truck system is highly influenced by the stiffness of the adapter pad 200.
More
specifically, in certain embodiments, it has been determined that truck
performance
can be improved with improved adapter pad system performance. The adapter pad
system performance can be improved by increasing the stiffness of the adapter
pad
system 198 (measured in pounds of force per inch of displacement).
Additionally, for
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example, it has been determined that acceptable life expectancy (measured in
distance traveled under load of a truck system that includes an adapter pad
200
installed, which a design life has been determined to be 1 million miles of
railcar
travel) is expected for an adapter pad 200 like embodiments discussed herein
when
a longitudinal stiffness is at least 45,000 pounds per inch or in the range of
about
45,000 pounds per inch to about 80,000 pounds per inch, and/or when a lateral
stiffness is at least 45,000 pounds per inch or in the range of about 45,000
pounds
per inch to about 80,000 pounds per inch, and/or when a rotational stiffness
(i.e.
stiffness to resist rotation about the vertical axis) is at least 250,000
pound * inches
per radian or in the range of about 250,000 pound * inches per radian to about
840,000 pound*inches per radian (each of these measured when a 35,000 pound
vertical load is applied to the central portion of the adapter 200). These
unique
stiffness combinations can maximize the hunting threshold speed, while still
maintaining a curve resistance below 0.40 lbs/ton/degree of curvature as
required by
the M-976 specification without the use of premium truck technologies
utilizing
transoms, frame bracing, steering arms, spring planks, yaw dampers, cross
bracing,
or additional friction wedges to improve performance.
[00149] Stiffness of the adapter pad system is quantified by measuring the
adapter assembly resistance to relative shear displacement of the top plate
(which is
engaged with the side frame), and the bottom plate (which is engaged with the
roller
bearing adapter). To determine the stiffness, the adapter assembly can be
displaced
relative to the side frame in multiple directions, such as, longitudinal (in
the direction
of railcar travel), lateral (across the rail tracks), yaw (rotation about a
vertical axis
and in line with axle center line), and vertical (between side frame pedestal
roof and
adapter pad top surface). A vertical load of 35,000 should be maintained
during
shear stiffness testing to simulate a loaded car scenario.
[00150] During testing, the force to displace the top plate relative to the
bottom
plate can be measured using load cells attached to a force actuator.
Displacement
measurements can be collected with displacement transducers, dial indicators,
potentiometers, or other displacement measuring instruments. As described in
more
detail below, the force and displacement is plotted, with the slope of the
hysteresis
loop indicating the stiffness in the respective direction. The area contained
within the
loop is proportional to the energy displaced during the load cycle.
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[00151] Embodiments of the adapter pad system 198 described herein provide
a thrust lug opening width and spacing sufficient to not limit displacement
within the
AAR values, even with the use of high stiffness shear pads as described
herein. The
disclosed adapter design may utilize target adapter displacements shown in
Table 1
below.
Table 1
AAR ADAPTER TO SIDE FRAME CLEARANCE STACKUP
NEW COMPONENTS
Features Maximun Minimun
Longitudinal Clearance
.139 .017
(Each direction from center: in.)
Lateral Clearance
.234 .126
(Each direction from center: in.)
Rotataional Clearance
41.0 9.2
(Each direction from center: mRad.)
[00152] Disclosed embodiments of the adapter pad system 198 with the
disclosed longitudinal, lateral, and rotational shear stiffness as described
herein can
provide an advantageous combination of high speed stability and low curve
resistance for the 3-piece truck system. Disclosed embodiments of the adapter
pad
system 198 can increase the warp restraint of the 3-piece truck system as
compared
to other adapter pad designs. This can allow for increased high speed
stability. In
addition to improvements in high speed stability, embodiments of the adapter
pad
system 198 described herein can promote longitudinal displacement of the
wheelset
during curving, allowing the leading and trailing axle of the truck assembly
to develop
an inter-axle yaw angle proportional to the curve which can lower wheelset
forces.
In combination, the adapter pad system 198 promotes lateral wheelset shift to
develop an optimal rolling radius difference during curving. The adapter pad
system
stiffness and displacement ranges disclosed herein can allow for optimal inter-
axle
yaw angle and lateral wheelset shift, promoting low wheelset force solution
through
curves. Reduction in curving forces and improved high speed stability can
contribute
to improvements in wheelset and rail life.
22
[00153] Some adapter pad designs utilize multiple elastomer layers to
reduce
shear strain. These multiple layers can add significant thickness to the
adapter
system and when used in conventional trucks, raise the height of the car.
Raising
the height of the car creates issues coupling to other cars, as well as raises
the
center of gravity. As a result some designs required the use of special, non-
conventional side frames to minimize the height difference. Embodiments
discussed
herein can allow for improved dynamic performance, without requiring the use
of
special, non-conventional truck components.
[00154]
Embodiments discussed herein can be used with side frames having
AAR standard geometry, including AAR standard pedestal geometry and AAR
standard thrust lug clearances, as described in the Association of American
Railroads Manual of Standards and Recommended Practices, Section SII
(10/25/2010), Specification S-325 (6/11/2009) ¨ "Side Frame, Narrow Pedestal -
Limiting Dimensions". AAR
standard
pedestal geometry can be described as including nominal longitudinal thrust
lug
spacing of about 7.25 - 8.25 inches; nominal thrust lug width of about 3.5-
3.75
inches; nominal longitudinal jaw spacing of about 8.88-11.06 inches; and
nominal
pedestal roof height above the centerline of the axle of about 5.38 - 6.89
inches.
Embodiments of the adapter pad system 198 disclosed herein can be used with
existing and/or standard 3 piece truck systems, including truck systems having
AAR
standard geometry as described in the Association of American Railroads Manual
of
Standards and Recommended Practices, and more specifically, Section H
(1/1/2012), Specification M-924 (2/1/2014) - "Journal Roller Bearing Adapters
for
Freight Cars" . AAR
standard thrust lug
clearance can be found above in Table 1 for new casting manufacturing
dimensions. The thrust lug clearance is determined through the distance
between
the pedestal area and the roller bearing adapter openings. Standard AAR
adapter
dimensions can include nominal longitudinal thrust lug bearing surface spacing
of
about 7.156 - 8.656 inches; and a nominal lateral thrust lug opening of about
3.812 -
4.062 inches. Embodiments of the adapter pad system 198 described herein can
also meet American Association of Railroads ("AAR") M-976 specification (AAR
Manual of Standards and Recommended Practices, Section D (9/1/2010),
Specification M-976 (12/19/2013) - "Truck Performance for Rail Cars").
For example, embodiments of the adapter pad
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system 198 can be used in existing and/or standard 3 piece truck systems
without
the use of additional pieces such as transoms, frame braces, or spring planks.
Additionally, for example, adapter pad systems 198 disclosed herein can fit
between
the roller bearing 5 and the pedestal roof 152 of existing trucks. Thus,
adapter pad
systems 198 disclosed herein can have a total height measured between an upper
surface of the roller bearing 5 and the pedestal roof 152 of about 1.3 inches
or in the
range of about 1.1 inches to about 1.5 inches. While the embodiments described
herein are specific to the 110T truck, the disclosed adapter and matching
adapter
pad system can be scalable for use with and improve the performance of trucks
for
all car capacities (70 ton, 100 ton, 110 ton, and 125 ton), including those
trucks that
do not require compliance with the M-976 standard.
[00155] A roller
bearing adapter 198 in accordance with the present disclosure
is shown in Figures 4-10. As shown in Figure 4, the roller bearing adapter 199
includes a pedestal crown surface 102. The pedestal crown surface or top
surface
102 can in some embodiments be a crowned or curved surface such that the
central
area of the pedestal crown surface is higher than the lateral edges. Thus, the
pedestal crown surface 102 can be generally flat in the longitudinal direction
and
curved in the lateral direction. The pedestal crown surface 102 can be an AAR
standard pedestal crown surface but can have a thinner cross-sectional
thickness
than a typical roller bearing adapter. For example, in some embodiments, the
roller
bearing adapter thickness can be between about 0.6 inches thick (measured from
the bearing surface 117 to the pedestal crown surface 102 at the centerline)
to about
0.75 inches thick and in some embodiments less than about 0.75 inches thick.
[00156] As shown
in Figures 4-8 the roller bearing adapter 199 can have an
overall height of about 4.83 inches or within the range of about 4 inches to
about 6
inches; an overall length of about 9.97 inches or in the range of about 9
inches to
about 11 inches; and an overall width of about 10 inches or at least 7.5
inches or in
the range of about 9 inches to about 11 inches.
[00157] The
roller bearing adapter 199 can include features to limit the motion of
the adapter pad 200 relative to the roller bearing adapter 199. For example,
the
roller bearing adapter can include longitudinal adapter pad stops 104. As
shown in
Figure 4, the longitudinal pad stops 104 can be raised vertically relative to
the lateral
edges of the pedestal crown surface 102. The longitudinal adapter pad stops
104
are designed to interface with slots, recesses, or edges of the bottom plate
240 of
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the adapter pad 200 and can engage the adapter pad 200 such that the
longitudinal
motion of the adapter pad 200 can be restricted or controlled to a specified
value
while not restricting the lateral movement of the adapter pad. Although four
longitudinal adapter pad stops 104 are shown in Figure 4, any number or design
of
longitudinal pad stops can be used, including continuous longitudinal pad
stops that
extend the entire length of the lateral edge of the pedestal crown surface
102.
Examples of other possible longitudinal stops 104 are shown in Figures 5A-5D.
For
example, the longitudinal stops 104 can comprise two bosses per lateral side
as
shown in Figure 5A. The longitudinal stops 104 shown in Figure 5A can
interface
with reliefs in the bottom plate 240 of the adapter pad 200 that can engage
these
stops 104 such that the longitudinal motion can be restricted. Similar to
Figure 5A,
Figure 5B shows three stops 104 that can restrain the longitudinal movement of
the
adapter pad 200 relative to the adapter 199 in the same way.
[00158]
Longitudinal stops can be incorporated into other portions of the adapter
pad. For example, as shown in Figures 50 and 5D, longitudinal stops 104 can be
incorporated into the top surface of the vertical shoulder 106. Similarly, in
these
examples, reliefs in the bottom plate 240 of the adapter pad can fit around
these
stops 104 or bosses and provide longitudinal movement restraint of the bottom
plate
240 relative to the top plate 220.
[00159] Various
other combinations of sizes, shapes, and locations can be
utilized for the longitudinal stops 104 in order to provide the desired
restraint of
movement.
[00160] As shown
in Figures 4-8, the roller bearing adapter 199 also includes
vertical shoulders 106. The vertical shoulders 106 can be raised vertically
relative to
the longitudinal edges of the pedestal crown surface 102. The vertical
shoulders 106
are designed to improve the bending strength of the adapter 199 and minimize
distortion of the adapter 199 under the high forces imparted by the adapter
pad 200.
By minimizing distortion of the adapter pad 200 under load, the vertical
shoulders
106 can improve the load distribution to the roller bearing components and can
improve bearing life. The vertical shoulders 106 are designed to interface
with slots,
recesses, edges, or surfaces of the bottom plate 240 of the adapter pad 200
such
that the lateral motion of the bottom plate 240 is restricted or controlled to
a specified
value. In addition to limiting movement of the bottom plate, the vertical
shoulders
can provide vertical support to the laterally projecting flanges 116, 118 of
the adapter
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pad 200 in some embodiments. The vertical shoulders 106 can extend laterally
to
inches wide for a 6.5 inch x 9 inch adapter, and vertically about 1 inch above
the
standard pedestal crown surface. In some embodiments the upper surface of the
vertical shoulders 106 can be up to about 0.75 inch or up to about 3 inches
above
the pedestal crown surface 102. The vertical shoulders may also be up to about
8
inches in the longitudinal direction. The vertical shoulders may be cast
integral to
the adapter, and used on standard adapters for 70T, 100T, 110T, or 125T
service.
Although continuous vertical shoulders are shown, any number of vertical
shoulders
can be used. The width of the vertical shoulders can be at least 0.5 inches.
[00161] The roller bearing adapter 199 can also include features, such as
the
vertical shoulders 106, to improve the bending strength or cross-sectional
moment of
inertia of the adapter 199 to minimize distortion of the adapter 199 under the
high
forces imparted by the adapter pad 200. For example, for the embodiment shown
in
Figures 4, and 6-10, and more particularly shown in Figures 8 and 10, a cross-
section of the adapter 199 can be taken approximately through the longitudinal
center of the roller bearing adapter 199 as shown in Figures 8 and 10. As
shown in
Figure 10, a neutral Y-axis 108 can extend in the vertical direction through
the lateral
center of the adapter 199. A neutral Z-axis 110 can extend in the lateral
direction
about 5.2 inches, or in the range of about 5.0 inches and 5.5, above a center
axis of
an axle 111. The cross-sectional moment of inertia of the cross-section shown
in
Figure 10 around the neutral Z-axis 110, I z-z, at the center of the adapter
can be
about 1.4 in4, or in the range of about 1.0 to about 2.0 in4. The cross-
sectional
moment of inertia around the neutral Y-axis 108 at the center of the adapter,
I y-y at
the cross-section can be about can be about 86.8in4, or in the range of about
50 to
about 100 in4. Adapter designs which do not utilize vertical shoulders have
significantly lower area moment of inertia through lateral sections. For
example, an
adapter design as shown in Figure 10 but without vertical shoulders 106 at the
same
lateral centerline cross section can have a moment of inertia around the
neutral Z-
axis of about 0.2 in4 and can have a moment of inertia around the neutral Y-
axis of
about 32.9 in4. The resulting lower moment of inertia compared to the
disclosed
adapter can result in a lower stiffness and higher stresses in the adapter
under
similar load configurations, and possibly reduced roller bearing performance.
[00162] The roller bearing adapter 199 may be made from one or more
different types of alloys of steel that have suitable strength and other
performance
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characteristics. For example, roller bearing adapter 199 may be manufactured
from
cast iron of grade ASTM A-220, A-536, or cast or forged steel of grades ASTM A-
148, A-126, A-236, or A-201. In some embodiments, the entire roller bearing
adapter 199 is formed (cast, machined, pressed or another suitable metal
forming
operation) from a single monolithic member.
[00163] Moving now to the adapter pad 200 of the adapter system 198 which
is
configured to be disposed between and can engage with the roller bearing
adapter
199 and the side frame pedestal roof 152 of the side frame 4. As shown in
Figures
11-11C, and primarily Figure 11A, the adapter pad 200 generally includes an
upper
member or top plate 220 having an inner surface 222 and an outer surface 224,
a
lower member or bottom plate 240 having an inner surface 242 and an outer
surface
244, and an elastomeric member 360 disposed between the inner surfaces 222,
242
of the top and bottom plates 220, 240 along a portion of the adapter pad 200.
The
adapter pad 200 includes a central portion 210 that is disposed under the
lower
surface of the pedestal roof 152 with each plate 220, 240 having a
corresponding
central portion 226, 246. The adapter pad 200 further includes first and
second
upturned regions 212, 214 and first and second lateral flanges 216, 218. The
top
plate 220 has corresponding first and second upturned regions 228, 230
projecting
upward from opposite edges of the central portion 226 of the upper plate 220,
a first
lateral flange 232 projecting outward from the first upturned region, and a
second
lateral flange 234 projecting outward from the second upturned region 230.
Similarly, the bottom plate 240 has corresponding first and second upturned
regions
248, 250 projecting upward from opposite edges of the central portion 246 of
the
bottom plate 240, a first lateral flange 252 projecting outward from the first
upturned
region, and a second lateral flange 254 projecting outward from the second
upturned
region 250. As shown in Figure 3, the lateral flanges 216, 218 are disposed
laterally
outboard of the pedestal roof 152 when the truck system is assembled, and the
central portion 210 is disposed below the pedestal roof 152. First and second
upturned regions 212, 214 are disposed between the central portion 210 and the
respective first and second lateral flanges 216, 218 and provide a transition
there between.
[00164] Turning first to the central portion 210, which can in some
embodiments comprise primarily three parts including the central portion 226
of the
top plate, the central portion 246 of the bottom plate and the elastomeric
member
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360 disposed therebetween. As discussed above, the adapter pad 200 is disposed
between the side frame pedestal roof 152, which generally has a substantially
flat
horizontal engaging surface, and the roller bearing adapter 199 which can
generally
have a curved or crowned roof. As shown in Figure 11A and 12 the central
portion
246 of the bottom plate 240 can have a curved lower surface 244 such that the
outer
surface 244 generally follows the curve or crown of the adapter 199. More
specifically, in some embodiments the central portion 246 can have a greater
thickness toward the edges 261, 262 of the central section 246 than at the
center of
the central section 246. For example, as shown in Figure 12, the thickness at
the
center of the center portion 246 can be about 0.15 inches or in the range of
about
0.06 inches to about 0.35 inches and the thickness at the edges 261, 262 can
be
about 0.26 inches or in the range of about 0.15 inches to about 0.5 inches.
[00165] In some embodiments, the central section 226 of the top plate 220
can
include an outer surface 224 and an inner surface 222 that are substantially
horizontal and parallel as shown in Figure 11 A. The thickness of the center
portion
226 of the top plate 220 can be about 0.28 inches or in the range of about
0.15
inches to about 0.4 inches. In such a system, the thickness of the elastomeric
section 360 can be substantially similar throughout the central portion 210
which can
in some embodiments increase performance characteristics.
[00166] It has been found that an elastomeric section having a uniform
thickness can in some circumstances have certain advantages. For example, in
certain embodiments, linear thermal shrinkage can be constant along the length
and
width of the pad if the plurality of elastomer layers have common length and
width
dimensions among all members. For example, in some embodiments, during
molding the rubber forming the elastomeric member can be injected into the
mold at
around 300 degrees Fahrenheit, and it can subsequently cool to room
temperature.
Linear thermal shrink normal to the shear plane can be related to the section
thickness "T" the change in temperature, and the coefficient of thermal
expansion. A
non-uniform elastomer thickness can result in non-uniform shrinkage during the
cooling process. Non-uniform shrinkage can result in residual tensile stresses
in the
areas last to cool which can negatively impact fatigue life.
[00167] With further reference to Figures 11-110, and primarily Figure 110,
in
some embodiments, the first and second upturned portions 228, 230 of the top
plate
220 can include an outer planar portion 228a, 230a (only the first upturned
region
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shown in Figure. 110) and an inner planer portion 228d, 230d. In some
embodiments, the planar portions 228a, 230a and 228d, 230d can extend at an
angle A with respect to a plane P that extends along the outer surface 224 of
the
center portion 226. In some embodiments, the angle A may be an obtuse angle
and
in some embodiments the angle can be within the range of about 95 degrees to
about 115 degrees, such as 105 degrees, or any other angle within this range.
In
embodiments, as described in more detail below, where the first and/or second
upturned portions 212, 214 include a grip, the planar surface may surround one
or
both sides of the grip, or may be alternatively arranged with respect to the
grip. The
first and second upturned portions 228, 230 of the top plate 220 can also
include
lower curved portions 228b, 230b and 228e, 230e that transition between the
central
portion 226 and the planar portions 228a, 230a and 228d, 230d. Similarly, the
first
and second upturned portions 228, 230 of the top plate 220 can also include
upper
curved portions 228c, 230c and 228f, 230f that transition between the lateral
flanges
232, 234 and the planar portions 228a, 230a and 228d, 230d. The upper or lower
curved portions 228b, 230b, 228e, 230e, 228c, 230c, 228f, and 230f may be
formed
with a constant curvature and/or a varying curvature. The bottom plate 240 can
include similar planar portions and upper and lower curved regions. The
upturned
regions 212, 214 may in some embodiments not include a planar portion and may
be
formed with a constant curvature and/or a varying curvature.
[00168] With further reference to Figure11A, the first and second lateral
flanges
216, 218 can extend laterally outside of the side frame 4 and are disposed at
a
vertical height or in a plane that is different or above the central portion
210, which is
disposed under and in contact with the pedestal roof 152. Accordingly, the
first and
second lateral flanges 216, 218 are disposed in a vertically raised position
with
respect to the central portion 210. The lateral projecting flanges 216, 218
can
provide more area for elastomer, and as discussed below, can increase
stiffness of
the adapter pad. In some embodiments, as shown in Figure 13B, the outer
surface
244 of the first and second lateral flanges 252, 254 of the bottom plate 240
may be
about 0.92 inches above the outer surface 244 of the lowest edge of the bottom
plate
240 or in the range of about 0.25 inches to about 2 inches. In some
embodiments,
the first and second lateral flanges 216, 218 can include a planar and
horizontal
outer surfaces 224, 244, which can be parallel to the outer surface 244 of the
central
portion 226. In some embodiments, the outer surface 244 of the first and
second
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lateral flanges 252, 254 of the bottom plate 240 can rest on the vertical
shoulders
106 of the roller bearing adapter 199. In other embodiments, the outer surface
244
of the first and second lateral flanges 252, 254 of the bottom plate 240 does
not
contact the vertical shoulders 106. And in still other embodiments, the outer
surface
244 of the first and second lateral flanges 252, 254 of the bottom plate 240
can
indirectly contact the vertical shoulders 106 through another piece such as a
compression shim. As will be discussed in more detail below, in some
embodiments, about 10 percent to 30 percent of vertical force from the
pedestal roof
152 can be distributed to each of the adapter pad lateral flanges 216, 218
when a
vertical force is applied to the central portion 210 of the adapter pad.
[00169] Although the embodiment of the adapter pad 200 shown in at least
Figures 11-13 includes upturned portions 212, 214 and lateral flanges 216,
218, it
need not include these portions in all embodiments. The center portion 210 can
in
some embodiments be used without the lateral flanges 216, 218 and/or without
the
upturned portions 212, 214, although such designs may affect performance. In
an
embodiment, the lateral flanges 216, 218 can extend from the central portion
without
upturned portions, and without decreased performance characteristics.
Similarly, in
some embodiments the lateral flanges can extend outside of the central portion
but
in the same plane as the central portion. In still other embodiments, the
adapter pad
200 can include downturned portions that can connect to lateral flanges.
[00170] The top plate 220 may be made from one or more different types of
alloys with suitable strength and other performance characteristics. For
example,
the top plate 220 may be manufactured from ASTM A36 steel plate, or steels
with a
strength equivalent to or higher than those specified in ASTM A-572. In some
embodiments, the entire top plate 220 is formed (cast, machined, pressed,
rolled,
stamped, forged or another suitable metal forming operation) from a single
monolithic member. In some embodiments, the top plate 220 may be formed from a
material with a constant thickness throughout. In other embodiments, the top
plate
220 has a variable thickness. For example in some embodiments, the lateral
flanges
232, 236 of the top plate 220 can have a thickness that is greater than or
less than
the thickness of the center portion 226. Similarly and as previously
discussed, the
bottom plate 240 can have a constant or variable thickness. In some
embodiments,
one, some, or all of the corners 233 of the top plate 220 may be curved.
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[00171] In some embodiments, the outer surface 226 of the top plate 220 may
receive a coating of an elastomeric material 265 which may be the material
that
contacts the pedestal roof 152. As discussed elsewhere herein the elastomeric
layer
265 may provide dampening and a calibrated flexibility to the pad, as well as
a
compressible surface to minimize wear between the adapter pad 199 and the
pedestal roof 152. The elastomeric coating 265 may be formed with a flat outer
surface that follows along the geometric profile of the steel portion of the
top plate
220, and can have a uniform thickness, either along the entire top plate 220,
or in
other embodiments, a uniform thickness within discrete portions of the pad
(such as
a uniform thickness in the central portion 210, a (potentially different or
potentially
the same) uniform thickness on one or both of the upper portions lateral
flanges 232,
234, a (potentially different or potentially the same) uniform thickness on
one or both
of the upturned portions 228, 230, and the like.
[00172] During use, there can be heat generation in the adaptor pad 200
through friction of the pad 200 and sliding relative to the side frame
pedestal roof 152
and/or relative to the bearing adaptor 199; and or the hysteretic damping of
the
elastomeric member 360 of the adaptor pad 200. These heat sources can cause
adaptor pad temperatures to increase, which can result in lower durability and
reduced stiffnesses.
[00173] In some embodiments, the first and second lateral flanges 216, 218
can include upper and lower surfaces exposed to air outside of the side frame
envelope at the pedestal area (when the adapter pad is installed within a
pedestal of
a truck). The exposed surfaces can readily allow for heat loss from the
adapter pad
during operation of the railcar (acting as a fin) and can cause net heat flow
from the
central portion 210 of the adapter pad 200) and toward the lateral flanges
216, 218.
As is easily understood, and as discussed below, heat is generated within the
adapter pad 200 during railcar operation due to various reasons, such as due
to
friction that resists relative translation or rotation between the adapter pad
200 and
the side frame and between the adapter pad 200 and the bearing adapter 199.
Further, because the adapter pad 200 is in surface-to-surface contact with the
side
frame 4 and the bearing adapter 199, the adapter pad 200 may receive heat that
is
generated elsewhere and transferred to the adapter pad 200. Also, the cyclic
dampening of the elastomeric portion produces heat. This heat must be
ultimately
removed to avoid a significant increase in the temperature of the components
of the
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adapter pad 200 to increase the life of the components, as well to decrease
the
possible design constraints that might be necessary if the adapter pad 200 (or
portions of the adapter pad 200) continuously operate with higher temperatures
absent heat removal. This heat flow out of the adapter pad 200 may assist with
the
thermal design of the adapter pad 200 and the remainder of the truck system,
which
can have various design benefits such as broadening the possible elastomeric
material choices, as well increasing the life of the elastomeric material by
reducing
its operating temperature, as other possible benefits.
[00174] In some embodiments, the adapter pad 200 can include additional
features that can increase its ability to reduce heat in the adapter pad 200.
For
example, in some embodiments, first and/or second lateral flanges 216, 218 may
include a portion that extends laterally from the side walls of the side frame
pedestal
area. During use, the laterally projecting flanges are in direct contact with
airflow
generated by the moving car, as opposed to the central portion which is
insulated by
the metal roller bearing adapter and the steel side frame pedestal region.
These
laterally projecting flanges can provide free surface area to transfer heat to
atmosphere from the adapter pad 200. This can help dissipate heat from the
hysteretic cycling of the elastomer, temperature increases of the roller
bearing, and
any other heat in the adapter pad 200. In certain embodiments, having first
and/or
second lateral flanges 216, 218 the operating temperature of the adapter pad
system
198 can be reduced. For example under normal lateral shear cycling, as
described
below, the temperature differential between the lateral flanges 216, 218 and
the
center of the pad using a 5 mph constant velocity airflow over the first and
second
lateral flanges 216, 218 can be about 15 degrees Fahrenheit or in the range of
about
degrees Fahrenheit to about 25 degrees Fahrenheit. Increased temperature
transfer from the center of the pad to the lateral flanges can allow for
further
increased heat transfer to atmosphere, and therefore improved durability.
[00175] In some embodiments, one or both of the outer surface 224 of the
central portion 226, or the inner surface 244 of the central portion 246 may
include
one or more of various surface features, and in some embodiments a pattern of
surface features to make these surfaces non-smooth. For example, the upper
surface may include one or more of bumps, ridges and valleys, roughened
surfaces,
"sticky" surfaces, and the like. These surfaces can be created through a
number of
methods including shot blasting surface, machining the surface, applying
different
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substances such as different types of rubbers to the surface and the like.
These
surface features, when provided, may reduce the potential for lateral and/or
longitudinal sliding, and/or relative rotation of the adapter pad with respect
to the
pedestal roof 152, which may improve adapter pad 200 dynamic loading and
strength performance, and may also reduce localized heat generation within the
adapter pad 800 due to friction between the adapter pad 200 and the pedestal
roof
152, which must be removed from the adapter pad 200 (as discussed elsewhere
herein). Similarly, a thermal barrier coating such as ceramic or porcelain can
be
applied to top or bottom plates 220, 240. Optionally, a thermal barrier plate
can be
used to thermally isolate the heat generated from the frictional sliding
during the high
amplitudes. This can be done in conjunction with the wear plate that is
typically used
with the steel-on-steel adapter plates. The plate can be formed such that an
air gap
is maintained and the contact areas located to the outside edges of the
adapter.
[00176] The
bottom plate 240 may be formed from a similar construction and
materials as the top plate 220. Similarly, the outer surface 244 of the bottom
plate
can include surface treatments and coatings of an elastomeric material 265 as
the
top member.
[00177] In some
embodiments the entire or a majority of adapter pad 200 can
include a coating of an elastomeric material 265, as shown for example in
Figure
13C and Figure 13E. In some embodiments, for example, the coating of
elastomeric
material may contact the pedestal roof 152, the side frame 4, and the roller
bearing
adapter pad 199, including the pedestal crown surface 102 and the vertical
shoulders 106. In other embodiments, for example, the portions of the adapter
pad
200 that contact the pedestal roof 152, side frame 4, and the roller bearing
adapter
pad 199, can be free of elastomeric material. As discussed elsewhere herein,
the
elastomeric layer 265 may provide dampening and a calibrated flexibility to
the pad,
as well as a compressible surface to minimize wear between the adapter pad
200,
the pedestal roof 152, and the roller bearing adapter 199. The elastomeric
coating
265 may follow the outer surfaces of the adapter pad 200 and can have a
uniform
thickness, along the outer surfaces of the adapter pad 200, or in other
embodiments,
a uniform thickness within discrete portions of the pad such as a uniform
thickness in
the central portion 210, a (potentially different or potentially the same)
uniform
thickness on one or both of the upper portions lateral flanges 232, 234, a
(potentially
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different or potentially the same) uniform thickness on one or both of the
upturned
portions 228, 230, and the like.
[00178] In some embodiments, it may be possible to use an electrically
conductive additive in the elastomeric materials discussed herein to provide
electrical conductivity and shunting ability through the top and bottom plates
220,
240. These additive particles may include materials such as nickel plated
graphite,
silver plated aluminum, or silver plated copper. The quantity of these
additives may
be as little as 0.5% of the total elastomer volume to provide sufficient
electrical
conductivity. Similarly, to create an electrical connection between the truck
side
frame to the adapter, a flexible conductor can be molded into the elastomeric
pad
connecting the upper pad plate to the bottom plate. The encasement of the
conductor can protect the conductor from environmental corrosion. Its
flexibility
allows it to flex as the elastomeric (e.g., rubber) material strains. In some
embodiments, as shown in Figures 13D-13E, the electrical continuity between
the
side frame 4 and adapter 199 is enabled through the use of a wire ground strap
266.
As shown in Figures 13D-13E, the wire ground strap 266 can be attached to the
top
and bottom plates 220, 240 using apertures 267 that can be less than about
0.20
inches from the edge of the plate. The wire ground strap 266 passes through
the
apertures 267 in the top and bottom plates 220, 240. The edges of the plates
can be
indented or deformed 268 to crimp or secure the wire ground strap 266. In some
embodiments, the wire ground strap 266 may be stainless steel braid, about
.100
inches in diameter, but may be as small as .050 inches.
[00179] In some embodiments, as shown in Figure 11, the adapter pad 200 is
constructed such that it is symmetrical about a lateral vertical plane that
cuts through
the geometric center C of the adapter pad (depicted as cutting through line B
in
Figure 11) and/or symmetrical about a longitudinal vertical plane that cuts
through
the geometric center C of the adapter pad 200 (depicted as cutting through
line A in
Figure 11).
[00180] In some embodiments, the outer lateral edges 281, 282 of the
lateral
flanges of the top and bottom plates 220,240 are each aligned along the same
vertical plane, as best shown in Figure 11C. In these embodiments, the lateral
length of the lateral flange of the bottom plate 240 is less than the lateral
length of
the lateral flange of the top plate 220.
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[00181] Exemplary dimensions of the adapter pad 200 are shown and
described in this application; however, other dimensions may be used for
portions of
the adapter pad, depending upon the fixed dimensions of the side frame and the
bearings used with the particular railcar truck system.
[00182] The adapter pad 200 can, in some embodiments, as shown for example
in Figures 3 and 11-110, also include pads or grips on top and bottom plates
220,
240 of the adapter pad which can be configured to position the adapter pad 200
relative to the side frame pedestal roof 152 and the bearing adapter 199 and
also
engage and restrict movement of the adapter pad 200 relative to the pedestal
roof
152 and the bearing adapter 199 which can focus movement (i.e. shear) of the
adapter pad 200 to the elastomeric member 360. The assembly of the adapter pad
200 to the roller bearing adapter 199 can force the adapter pad 200 to be
reasonably
centered with regard to the roller bearing adapter 199, and the bearing by the
use of
the vertical shoulders 106 and including grips. Further, the adapter pad
system 198
promotes the return of the adapter 200 and wheelset to a centered, or near
zero
force center position.
[00183] For example, the adapter pad 200 can include a first lateral
adapter
grip 270 disposed between the first vertical shoulder 106 of the adapter 199
and the
first upturned region 248 of the bottom plate 240; and a second lateral
adapter grip
271 disposed between the second vertical shoulder 106 of the adapter 199 and
the
second upturned region 250 of the bottom plate 240. The lateral adapter grips
270,
271 can run the entire longitudinal length of the adapter pad 200 or a portion
of the
longitudinal length of the adapter pad 200. In other embodiments, the lateral
adapter
grips 270, 271 can comprise a plurality of lateral adapter grips that run the
entire
lateral length of the adapter pad 200 or any portion thereof.
[00184] The lateral adapter pad grips 270, 271 can be integrally formed
with
the bottom plate 240, including with being integrally formed with any
elastomeric
coating 265 on the adapter pad 200. In other embodiments the lateral adapter
pad
grips 270, 271 can be integrally formed with the adapter 199. In still other
embodiments, the lateral adapter pad grips 270, 271 can be attached to the
adapter
199 and/or adapter pad 200 through use of adhesives or other known methods.
[00185] The adapter pad 200 can also include a first lateral side frame
grip 272
disposed on the outer surface 224 of the first upturned region 228 of the top
plate
220; and a second lateral side frame grip 273 disposed on the outer surface
224 of
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the second upturned region 230 of the top plate 220. In some embodiments, the
first
lateral side frame grip 272 can be disposed on the outer surface 224 of the
first
lateral flange 232 of the top plate 220; and the second lateral side frame
grip 273 is
disposed on the outer surface 224 of the second lateral flange 234 of the top
plate
220. The lateral side frame grips 272, 273 can run the entire longitudinal
length of
the adapter pad 200 or a portion of the longitudinal length of the adapter pad
200. In
other embodiments, the lateral adapter grips 272, 273 can comprise a plurality
of
lateral adapter grips that run the entire lateral length of the adapter pad
200 or any
portion thereof.
[00186] The grips 270, 271, 272, 273 can be formed of an elastomeric
material
or any other suitable material and can in certain embodiments act to properly
position the adapter pad 200 with respect to the side frame pedestal 152 and
the
adapter 199. Additionally, the first and second lateral adapter grips 270, 271
can be
configured to reduce or eliminate sliding between the adapter 199 and the
bottom
plate 240 of the adapter pad 200. Similarly, the first and second lateral side
frame
grips 272, 273 can be configured to reduce or eliminate sliding between the
outer
surface 224 of the top plate 220 and the pedestal 152. This can in certain
embodiments, reduce or eliminate sliding between the mating surfaces of
adapter
199 and the adapter pad 200, and between mating surfaces of the side frame
pedestal roof 199 and the adapter pad 200 during operation of the system.
Additionally, this reduction of sliding between the contacting surfaces can in
some
embodiments reduce heat generated by any such sliding.
[00187] As discussed above, the grip features can significantly reduce
relative
motions between the horizontal surfaces of the adapter pad system by
maintaining
close-fitting contact between the vertical mating surfaces of the adapter pad
assembly. Reduction of relative motions between the side frame pedestal 152
and
the adapter pad 200 can improve the stiffness behavior of the adapter pad 200.
As
shown in Figure 14 comparing lateral stiffness, for example, in an adapter pad
system with and without grips, improvement can be seen at the end of the
stroke
where instead of sliding, the adapter pad/pedestal interface shows more
resistance
for longer lateral travel than an adapter pad system that does not include
grips.
Reduced sliding between the parts can also reduce physical wear of the adapter
pad
system.
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[00188] In certain embodiments, heat can be generated by movement of the
adapter pad 200 relative to the roller bearing adapter 199 and the pedestal
roof 152.
This heat is generated by the hysteresis of the elastomer material cycling in
shear
displacement. As discussed above, excess heat can negatively affect the
performance of the elastomeric member 360, and decrease the durability of the
adapter pad. As shown in Figure 15 which compares adapter pad fatigue dynamic
characteristics with and without grips, the adapter pad 200 with grips
generates less
heat when compared to an adapter pad 200 without grips. In some embodiments
the adapter pad 200 will not exceed about 130 degrees Fahrenheit when the
adapter
pad 200 is positioned between the roller bearing adapter 199 and the pedestal
roof
152 of a side frame of a moving railcar. In some embodiments, the adapter pad
system 198 can be configured to restrict the elastomer temperatures below the
degradation temperature of the specific elastomeric and/or adhesive materials
used
in pad construction and in some embodiments the adapter pad system can be
configured to reduce melting of the elastomeric member.
[00189] As discussed above, and as shown primarily in Figures 16A-B, and
11B-C, an elastomeric member 360 is disposed between the top plate 220 and the
bottom plate 240. The elastomeric member 360 supports the vertical load and
allows limited longitudinal, lateral, and rotational motion of the top plate
220
(supporting the side frame) relative to the bottom plate 240 (supported by the
adapter). This allows the relative motion of the side frame relative to the
adapter by
a low stiffness, and hence, low loads as compared to sliding adapter designs.
As
shown in Figures 17A-17D the movement of the top plate 220 relative to the
bottom
plate 240 can be measured in longitudinal displacement (Figure 17B), lateral
displacement (Figure 17C), and rotational displacement (Figure 17D). The
adapter
pad elastomeric material 360 may be a hysteretic material and have material
damping during deflection cycling. This provides another energy absorption
feature,
depending on selection of the material and damping. For example, a material
with
too much damping may cause over heating of the elastomeric member 360 and
reduce its short term stiffness and long term durability. The elastomeric
member 360
may be formed from any suitable elastomeric materials, such as rubber, with
suitable
strength, flexibility, and stiffness characteristics. In some embodiments the
material
used for the elastomeric material should have a durometer (hardness) of Shore
A 70
+/- 10. Elastomers that can be used can include, but are not limited to:
natural
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rubber; nitrile; hydrogenated nitrile; butadiene; isoprene, or polyurethane
and can
have a durometer of about 60-80 Shore A.
[00190] In general the elastomeric member 360 can be attached to the top
and
bottom plates 220, 240 through injection molding. Generally the top and bottom
plates 220, 240 can be placed within the mold. In some embodiments, portions
of
the top and bottom plates 220, 240 can be coated with adhesive to allow the
elastomeric member 360 to adhere to the plates. Additionally, in some
embodiments, spacers can be placed within the mold in certain areas where the
elastomeric material is not needed. Once setup is complete, elastomeric
material
can be heated and inserted into the mold, and the elastomeric material can
flow
throughout the mold cavity, adhering to the areas applied with adhesive. The
elastomeric can then undergo vulcanization and/or curing.
[00191] The elastomeric member 360 may provide for dampening within the
adapter pad 200, allow for discrete changes in stiffness and/or flexibility
within the
adapter pad 200, and to allow for differences in the dampening, stiffness,
flexibility or
other parameters within the different portions of the adapter pad 200 to allow
for a
suitable design.
[00192] As shown in Figure 11A, the elastomeric member 360 includes a
central portion 362 that is disposed within the central portion 210 of the
adapter pad
200, and first and second outer elastomeric members 364, 366 that are disposed
within the respective first and second lateral flanges 216, 218. The outer
elastomeric
members 364, 366, increase the shear area and volume of the elastomer layer
360
by extending the elastomeric material beyond the standard adapter clearance
envelope through the use of the lateral flanges 216, 218. This provides more
area
for the elastomeric member 360 and can increase stiffness of the adapter pad
200.
[00193] As best shown in Figure 16A, from a top view, the central
elastomeric
portion 362 can be generally square shaped and in some embodiments, as shown
in
Figure 16A can have one or more rounded corners 363. Rounded corners
throughout the elastomeric member 360 can reduce or eliminate stress
concentrations as compared to an elastomeric member 360 with square corners.
As
discussed above, the thickness of the elastomeric member 362 can have a
uniform
thickness throughout the central portion 210.
[00194] The central elastomeric portion 362 can be primarily disposed in
the
central portion 210, but in some embodiments can also be disposed in the first
and
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second upturned regions 212, 214, as shown in Figure 16B, and in the lateral
flanges 216, 218. As shown in Figure 16B, the central elastomeric member 362
can
have a lateral length of about 6.7 inches or in the range of about 6.5 inches
to about
inches. In some embodiments, and as shown in Figure 16B, the elastomer 360
can be disposed between the top and bottom plates 220, 240 in the upturned
regions
212, 214. In embodiments where elastomer 360 is disposed between the plates in
the upturned region it can compress or shear under lateral loading. This
compression of the elastomer in the upturned regions 212, 214, in concert with
the
shearing of the elastomer in the other regions, can allow the adapter pad to
reach
high stiffnesses which can increase performance.
[00195] As best shown in Figure 16A, from a top view, the outer elastomeric
portions 364, 366 within one or both of the first and second lateral flanges
216, 218
forms an outer edge 374, 376, respectively. The outer edge 374, 376 may be
disposed between the top and bottom plates 220, 240 such that a portion of one
or
both of the top or bottom plates 220, 240 extends radially outward past at
least a
portion of the outer edge 374, 376 of the elastomeric portion.
[00196] In some embodiments, the outer edge 374, 376 may be a longitudinal
outer edge (374a, 376a) (i.e. may extend generally in the longitudinal
direction when
the adapter pad 200 is installed within a truck system) and may include a
curved
portion that is not in the same shape and alignment with the outer
longitudinal edge
of the top and/or bottom plates 220, 240. While the term "longitudinal outer
edge" is
used, this is meant to define the portion of the outer edge that extends
between the
opposed lateral edges 280, 282 (i.e. the two edges that extend laterally
between the
first and second lateral flanges 216, 218 and through the central portion
210), and as
discussed herein may be curved with each portion of the curve including at
least a
vector component that faces in the lateral direction (i.e. perpendicular to
the direction
of motion of the truck that receives the adapter pad 200).
[00197] For example, at least a portion 374R, 376R of the outer edge 374,
376
may be formed with a continuous radius (R) with respect to a geometric center
of the
adapter pad, as annotated as "C" on Figure 16A. In some embodiments each outer
edge 374, 376 may include two discontinuous curved edges 374R, 376R with a
constant radius, with a center section between the two that may be straight or
at a
different curve(s) than the constant radius portions. In other embodiments,
the
constant radius portion may be continuous and extend from proximate to both
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opposite lateral edges 380, 382 upon the respective lateral flange, such as
throughout the entirety of the respective lateral flange, or between the
opposed
lateral edges but mating with a portion 374z, 376z extending from the
respective
upturned portion 212, 214 to the edge 374, 376 with the radius geometry.
[00198] In some embodiments, the lateral edges 380, 382 and the
longitudinal
outer edges 374a, 376a, and any other edge of the elastomeric portion 360 may
include an internally recessed contour 381, as best depicted in Figure 11A -
11C. In
some embodiments, the internally recessed contour 381 may be the same profile
about the entire perimeter of the elastomeric member 360, while in other
embodiments; the internally recessed contour 381 may be at differing profiles
depending upon the expected compression to be felt by that portion of the
elastomeric member 360.
[00199] As can be appreciated, and discussed elsewhere herein, the
elastomeric member 360 compresses and deforms under load and the elastomeric
material presses radially outward proximate to the outer edges. The internally
recessed contour 381 minimizes or eliminates the deformation of the
elastomeric
member 360 beyond the nominal outer edge of the member 360, which can in
certain embodiments enhance the fatigue life of the adapter pad 200.
[00200] The internally recessed contour 381 may include a first portion 383
that
generally extends downward from a lower surface of the top plate 220, a second
portion 385 that generally extends upward from the upper surface of the bottom
plate
240, and a transition 384 therebetween. In some embodiments, one or both of
the
first and second portions 383, 385 may be planar (along a straight portion of
the
elastomeric portion) or linear (along curved portions of the elastomeric
portion)
(collectively a linear portion) that extends from the respective surface of
the top and
bottom plates 220, 240 at angles a, and 13.
[00201] In some embodiments, the first and second portions 383, 385 may
extend at the same relative angle, while in other embodiments, the first and
second
portions 383, 385 may extend at differing relative angles. In some
embodiments, the
angle(s) may be about 30 degrees to the neighboring surface of the top or
bottom
plate 220, 240, such as an angle within the range of between about 15 and
about 45
degrees, inclusive of all angles within this range. As shown in Figure 11B,
the
central elastomeric portion 362 can likewise include a similar internally
recessed
contour 381 extending around the outer edge of the central portion.
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[00202] As best shown in Figures 11A, 11C, and 16B, one or both of the
upturned portions 212, 214 may include a hollow portion(s) 372 within a cavity
formed between the top and bottom plate 220, 240, which is a void where
substantially no elastomeric material is provided, and can establish a
discontinuity
within the elastomeric member within the respective first and/or second
upturned
portions 212, 214. The hollow portions 372 may provide a complete separation
between the elastomeric member 360 disposed within the central portion 210,
and
the elastomeric member disposed in the lateral flanges 216, 218. In certain
embodiments, the void may include a very small thickness layer of elastomeric
material that contact each of the top and bottom plate 220, 240 through the
transition, which can be a function of possible limitations of the tooling
used in the
molding process, but this thin layer (when existing) does not materially
contribute to
the performance of the adapter pad 200. Additionally, in some embodiments the
hollow portion 372 can include small portions of elastomeric material that
extend
between the top and bottom plates 220, 240, but it is otherwise substantially
hollow.
In some embodiments, the width of the hollow portion 372 can be about 0.25
inches
or in the range of about 0.1 inches to about 0.5 inches, or at least as wide
as the
maximum lateral and rotational motion on the adapter pad 200. In some
embodiments, the hollow portion(s) 372 are configured to provide a lateral
void
between the top and bottom plate 220, 240 extending through the respective
transition portion 212, 214, such that the respective inner surfaces of the
top and
bottom plates 220, 240 within the transition portion do not contact each other
during
lateral or rotation relative motion therebetween and/or in view of the lateral
and/or
rotational displacement during railcar operations with the adapter pad 200
disposed
in position in the railcar truck system.
[00203] The hollow portion 372 can function to limit the bending stresses
in the
top and bottom plates 220, 240. The hollow portion 372 may be about 0.25
inches.
At the about 0.25 inch motion range, the upturned regions of the top and
bottom
plate 220, 240 can engage and prevent further relative motion. This can put an
upper limit on the elastomer strain in the lateral direction and the metal
stress.
[00204] As will be discussed in more detail below, the elastomeric member
360
and particularly the outer elastomeric members 364, 366 can be configured in
such a
manner that the elastomer's rotational shear stresses, through a displacement
of up
to 41 milliradians, are no greater than the elastomer's lateral and
longitudinal shear
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stresses through a displacement of up to 0.23 inches laterally and of up to
0.14
inches longitudinally. For example, the outer elastomeric members 364, 366 can
be
configured such that any point on curves 374R, 376R has less than or equal
rotational shear displacement as the lateral or longitudinal shear
displacements.
And because shear strain is directly proportional to shear displacement, all
points
along the curve 374R, 376R can be subject to the same strain.
[00205] The elastomeric member 360 can be measured in a cross-sectional
plane through about the center of the elastomeric material 360 centered
between the
inner surfaces of the top and bottom plates 220, 240. In embodiments where
there
are a plurality of elastomeric members each member can be measured separately
and each member can be added together to determine the measurements of the
entire elastomeric member 360. In some embodiments, the total shear width, or
length in the lateral direction, of the elastomeric member 360 can be about
9.6
inches or in the range of about 6 inches to about 14 inches. Similarly, the
total shear
length, or length in the longitudinal direction, of the elastomeric member 360
can be
about 6.9 inches or in the range of about 6 inches to about 10 inches. The
composite shear perimeter, or perimeter of all portions of the elastomeric
member
can be about 51.70 inches or in the range of about 35 inches to about 75
inches. In
some embodiments the total surface area of the elastomeric member 360 in the
shear plane can be about 55.5 square inches or in the range of about 50 square
inches to about 70 square inches. The total surface area of the elastomeric
member
360 outside of the central portion can be about 15.5 square inches or in the
range of
about 5 square inches to about 30 square inches, or greater than 5 square
inches.
Thus, the surface area of the elastomeric member in the lateral flanges 216,
218 can
be about 7.75 square inches each or in the range of about 2.5 square inches to
about 15 square inches, or greater than 2.5 square inches.
[00206] As will be discussed in more detail below, the elastomer layers
364,
366 outside of the central area 210 can contribute to the overall stiffness of
the
adapter pad 200. For example in some embodiments, the elastomeric member 360
outside of the central area 210 can contribute about 15%, or in the range of
about
5% to about 30%, of the total lateral and longitudinal stiffness of the
adapter pad,
and 33%, or in the range of about 15% to about 60%, of the rotational
stiffness of the
adapter pad 200.
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[00207] As previously discussed, the elastomeric member 360 of the adapter
pad 200 provides shear resistance during loading in the lateral, longitudinal,
and
rotational directions under a vertical load. This shear resistance is caused
by
relative movement between the top and bottom plates 220, 240 reacted through
the
elastomeric member 360. Simple shear strain is defined as d/t where d =
displacement of the elastomeric member and t = thickness of the elastomeric
member. In some embodiments, the shear strain can reach values greater than
100% under maximum displacement conditions. For example, in some
embodiments, lateral strain achieves 110% or 120% or 130%. In some
embodiments shear strain does not exceed 105%, 110%, 115%, or 120%, or 130%
under maximum displacement.
[00208] To reduce the stresses in the elastomeric member 360 under
maximum shear displacement, it can be beneficial to provide normal stress, or
compression, to the elastomeric member 360 during shear loading. In some
embodiments, vertical loading of adapter pads is transferred through the
pedestal
roof 152 of the side frame, to the central area 210. Additionally, although
the top and
bottom plates 220, 240 can contact the vertical shoulders of the adapter, in
some
embodiments, the top and bottom plates 220, 240 are flexible and the vertical
load
on the central region 210 is not transferred equally to the lateral flanges
216, 218
and can create a non-uniform distribution of the vertical load to the
elastomeric
member 360. This can result in less compression of the elastomeric member 360
outside of the area under the pedestal roof 152. Various methods can be used
that
can increase the normal stress or compression in the elastomeric member 360
outside of the pedestal roof 152, for example, in the lateral flanges 216,
218.
[00209] In embodiments, the elastomeric member 360, outside the pedestal
roof 152 area can be compressed greater than 0.020 inches, or greater than 7%
of
the static thickness of the elastomeric member 360. In certain embodiments,
pre-
compression of this magnitude allows for improved fatigue life of the
elastomeric
member 360. Additionally, in embodiments discussed herein about 10 percent to
30
percent of vertical force can be distributed to each of the adapter pad
lateral flanges
216, 218 when a vertical force is applied to the central portion 210 of the
adapter pad
200. And in embodiments discussed herein the reaction of the vertical load at
the
vertical shoulders 106 can provide a vertical force greater than 3000 pounds
to
precompress the elastomeric member.
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[00210] In some embodiments, as shown primarily in Figure 18, compression
of
the elastomeric member 360 in the region outside the pedestal roof 152 (in the
outer
elastomeric members 364, 366), can be accomplished with an elastomeric member
360 having a non-uniform thickness along the length of the elastomeric member
360.
For example, in some embodiments, the first and/or second outer portions 364,
366
may be formed with a thickness X while the central portion 362 may be formed
with a
different or smaller thickness Y. The geometry (such as the bends through the
upturned portions 212, 214) of the top and bottom plates 220, 240 may be
formed to
accommodate the differences in thickness between X, Y allowing the elastomeric
portions in the central and outer portions to contact the inner surfaces of
the top and
bottom plates 220, 240 as desired. In certain embodiments, the difference in
thickness of the elastomeric member forming the first and/or second outer
portions
364, 366 and the central portion 362 can assist in reducing the simple shear
strains
of the outer layers based upon in-plane forces applied to the adapter pad in
the
longitudinal, lateral, and rotational directions.
[00211] In some embodiments, as shown in Figure 18, one or both of the
lateral
flanges 216, 218 may be formed such that the elastomeric layers 364, 366
therewithin includes a thickness, X that is about 0.25 inches, such as within
a range
of 0.15 inches to 0.30 inches, inclusive of all thicknesses within the range.
In this
embodiment, the thickness Y of the elastomeric layer 360 in the central
portion 362
may be about 0.20 inches, such as within a range of 0.15 inches to 0.25
inches,
inclusive of all thicknesses within the range. The thicknesses of elastomeric
layers
discussed herein refer to the static thickness of the elastomeric layers or
the
thickness of the elastomeric layers without an external load on the
elastomeric layer.
One or both of the lateral flange portions 364, 366 and central portions 362
may
have a different thickness, with the upper portions being thicker than the
central
portion this can achieve a desired effect, generally of increasing the load or
compression of one or both of the lateral flange portions 364, 366, which due
to the
material properties of the elastomeric layer additionally increases its
strength and
durability based upon the contemplated loading during railcar operation.
[00212] In some embodiments, as shown in Figure 18, the adapter pad 200 can
be formed by injection molding without bonding the top plate 220 (as shown in
Figure
18), or alternatively the bottom plate 240, to the elastomeric member 360.
After
vulcanization of the elastomeric member 360, the top plate 220 (as shown in
Figure
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18), or alternatively the bottom plate 240, can be attached or bonded to the
elastomeric member. Because the outer elastomeric members 364, 366 have a
greater thickness than the center elastomeric member 362, the lateral flanges
216,
218 must be compressed to attach or bond the top plate 220 (as shown in Figure
24), or alternatively the bottom plate 240, to the elastomeric member. In some
embodiments, the center elastomeric member 362 will react the compression load
keeping the wings in a state of compressive strain.
[00213] In some embodiments, as shown in Figures 19-23, compression of the
elastomeric member 360 in the region outside the pedestal roof 152, can be
accomplished by forming the elastomeric member 360 with gaps in the central
portion 362. In some embodiments, for example, the central portion 362
includes one
or in other embodiments a plurality of elongate gaps 868 that partially or
completely
separate the central portion 362 into multiple portions 862a, 862b, 862c,
862d, 862e
as shown in Figure 19. The one or plurality (for convenience referred to as "a
plurality hereafter, although a single gap is contemplated as well) of gaps
868
collectively establish a plurality of discontinuities within the central
portion 362.
When the adapter pad 200 is assembled between the side frame and the bearing
adapter 199, the central portion 210 of the adapter pad 200 can carry
significant
compressive force, which is felt by the relatively compressible elastomeric
portion
360 (when compared to the top and bottom plates 220, 240), which tends to
deform
and expand the elastomeric member 360 laterally and longitudinally (based upon
the
material being vertically compressed). The presence of the plurality of gaps
868 can
provide a dedicated volume for the lateral expansion (in embodiments where the
plurality of gaps 868 each extend longitudinally). Likewise, in embodiments
where
the plurality of gaps also or instead extend laterally, the presence of the
gaps 868
provides a dedicated volume for longitudinal expansion.
[00214] As best shown in Figure 19, in some embodiments, the plurality of
gaps 868 each extend longitudinally between the opposite lateral edges of the
880,
882 of the elastomeric portion 860, and extend in parallel with each other. In
some
embodiments, the plurality of gaps 868 each communicate through both of the
first
and second longitudinal edges 880, 882 when the adapter pad 800 is in an
unloaded
configuration. Under load, all, or a portion of the plurality of gaps 868 may
be
deformed (as discussed above) such that only a portion of the respective gap
868
communicates through the respective longitudinal edge 880, 882, or in some
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embodiments, substantially the entire gap 868 may be closed intersecting the
longitudinal edge 880, 882, such that no visual opening may be perceived into
the
gap 868 (which is visible from the respective edge 880, 882 in an unloaded
configuration.
[00215] In some embodiments as shown in Figures 19 and 22, each of the
plurality of gaps 868 may be formed with a uniform cross-section along its
length,
and either all of the plurality of gaps 868 may be formed with the same cross-
section
(in an unloaded state), or each of the plurality of gaps 868 may be defined
with a
constant cross-section along its length.
[00216] Figures 20A-20C depict various types of cross-sections for the
plurality
of gaps 868. Generally, the plurality of gaps 868 are contemplated to include
one or
more curved or planar sides, and each of the plurality of gaps 868 may include
a
combination of curved and planar features. For example, the plurality of gaps
868a
that have a round cross-section, or include curved sides. In some embodiments,
the
opposite sides (that extend between the top and bottom plates 220, 240) may be
of
the same size and geometry, while as depicted in Figure 20a, one side may have
a
different shape or size than the opposite side (see 866' and 868" in Figure
20a).
[00217] Figure 20B depicts alternately shaped gaps 868c that are generally
oval shaped. Figure 20C depicts alternatively shaped gaps 868d that are shaped
as
a truncated diamond with two opposite planar sides (with the truncated portion
contacting the bottom plate 240). Figures 21A-210 provide schematic
representations of the potential shape of the various plurality of gaps 868
with a load
(F) applied to the adapter pad 200.
[00218] In some embodiments, and as depicted in Figure 22, the plurality of
gaps 868e extend only a partial longitudinal distance through the elastomeric
member 860 and as depicted do not reach the longitudinal edges 880, 882, while
other placement (such as extending to one of the two longitudinal edges 880,
882, or
with ends closer to one of the two longitudinal edges 880, 882 is
contemplated). The
gaps 868d in this embodiment may be sized and shaped based upon the various
sizes and shapes contemplated above.
[00219] In other embodiments depicted in Figure 23, the plurality of gaps
868f
may extend for a thickness that is less than a total distance between the top
plate
220 and the bottom plate 240, with a portion of the elastomeric member being
vertically disposed with respect to one or more of the plurality of gaps 868f
and
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contacting one or both of the top and bottom plates 220, 240. As depicted in
Figure
23, the gap 868f contacts the lower surface of the top plate 220, but does not
contact
the bottom plate 240.
[00220] As best shown in Figure 23, the inner surfaces of the top or bottom
plate 220, 240 may include a recessed portion 825a located along the portions
of the
top or bottom plate 220, 240 that communicate with the plurality of gaps 868.
The
recessed portions 825a may be provided to index the tooling (such as a core or
other
types of molding equipment known in the art) for the elastomeric portion to
establish
the gaps 868 with respect to the top or bottom plate 220, 240. The recessed
portion
825a may additionally provide space for expansion / deformation of the
elastomeric
member 860 under load, to minimize the size of the gaps 868 yet still provide
the
benefits of the expansion / deformation space as needed.
[00221] Additionally, other methods that can increase the compression of
the
elastomeric member 360 in the lateral flanges 216, 218 exist. For example, as
shown in Figure 24, in some embodiments, the lateral flanges 216, 218 can be
compressed together after inserting the elastomeric members 364, 366 between
the
top and bottom plates 220, 240. Compressing the top and bottom plates 220, 240
together can induce plastic deformation of the steel. The plastic deformation
of the
top and bottom plates 220, 240 can induce a normal stress in the outer
elastomer
layers 364, 366 and can increase the compression. Compression of the top and
bottom plates 220, 240 can be accomplished using a die or other suitable
equipment. As used herein the term inserting can encompass a number of
processes including inserting elastomer using an injection molding process or
a
casting process, and other known techniques.
[00222] In still other embodiments, for example, compression in the lateral
flanges 216, 218 can be induced by manufacturing the lateral flanges 216, 218
of the
top and bottom plates 220, 240 to angle towards each other and then mold the
flanges to a generally parallel position. For example, the top plate 220 can
be
manufactured such that the lateral flanges 232, 234 are angled outward and
downward and the bottom plate 240 lateral flanges 252, 254 are angled outward
and
upward prior to assembling the adapter pad 200. Thus, when originally
manufactured, the lateral flanges of the top and bottom plates are not
parallel and
instead are angled towards each other. The plates 220, 240 are then assembled
with the elastomeric section 360 and the lateral flanges 232, 234, 252, 254
are
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forced to elastically bend to a generally parallel alignment with each other.
In some
embodiments, this step can be accomplished, using an injection molding machine
wherein the elastic member 360 is injected into the mold. Once the adapter pad
is
cured, there can be an elastic strain in the laterally projecting flanges that
applies a
normal load to the outer elastomer layers 364, 366 that can create compressive
strain.
[00223] In still other embodiments, as shown in Figures 25 and 26,
compression of the elastomeric member 360 in the lateral flanges 216, 218 can
be
increased by using compression shims within or under the lateral projecting
flanges
216, 218. Compression shims can be used herein such that reaction of the
vertical
load at the vertical shoulders 106 provides a vertical force greater than 3000
pounds
such that about 10 percent to 30 percent of vertical force is distributed to
each of the
adapter pad lateral flanges 216, 218 when a vertical force is applied to the
central
portion 210 of the adapter pad 200. Compression shims can in some embodiments
force more of the vertical load of the car to be distributed from the center
elastomer
layer 360 to the outer elastomer layers 364, 366. As shown in Figure 25, a
first
adapter compression shim 290 can be disposed between an upper surface of the
vertical shoulder of the roller bearing adapter 199 and the outer surface 244
of the
first lateral flange 216 of the bottom plate 240. Similarly, though not shown
in a
Figure, a second adapter compression shim 290 can be similarly placed in
relation to
the second lateral flange 218 (not shown). The adapter compression shims 290
can
be about 0.05 inches thick or within the range of about 0.06 inches to about
0.18
inches. Compression shims as discussed herein can have any number of different
shapes and configurations to provide the necessary loads to compress the outer
elastomer. For example compression shims can be rectangular, square,
trapezoidal,
pyramidal, can have a hollow cross-section, and can be a plurality of
compression
shims. Further, compression shims as discussed herein can be integrally formed
with the adapter pad during the molding process, can be integrally formed with
the
roller bearing adapter, or can be added to the roller bearing adapter system
after the
molding process.
[00224] As shown, for example, in Figures 25A-I, compression shims as
discussed herein can have a number of different shapes and configurations. As
shown in Figure 25A, the compression shims 290 can be substantially
rectangular
and can have a width equal to or less than the width of the outer surface 244
of the
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lateral flange 252, 254 of the bottom plate 240. Similarly, the compression
shims
290 as shown in Figure 25A can have a length that is less than or equal to the
length
of the outer surface 244 of the lateral flange 252, 254 of the bottom plate
240. The
compression shims 290 can have a constant or variable thickness. As shown in
Figures 25B, 25C, and 250 the compression shims 290 can have a curved,
trapezoidal, or triangular cross-section shape. Additionally, as shown in
Figures 25E
and 25D the compression shims 290 can have a raised center portion 295 that
can
be generally curved as shown in Figure 25E or generally triangular as shown in
Figure 25F, or any other suitable shape. As shown in Figure 25G, the
compression
shims 290 can include a hollow portion 296. Additionally, as shown in Figures
25H,
and 251 the compression shims 290 can comprise a plurality of compression
shims.
[00225] As shown in Figure 26, the adapter pad 200 can also include
compression shims between the elastomeric member 360 and either the top or
bottom plate 220, 240. As shown in Figure 26, the adapter pad 200 can include
a
first upper adapter pad compression shim 291 disposed in the first lateral
flange 216
between the top plate 220 and the first outer elastomeric member 364.
Similarly,
although not shown in a Figure, a second upper adapter pad compression shim
291
can be disposed in the second lateral flange 218 between the top plate 220 and
the
second outer elastomeric member 366. Additionally, although not shown in a
Figure,
similar first and second lower adapter pad compression shims can be disposed
in
the first and second lateral flanges 216, 218 between the elastomeric member
360
and the bottom plate 240. The upper and lower adapter pad compression shims
291 can be about 0.05 inches thick or within the range of about 0.06 inches to
about
0.18 inches.
[00226] To apply the upper or lower adapter pad compression shims 291,
shown in Figure 26, the adapter pad 200 can be formed through injection
molding
without adhesive applied to one of the top or bottom plates 220, 240 in the
laterally
projecting flanges 216, 218. This can prevent the outer elastomer layer 364,
366
from adhering to the top or bottom plate 220. 240. After vulcanization, the
upper or
lower adapter pad compression shims 291 can be inserted between the outer
elastomer 364, 366 and the top or bottom plate 220, 240. As discussed above,
this
can compress the elastomeric member 360 in the laterally projecting flanges
216,
218, increasing the normal stress.
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[00227] As discussed above, it has been determined through testing that the
performance of the adapter pad system 198 is a function of the stiffness of
the
adapter pad 200. More specifically in certain embodiments, it has been
determined
that adapter pad performance, including design life, can be improved by
increasing
the stiffness of the adapter pad system 198 (measured in pounds of force per
inch of
deformation).
[00228] Physical measurement of the pad stiffness can be determined by
cycling the adapter pad 200 in three principal directions: laterally,
longitudinally, and
rotationally; while withstanding a constant vertical load on the pad,
typically of 35,000
pounds. The force to displace the pad relative to the distance the pad
displaces is
recorded throughout the measurement test. The data from the test can then be
collected and plotted on force vs. displacement plots, an example of which is
shown
in Figure 27. The stiffness, damping, and hysteresis for each direction of
motion
may then be determined using the following methods: Stiffness of the pad 200
can
be determined by determining the upper and lower bounds which capture the
linear
portion of the force vs. displacement curve, then calculating the slope of the
best fit
line between the upper and lower bounds, for the upper and lower portion of
the
curve. The stiffness is then determined by averaging the upper and lower
slopes.
As discussed above, longitudinal stiffness is measured in the rail or track
direction,
lateral stiffness is measured perpendicular to the track direction, and
rotational
stiffness is measured as resisting rotation of the adapter about a vertical
axis at the
longitudinal and lateral centerline of the pedestal opening (annotated as "C"
on
Figure 16A). The hysteresis is determined, an example of which is shown in
Figure
27, by measuring the upper and lower y-intercepts and subtracting the lower y-
intercept from the upper y-intercept. The damping is determined, as shown in
Figure 27 by measuring the area within the force displacement loop. The amount
of
pad damping over the given displacement range is directly proportional to the
area
contained within the loop at the desired frequency.
[00229] The target damping value for embodiments disclosed herein is 0.10
to
0.30 tan 6 with a rubber / elastomeric material durometer target of 60A to
80A. Tan
is a measure of the material damping when subjected to cyclic loads, defined
as
the ratio of the out-of-phase load (90 degrees on a sinusoidal load) to the in-
phase
load (0 degrees). Typical values for elastomers can be .04 to .35.
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[00230] A more
direct measure of the energy absorption for an adapter pad is
the area of the hysteresis loop per cycle. For the embodiments described
herein, the
hysteretic energy absorption can be estimated by Tr3GTan6E2 where G is the
shear
modulus of - 360 psi, Tan 6 - 0.3 and c the strain during hunting at - 100% =
1. At
4 Hz, the energy absorption would be about 4,070 in-lb./sec. A reasonable
range
may be +/- 25%.
[00231] As
discussed herein, certain embodiments include elastomeric member
360 (portions 364, and 366) in shear, outside of the area beneath the pedestal
roof
152. In such embodiments, there can be more elastomeric material than can be
used in shear than in a typical adapter pad. This can allow the adapter pad
200 to
achieve increased stiffness without decreasing the shear thickness, or
increasing
elastomer durometer. Decreasing the shear thickness and/or increasing the
elastomer durometer which can increase the strain and reduce the useful life
of the
pad. Thus, the adapter pad 200 can increase the stiffness of the adapter pad
system 198 which can improve railcar overall performance while increasing the
useful life of the adapter pad 200. The outer elastomer layers 364, 366 can
increase
the rotational stiffness of the adapter pad 200 by providing additional
elastomer at a
distance farther from the axis of rotation. In some embodiments, for example,
the
outer elastomeric layers 364, 366 can account for about 15% or about 10% to
about
20%, or greater than 10% of the total lateral and longitudinal stiffness of
the adapter
pad 200, and can account for about 33% or about 25% to about 40%, or greater
than
25% of the rotational stiffness of the adapter pad 200.
[00232]
Embodiments disclosed herein can have high lateral and longitudinal
stiffness, without having high force vs. displacement hysteresis. Hysteresis
is
proportional to energy dissipated through the displacement cycles, and can be
lost in
the form of heat or noise. Generally, the higher the hysteresis, the greater
the
temperature rise in the adapter pad 200, and the lower the fatigue life.
Embodiments
disclosed herein attain high stiffness of the adapter pad, while improving
fatigue life
by minimizing hysteresis and allowing the pad to displace to maximum
magnitudes
set by the AAR: 41 milliradians rotationally, 0.23 inches laterally, and 0.14
inches
longitudinally.
[00233]
Embodiments disclosed herein may require increasing amounts of force
to displace the top plate 220 relative to the bottom plate 240 with higher
magnitudes.
The thickness, length, and amount of elastomeric material in the hollow
section 372
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can be adjusted to change the slope, and shape of the force vs. displacement
graphs. In some embodiments, it is possible to have different stiffness
properties for
the elastomeric material of the pad located adjacent to the upturned adapter
wings
compared to the properties of the elastomeric material located in the central
area of
the adapter pad.
[00234] Using the above described test methods, exemplary measurements
and testing results of embodiments disclosed herein are shown below in Table
2. It
is understood that these embodiments are examples, and that other structural
embodiments with other testing results can exist.
Table 2
Embodiments Described Herein
Elastomer Normal 55.5 in2
Area (in2) or about 50 in2 to about 70 in
Elastomer Normal
Area Outside of 15.5 in2
Pedestal Roof or about 5 in2 to about 30 in2
Contact (in2)
Pad Elastomer Shear
9.6 in2
Width (Lateral
or about 6 in2 to about 14 in2
Length) (in)
Pad Elastomer Shear
6.9 in2
Length (Longitudinal
or about 6 in2 to about 10 in2
Length) (in)
Lateral Stiffness
60 kips/in
(tested at 3hz cycling
or about 45 kips/into about 80 kips/in
frequency and 35 kip
or at least 45 kips/in
vertical load)
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Longitudinal
Stiffness 64 kips/in
(tested at 3hz cycling or about 45 kips/into about 80 kips/in
frequency and 35 kip or at least 45 kips/in
vertical load)
Rotational Stiffness 670 kip*in/mRad
(tested at 3hz cycling or about 250 kip*in/mRad to about 840
frequency and 35 kip kip*in/mRad
vertical load) or at least 250 kip*in/mRad
Vertical Stiffness at least 5,000 kips/in
Lateral Hysteresis
5000 lbs.
(tested at 3hz cycling
or about 3750 lbs. to about 6250 lbs.
frequency and 35 kip
or less than 6000 lbs.
vertical load)
Longitudinal
Hysteresis 500 lbs.
(tested at 3hz cycling or about 375 lbs. to about 1500 lbs.
frequency and 35 kip or less than 1500 lbs.
vertical load)
Rotational
Hysteresis 12000 lbs.*in
(tested at 3hz cycling or about 9000 lbs.*in to about 16000 lbs.*in
frequency and 35 kip or less than 16000 lbs.*in
vertical load)
Center Elastomer
25.5 in.
Layer Shear
or about 20 in. to about 30 in.
Perimeter
Outer Elastomer
13.1 in. each
Layer Shear
or about 8 to 18 in. each
Perimeter
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Composite Elastomer
51.7 in.
Layer Shear
or about 35 in. to 75 in.
Perimeter
Center Elastomer 8.3
Layer Shape Factor or about 6 to 10
Outer Elastomer 1.6 each
Layer Shape Factor or about .5 to 3 each
Composite Shape 4.5
Factor or about 2.5 to about 7
[00235] An additional embodiment of an adapter pad 400 is shown in Figures
28-43. The embodiment of the adapter pad 400 shown in Figures 28-43 is similar
in
many ways to adapter pad embodiments previously discussed. As described above,
the adapter pad 400 is configured to be disposed between and can engage with
the
roller bearing adapter 199 (as shown in Figures 36A-36E) and the side frame
pedestal roof 152 of the side frame 4. As shown in Figures 28-43, the adapter
pad
400 generally includes an upper member or top plate 420 having an inner
surface
422 and an outer surface 424, a lower member or bottom plate 440 having an
inner
surface 442 and an outer surface 444, and an elastomeric member 560 disposed
between the inner surfaces 422, 442 of the top and bottom plates 420, 440
along a
portion of the adapter pad 400. The adapter pad 400 includes a central portion
410
that is disposed under the lower surface of the pedestal roof 152 with each
plate
420, 440 having a corresponding central portion 426, 446. The adapter pad 400
further includes first and second upturned regions 412, 414 and first and
second
lateral flanges 416, 418. The top plate 420 has corresponding first and second
upturned regions 428, 430 projecting upward from opposite edges of the central
portion 426 of the upper plate 420, a first lateral flange 432 projecting
outward from
the first upturned region, and a second lateral flange 434 projecting outward
from the
second upturned region 430. Similarly, the bottom plate 440 has corresponding
first
and second upturned regions 448, 450 projecting upward from opposite edges of
the
central portion 446 of the bottom plate 440, a first lateral flange 452
projecting
outward from the first upturned region, and a second lateral flange 454
projecting
outward from the second upturned region 450. The lateral flanges 416, 418 are
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disposed laterally outboard of the pedestal roof 152 when the truck system is
assembled, and the central portion 410 is disposed below the pedestal roof
152.
First and second upturned regions 412, 414 are disposed between the central
portion 410 and the respective first and second lateral flanges 416, 418 and
provide
a transition therebetween.
[00236] As described above, with regard to other embodiments, the central
portion 410 can comprise primarily three parts including the central portion
426 of the
top plate, the central portion 446 of the bottom plate and the elastomeric
member
560 disposed therebetween. As discussed above, the adapter pad 400 is disposed
between the side frame pedestal roof 152, which generally has a substantially
flat
horizontal engaging surface, and the roller bearing adapter 199 which can
generally
have a curved or crowned roof. As shown in Figure 30, the central portion 446
of the
bottom plate 440 can have a curved lower surface such that the outer surface
444
generally follows the curve or crown of the adapter 199. More specifically, in
some
embodiments the central portion 446 can have a greater thickness toward the
edges
461, 462 of the central section 446 than at the center of the central section
446. As
described above, the thickness at the center of the center portion 246 can be
about
0.15 inches or in the range of about 0.06 inches to about 0.35 inches and the
thickness at the edges 461, 462 can be about 0.26 inches or in the range of
about
0.15 inches to about 0.5 inches.
[00237] In some embodiments, the central section 426 of the top plate 420
can
include an outer surface 424 and an inner surface 422 that are substantially
horizontal and parallel as shown in Figure 30. The thickness of the center
portion
426 of the top plate 420 can be about 0.25 inches or in the range of about
0.15
inches to about 0.5 inches. In such a system, the thickness of the elastomeric
section 560 can be substantially similar throughout the central portion 410
which can
in some embodiments increase performance characteristics.
[00238] With further reference to Figure 31, the first and second upturned
portions 428, 430 of the top plate 420 can include outer planar portion 428a,
430a
(only the first upturned region shown in Figure. 31) and an inner planar
portion 428d,
430d. In some embodiments, the planar portions 428a, 430a and 428d, 430d can
extend at an angle D. with respect to a plane P that extends along the outer
surface
424 of the center portion 426. In some embodiments, the angle A may be an
obtuse
angle and in some embodiments the angle can be within the range of about 95
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degrees to about 115 degrees, such as 105 degrees, or any other angle within
this
range. In embodiments, as described in more detail below, where the first
and/or
second upturned portions 412, 414 include a grip, the planar surface may
surround
one or both sides of the grip, or may be alternatively arranged with respect
to the
grip. The first and second upturned portions 428, 430 of the top plate 420 can
also
include lower curved portions 428b, 430b and 428e, 430e that transition
between the
central portion 426 and the planar portions 428a, 430a and 428d, 430d.
Similarly,
the first and second upturned portions 428, 430 of the top plate 420 can also
include
upper curved portions 428c, 430c and 428f, 430f that transition between the
lateral
flanges 432, 434 and the planar portions 428a, 430a and 428d, 430d. The upper
or
lower curved portions 428b, 430b, 428e, 430e, 428c, 430c, 428f, and 430f may
be
formed with a constant curvature and/or a varying curvature. The bottom plate
440
can include similar planar portions and upper and lower curved regions. The
upturned regions 412, 414 may in some embodiments not include a planar portion
and may be formed with a constant curvature and/or a varying curvature.
[00239] With further reference to Figures 30 and 31, the first and second
lateral
flanges 416, 418 can extend laterally outside of the side frame 4 and are
disposed at
a vertical height or in a plane that is different or above the central portion
410, which
is disposed under and in contact with the pedestal roof 152. Accordingly, the
first
and second lateral flanges 416, 418 are disposed in a vertically raised
position with
respect to the central portion 410. The lateral projecting flanges 416, 418
can
provide more area for elastomer 560, and as discussed above, can increase
stiffness of the adapter pad 400. In some embodiments, the outer surface 444
of the
first and second lateral flanges 452, 454 of the bottom plate 440 may be about
0.92
inches above the outer surface 444 of the lowest edge of the bottom plate 440
or in
the range of about 0.25 inches to about 2 inches. The first and second lateral
flanges 416, 418 can include a planar and horizontal outer surfaces 424, 444,
which
can be parallel to the outer surface 444 of the central portion 426. In some
embodiments, the outer surface 444 of the first and second lateral flanges
452, 454
of the bottom plate 440 can rest on the vertical shoulders 106 of the roller
bearing
adapter 199. In other embodiments, the outer surface 444 of the first and
second
lateral flanges 452, 454 of the bottom plate 440 does not contact the vertical
shoulders 106. And in still other embodiments, the outer surface 444 of the
first and
second lateral flanges 452, 454 of the bottom plate 440 can indirectly contact
the
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vertical shoulders 106 through another piece such as a compression shim 290.
As
discussed above, in some embodiments, about 2500 lbs, or about 5 percent to 30
percent of vertical force from the pedestal roof 152 can be distributed to
each of the
adapter pad lateral flanges 416, 418 when a vertical force is applied to the
central
portion 410 of the adapter pad.
[00240] Although the embodiment of the adapter pad 400 shown in at least
Figures 28-43 includes upturned portions 412, 414 and lateral flanges 416,
418, it
need not include these portions in all embodiments. The center portion 410 can
in
some embodiments be used without the lateral flanges 416, 418 and/or without
the
upturned portions 412, 414, although such designs may affect performance. In
an
embodiment, the lateral flanges 416, 418 can extend from the central portion
without
upturned portions, and without decreased performance characteristics.
Similarly, in
some embodiments the lateral flanges can extend outside of the central portion
but
in the same plane as the central portion. In still other embodiments, the
adapter pad
400 can include downturned portions that can connect to lateral flanges.
[00241] As shown, for example in Fig. 29 wherein the top 420 and bottom 440
plates are shown in dotted lines, the top and bottom plates 420, 440 may
include
lateral edges 480a, 480b, 482a, and 482b. The top and bottom plates 420, 440
may
also include longitudinal edges 484a, 484b, 486a, and 486b. The edges 480a,
480b, 482a, 482b, 484a, 484b, 486a, and 486b, as viewed from a side or front
or
back, may be straight or may include curved or angled portions. As shown, for
example, primarily in side views Figures 30-33 (including Figures 31A, 31B,
33A,
and 33B), the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of each
of
the top and bottom plate 420 and 440 may include a shape wherein the edges
curve
(Figures 31, 31A, 33, and 33A) or angle (Figures 33A, and 33B) inward from the
outer surfaces 424, 444 toward the inner surfaces 422, 442 of the plates 420,
440
respectively. Additionally, as shown primarily in Figures 31A, 31B, 33A, and
33B
one or more of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b
may
include a substantially vertical portion. The substantially vertical portions
may be
adjacent the outer surfaces 424, 444 prior to the edges 480a, 480b, 482a,
482b,
484a, 484b, curving (Figures 31, 31A, 33, and 33A) or angling (Figures 31B,
and
33B) inward from the outer surfaces 424, 444 toward the inner surfaces 422,
442 of
the plates 420, 440. In other embodiments, the vertical portion, need not be
vertical,
for example, it may be at a different angle and/or different curve than the
remaining
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portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b. One
or
more portions of the perimeter of the top and bottom plates 420, 440,
including
edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b, can include a
continuous radius. In some embodiments, the continuous radius can be a radius
of
about 0.25 inches or greater than half the thickness of the plate.
Additionally, one or
more portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b
of
the top and bottom plates 420, 440 can include a splined curvature profile
around the
perimeter including one or more varying radii and/or planar sections. The
radii
portions of the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of
the
top and bottom plates 420, 440 can extend at a tangent angle 0 with respect to
the
inner surfaces 422, 442 of the top and bottom plates 420, 440. In some
embodiments, the angle 0 may be an angle of about 25 degrees or in the range
of
about 10 degrees to about 40 degrees. In some embodiments the splined
curvature
profile will become tangent at a distance of .38 inches from the outermost
portions of
edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and 486b of the top and bottom
plates 420, 440 or about .12 to .6 inches from the outermost portions of the
edges.
In some embodiments, the edges 480a, 480b, 482a, 482b, 484a, 484b, 486a, and
486b can extend from the outer surfaces 424, 444 of the top and bottom plates
420,
440 at an angle substantially perpendicular to the outer surfaces 424, 444 and
extend from the inner surfaces 422, 442 of the top and bottom plates 420, 440
at an
angle substantially tangent to the inner surfaces 442, 444. Additionally, in
such
embodiments, certain portions of the edges 480a, 480b, 482a, 482b, 484a, 484b,
486a, and 486b may not be perpendicular or tangent to the inner or outer
surfaces
422, 442, 442, 444. For example, as shown in Fig. 33, edge 482a may not extend
perpendicularly to the outer surface 444 at all locations around the perimeter
of the
top and bottom plates 420, 440.
[00242] In other
embodiments, and as discussed above, the perimeter of the
top and bottom plates 420, 440 may be constructed such that at the edges 480a,
480b, 482a, 482b, 484a, 484b, 486a, and 486b the outer surfaces 424, 444
extend
further out than the substantially flat portion of the inner surfaces 422,
442. For
example, in some embodiments, a chamfered or angled edge can be used around
the perimeter of the plate.
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[00243] In some embodiments, the lateral and/or longitudinal edges 480a,
480b, 482a, 482b, 484a, 484b, 486a, and 486b of the lateral flanges of the top
and
bottom plates 420,440 are each aligned along the same vertical plane, as best
shown in Figures 30-33. In these embodiments, the lateral length of the
lateral
flange of the bottom plate 440 is less than the lateral length of the lateral
flange of
the top plate 420.
[00244] In some embodiments, the outer edges 484a, 484b, 486a, 486b, as
viewed from a top view and as shown in Figure 29B, may include one or more
curved portions. For example, at least a portion 484R, 486R of the outer edge
484a,
484b, 486a, 486b may be formed with a continuous radius (R) with respect to a
geometric center of the adapter pad. In some embodiments each outer edge 484a,
484b, 486a, 486b may include two discontinuous curved edges 484R, 486R with a
constant radius, with a center section between the two that may be straight or
at a
different curve(s) than the constant radius portions. In other embodiments,
the
constant radius portion may be continuous and extend from proximate to
opposite
lateral edges 480a, 480b, 482a, 482b.
[00245] In some embodiments, any point on the lateral edge of the roller
bearing adapter when the top plate is rotated up to 41 milliradians from the
neutral
position relative to the bottom plate may have a linear displacement less than
or
equal to 0.234. Additionally, in some embodiments, any point on the lateral
edge
when the top plate is rotated up to 41 milliradians from the neutral position
relative to
the bottom plate has a linear displacement less than or equal to the maximum
longitudinal displacement and maximum lateral displacement. As discussed above
with regard to other embodiments, the top plate and bottom plates 420, 440 may
be
made from one or more different types of alloys with suitable strength and
other
performance characteristics. For example, the plates 420, 440 may be
manufactured from ASTM A36 steel plate, or steels with a strength equivalent
to or
higher than those specified in ASTM A-572. In some embodiments, the entire top
plate and/or bottom plate 420, 440 is formed (cast, machined, pressed, rolled,
stamped, rolled, forged or another suitable metal forming operation) from a
single
monolithic member. In some embodiments, the plates 420, 440 may be formed from
a material with a constant thickness throughout. In other embodiments, the
plates
420, 440 have a variable thickness. For example, as shown in Figure 30 and as
described above, the bottom plate 440 may be thinner toward the center of the
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central section 446. Additionally, for example in some embodiments, the
lateral
flanges 432, 434, 452, 454 can have a thickness that is greater than or less
than the
thickness of the center portion 426, 446.
[00246] As discussed above with regard to other embodiments, and as shown
primarily in Figures 30-33, an elastomeric member 560 is disposed between the
top
plate 420 and the bottom plate 440. As will be discussed in greater detail
below the
elastomeric member 560 can extend on the outside of the top and bottom plates
420, 440 and can extend beyond the lateral and longitudinal edges of the
plates. For
example, the elastomeric member can extend laterally and/or longitudinally at
least
0.05 inches, or in the range of about 0.01 inches to 0.25 inches, beyond the
respective lateral and longitudinal edges of the plates. The elastomeric
member 560
supports the vertical load and allows limited longitudinal, lateral, and
rotational
motion of the top plate 420 (supporting the side frame) relative to the bottom
plate
440 (supported by the adapter). This allows the relative motion of the side
frame
relative to the adapter by a low stiffness, and hence, low loads as compared
to
sliding adapter designs. As discussed above the movement of the top plate 420
relative to the bottom plate 440 can be measured in longitudinal displacement
(Figure 17B), lateral displacement (Figure 17C), and rotational displacement
(Figure
17D). The adapter pad elastomeric material 560 may be materials as previously
discussed.
[00247] In general the elastomeric member 560 can be attached to the top
and
bottom plates 420, 440 through injection molding. Generally the top and bottom
plates 420, 440 can be placed within the mold. In some embodiments, portions
of
the top and bottom plates 420, 440 can be coated with adhesive to allow the
elastomeric member 560 to adhere to the plates. Additionally, in some
embodiments, spacers can be placed within the mold in certain areas where the
elastomeric material is not needed. Once setup is complete, elastomeric
material
can be heated and inserted into the mold, and the elastomeric material can
flow
throughout the mold cavity, adhering to the areas applied with adhesive. In
some
embodiments, the top plate 420 and/or the bottom plate 440 may include one or
more apertures to allow elastomeric material to pass through the respective
plate
during the molding process. The elastomeric can then undergo vulcanization
and/or
curing.
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[00248] As previously discussed, the elastomeric member 560 may provide for
dampening within the adapter pad 400, allow for discrete changes in stiffness
and/or
flexibility within the adapter pad 400, and to allow for differences in the
dampening,
stiffness, flexibility or other parameters within the different portions of
the adapter
pad 400 to allow for a suitable design.
[00249] As shown in Figure 30, the elastomeric member 560 may include a
central portion 562 that is disposed within the central portion 410 of the
adapter pad
400, and first and second outer elastomeric members 564, 566 that are disposed
within the respective first and second lateral flanges 416, 418. The outer
elastomeric
members 564, 566, increase the shear area and volume of the elastomer layer
560
by extending the elastomeric material beyond the standard adapter clearance
envelope through the use of the lateral flanges 416, 418. This provides more
area
for the elastomeric member 560 and can increase stiffness of the adapter pad
400.
[00250] The central elastomeric portion 562 can be generally square shaped
and in some embodiments can have one or more rounded corners. Rounded
corners throughout the elastomeric member 560 can reduce or eliminate stress
concentrations as compared to an elastomeric member 560 with square corners.
As
discussed above, the elastomeric member 562 can have a uniform thickness
throughout the central portion 410.
[00251] The central elastomeric portion 562 can be primarily disposed in
the
central portion 410, but in some embodiments can also be disposed in the first
and
second upturned regions 412, 414, as shown in Figures 30 and 31, and in the
lateral
flanges 416, 418. The central elastomeric member 562 can have similar
dimensions to central elastomeric members discussed above. In some
embodiments, and as shown in Figures 30 and 31, the elastomer 560 can be
disposed between the top and bottom plates 420, 440 in the upturned regions
412,
414. In embodiments where elastomer 560 is disposed between the plates in the
upturned region it can compress or shear under lateral loading. This
compression of
the elastomer in the upturned regions 412, 414, in concert with the shearing
of the
elastomer in the other regions, can allow the adapter pad to reach high
stiffnesses
which can increase performance.
[00252] As best shown in Figure 29B, from a top view, the outer elastomeric
portions 564, 566, at least a portion of which, is within one or both of the
first and
second lateral flanges 416, 418 forms an outer longitudinal edge 574, 576,
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respectively. The outer longitudinal edge 574, 576 of the elastomeric portion
may
extend outward beyond the top and bottom plates 420, 440. The distance the
outer
edge 574, 576 of the elastomeric portion extends beyond edges of the top and
bottom plate 420, 440 may be substantially similar or may vary over the length
of the
edge. The elastomeric portion may also form lateral edges 578, 580. The outer
lateral edge 578, 580 of the elastomeric portion may extend outward beyond the
top
and bottom plates 420, 440. The distance the outer edge 578, 580 of the
elastomeric portion extends beyond edges of the top and bottom plate 420, 440
may
be substantially similar or may vary over the length of the edge. One or more
of the
edges 574, 576, 578, 580, may be substantially straight in the vertical
direction as
shown, for example, in Figure 28.
[00253] As
described above with regard to other embodiments, outer surfaces
of the plates 420, 440 may receive a coating of an elastomeric material 565
which
may be the material that contacts the pedestal roof 152. The elastomeric
coating
565 may be formed with a flat outer surface that follows along the geometric
profile
of the steel portion of the top plate 420, and can have a uniform thickness,
either
along the entire top plate 420, or in other embodiments, a uniform thickness
within
discrete portions of the pad (such as a uniform thickness in the central
portion 410, a
(potentially different or potentially the same) uniform thickness on one or
both of the
upper portions lateral flanges 432, 434, a (potentially different or
potentially the
same) uniform thickness on one or both of the upturned portions 428, 430, and
the
like.
[00254] In some
embodiments the entire or a majority of adapter pad 400 can
include a coating of an elastomeric material 565 which may be integrally
formed with
the elastomeric member 560. For example, in some embodiments, the majority of
the adapter pad 400 may include a coating of elastomeric material 565 except
for
those portions of the adapter pad 400 which contact the pedestal roof 152 and
the
top surface of the adapter 199 such as the outer surface of the top and bottom
plates
420, 440. In some embodiments, for example, the coating of elastomeric
material
565 may contact the pedestal roof 152, the side frame 4, and the roller
bearing
adapter pad 199, including the pedestal crown surface 102 and the vertical
shoulders 106. In other embodiments, for example, the portions of the adapter
pad
400 that contact the pedestal roof 152, side frame 4, and the roller bearing
adapter
pad 199, can be free of elastomeric material. As discussed elsewhere herein,
the
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elastomeric layer 565 may provide dampening and a calibrated flexibility to
the pad,
as well as a compressible surface to minimize wear between the adapter pad
400,
the pedestal roof 152, and the roller bearing adapter 199. The elastomeric
coating
565 may follow the outer surfaces of the adapter pad 400 and can have a
uniform
thickness, along the outer surfaces of the adapter pad 400, or in other
embodiments,
a uniform thickness within discrete portions of the pad such as a uniform
thickness in
the central portion 410, a (potentially different or potentially the same)
uniform
thickness on one or both of the upper portions lateral flanges 432, 434, a
(potentially
different or potentially the same) uniform thickness on one or both of the
upturned
portions 428, 430, and the like.
[00255] As best
shown in Figures 28-30, and as described above, one or both
of the upturned portions 412, 414 may include a hollow portion(s) 572 within a
cavity
formed between the top and bottom plate 420, 440, which is a void where
substantially no elastomeric material is provided, and can establish a
discontinuity
within the elastomeric member 560 within the respective first and/or second
upturned
portions 412, 414. The hollow portions 572 may provide a complete separation
between the elastomeric member 560 disposed within the central portion 410,
and
the elastomeric member disposed in the lateral flanges 416, 418. In certain
embodiments, the void may include a very small thickness layer of elastomeric
material that contact each of the top and bottom plate 420, 440 through the
transition, which can be a function of possible limitations of the tooling
used in the
molding process, but this thin layer (when existing) may not materially
contribute to
the performance of the adapter pad 400. Additionally, in some embodiments the
hollow portion 572 can include small portions of elastomeric material that
extend
between the top and bottom plates 420, 440, but it is otherwise substantially
hollow.
In some embodiments, the width of the hollow portion 572 can be about 0.25
inches
or in the range of about 0.1 inches to about 0.5 inches, or at least as wide
as the
maximum lateral and rotational motion on the adapter pad 200. In some
embodiments, the hollow portion(s) 572 are configured to provide a lateral
void
between the top and bottom plate 420, 440 extending through the respective
transition portion 412, 414, such that the respective inner surfaces of the
top and
bottom plates 420, 440 within the transition portion do not contact each other
during
lateral or rotation relative motion therebetween and/or in view of the lateral
and/or
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rotational displacement during railcar operations with the adapter pad 400
disposed
in position in the railcar truck system.
[00256] As described above, the hollow portion 572 can function to limit
the
bending stresses in the top and bottom plates 420, 440. The hollow portion 572
may
be about 0.25 inches. At the about 0.25 inch motion range, the upturned
regions of
the top and bottom plate 420, 440 can engage and prevent further relative
motion.
This can put an upper limit on the elastomer strain in the lateral direction
and the
metal stress.
[00257] As described above, during use, there can be heat generation in the
adaptor pad 400 through friction of the pad 400 and sliding relative to the
side frame
pedestal roof 152 and/or relative to the bearing adaptor 199; and or the
hysteretic
damping of the elastomeric member 560 of the adaptor pad 200. These heat
sources can cause adaptor pad temperatures to increase, which can result in
lower
durability and reduced stiffnesses. As described above, in some embodiments,
the
adapter pad 400 can include features which can increase its ability to reduce
heat in
the adapter pad 200.
[00258] Additionally, as described above, one or both of the outer surfaces
424
of the central portion 426, or the inner surface 444 of the central portion
446 may
include one or more of various surface features, and in some embodiments a
pattern
of surface features to make these surfaces non-smooth.
[00259] As described above, in some embodiments electrical conductivity may
be provided between the top and bottom plates 420, 440. As shown in Figure 28,
a
wire ground strap 266 can be attached to apertures in sides of the top and
bottom
plates 420, 440. The wire ground strap 266 may pass through the apertures in
the
top and bottom plates 220, 240. The top and bottom plates 420, 440 can be
indented
or deformed at a point 267 to crimp or secure the wire ground strap 266 in the
top
and bottom plate 420, 440. In some embodiments, the wire ground strap 266 may
be stainless steel braid, about .100 inches in diameter, but may be as small
as .050
inches.
[00260] The adapter pad 400 can, and as described above, include pads or
grips on top and bottom plates 420, 440 of the adapter pad which can be
configured
to position the adapter pad 200 relative to the side frame pedestal roof 152
and the
bearing adapter 199 and also engage and restrict movement of the adapter pad
400
relative to the pedestal roof 152 and the bearing adapter 199 which can focus
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movement (i.e. shear) of the adapter pad 200 to the elastomeric member 360. As
described above, the assembly of the adapter pad 400 to the roller bearing
adapter
199 can force the adapter pad 400 to be reasonably centered with regard to the
roller bearing adapter 199, and the bearing by the use of the vertical
shoulders 106
and including grips. Further, the adapter pad system 198 promotes the return
of the
adapter 200 and wheelset to a centered, or near zero force center position.
[00261] As described above, the adapter pad 400 may include a first and
second lateral adapter grips 270, 271. The lateral adapter pad grips 270, 271
can be
integrally formed with the bottom plate 440, including with being integrally
formed
with the elastomeric member 560 and/or any elastomeric coating 565 on the
adapter
pad 400. As described above, the adapter pad 400 can also include a first and
second lateral side frame grips 272, 273. The lateral side frame grips 272,
273 can
be integrally formed with the bottom plate 440, including with being
integrally formed
with the elastomeric member 560 and/or elastomeric coating 565 on the adapter
pad
400.
[00262] As discussed above, the elastomeric member 560 and particularly the
outer elastomeric members 564, 566 can be configured in such a manner that the
elastomer's rotational shear stresses, through a displacement of up to 41
milliradians, are no greater than the elastomer's lateral and longitudinal
shear
stresses through a displacement of up to 0.23 inches laterally and of up to
0.14
inches longitudinally.
[00263] The elastomeric member 560 can be measured as described above
with regard to other embodiments. The total shear width, or length in the
lateral
direction, of the elastomeric member 560 shown in Figures 28-33 can be about
10
inches or in the range of about 6 inches to about 14 inches. Similarly, the
total shear
length, or length in the longitudinal direction, of the elastomeric member 560
can be
about 6.9 inches or in the range of about 6 inches to about 10 inches. The
composite shear perimeter, or perimeter of all portions of the elastomeric
member
can be about 51.70 inches or in the range of about 35 inches to about 75
inches.
The total surface area of the elastomeric member 560 in the shear plane can be
about 55.5 square inches or in the range of about 50 square inches to about 70
square inches. The total surface area of the elastomeric member 560 outside of
the
central portion can be about 15.5 square inches or in the range of about 5
square
inches to about 30 square inches, or greater than 5 square inches. Thus, the
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surface area of the elastomeric member in the lateral flanges 416, 418 can be
about
7.75 square inches each or in the range of about 2.5 square inches to about 15
square inches, or greater than 2.5 square inches.
[00264] As discussed above, to reduce the stresses in the elastomeric
member
560 under maximum shear displacement, it can be beneficial to provide normal
stress, or compression, to the elastomeric member 560 during shear loading.
[00265] For example, as discussed above, the elastomeric member 560,
outside the pedestal roof 152 area can be compressed greater than 0.020
inches, or
greater than 7% of the static thickness of the elastomeric member 560. In
certain
embodiments, pre-compression of this magnitude allows for improved fatigue
life of
the elastomeric member 560. Additionally, in embodiments discussed herein
about
percent to 30 percent of vertical force can be distributed to each of the
adapter
pad lateral flanges 416, 418 when a vertical force is applied to the central
portion
410 of the adapter pad 400. And in embodiments discussed herein the reaction
of
the vertical load at the vertical shoulders 106 can provide a vertical force
greater
than 3000 pounds to precompress the elastomeric member.
[00266] Additionally, as discussed above, compression of the elastomeric
member 560 in the region outside the pedestal roof 152 (in the outer
elastomeric
members 464, 466), can be accomplished with an elastomeric member 560 having a
non-uniform thickness along the length of the elastomeric member 560. For
example, the first and/or second outer portions 564, 566 may be formed with a
thickness X while the central portion 462 may be formed with a different or
smaller
thickness Y. The geometry (such as the bends through the upturned portions
412,
414) of the top and bottom plates 420, 440 may be formed to accommodate the
differences in thickness between X, Y allowing the elastomeric portions in the
central
and outer portions to contact the inner surfaces of the top and bottom plates
420,
440 as desired. In certain embodiments, the difference in thickness of the
elastomeric member forming the first and/or second outer portions 464, 466 and
the
central portion 462 can assist in reducing the simple shear strains of the
outer layers
based upon in-plane forces applied to the adapter pad in the longitudinal,
lateral, and
rotational directions.
[00267] Additionally, as discussed above, one or both of the lateral
flanges 416,
418 may be formed such that the elastomeric layers 564, 566 therewithin
includes a
thickness, X that is about 0.25 inches, such as within a range of 0.15 inches
to 0.30
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inches, inclusive of all thicknesses within the range. In this embodiment, the
thickness Y of the elastomeric layer 560 in the central portion 562 may be
about 0.20
inches, such as within a range of 0.15 inches to 0.25 inches, inclusive of all
thicknesses within the range. The thicknesses of elastomeric layers discussed
herein refer to the static thickness of the elastomeric layers or the
thickness of the
elastomeric layers without an external load on the elastomeric layer. One or
both of
the lateral flange portions 564, 566 and central portions 562 may have a
different
thickness, with the upper portions being thicker than the central portion this
can
achieve a desired effect, generally of increasing the load or compression of
one or
both of the lateral flange portions 564, 566, which due to the material
properties of
the elastomeric layer additionally increases its strength and durability based
upon
the contemplated loading during railcar operation.
[00268]
Additionally, as discussed above, and as shown in Figures 30 and 31,
compression of the elastomeric member 560 in the lateral flanges 416, 418 can
be
increased by using compression shims 290 within or under the lateral
projecting
flanges 416, 418. Compression shims can be used herein such that reaction of
the
vertical load at the vertical shoulders 106 provides a vertical force greater
than 3000
pounds such that about 10 percent to 30 percent of vertical force is
distributed to
each of the adapter pad lateral flanges 416, 418 when a vertical force is
applied to
the central portion 410 of the adapter pad 400. Compression shims can in some
embodiments force more of the vertical load of the car to be distributed from
the
center elastomer layer 560 to the outer elastomer layers 564, 566. As shown in
Figures 30 and 31, a first adapter compression shim 290 can be disposed
between
an upper surface of the vertical shoulder of the roller bearing adapter 199
and the
outer surface 244 of the first lateral flange 416 of the bottom plate 440. A
second
adapter compression shim 290 can be similarly placed in relation to the second
lateral flange 418. The adapter compression shims 290 can be about 0.05 inches
thick or within the range of about 0.03 inches to about 0.18 inches.
Compression
shims as discussed herein can have any number of different shapes and
configurations to provide the necessary loads to compress the outer elastomer.
For
example, compression shims can be rectangular, square, trapezoidal, pyramidal,
can
have a hollow cross-section, and can be a plurality of compression shims.
Further,
compression shims as discussed herein can be integrally formed with the
adapter
pad during the molding process, can be integrally formed with the roller
bearing
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adapter, or can be added to the roller bearing adapter system after the
molding
process.
[00269] As discussed above, it has been determined through testing that the
performance of the adapter pad system 198 is a function of the stiffness of
the
adapter pad 400. More specifically in certain embodiments, it has been
determined
that adapter pad performance, including design life, can be improved by
increasing
the stiffness of the adapter pad system 198 (measured in pounds of force per
inch of
deformation). Physical measurement of the pad stiffness can be determined as
previously discussed.
[00270] Using the above described test methods, exemplary measurements
and testing results of embodiments disclosed herein are shown below in Table
3. It
is understood that these embodiments are examples, and that other structural
embodiments with other testing results can exist.
Table 3
Embodiments Described Herein
Elastomer Normal 55.5 in2
Area (in2) or about 50 in2 to about 70 in2
Elastomer Normal
Area Outside of 15.5 in2
Pedestal Roof or about 5 in2 to about 30 in2
Contact (in2)
Pad Elastomer Shear
9.6 in2
Width (Lateral
or about 6 in2 to about 14 in2
Length) (in)
Pad Elastomer Shear
6.9 in2
Length (Longitudinal
or about 6 in2 to about 10 in2
Length) (in)
Lateral Stiffness
60 kips/in
(tested at 3hz cycling
or about 45 kips/into about 80 kips/in
frequency and 35 kip
or at least 45 kips/in
vertical load)
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Longitudinal
Stiffness 64 kips/in
(tested at 3hz cycling or about 45 kips/into about 80 kips/in
frequency and 35 kip or at least 45 kips/in
vertical load)
Rotational Stiffness 670 kip*in/mRad
(tested at 3hz cycling or about 250 kip*in/mRad to about 840
frequency and 35 kip kip*in/mRad
vertical load) or at least 250 kip*in/mRad
Vertical Stiffness at least 5,000 kips/in
Lateral Hysteresis
5000 lbs.
(tested at 3hz cycling
or about 3750 lbs. to about 6250 lbs.
frequency and 35 kip
or less than 6000 lbs.
vertical load)
Longitudinal
Hysteresis 500 lbs.
(tested at 3hz cycling or about 375 lbs. to about 1500 lbs.
frequency and 35 kip or less than 1500 lbs.
vertical load)
Rotational
Hysteresis 12000 lbs.*in
(tested at 3hz cycling or about 9000 lbs.*in to about 16000 lbs.*in
frequency and 35 kip or less than 16000 lbs.*in
vertical load)
Center Elastomer
25.5 in.
Layer Shear
or about 20 in. to about 30 in.
Perimeter
Outer Elastomer
13.1 in. each
Layer Shear
or about 8 to 18 in. each
Perimeter
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Composite Elastomer
51.7 in.
Layer Shear
or about 35 in. to 75 in.
Perimeter
Center Elastomer 8.3
Layer Shape Factor or about 6 to 10
Outer Elastomer 1.6 each
Layer Shape Factor or about .5 to 3 each
Composite Shape 4.5
Factor or about 2.5 to about 7
[00271] As discussed above, the elastomer layers 564, 566 outside of the
central area 210 can contribute to the overall stiffness of the adapter pad
200. For
example in some embodiments, the elastomeric member 560 outside of the central
area 210 can contribute about 15%, or in the range of about 5% to about 30%,
of the
total lateral and longitudinal stiffness of the adapter pad, and 33%, or in
the range of
about 15% to about 60%, of the rotational stiffness of the adapter pad 200.
[00272] As previously discussed, the elastomeric member 560, which can
include elastomeric coating 565, of the adapter pad 400 provides shear
resistance
during loading in the lateral, longitudinal, and rotational directions under a
vertical
load. This shear resistance is caused by relative movement between the top and
bottom plates 420, 440 reacted through the elastomeric member 560. Simple
shear
strain or strain is defined as d/t where d = displacement of the elastomeric
member
and t = thickness of the elastomeric member. Figures 34a and 34b depict
simulations of lateral displacement of the top plate 420 relative to the
bottom plate
440 of 0.234 inches. As shown in Figures 34a and 34b the strain is lower in
the
lateral flanges 416, 418 than it is in the center section 410. In some
embodiments,
this can improve the life of an adapter pad. Additionally, as shown in Figures
34a
and 34b, the highest strain values occur inward of the outer edges of the
elastomeric
section. Similarly, Figures 35a and 35b depict simulations of longitudinal
displacement of the top plate 420 relative to the bottom plate 440 of 0.234
inches.
As shown in Figures 35a and 35b the strain is lower in the lateral flanges
416, 418
than it is in the center section 410. In some embodiments, this can improve
the life
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of an adapter pad. Additionally, as shown in Figures 35a and 35b, the highest
strain
values occur inward of the outer edges of the elastomeric section.
[00273] Additionally, in some embodiments, the shear strain of adapter pad
400
does not exceed 100% under maximum displacement conditions. For example, the
lateral strain can be about 74% or under 80%, or under 90% for a lateral
displacement of 0.234 inches. This may be about 45% less strain than existing
adapter pad systems for a lateral displacement of 0.234 inches. Additionally,
for
example, the longitudinal strain can be about 72% or under 80%, or under 90%
for a
longitudinal displacement of 0.139 inches. This may be about 30% less strain
than
existing adapter pad systems for a longitudinal displacement of .139 inches.
[00274] Exemplary dimensions of the adapter pad 400 are shown and
described in this application; however, other dimensions may be used for
portions of
the adapter pad, depending upon the fixed dimensions of the side frame and the
bearings used with the particular railcar truck system.
125-Ton Adapter Pad System
[00275] As described above rail car types and services native to the North
American Rail Industry require different truck sizes. While the adapter pad
systems
described throughout this document may be used with any size railcar, certain
design changes may be advantageous for certain size railcars. Described below
are
aspects of adapter pad systems that may be advantageously used with rail cars
designed for 125 ton service and/or services with Gross Rail Load greater than
286,000 lbs. In particular, these adapter pad systems can be targeted for use
on
cars which utilize articulated connectors at truck locations, thereby sharing
the truck
between two car bodies. These articulated truck locations typically utilize 4
truck
side bearings and plastic centerbowl liners, which differ from conventional
truck
systems.
[00276] As described above, embodiments of the adapter pad system
described herein provide a thrust lug opening width and spacing sufficient to
not limit
displacement within the AAR values, even with the use of high stiffness shear
pads
as described herein. The disclosed adapter design which may be optimized for
125
ton service may utilize target adapter displacements shown in Table 4 below.
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Table 4
AAR ADAPTER TO SIDE FRAME CLEARANCE STACKUP
NEW COMPONENTS
Features Maximun Minimun
Longitudinal Clearance
.139 .017
(Each direction from center: in.)
Lateral Clearance
.279 .126
(Each direction from center: in.)
Rotataional Clearance
52.4 17.5
(Each direction from center: mRad.)
[00277] Additionally, adapter pad systems which may be optimized for 125
ton
service disclosed herein may have a total height measured between an upper
surface of the roller bearing 5 and the pedestal roof 152 of about 1.5 inches
or in the
range of about 1.15 inches to about 1.8 inches and may not require the use of
a
special side frame. Additional possible dimensions of the adapter pad system
which
may be optimized for 125 ton service are shown in table 5 below. While this
embodiment is specific to the 125T truck, the disclosed adapter and matching
adapter pad system can be scalable for use with and improve the performance of
trucks for all car capacities (70 ton, 100 ton, 110 ton, and 125 ton),
including those
trucks that do not require compliance with the M-976 standard.
Table 5 - 125T Adapter/Pad Thickness
Adapter Thickness Adapter Pad Total
Thickness Thickness
1.00" +/- 0.1 0.60" +/- 0.06 1.60" +/- 0.16
0.80" +/- 0.08 0.80" +/- 0.08 1.60" +/- 0.16
1.20" +/- 0.12 0.40"+/- 0.04 1.60" +/- 0.16
0.84" +/- 0.084 0.61" +/- 0.061 1.45" +/- 0.16
[00278] Additionally, using the above described test methods, exemplary
measurements and testing results of embodiments which may be optimized for 125
ton service disclosed herein are shown below in Table 6 below. It is
understood that
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these embodiments are examples, and that other structural embodiments with
other
testing results can exist.
Table 6
Embodiments Described Herein
Elastomer Normal 85 in2
Area (in2) or about 70 in2 to about 100 in2
Elastomer Normal
Area Outside of 15.5 in2
Pedestal Roof or about 5 in2 to about 30 in2
Contact (in2)
Pad Elastomer Shear
in
Width (Lateral
or about 6 in2 to about 14 in2
Length) (in)
Pad Elastomer Shear
8.5 in
Length (Longitudinal
or about 6 in2 to about 10 in2
Length) (in)
Lateral Stiffness
60 kips/in
(tested at 3hz cycling
or about 45 kips/into about 80 kips/in
frequency and 35 kip
or at least 45 kips/in
vertical load)
Longitudinal
Stiffness 64 kips/in
(tested at 3hz cycling or about 45 kips/into about 80 kips/in
frequency and 35 kip or at least 45 kips/in
vertical load)
Rotational Stiffness 670 kip*in/mRad
(tested at 3hz cycling or about 250 kip*in/mRad to about 840
frequency and 35 kip kip*in/mRad
vertical load) or at least 250 kip*in/mRad
Vertical Stiffness at least 5,000 kips/in
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Lateral Hysteresis
5000 lbs.
(tested at 3hz cycling
or about 3750 lbs. to about 6250 lbs.
frequency and 35 kip
or less than 6000 lbs.
vertical load)
Longitudinal
Hysteresis 500 lbs.
(tested at 3hz cycling or about 375 lbs. to about 1500 lbs.
frequency and 35 kip or less than 1500 lbs.
vertical load)
Rotational
Hysteresis 12000 lbs.*in
(tested at 3hz cycling or about 9000 lbs.*in to about 16000 lbs.*in
frequency and 35 kip or less than 16000 lbs.*in
vertical load)
Center Elastomer
30 in.
Layer Shear
or about 25 in. to about 35 in.
Perimeter
Outer Elastomer
18 in. each
Layer Shear
or about 10 to 25 in. each
Perimeter
Composite Elastomer
66 in.
Layer Shear
or about 50 in. to 80 in.
Perimeter
Center Elastomer 8
Layer Shape Factor or about 6 to 10
Outer Elastomer 1.5 each
Layer Shape Factor or about .5 to 3 each
Composite Shape 4.5
Factor or about 2.5 to about 7
[00279] In certain embodiments, including those which may be optimized for
125 ton service, it may be advantageous to increase the stiffness of the
adapter pad
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system. An additional embodiment of an adapter pad system 500 which may be
optimized for 125 ton service is shown in Figures 51A-52C. The embodiment of
the
adapter pad system 500 shown in Figures 51A-52C is similar in many ways to
adapter pad embodiments previously discussed and therefore descriptions of
similar
parts are not repeated with respect to the embodiment 500 shown in Figures 51A-
52C. As described above, the adapter pad system 500 may include an adapter pad
502 and a roller bearing adapter 504. The system 500 is configured to be
disposed
between a roller bearing and a side frame pedestal roof of a side frame. As
shown
in Figures 51A-51B, the adapter pad 502 generally includes an upper member or
top
plate 520, a lower member or bottom plate 540, and an elastomeric member 560
disposed between the top and bottom plates 520, 540 along a portion of the
adapter
pad 502.
[00280] The top plate 520 includes first and second upturned regions 528,
530
projecting upward from opposite edges of the central portion 526 of the top
plate
520, a first lateral flange 532 projecting outward from the first upturned
region, and a
second lateral flange 534 projecting outward from the second upturned region
530.
Similarly, the bottom plate 540 has corresponding first and second upturned
regions
548, 550 projecting upward from opposite edges of the central portion 546 of
the
bottom plate. However, unlike in some designs described above, the bottom
plate
540 may not include lateral flanges.
[00281] To increase stiffness, the adapter pad system 500 may instead
include
one or more bushing systems 570. The bushing system may include a bushing 572
and a shaft 574 and may include elastomeric material 576 disposed between the
bushing 572 and the shaft 574. As shown in Fig 51A the bushings 572 may be
engaged or integrally formed with the lateral flanges 532, 534 of the top
plate 520
and the shafts 574 may be engaged or integrally formed with the roller bearing
adapter. In other embodiments (not shown) this arrangement may be reversed
such
that the bushings 572 are engaged with the roller bearing adapter and the
shafts are
engaged with the lateral flanges 532, 534 of the top plate 520. Additionally,
although
the bushing 572 and shafts 574 are shown as having generally cylindrical
shapes,
any other suitable shapes may be used including, for example, elliptical
cylinders,
triangular prisms, cuboids, pentagonal prisms, octagonal prisms, and hexagonal
prisms. Additionally the relative sizes of the bushing 572 and shaft 574 may
differ as
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shown in Figs. 51A and 51C which may permit more or less elastomeric material
between the bushing 572 and the shaft 574.
[00282] Additionally, the elastomeric material 576 disposed between the
bushing 572 and the shaft 574 may have any shape. For example, as shown in
Fig.
51B, the elastomeric material 576 may occupy substantially all the area
between the
bushing and the shaft. As shown in Figs. 52A-52B, the elastomeric 576 material
may be engaged with only a portion of the length of the bushing 572 or shaft
574.
This may be advantageous in reducing the stiffness compared to a bushing
system
500 entirely filled with elastomeric material. In other embodiments, the
stiffness of
the bushing system 500 may be adjusted by adjusting the type of elastomeric
material 576.
Examples
[00283] In one example an adapter pad system configured to be disposed
between a wheelset roller bearing and side frame pedestal roof of a railcar
truck is
disclosed. The adapter pad system can include a roller bearing adapter having
first
and second vertical shoulders that project upward from a top surface of the
adapter.
The adapter pad system can also include an adapter pad configured to interface
with
the roller bearing adapter with a top plate having inner and outer surfaces, a
central
portion, first and second upturned regions projecting upward from opposite
edges of
the central portion, a first lateral flange projecting outward from the first
upturned
region, and a second lateral flange projecting outward from the second
upturned
region; a bottom plate having inner and outer surfaces, a central portion,
first and
second upturned regions projecting upward from opposite edges of the central
portion, a first lateral flange projecting outward from the first upturned
region, and a
second lateral flange projecting outward from the second upturned region. The
first
and second laterally projecting flanges of the top plate and the bottom plate
of the
adapter pad system can be disposed above the vertical shoulders of the roller
bearing adapter.
[00284] The roller bearing adapter of the adapter pad system can be cast or
forged. The adapter pad can be engaged with the side frame and engaged with
the
roller bearing adapter. The top plate of the adapter pad can be engaged with
the
side frame such that movement between the top plate and the side frame is
restricted. The bottom plate of the adapter pad can be engaged with the roller
bearing adapter such that movement between the bottom plate and the roller
bearing
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adapter is restricted. The roller bearing adapter can include longitudinal
stops
configured to restrict longitudinal movement of the bottom plate with respect
to the
roller bearing adapter. The vertical shoulders can be configured to restrict
lateral
movement of the bottom plate with respect to the roller bearing adapter. The
roller
bearing adapter top surface can include a crowned surface. The longitudinal
stops
and vertical shoulders can be configured to restrict rotational movement of
the
bottom plate with respect to the roller bearing adapter. The roller bearing
adapter
can be symmetrical about a lateral centerline. The roller bearing adapter can
be
symmetrical about a longitudinal centerline. The top plate of the roller
bearing
adapter can be continuous. The bottom plate of the roller bearing adapter can
be
continuous.
[00285] The
adapter pad system can include an elastomeric member disposed
between the inner surfaces of the top plate and the bottom plate. The
elastomeric
member disposed between the top plate and the bottom plate can be a plurality
of
elastomeric members. The plurality of elastomeric members can include a first
outer
elastomeric member disposed between the first lateral flanges of the top and
bottom
plates, a second outer elastomeric member disposed between the second lateral
flanges of the top and bottom plates, and a central elastomeric member
disposed
between the central portion of the top and bottom plates. A first hollow
portion can
be disposed between the central elastomeric member and the first outer
elastomeric
member and a second hollow portion can be disposed between the central
elastomeric member and the second outer elastomeric member. The first and
second hollow portions can be about 0.25 inches wide. The first and second
hollow
portions can be configured to limit bending stresses in the top and bottom
plates.
The outer elastomeric members can be in compression. The thickness of the
outer
elastomeric members can be compressed at least 0.020 inches from a static
state.
The thickness of the outer elastomeric members can be compressed at least 7%
from a static state. The first outer elastomeric member, second outer
elastomeric
member, and central elastomeric member can each be substantially planar and
each
can be substantially horizontal when the adapter pad is disposed below a side
frame
pedestal roof of a railcar truck. The elastomeric material can be positioned
normal to
the direction of lateral displacement to increase compression stiffness.
The
elastomeric material can be positioned normal to the direction of longitudinal
displacement to increase compression stiffness. The elastomeric material can
be
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positioned normal to the direction of rotational displacement to increase
compression
stiffness. The elastomeric material can be positioned normal to the direction
of
vertical displacement to increase compression stiffness.
[00286] The surface area of the first outer elastomeric member at a cross-
sectional plane through the first outer elastomeric member centered between
the
inner surfaces the top and bottom plates can be greater than 2.5 square
inches. The
surface area of the second outer elastomeric member at a cross-sectional plane
through second outer elastomeric member in a plane centered between the inner
surfaces of the top and bottom plates can be greater than 2.5 square inches.
The
combined surface area of the first and second outer elastomeric members at
cross-
sectional planes through the first and second outer elastomeric members in
planes
centered between the inner surfaces of the top and bottom plates can be
greater
than 5 square inches. The combined surface area of the first and second outer
elastomeric members at cross-sectional planes through the first and second
outer
elastomeric members in planes centered between the inner surfaces of the top
and
bottom plates can be at least 10 percent of the surface area of the central
elastomeric member at a cross-section plane through the center of the central
elastomeric member in a centered between the inner surfaces of the top and
bottom
plates.
[00287] The central elastomeric member can define a plurality of gaps that
establish a plurality of discontinuities within the elastomeric member
disposed
between the central portion of the top plate and the central portion of the
bottom
plate. The plurality of gaps can be a thickness less than a total distance
between the
top plate and the bottom plate, with a portion of the elastomeric member being
vertically disposed with respect to the one or more of the plurality of gaps
and
contacting one or both of the top and bottom plates.
[00288] The central elastomeric member can define an outer edge, wherein
one or more portions of the outer edge is curved from a top view. At least a
portion
of the outer edge of the central elastomeric portion can define an internally
recessed
contour. The first and second outer elastomeric members can define an outer
edge,
wherein one or more portions of the outer edge is curved from a top view. One
or
more portions of outer edges of elastomeric members can include a continuous
radius measured from a center point of the central portion of the top plate.
Any edge
of the elastomeric member can define an internally recessed contour.
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[00289] One or both of the first and second outer elastomeric members can
define an outer edge, wherein one or both of the first and second lateral
flanges of
the top and bottom plates extend outward past at least a portion of the outer
edge
within the respective first and second lateral flanges.
[00290] The adapter pad can include an elastomeric support disposed between
the outer surfaces of the first and second lateral flanges of the bottom plate
and the
vertical shoulders of the roller bearing adapter.
[00291] At least a portion of an outer edge of the elastomeric members can
define an internally recessed contour. The internally recessed contour can be
defined by a first linear portion that extends from proximate to the inner
surface of
the top plate and a second linear portion that extends from proximate to the
inner
surface of the bottom plate. The first and second linear portions can be
connected
with a transition as it extends between the first and second linear portions.
The first
and second linear portions can each extend from the neighboring respective top
or
bottom plate at an angle within the range of about 25 degrees to about 35
degrees to
a plane through the surface of the respective top or bottom plate from which
the
respective linear portion extends.
[00292] The first and second outer elastomeric members can be the same or
greater thickness than the central elastomeric member. The thickness of the
first
and second outer elastomeric members can be within the range of about 0.15
inches
to about 0.30 inches. The thickness of the central elastomeric member can be
within
the range of about 0.15 inches to about 0.25 inches. The thickness of the
adapter
pad can be within the range of about 0.4 inches to about 0.8 inches.
[00293] The adapter pad system can also include an elastomeric layer
disposed above an outer surface of the top plate and/or can include an
elastomeric
layer disposed below an outer surface of the bottom plate. The elastomeric
layer
can cover all or portions of the outer surface of the adapter pad. The top and
bottom
plates of the adapter pad can be of non-uniform thickness. The top and bottom
plates can be of uniform thickness. The top plate can have a non-uniform
thickness.
The top plate can have a uniform thickness. The bottom plate can have a non-
uniform thickness. The bottom plate can have a uniform thickness.
[00294] The adapter pad system can be configured to return to a neutral or
central position within the side frame pedestal after removal of a load placed
thereon.
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[00295] The first and second lateral flanges of the top plate can include a
planar outer surface that can be parallel to the outer surface of the central
portion of
the top plate.
[00296] The inner surfaces of each of the first and second upturned regions
of
the first and second plates of the adapter pad can include a planar portion.
The
inner surfaces of each of the first and second upturned regions of the first
and
second plates of the adapter pad can include a curved portion. The first and
second
upturned regions of the first and second plates of the adapter pad can include
at
least a portion that extends at an obtuse angle to a plane through the outer
surface
of the central portion of the top plate.
[00297] The first and second lateral flanges of the top plate of the
adapter pad
can include exposed outer surfaces when the adapter pad contacts a side frame
pedestal. The first and second lateral flanges can contact air outside of
the
envelope of the side frame at the pedestal opening. The first and second
lateral
flanges can be configured to reduce heat of the adapter pad. The first and
second
lateral flanges can be configured to reduce heat of the adapter pad system.
[00298] The adapter pad can include a lateral length of the central portion
that
can be equal to the distance between the sidewalls of at the pedestal roof
surface.
The lateral length of the central portion can be about 0.125 inches greater
than the
length between the side walls of the side frame at the pedestal roof surface.
The
overall lateral length of the top plate can be at least 7.5 inches.
[00299] The adapter pad system can also include a first lateral adapter
grip
disposed between an inside surface of the first vertical shoulder of the
roller bearing
adapter and the first upturned region of the bottom plate; and a second
lateral
adapter grip disposed between an inside surface of the second vertical
shoulder of
the roller bearing adapter and the second upturned region of the bottom plate.
The
first and second lateral adapter grips can be formed of an elastomeric
material. The
first and second lateral adapter grips can be configured to limit sliding or
relative
movement between the roller bearing adapter and the outer surface of the
bottom
plate of the adapter pad. The first and second lateral adapter grips can be
configured to center the bottom plate of the adapter pad on the roller bearing
adapter.
[00300] The adapter pad system can also include a first lateral side frame
grip
disposed on the outer surface of the first upturned region of the top plate;
and a
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second lateral side frame grip disposed on the outer surface of the second
upturned
region of the top plate. The first lateral side frame grip can be disposed
between the
outer surface of the first lateral flange of the top plate and a side frame
pedestal, and
the second lateral side frame grip can be disposed between the outer surface
of the
second lateral flange of the top plate and a side frame pedestal. The first
and
second lateral side frame grips can be formed of an elastomeric material. The
first
and second lateral side frame grips can be configured to limit sliding or
relative
movement between an outer surface of the top plate and the side frame
immediately
above the pedestal area.
[00301] In some examples, the adapter pad system can be configured to
restrict the elastomer temperatures below the degradation temperature of the
specific elastomeric and/or adhesive material used in pad construction. The
adapter
pad system can also be configured to reduce melting of the elastomeric member.
[00302] The adapter pad system can include a first adapter compression shim
disposed between an upper surface of the first vertical shoulder of the roller
bearing
adapter and the outer surface of the first lateral flange of the bottom plate.
The
adapter pad system can also include a second adapter compression shim is
disposed between an upper surface of the second vertical shoulder of the
roller
bearing adapter and the outer surface of the second lateral flange of the
bottom
plate. The thickness of the first and second adapter compression shims can be
within the range of about 0.06 inches to about 0.18inches.
[00303] The adapter pad can include a lower first adapter pad compression
shim disposed between the elastomeric member and the first lateral flange of
the
bottom plate. The adapter pad can also include a second lower adapter pad
compression shim is disposed between the elastomeric member and the second
lateral flange of the bottom plate. The thickness of the first and second
lower
adapter pad compression shims can be within the range of about 0.06 inches to
about 0.18 inches.
[00304] The adapter pad can include a first upper adapter pad compression
shim disposed between the first lateral flange of the top plate and the first
outer
elastomeric member. The adapter pad can also include a second upper adapter
pad compression shim is disposed between the second lateral flange of the top
plate
and the second outer elastomeric member. The thickness of the first and second
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upper adapter pad compression shims can be within the range of about 0.06
inches
to about 0.18 inches.
[00305] The compression shims can be configured to provide at least 3000
pounds of vertical compressive load into the outer elastomeric members when a
vertical load of 35,000 pounds is applied to the central portions of the
adapter pad.
The compression shims can be rectangular. The compression shims can have a
rectangular cross-section shape, a curved cross-sectional shape, a triangular
cross-
sectional shape, or a trapezoidal cross-sectional shape. The compression shims
can include a raised portion. The compression shims can include a hollow
portion.
The compression shims can comprise a plurality of compression shims.
[00306] The lateral flanges of the adapter pad can be vertically supported
by
the vertical shoulders of the roller bearing adapter. About 10 percent to 30
percent
of vertical force can be distributed to each of the adapter pad lateral
flanges when a
vertical force is applied to the central portions of the adapter pad. The
reaction of
the vertical load at the vertical shoulders can provide a vertical force of at
least 3000
pounds to precompress the elastomeric member.
[00307] The combined top plate, bottom plate, and elastomeric member of the
adapter can pad provide a longitudinal stiffness that can be at least 45,000
pounds
per inch through a longitudinal displacement of the top plate relative to the
bottom
plate of up to 0.139 inches from a central position, when a vertical load of
35,000
pounds is applied to the central portions of the adapter pad. The longitudinal
hysteresis of the adapter pad system can be less than about 1500 lbs.
[00308] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide a lateral stiffness that can be at least 45,000 pounds
per
inch through a lateral displacement of the top plate relative to the bottom
plate of up
to 0.234 inches from a central position, when a vertical load of 35,000 pounds
is
applied to the central portions of the adapter pad. The lateral displacement
hysteresis of the adapter pad system can be less than about 6,000 lbs.
[00309] The top plate, bottom plate, and elastomeric member of the adapter
pad can provide a rotational stiffness that can be at least 250,000 pound *
inches per
radian of rotation through a rotational displacement of the top plate relative
to the
bottom plate of up to 41 milliradians from a central position when a vertical
load of
35,000 pounds is applied to the central portions of the adapter pad. The twist
hysteresis can be less than about 16,000 lbs.*in.
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[00310] The top plate, bottom plate, and elastomeric member of the adapter
pad can provide a vertical stiffness that can be at least 5,000,000 pounds per
inch
through a vertical displacement of 0.05 inches. Vertical displacement can be
non-
linear and can range from 5,000,000 pounds per inch to 30,000,000 pounds per
inch
depending on variations in durometer, thickness tolerances, and non-linearity
of the
compression stiffness.
[00311] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide a lateral stiffness that is within about ten percent
of a
longitudinal stiffness when a vertical load is applied to the central portions
of the
adapter pad.
[00312] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide a lateral strain in the elastomeric member that is
substantially similar throughout the elastomeric member when a vertical load
is
applied to the central portions of the adapter pad.
[00313] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide a longitudinal strain in the elastomeric member that
is
substantially similar throughout the elastomeric member when a vertical load
is
applied to the central portions of the adapter pad.
[00314] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide a rotational strain in the elastomeric member that can
be
substantially similar throughout the elastomeric member when a vertical load
is
applied to the central portions of the adapter pad.
[00315] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide a rotational strain that is less than or equal to the
lateral
strain at any point in the elastomeric member when a vertical load is applied
to the
central portions of the adapter pad.
[00316] The combined top plate, bottom plate, and elastomeric member of the
adapter pad can provide shear strain that does not exceed 120% under maximum
displacement
[00317] The thickness of the central portion of the bottom plate of the
adapter
pad can be non-uniform. The thickness of the central portion of the bottom
plate can
be greater at the lateral edges than at the center of the central portion.
[00318] The thickness of the elastomeric member disposed between the
central
portions of the top and bottom plate can be substantially uniform.
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[00319] In another example a method for forming an adapter pad can include
providing a top plate having a central portion, first and second upturned
regions
projecting upward from opposite edges of the central portion, a first lateral
flange
projecting outward from the first upturned lateral portion, and a second
lateral flange
projecting outward from the second upturned lateral portion; providing a
bottom plate
having a central portion, first and second upturned regions projecting upward
from
opposite edges of the central portion, a first lateral flange projecting
outward from the
first upturned lateral portion, and a second lateral flange projecting outward
from the
second upturned lateral portion; inserting an elastomeric member between the
top
plate and the bottom plate wherein a first outer elastomeric member is
disposed
between the first lateral flanges, a second outer elastomeric member is
disposed
between the second lateral flanges, and a central elastomeric member is
disposed
between the central portions; and compressing the first lateral flange of the
top plate
and the first lateral flange of the bottom plate towards each other; and
compressing
the second lateral flange of the top plate and the second lateral flange of
the bottom
plate towards each other.
[00320] The compressing steps can create deformation of the first and
second
lateral flanges after the molding operation is complete. This deformation can
result
in preloading of the outer elastomeric members. The compressing steps can
apply
greater than 3000 pounds force of compression in the outer elastomer members.
The compressing steps can compress the outer elastomeric member at least 0.02
inches of a static thickness of the outer elastomeric members. The compressing
steps compress the outer elastomeric member greater than 7 percent of a static
thickness of the outer elastomeric members.
[00321] In another example a method for forming an adapter pad can include
providing a top plate having a central portion, first and second upturned
regions
projecting upward from opposite edges of the central portion, a first lateral
flange
projecting outward and downward from the first upturned lateral portion, and a
second lateral flange projecting outward and projecting downward from the
second
upturned lateral portion; providing a bottom plate having a central portion,
first and
second upturned regions projecting upward from opposite edges of the central
portion, a first lateral flange projecting outward and upward from the first
upturned
lateral portion, and a second lateral flange projecting outward and projecting
upward
from the second upturned lateral portion; inserting an elastomeric member
between
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the top plate and the bottom plate; and compressing the top plate and the
bottom
plate such that the lateral portions of the top and bottom plates are
substantially
parallel.
[00322] The compressing steps can compress the outer elastomeric member at
least 0.02 inches of a static thickness of the outer elastomeric members. The
compressing steps can compress the outer elastomeric member greater than 7
percent of a static thickness of the outer elastomeric members.
[00323] In another example a method for forming an adapter pad can include
providing a top plate having a central portion, first and second upturned
regions
projecting upward from opposite edges of the central portion, a first lateral
flange
projecting outward from the first upturned lateral portion, and a second
lateral flange
projecting outward from the second upturned lateral portion; providing a
bottom plate
having a central portion, first and second upturned regions projecting upward
from
opposite edges of the central portion, a first lateral flange projecting
outward from the
first upturned lateral portion, and a second lateral flange projecting outward
from the
second upturned lateral portion; inserting a first outer elastomeric member
between
the first lateral flange of the top plate and the first lateral flange of the
bottom plate;
and inserting a second outer elastomeric member between the second lateral
flange
of the top plate and the second lateral flange of the bottom plate; and
inserting a
central elastomeric member between the central region of the top plate and the
central region of the bottom plate
[00324] The thickness of the central elastomeric member can be less than or
equal to the thickness of the first and second outer elastomeric members.
[00325] In another example a method for forming an adapter pad can include
providing a top plate having a central portion, first and second upturned
regions
projecting upward from opposite edges of the central portion, a first lateral
flange
projecting outward from the first upturned lateral portion, and a second
lateral flange
projecting outward from the second upturned lateral portion; providing a
bottom plate
having a central portion, first and second upturned regions projecting upward
from
opposite edges of the central portion, a first lateral flange projecting
outward from the
first upturned lateral portion, and a second lateral flange projecting outward
from the
second upturned lateral portion; inserting a first outer elastomeric member
between
the first lateral flange of the top plate and the first lateral flange of the
bottom plate;
and inserting a second outer elastomeric member between the second lateral
flange
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of the top plate and the second lateral flange of the bottom plate; and
inserting a
central elastomeric member between the central region of the top plate and the
central region of the bottom plate; compressing the first and second lateral
flanges of
the top plate and the bottom plate together; and bonding the top plate to the
first
outer elastomeric member, the second outer elastomeric member, and the central
elastomeric member.
[00326] The thickness of the central elastomeric member can be less than
the
thickness of the first and second outer elastomeric members.
[00327] The compressing steps can compress the outer elastomeric member at
least 0.02 inches of a static thickness of the outer elastomeric members. The
compressing steps compress the outer elastomeric member greater than 7 percent
of a static thickness of the outer elastomeric members.
[00328] In another example, an adapter pad system for use between a railcar
side frame pedestal and a rail car axle roller bearing adapter is disclosed.
The side
frame pedestal can define a first outer side, an opposite second outer side,
and a
pedestal roof located and extending between the first outer side and the
second
outer side. The adapter pad system can include a bearing adapter defining a
bottom
surface and a top surface, the bottom surface mounted to the railcar axle
roller
bearing, the top surface defining opposing first and second vertical shoulders
that
project upwardly from the top surface, on either side of the side frame just
above the
pedestal roof. The adapter pad system can include an adapter pad configured to
interface with the bearing adapter including a top plate having inner and
outer
surfaces, a central portion, first and second upturned regions projecting
upwardly
from opposite edges of the central portion, a first lateral flange projecting
outwardly
from the first upturned region, and a second lateral flange projecting
outwardly from
the second upturned region; and a bottom plate having inner and outer
surfaces, a
central portion, first and second upturned regions projecting upwardly from
opposite
edges of the central portion, a first lateral flange projecting outwardly from
the first
upturned region, and a second lateral flange projecting outwardly from the
second
upturned region.
[00329] The top plate and bottom plate central portions can be disposed
beneath the pedestal roof of the side frame pedestal, and the first and second
laterally projecting flanges of the top plate and the bottom plate can be
disposed
above the vertical shoulders of the roller bearing adapter and outside of the
pedestal
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roof of the side frame pedestal and along the first and second outer sides of
the side
frame pedestal.
[00330] In another example, an adapter pad configured to be disposed
between an adapter and a side frame pedestal roof of a railcar truck is
disclosed.
The adapter pad can include a top plate having inner and outer surfaces, a
central
portion, first and second upturned regions projecting upward from opposite
edges of
the central portion, a first lateral flange projecting outward from the first
upturned
region, and a second lateral flange projecting outward from the second
upturned
region; and a bottom plate having inner and outer surfaces, a central portion,
first
and second upturned regions projecting upward from opposite edges of the
central
portion, a first lateral flange projecting outward from the first upturned
region, and a
second lateral flange projecting outward from the second upturned region.
[00331] The outer surfaces of the first and second laterally projecting
flanges of
the bottom plate can be vertically higher than the outer surface of the
central portion
of the top plate.
[00332] In another example, a method for forming an adapter pad can include
providing a top plate having a central portion, first and second upturned
regions
projecting upward from opposite edges of the central portion, a first lateral
flange
projecting outward from the first upturned lateral portion, and a second
lateral flange
projecting outward from the second upturned lateral portion; providing a
bottom plate
having a central portion, first and second upturned regions projecting upward
from
opposite edges of the central portion, a first lateral flange projecting
outward from the
first upturned lateral portion, and a second lateral flange projecting outward
from the
second upturned lateral portion; inserting a first outer elastomeric member
between
the first lateral flange of the top plate and the first lateral flange of the
bottom plate;
inserting a second outer elastomeric member between the second lateral flange
of
the top plate and the second lateral flange of the bottom plate; inserting a
central
elastomeric member between the central region of the top plate and the central
region of the bottom plate; vulcanizing or curing the elastomeric members;
inserting
a first compression shim in the first lateral flange; and inserting a second
compression shim in the second lateral flange. In some embodiments compression
shims can be added after vulcanization or curing of the elastomer is complete.
[00333] In another example, a method for forming an adapter pad can
include,
providing a top plate having a central portion, first and second upturned
regions
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projecting upward from opposite edges of the central portion, a first lateral
flange
projecting outward from the first upturned lateral portion, and a second
lateral flange
projecting outward from the second upturned lateral portion; providing a
bottom plate
having a central portion, first and second upturned regions projecting upward
from
opposite edges of the central portion, a first lateral flange projecting
outward from the
first upturned lateral portion, and a second lateral flange projecting outward
from the
second upturned lateral portion; inserting a first outer elastomeric member
between
the first lateral flange of the top plate and the first lateral flange of the
bottom plate;
and
inserting a second outer elastomeric member between the second lateral
flange of the top plate and the second lateral flange of the bottom plate; and
inserting
a central elastomeric member between the central region of the top plate and
the
central region of the bottom plate; curing the elastomeric members; inserting
a first
compression shim in the first lateral flange; and inserting a second
compression
shim in the second lateral flange. The steps of inserting the first and second
compression shims can be performed after curing the elastomeric members.
[00334] The
compressing steps can compress the outer elastomeric member at
least 0.02 inches of a static thickness of the outer elastomeric members. The
compressing steps compress the outer elastomeric member greater than 7 percent
of a static thickness of the outer elastomeric members.
[00335] In
another example, an adapter pad system for use between a railcar
side frame pedestal and a rail car axle roller bearing is disclosed. The side
frame
pedestal can define a first outer side, an opposite second outer side, and a
pedestal
roof located and extending between the first outer side and the second outer
side.
The adapter pad system can include a bearing adapter defining a bottom surface
and a top surface, the bottom surface mounted to the railcar axle roller
bearing. The
adapter pad can be configured to interface with the bearing adapter and can
further
include a top plate having inner and outer surfaces, a central portion, and
outer
portions; a bottom plate having inner and outer surfaces, a central portion,
and outer
portions, and an elastomeric member having a central portion and outer
portions
disposed between the inner surfaces of the top and bottom plates.
[00336] The top
plate and bottom plate central portions can be disposed
beneath the pedestal roof of the side frame pedestal, and the outer portions
of the
top and bottom plate can be disposed outside of the pedestal roof of the side
frame
pedestal.
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[00337] The adapter pad system can include a continuous top plate. The
adapter pad system can include a continuous bottom plate.
[00338] The combined surface area of the outer portions of the elastomeric
member at cross-sectional planes through the outer portions of the elastomeric
members in planes centered between the inner surfaces of the top and bottom
plates
can be greater than 5 square inches.
[00339] The combined surface area of the outer portions of the elastomeric
members at cross-sectional planes through the outer portions of the
elastomeric
members in planes centered between the inner surfaces of the top and bottom
plates
can be at least 10 percent of the surface area of the central portion of the
elastomeric member at a cross-sectional plane through the center of the
central
portion of the elastomeric member in a plane centered between the inner
surfaces of
the top and bottom plates.
[00340] The central portion of the elastomeric member can be in a different
plane than the outer portions of the elastomeric member. The central portion
of the
elastomeric member can be in a parallel plane with the outer portions of the
elastomeric member. The outer portions can be vertically spaced from the
central
portions.
[00341] The top plate can be engaged with the side frame, and the bottom
plate can be engaged with the roller bearing adapter.
[00342] In another example, an adapter pad system for use between a railcar
side frame pedestal and a rail car axle roller bearing is disclosed. The side
frame
pedestal can define a first outer side, an opposite second outer side, and a
pedestal
roof located and extending between the first outer side and the second outer
side.
The adapter pad system can include a bearing adapter defining a bottom surface
and a top surface, the bottom surface mounted to the railcar axle roller
bearing. The
adapter pad system can include an adapter pad configured to interface with the
bearing adapter that includes a top plate having inner and outer surfaces, a
central
portion, and outer portions; a bottom plate having inner and outer surfaces, a
central
portion, and outer portions, and an elastomeric member having a central
portion and
outer portions disposed between the inner surfaces of the top and bottom
plates.
[00343] The top plate and bottom plate central portions can be disposed
beneath the pedestal roof of the side frame pedestal, and the outer portions
of the
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top and bottom plate can be disposed outside of the pedestal roof of the side
frame
pedestal.
[00344] The outer portions of the top and bottom plates can be configured
to
accept about 10 percent to 30 percent of vertical force applied to the central
portions.
[00345] The outer portions of the adapter pad can be supported by vertical
shoulders of the bearing adapter.
[00346] In another example, a roller bearing adapter configured to be
disposed
between a roller bearing and an adapter pad of a railcar truck is disclosed.
The roller
bearing adapter can have a bearing surface, an adapter crown surface, a
longitudinal centerline, and first and second vertical shoulders that project
upward
from the pedestal crown surface of the adapter. The thickness of the center
section
of the roller bearing adapter can be less than 0.75 inches as measured at the
longitudinal centerline from a bearing surface to a pedestal crown surface of
the
adapter.
[00347] The thickness of the roller bearing adapter can be between
approximately 0.60 and 0.75 inches as measured at the longitudinal centerline
from
a bearing surface to a pedestal crown surface of the adapter. The width of the
vertical shoulders can be at least 0.5 inches.
[00348] The roller bearing adapter can have a cross-sectional moment of
inertia of a cross-section at the longitudinal centerline of the roller
bearing adapter
around a lateral axis about 5.2 inches above a center axis of an axle that is
about 1.4
in4, or in the range of about 1.0 to about 2.0 in4. The lateral axis can be
between
about 5.0 inches and 5.5 inches from the center axis of the axle. The roller
bearing
adapter can have a cross-sectional moment of inertia of a cross-section at the
longitudinal centerline of the roller bearing adapter around a vertical axis
at the
center of the adapter that can be about can be about 86.8in4 , or in the range
of
about 50 to about 100 in4.
[00349] The present invention is disclosed above and in the accompanying
drawings with reference to a variety of examples. The purpose served by the
disclosure, however, is to provide examples of the various features and
concepts
related to the invention, not to limit the scope of the invention. The terms
and
descriptions used herein are set forth by way of illustration only and are not
meant as
limitations. One skilled in the relevant art will recognize that numerous
variations
and modifications may be made to the examples described above without
departing
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from the scope of the present invention. For example, the steps of the methods
need not be executed in a certain order, unless specified, although they may
have
been presented in that order in the disclosure.
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