Note: Descriptions are shown in the official language in which they were submitted.
RAPID DISCHARGE DOOR LOCKING SYSTEM
TECHNICAL FIELD
Particular embodiments relate generally to railcars, and more particularly to
a door
locking system for rapid discharge railcars, such as hopper cars for carrying
bulk materials.
BACKGROUND
Railway hopper cars transport and sometimes store bulk materials. Hopper cars
generally
include one or more hoppers which may hold cargo or lading during shipment.
Hopper cars are
frequently used to transport coal, sand, metal ores, aggregates, grain and any
other type of lading
which may be satisfactorily discharged through openings formed in one or more
hoppers.
Discharge openings are typically provided at or near the bottom of each hopper
to rapidly
discharge cargo. A variety of door assemblies or gate assemblies along with
various operating
mechanisms have been used to open and close discharge openings associated with
railway
hopper cars.
Transversely oriented discharge openings and gates are frequently coupled with
a
common linkage operated by an air cylinder. The air cylinder is typically
mounted in the same
orientation as the operating gate linkage which is often a longitudinal
direction relative to the
associated hopper.
Longitudinally oriented discharge openings and associated doors may provide a
quicker
discharge than transverse gates. Longitudinally oriented discharge openings
and doors are often
used in pairs that may be rotated or pivoted relative to the center sill or
side sills of a hopper car.
Longitudinally oriented discharge openings and doors may be coupled via
linkages with a beam
operated by an air cylinder. The air cylinder is typically mounted in the same
orientation as the
operating beam which is often a longitudinal direction relative to the
associated hopper. The
operating beam may be coupled to the discharge doors by door struts (linkages)
that push (or
pull) the gates open or pull (or push) them closed as the air cylinder moves
the operating beam
back and forth.
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Date Recue/Date Received 2021-08-31
A hopper car is an example of a rapid discharge railcar. In general, rapid
discharge
railcars may use air cylinders, operating beams, and linkages to operate the
bottom outlet doors.
SUMMARY
According to some embodiments, a railcar comprises an underframe, a hopper
coupled to
the underframe, a discharge door coupled to the hopper proximate the
underframe, and an
operating beam coupled to the discharge door and the underframe. The operating
beam
comprises a lock piston receiving recess. The railcar further comprises an
operating cylinder
coupled to the operating beam. The operating cylinder comprises a first input
and a second
input. The operating cylinder is configured to move the operating beam between
a first position
where the discharge door is in a closed position and a second position where
the discharge door
is in an open position, wherein activation of the first input causes the
operating cylinder to move
the operating beam to the first position and activation of the second input
causes the operating
cylinder to move the operating beam to the second position.
The railcar further comprises a discharge door locking system coupled to the
underframe.
The discharge door locking system comprises a lock piston, a first input, and
a second input.
The discharge door locking system is configured to move the lock piston
between a first position
where the lock piston is not engaged with the lock piston receiving recess and
a second position
where the lock piston is engaged with the lock piston receiving recess.
Activation of the first
input moves the lock piston to the first position, and activation of the
second input moves the
lock piston to the second position.
The second input of the operating cylinder is coupled to the first input of
the discharge
door locking system, and the first input of the operating cylinder is coupled
to the second input
of the discharge door locking system. When the second input of the operating
cylinder is
activated to move the discharge door to the open position, the first input of
the discharge door
locking system is also activated to disengage the lock piston from the lock
piston receiving
recess. When the first input of the operating cylinder is activated to move
the discharge door to
the closed position, the second input of the discharge door locking system is
also activated to
engage the lock piston with the lock piston receiving recess.
In particular embodiments, the first input and the second input of the
operating cylinder
and the first input and the second input of the discharge door locking system
comprise pneumatic
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Date Recue/Date Received 2021-08-31
inputs. In other embodiments, the first and second inputs may comprise
electrical, mechanical,
or hydraulic inputs.
In particular embodiments, the second input of the operating cylinder is
coupled to the
first input of the discharge door locking system via a check valve, and the
first input of the
operating cylinder is coupled to the second input of the discharge door
locking system via a
check valve. In particular embodiments, the second input of the operating
cylinder is coupled to
the first input of the discharge door locking system via a 3-way valve and the
first input of the
operating cylinder is coupled to the second input of the discharge door
locking system via a 3-
way valve. In particular embodiments, the second input of the discharge door
locking system
comprises a spring.
In particular embodiments, the discharge door locking system further comprises
an
operating cylinder actuating valve coupled to the lock piston, the first input
of the operating
cylinder, and the second input of the operating cylinder. When the lock piston
is in the first
position, the operating cylinder actuating valve is configured to activate the
second input of the
operating cylinder to move the discharge door to the open position. When the
lock piston is in
the second position, the operating cylinder actuating valve is configured to
activate the first input
of the operating cylinder to move the discharge door to the closed position.
In particular embodiments, the discharge door comprises one of a transverse
discharge
door and a longitudinal discharge door. The railcar may comprise a hopper car.
According to some embodiments, a discharge door locking system for a railcar
discharge
door comprises a lock piston configured to move between a first position where
the lock piston is
not engaged with a lock piston receiving recess of an operating beam coupled
to a discharge door
and a second position where the lock piston is engaged with the lock piston
receiving recess.
The discharge door locking system further comprises a first input and a second
input. Activation
of the first input moves the lock piston to the first position; and activation
of the second input
moves the lock piston to the second position.
The first input of the discharge door locking system is coupled to a first
input of an
operating cylinder coupled to the operating beam. The first input of the
operating cylinder is
configured to, when activated, move the discharge door to the open position.
The second input
of the discharge door locking system is coupled to a second input of the
operating cylinder. The
second input is configured to, when activated, move the discharge door to the
closed position.
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Date Recue/Date Received 2021-08-31
In particular embodiments, the first input and the second input of the of the
discharge
door locking system comprise pneumatic inputs. The second input of the
discharge door locking
system may comprise a spring.
In particular embodiments, the first input of the discharge door locking
system is coupled
to the first input of the operating cylinder via a check valve, and the second
input of the
discharge door locking system is coupled to the second input of the operating
cylinder via a
check valve. In particular embodiments, the first input of the discharge door
locking system is
coupled to the first input of the operating cylinder via a 3-way valve, and
the second input of the
discharge door locking system is coupled to the second input of the operating
cylinder via a 3-
way valve.
In particular embodiments, the discharge door locking system further comprises
an
operating cylinder actuating valve coupled to the lock piston, the first input
of the operating
cylinder, and the second input of the operating cylinder.
According to some embodiments, a method of outfitting a railcar with a
discharge door
locking system comprises providing a railcar. The railcar comprising an
underframe, a hopper
coupled to the underframe, a discharge door coupled to the hopper proximate
the underframe,
and an operating beam coupled to the discharge door and the underframe. The
operating beam
comprises a lock piston receiving recess. The railcar further comprises an
operating cylinder
coupled to the operating beam. The operating cylinder comprises a first input
and a second
input. The operating cylinder is configured to move the operating beam between
a first position
where the discharge door is in a closed position and a second position where
the discharge door
is in an open position. Activation of the first input causes the operating
cylinder to move the
operating beam to the first position, and activation of the second input
causes the operating
cylinder to move the operating beam to the second position.
The method further comprises coupling a discharge door locking system to the
underframe of the railcar. The discharge door locking system comprises a lock
piston, a first
input, and a second input. The discharge door locking system is configured to
move the lock
piston between a first position where the lock piston is not engaged with the
lock piston
receiving recess and a second position where the lock piston is engaged with
the lock piston
receiving recess. Activation of the first input moves the lock piston to the
first position, and
activation of the second input moves the lock piston to the second position.
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Date Recue/Date Received 2021-08-31
The method further comprises coupling the second input of the operating
cylinder to the
first input of the discharge door locking system, and coupling the first input
of the operating
cylinder to the second input of the discharge door locking system. When the
second input of the
operating cylinder is activated to move the discharge door to the open
position, the first input of
the discharge door locking system is also activated to disengage the lock
piston from the lock
piston receiving recess. When the first input of the operating cylinder is
activated to move the
discharge door to the closed position, the second input of the discharge door
locking system is
also activated to engage the lock piston with the lock piston receiving
recess.
In particular embodiments, the discharge door locking system further comprises
an
operating cylinder actuating valve coupled to the lock piston, the first input
of the operating
cylinder, and the second input of the operating cylinder. The method further
comprises coupling
the first and second inputs of the operating cylinder to the operating
cylinder actuating valve.
When the lock piston is in the first position, the operating cylinder
actuating valve is configured
to activate the second input of the operating cylinder to move the discharge
door to the open
position. When the lock piston is in the second position, the operating
cylinder actuating valve is
configured to activate the first input of the operating cylinder to move the
discharge door to the
closed position.
According to some embodiments, a railcar comprises an underframe, a hopper
coupled to
the underframe, a discharge door coupled to the hopper proximate the
underframe, an operating
beam coupled to the discharge door and the underframe, an operating cylinder
coupled to the
operating beam via a mechanical operating beam lock configured to move between
a first, locked
position and a second, unlocked position, and a discharge door locking system
coupled to the
underframe. The discharge door locking system comprising a lock block slidably
coupled to the
underframe. The lock block is configured to move between a first position
where the lock block
prevents the mechanical operating beam lock from moving to the unlocked
position and a second
position where the lock block does not prevent the mechanical operating beam
lock from moving
to the unlocked position.
In particular embodiments, the discharge door locking system further comprises
an air
inlet valve. The air inlet valve is configured so that the lock block moves to
the first position
when compressed air is supplied to the railcar and the lock block moves to the
second position
when compressed air is removed from the railcar.
Date Recue/Date Received 2021-08-31
As a result, particular embodiments of the present disclosure may provide
numerous
technical advantages. For example, particular embodiments may provide improved
door
securement with less adjustment. Particular embodiments may include a
pneumatically operated
discharge door locking system that is automatically synchronized with the
discharge door
actuating system. For example, synchronizing the discharge door locking system
with the
operation of the operating cylinder improves the efficiency of the unloading
process. Railcars
may be unloaded faster, because an operator performs fewer operations.
Particular embodiments
of the present disclosure may provide some, none, all, or additional technical
advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the particular embodiments, and the
advantages
thereof, reference is now made to the following written description taken in
conjunction with the
accompanying drawings, in which:
FIGURE 1 is a schematic drawing in elevation showing a side view of an example
hopper car, according to a particular embodiment;
FIGURE 2 is a schematic drawing in elevation showing an end view of an example
hopper car, according to a particular embodiment;
FIGURE 3 is a schematic drawing showing a cross section view of an example
hopper
car taken along lines B-B of FIGURE 1;
FIGURE 4 is a block diagram illustrating longitudinal discharge doors
underneath an
example hopper car, according to a particular embodiment;
FIGURE 5A is a block diagram illustrating a discharge door locking system in
the
unlocked position, according to a particular embodiment;
FIGURE 5B is a block diagram illustrating a discharge door locking system in
the locked
position, according to a particular embodiment;
FIGURES 6A-6C are block diagrams illustrating a discharge door locking system
coupled to the operating cylinder with ball valves, according to particular
embodiments;
FIGURES 7A-7C are block diagrams illustrating a discharge door locking system
coupled to the operating cylinder with a three way valve, according to
particular embodiments;
FIGURE 8 is a block diagram illustrating a discharge door locking system
coupled to the
operating cylinder with a valve coupled to the lock piston, according to a
particular embodiment;
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Date Recue/Date Received 2021-08-31
FIGURE 9 is a section view of a discharge door locking system for a mechanical
lock,
according to a particular embodiment;
FIGURE 10 is a section view of a discharge door locking system for a
mechanical lock in
the locked position, according to a particular embodiment;
FIGURE 11 is a section view of a discharge door locking system for a
mechanical lock in
the unlocked position, according to a particular embodiment; and
FIGURE 12 is a flow diagram illustrating an example method of outfitting a
railcar with
a discharge door locking system, according to some embodiments.
DETAILED DESCRIPTION
Rapid discharge railcars, such as hopper cars, may use air cylinders,
operating beams,
and linkages to operate bottom outlet doors. When the bottom outlet doors are
closed, two
features typically secure the doors. First, the linkages are in the over-
center position. In the
over-center position, the force from the weight of the lading on the doors
pushes the operating
beam and air cylinder toward the closed position. The second securement is a
locking feature
that prevents the beam, and therefore the air cylinder, from moving toward the
open position. To
open the doors, the locking feature needs to be released. Current locking
features use a spring-
loaded latch that must be mechanically pushed open as the air cylinder's
piston extends to open
the doors. Existing mechanical locks are dependent on timing and proper
adjustment to operate
efficiently.
Particular embodiments may provide improved door securement with less
adjustment.
Particular embodiments may include a pneumatically operated discharge door
locking system
that is automatically synchronized with the discharge door actuating system.
Particular embodiments are described with reference to FIGURES 1-12 of the
drawings.
Like numbers may be used for like and corresponding parts of the various
drawings. Various
features of the embodiments will be described with respect to hopper car 20
shown in FIGURES
1-4.
FIGURE 1 is a schematic drawing in elevation showing a side view of an example
hopper car, according to a particular embodiment. Hopper car 20 may carry bulk
materials such
as coal and other types of lading. Examples of such lading may include sand,
metal ores,
aggregate, grain, ballast, etc.
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Date Recue/Date Received 2021-08-31
Hopper car 20 may be generally described as a covered hopper car. However,
other
embodiments may include open hopper cars or any other cars suitable for
carrying bulk lading.
Hopper car 20 includes hoppers 22 with bottom discharge assemblies 24.
Discharge assemblies
24 may be opened and closed to control discharge of lading from hoppers 22. As
illustrated,
hopper car 20 includes two hoppers 22. In other embodiments, hopper car 20 may
include one,
two, three, or any suitable number of hoppers 22.
In particular embodiments, hopper 22 is configured to carry bulk materials and
the
interior walls of hopper 22 are generally sloped towards discharge assembly 24
to facilitate
discharge of the lading. Multiple hoppers 22 may be separated by interior
bulkheads.
In particular embodiments, hopper car 20 may include a pair of sidewall
assemblies 26
and sloped end wall assemblies 28 mounted on a railway car underframe. The
railway car
underframe includes center sill 34 and a pair of shear plates 32. A pair of
sill plates 32 provide
support for sidewall assemblies 26.
Center sill 34 is a structural element for carrying the loads of the hopper
car. Center sill
34 transfers the various longitudinal forces encountered during train
operation from car to car.
Shear plates 30 extend generally parallel with center sill 34 and are spaced
laterally from
opposite sides of center sill 34.
Hopper car 20 is an example of a rapid discharge railcar. Particular
embodiments may
include hopper cars, or any other type of rapid discharge railcar comprising
discharge doors.
FIGURE 2 is a schematic drawing in elevation showing an end view of an example
hopper car, according to a particular embodiment. FIGURE 2 illustrates
discharge assemblies
24, end wall assemblies 28, shear plates 30, and sill plates 32 of hopper car
20 illustrated in
FIGURE 1.
Discharge assembly 24 comprises slope sheet 36. Slope sheet 36 slopes from
sidewall
assembly 26 towards the center of hopper car 20 to facilitate discharge of the
lading from the
discharge opening of discharge assembly 24.
FIGURE 3 is a schematic drawing showing a cross section view of an example
hopper
car taken along lines B-B of FIGURE 1. FIGURE 3 illustrates side wall
assemblies 26, shear
plates 30, sill plates 32, and center sill 34 of hopper car 20 illustrated in
FIGURE 1.
FIGURE 4 is a schematic perspective drawing illustrating longitudinal
discharge doors
underneath an example hopper car, according to a particular embodiment. FIGURE
4 illustrates
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Date Recue/Date Received 2021-08-31
in more detail the two discharge assemblies 24 illustrated in FIGURE 1.
Discharge assembly 24
includes operating beam 62, discharge doors 64, guides 66, door struts 68, and
operating cylinder
70.
Operating beam 62 is coupled to center sill 34 by guides 66. Operating beam 62
is
coupled to discharge door 64 by door struts 68. Operating cylinder 70 is
coupled to operating
beam 62 and is operable to move operating beam 62 back and forth through
guides 66.
Operating beam 62 may comprise a steel box beam, may be extruded from aluminum
or
steel, may be pultruded as a fiber reinforced composite, such as a fiber or
carbon composite, or
any other suitable material.
Portions of slope sheet 36 cooperate with adjacent portions of center sill 34
to define
longitudinal discharge openings. Longitudinal discharge openings are disposed
along opposite
sides of center sill 34.
Discharge doors 64 are hinged proximate to center sill 34. Various types of
mechanical
hinges may engage discharge doors 64 with center sill 34.
Discharge doors 64 are illustrated in the closed position, which prevents the
discharge of
lading through the longitudinal discharge openings. In operation, operating
cylinder 70 moves
operating beam 62 through guides 66 to open discharge doors 64 via door struts
68.
At a first end, door struts 68 are rotationally coupled to operating beam 62.
At a second
end, door struts 68 are rotationally coupled to discharge door 64. In
particular embodiments,
rotational coupling may be achieved via ball joints.
Operating cylinder 70 is operable to move operating beam 62 back and forth
through
guides 66. In particular embodiments operating cylinder 70 may comprise a
pneumatic cylinder,
or any type of motor suitable for moving operating beam 62 in a longitudinal
direction.
Longitudinal movement of operating beam 62 results in radial extension of door
struts 68
to move discharge doors 64 from their open position to their closed position.
Movement of
operating beam 62 in the opposite direction results in pulling, pushing, or
moving discharge
doors from their closed position to their open position which allows rapid
discharge of any
lading contained within railway hopper car 20.
In particular embodiments, each hopper 24 of hopper car 20 may be operated
independently of each other. In other embodiments, each hopper 24 may be
operated in unison
by a single operating cylinder 70 and operating beam 62.
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Date Recue/Date Received 2021-08-31
Hopper car 20 may include a discharge door locking system. For example, to
prevent
accidental opening of discharge door 64, such as during transit, a discharge
door locking system
may fasten operating beam 62 to a portion of the underframe. For example, a
discharge door
locking system may be mounted to center sill 34, and may lock operating beam
62 to prevent
operating beam 62 from moving. An example discharge door locking system is
illustrated in
FIGURES 5A and 5B
FIGURE 5A is a block diagram illustrating a discharge door locking system in
the
unlocked position, according to a particular embodiment. Discharge door
locking system 100
includes a lock cylinder, a lock piston, an extending input, and a retracting
input. The lock
cylinder may comprise lock air cylinder 74. Lock air cylinder 74 houses lock
piston 76. Lock
air cylinder 74 is operable to extend (see FIGURE 5B) and retract (FIGURE 5A)
lock piston 76.
Operating beam 62, such as operating beam 62 described with respect to FIGURE
4,
comprises lock piston receiving recess 72. Lock piston receiving recess 72 is
configured to
receive lock piston 76 when lock piston 76 is in the extended position. In
some embodiments,
lock piston receiving recess 72 may comprise a recess extending partially into
operating beam 62
or completely through operating beam 62 (i.e., a hole in operating beam 62).
In particular embodiments, the extending input includes lock extending air
line 78 and the
retracting input includes lock retracting air line 80. When compressed air is
applied to lock
extending air line 78, lock piston 76 extends into lock piston receiving
recess 72, preventing
operating beam 62 from moving. When compressed air is applied to lock
retracting air line 80,
lock piston 76 retracts out of lock piston receiving recess 72, permitting
movement of operating
beam 62.
FIGURE 5B is a block diagram illustrating a discharge door locking system in
the locked
position, according to a particular embodiment. In FIGURE 5B, compressed air
has been
supplied to lock extending air line 78. Lock piston 76 extends into lock
piston receiving recess
72 and completely through operating beam 62. Operating beam 62, and thus
discharge doors 64,
are locked in the closed position.
FIGURES 5A and 5B illustrate a pneumatic discharge door locking system. Other
embodiments may include electrical, hydraulic, or mechanical discharge door
locking systems
(e.g., the extending input and the retracting input may comprise electrical,
hydraulic, and/or
manual inputs). Some embodiments may include manual operation via a lever or
cable. Some
Date Recue/Date Received 2021-08-31
embodiments may include a combination. For example, some embodiments may
pneumatically
unlock the discharge door locking system, while using a spring or gravity to
lock the discharge
door locking system (see FIGURES 6-11). FIGURES 6-11 illustrate discharge door
locking
systems synchronized with the operating cylinder of the discharge door.
FIGURE 6A is a block diagram illustrating a discharge door locking system
coupled to
the operating cylinder with ball valves, according to a particular embodiment.
Operating
cylinder 70 is coupled to operating beam 62 via operating piston 90. Operating
cylinder 70
includes extending air line 86 (coupled to operating cylinder 70 behind
operating piston 90) and
retracting air line 88 (coupled to operating cylinder 70 in front of operating
piston 90).
When compressed air is applied to extending air line 86, operating beam 62
moves in a
first direction opening discharge doors 64. When compressed air is applied to
retracting air line
88, operating beam 62 moves in a second, opposite direction closing discharge
doors 64.
Although a particular direction is illustrated, other embodiments may open or
close discharge
doors 64 by moving operating beam 62 in the opposite direction (e.g., push to
open, pull to close;
or pull to open, push to close).
In particular embodiments, discharge door locking system 100 may be
synchronized with
the operation of operating cylinder 70. For example, lock air cylinder 74 may
be coupled to
operating cylinder 70. As a particular example, lock retracting air line 80
may be coupled to
operating cylinder 70 (behind operating piston 90) via check valve 84a. Lock
extending air line
78 may be coupled to operating cylinder 70 (in front of operating piston 90)
via check valve 84b.
Check valves 84a and 84b may comprise a pneumatic ball check valve, or any
other suitable
valve.
When compressed air is applied to extending air line 86, compressed air also
flows
through check valve 84a to lock retracting air line 80, which retracts lock
piston 76 and permits
operating beam 62 to move in a first direction opening discharge doors 64.
When compressed
air is applied to retracting air line 88, compressed air also flows through
check valve 84b to lock
extending air line 78, which extends lock piston 76 into lock piston receiving
recess 72 and
prevents operating beam 62 from moving. Thus, operation of the discharge door
locking system
and the operating beam are synchronized.
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Date Recue/Date Received 2021-08-31
In some embodiments, lock air cylinder may include spring 82. In some
embodiments,
spring 82 may comprise a safety backup feature. For example, if air pressure
is lost, spring 82
may keep lock piston 76 engaged with lock piston receiving recess 72.
Other embodiments may include a hybrid pneumatic/mechanical system. For
example,
some embodiments may omit lock extending air line 78 (e.g., as illustrated in
FIGURE 6B).
Lock piston 76 may be retracted pneumatically, and may be extended
mechanically via spring, or
any other suitable mechanism (mechanical, electrical, hydraulic, or
otherwise).
FIGURE 6B is another block diagram illustrating a discharge door locking
system
coupled to the operating cylinder with ball valves, according to a particular
embodiment. The
illustrated example is similar to FIGURE 6A, but omits lock extending air line
78. In operation,
when compressed air is applied to extending air line 86, compressed air also
flows through check
valve 84a to lock retracting air line 80, which retracts lock piston 76 and
permits operating beam
62 to move in a first direction opening discharge doors 64. While operating
beam 62 is in the
open position, lock piston 76 may rest on operating beam 62. When compressed
air is applied to
retracting air line 88, operating beam 62 moves in a second, opposite
direction closing discharge
doors 64. Lock piston 76 may slide across operating beam 62 until lock piston
76 reaches lock
piston receiving recess 72. Lock piston 76 may engage with piston receiving
recess 72 via
gravity or may be assisted by spring 82 in some embodiments.
FIGURE 6C is another block diagram illustrating a discharge door locking
system
coupled to the operating cylinder with ball valves, according to a particular
embodiment. The
illustrated example is similar to FIGURE 6A, but omits lock extending air line
78 and instead
both check valves 84a and 84b are both coupled to lock retracting air line 80.
In operation, when
compressed air is applied to extending air line 86, compressed air also flows
through check valve
84a to lock retracting air line 80, which retracts lock piston 76 and permits
operating beam 62 to
move in a first direction opening discharge doors 64. While operating beam 62
is in the open
position, lock piston 76 may rest on operating beam 62. When compressed air is
applied to
retracting air line 88, compressed air also flows through check valve 84a to
lock retracting air
line 80, which retracts lock piston 76 and operating beam 62 moves in a
second, opposite
direction closing discharge doors 64. In the illustrated example, lock piston
76 is not in contact
with operating beam 62 until lock piston 76 reaches lock piston receiving
recess 72. Lock piston
12
Date Recue/Date Received 2021-08-31
76 may engage with piston receiving recess 72 via gravity or may be assisted
by spring 82 in
some embodiments.
Particular embodiments may synchronize discharge door locking system 100 with
the
operation of operating beam 62 in any suitable manner. FIGURES 7 and 8 include
additional
examples.
FIGURE 7A is a block diagram illustrating a discharge door locking system
coupled to
the operating cylinder with a three way valve, according to a particular
embodiment. Discharge
door locking system 100 may be synchronized with the operation of operating
cylinder 70
similar to the embodiment described with respect to FIGURE 6A, except that
compressed air
may be applied to both operating cylinder 70 and lock air cylinder 74 via 3-
way valves 92a and
92b.
In particular embodiments, 3-way valve 92a may direct compressed air to lock
retracting
air line 80 and extending air line 86. 3-way valve 92b may direct compressed
air to lock
extending air line 78 and retracting air line 88. Thus, operating cylinder 70
and lock air cylinder
74 may be operated at the same time.
FIGURE 7B is another block diagram illustrating a discharge door locking
system
coupled to the operating cylinder with a three way valve, according to a
particular embodiment.
The illustrated example is similar to FIGURE 6B, but omits lock extending air
line 78 and 3-way
valve 92b. In operation, 3-way valve 92a may direct compressed air to lock
retracting air line 80
and extending air line 86. Thus, operating cylinder 70 and lock air cylinder
74 may be operated
at the same time. While operating beam 62 is in the open position, lock piston
76 may rest on
operating beam 62. When compressed air is applied to retracting air line 88,
operating beam 62
moves in a second, opposite direction closing discharge doors 64. Lock piston
76 may slide
across operating beam 62 until lock piston 76 reaches lock piston receiving
recess 72. Lock
piston 76 may engage with piston receiving recess 72 via gravity or may be
assisted by spring 82
in some embodiments.
FIGURE 7C is another block diagram illustrating a discharge door locking
system
coupled to the operating cylinder with a three way valve, according to a
particular embodiment.
The illustrated example is similar to FIGURE 6C, but omits lock extending air
line 78 and 3-way
valves 92a and 92b are both coupled to lock retracting air line 80. In
operation, 3-way valve 92a
may direct compressed air to lock retracting air line 80 and extending air
line 86. Thus,
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Date Recue/Date Received 2021-08-31
operating cylinder 70 and lock air cylinder 74 may be operated at the same
time. While
operating beam 62 is in the open position, lock piston 76 may rest on
operating beam 62.
FIGURE 6C is another block diagram illustrating a discharge door locking
system
coupled to the operating cylinder with ball valves, according to a particular
embodiment. The
illustrated example is similar to FIGURE 6A, but omits lock extending air line
78 and instead
both check valves 84a and 84b are both coupled to lock retracting air line 80.
In operation, when
compressed air is applied to extending air line 86, compressed air also flows
through check valve
84a to lock retracting air line 80, which retracts lock piston 76 and permits
operating beam 62 to
move in a first direction opening discharge doors 64. While operating beam 62
is in the open
position, lock piston 76 may rest on operating beam 62. 3-way valve 92b may
direct compressed
air to lock retracting air line 80 and retracting air line 88, which retracts
lock piston 76 and
operating beam 62 moves in a second, opposite direction closing discharge
doors 64. In the
illustrated example, lock piston 76 is not in contact with operating beam 62
until lock piston 76
reaches lock piston receiving recess 72. Lock piston 76 may engage with piston
receiving recess
72 via gravity or may be assisted by spring 82 in some embodiments.
FIGURE 8 is a block diagram illustrating a discharge door locking system
coupled to the
operating cylinder with a valve coupled to the lock piston. Similar to FIGURES
4-7, operating
cylinder 70 facilitates movement of operating beam 62. Operating cylinder 70
is coupled to
operating beam 62 via operating piston 90. Operating cylinder 70 includes
extending air line 86
and retracting air line 88. When compressed air is applied to extending air
line 86, operating
beam 62 moves in a first direction opening discharge doors 64. When compressed
air is applied
to retracting air line 88, operating beam 62 moves in a second, opposite
direction closing
discharge doors 64.
Lock air cylinder 74 facilitates movement of lock piston 76. For example, lock
extending
air line 78 supplies compressed air to lock air cylinder 74 to extend lock
piston 76. Lock
retracting air line 80 supplies compressed air to lock air cylinder 74 to
retract lock piston 76.
In particular embodiments, discharge door locking system 100 may be
synchronized with
the operation of operating cylinder 70. For example, lock air cylinder 74 may
be coupled to
operating cylinder actuating valve 96. Operating cylinder actuating valve 96
controls operating
cylinder 70 by supplying compressed air to either the extending or retracting
inputs of operating
cylinder 70.
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Date Recue/Date Received 2021-08-31
Operating cylinder actuating valve 96 includes operating cylinder air line 98.
Operating
cylinder air line 98 provides compressed air for operating cylinder 70. For
example, in a first
position operating cylinder actuating valve 96 supplies compressed air from
operating cylinder
air line 98 to extending air line 86. In a second position, operating cylinder
actuating valve 96
supplies compressed air from operating cylinder air line 98 to retracting air
line 88. Thus,
operating cylinder actuating valve 96 controls operating cylinder 70 by
switching compressed air
from operating cylinder air line 98 to either extending air line 86 or
retracting air line 88.
Operating cylinder actuating valve 96 may be controlled by lock piston 76. For
example,
lock piston 76 may be coupled to operating cylinder actuating valve 96.
Movement of lock
piston 76 from the retracted to extended position, and vice versa, may switch
operating cylinder
actuating valve 96 from a first position to a second position.
For example, when compressed air is supplied to lock retracting air line 80,
compressed
air flows through retracting air line 80 and retracts lock piston 76. Lock
piston 76 may switch
operating cylinder actuating valve 96 to a first position so that operating
cylinder actuating valve
96 supplies compressed air from operating cylinder air line 98 to extending
air line 86 which
extends operating beam 62 in a first direction to open discharge doors 64.
When compressed air
is supplied to lock extending air line 78, compressed air flows through
extending air line 78 and
extends lock piston 76. Lock piston 76 may switch operating cylinder actuating
valve 96 to a
first position so that operating cylinder actuating valve 96 supplies
compressed air from
operating cylinder air line 98 to extending air line 86 which retracts
operating beam 62 in a
second direction to close discharge doors 64.
As operating beam 62 closes discharge doors 64, lock piston 76 engages into
lock piston
receiving recess 72, which prevents operating beam 62 from moving. Thus,
operation of the
discharge door locking system and the operating beam are synchronized.
In some embodiments, lock air cylinder may include spring 82. In some
embodiments,
spring 82 may comprise a safety backup feature. For example, if air pressure
is lost, spring 82
may keep lock piston 76 engaged with lock piston receiving recess 72.
A particular advantage of the illustrated embodiment is that if the lock
mechanism is not
disengaged (i.e., lock piston 76 is not retracted) the operating cylinder will
not receive air
pressure (e.g., lock piston 76 will not actuate operating cylinder actuating
valve 96). Thus, the
Date Recue/Date Received 2021-08-31
operating cylinder is not able to move the operating beam while the operating
beam is locked.
This prevents excessive loading and wear on components.
Other embodiments may include a hybrid pneumatic/mechanical system. For
example,
some embodiments may omit lock extending air line 78. Lock piston 76 may be
retracted
pneumatically, and may be extended mechanically via spring, or any other
suitable mechanism
(mechanical, electrical, hydraulic, or otherwise).
Some embodiments may include a pneumatic discharge door locking system in
conjunction with a mechanical operating beam lock. An example is illustrated
in FIGURE 9.
FIGURE 9 is a section view of a discharge door locking system for a mechanical
lock,
according to a particular embodiment. The section view is along the
longitudinal centerline of
the operating beam. Similar to FIGURES 4-8, operating cylinder 70 is coupled
to operating
beam 62 via operating piston 90. Operating cylinder 70 moves operating beam 62
in a first
direction to open discharge doors 64, and moves operating beam 62 in a second,
opposite
direction to close discharge doors 64. In the illustrated embodiment,
operating beam 62 moves
right and left.
The example embodiment includes a mechanical operating beam lock. The
mechanical
operating beam lock includes locking latch 102, lock cam 104, locking latch
pivot 106, and
locking rod 108. Locking latch 102 pivots up and down on locking latch pivot
106. Locking rod
108 is coupled to operating beam 62. In the down position, locking latch 102
partially surrounds
locking rod 108, preventing operating beam 62 from moving. In the up position,
locking latch
102 does not contact locking rod 108, and operating beam 62 is free to move
back and forth.
Operating piston 90 is coupled to operating beam 62 via lock cam 104. Lock cam
104
comprises a protrusion that lifts locking latch 102 as lock cam 104 moves to
the right in the
figure and lowers locking latch 102 as lock cam 104 moves to the left in the
figure. For
example, as operating cylinder 70 extends operating piston 90 to open
discharge doors 64, lock
cam 104 moves to the right, which causes the protrusion of lock cam 104 to
lift locking latch 102
and unlocks operating beam 62. As operating cylinder 70 retracts operating
piston 90 to close
discharge doors 64, lock cam 104 moves to the left, which lowers locking latch
102 onto lock
rod 108 and locks operating beam 62.
Lock cam 104 is coupled to operating beam 62 via lock cam pin 110 and
elongated hole
112. Lock cam 104 includes elongated hole 112. Lock cam pin 110 is coupled to
operating
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Date Recue/Date Received 2021-08-31
beam 62 through elongated hole 112. The width of elongated hole 112 is wider
than lock cam
pin 110. Lock cam pin 110 may move the width of elongated hole 112 before
operating beam 62
moves. Thus, elongated hole 112 enables lock cam 104 to unlock locking latch
102 before
operating beam 62 begins to move, and enables lock cam 103 to lock locking
latch 102 after
operating beam 62 has stopped moving.
For example, as operating cylinder 70 extends operating piston 90, lock cam
104 moves
to the right for the width of elongated hole 112 before lock cam pin 110
contacts the other side of
elongated hole 112 and causes operating beam 62 to move. The initial movement
of lock cam
104 is enough for the protrusion of lock cam 104 to unlock locking latch 102
before operating
beam 62 begins to move. Similarly, elongated hole 112 and stop bracket 126
enable lock cam
103 to lock locking latch 102 after operating beam 62 has stopped moving.
Stop bracket 126 is a mechanical stop that prevents operating beam 62 from
moving any
further in the direction towards operating cylinder 70. Stop bracket 126 is
coupled to center sill
34. Stop bracket 126 may comprise a steel bracket welded to center sill 34.
As operating cylinder 70 retracts operating piston 90, operating beam 62
contacts stop
bracket 126 which causes operating beam 62 to stop moving. After operating
beam 62 stops
moving, lock cam 104 continues moving to the left for the width of elongated
hole 112. The
additional movement of lock cam pin 110 lets locking latch 102 drop onto
locking rod 108 after
operating beam 62 has stopped moving. Locking latch 102 may drop onto locking
rod 108 via
gravity or with the assistance of springs.
A particular advantage of some embodiments is to prevent accidental unlocking
by using
a lock block that physically prevents the mechanical operating beam lock from
unlocking. Lock
block 114 is coupled to center sill 34 via bracket 118. When hopper car 20 is
in motion, lock
block 114 is positioned above locking latch 102, preventing locking latch 102
from lifting up.
Lock block 114 may comprise steel, rubber, plastic, or any other suitable
material.
Lock block 114 is also slidably coupled to track 116. Lock block 114 may slide
from a
first position over locking latch 102, and obstructing upward movement of
locking latch 102, to a
second position that does not obstruct the movement of locking latch 102. When
lock block 114
is in the second position, locking latch 102 may be lifted up to unlock
operating beam 62.
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Date Recue/Date Received 2021-08-31
Lock block 114 includes cylinder mount 20. Cylinder mount 20 couples lock
block 114
to a lock operating cylinder, such as lock operating cylinder 122 illustrated
in FIGURES 10 and
11.
FIGURE 10 is a section view of a discharge door locking system for a
mechanical lock in
the locked position, according to a particular embodiment. The section view is
along a
transverse line through hopper car 20 illustrating lock block 114 as described
with respect to
FIGURE 9.
Lock operating cylinder 122 is coupled to lock block 114 via cylinder mount
20. Lock
operating cylinder 122 is operable to move lock block 114 along track 116.
When hopper car 20
is in motion, lock operating cylinder 122 retracts and lock block 114 is in
the first position (as
illustrated) preventing locking latch 102 from moving. FIGURE 11 illustrates
lock block 114 in
the second, unlocked position.
FIGURE 11 is a section view of a discharge door locking system for a
mechanical lock in
the unlocked position, according to a particular embodiment. The section view
is the same as
FIGURE 10.
When hopper car 20 is stopped, operating cylinder 122 extends which moves lock
block
114 to the second position (as illustrated), enabling locking latch 102 to be
lifted up to the
unlocked position.
In particular embodiments, the discharge door locking system may be
synchronized with
the operation of operating cylinder 70. For example, lock operating cylinder
122 may include air
inlet 124. When lock operating cylinder 122 receives compressed air via air
inlet 124, the
compressed air causes lock operating cylinder 122 to extend and move lock
block 114 to the
second position. When lock block 114 is in the second position, operating
cylinder 70 may be
activated to open or close discharge doors 64. Lock operating cylinder 122
also includes one or
more springs that return lock operating cylinder 122 to the retracted position
when compressed
air is removed from air inlet 124.
In particular embodiments, air inlet 124 receives compressed air whenever
hopper car 20
is connected to a compressed air source. For example, when hopper car 20 is in
a rail yard and a
rail operator connects hopper car 20 to a compressed air source, lock
operating cylinder 122 is
automatically extended to move lock block 114 to the second position. Then,
the rail operator
may activate or deactivate operating cylinder 70 using the separate pneumatic
controls for
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Date Recue/Date Received 2021-08-31
operating cylinder 70. When the rail operator disconnects hopper car 20 from a
compressed air
source, lock operating cylinder automatically retracts to move lock block 114
to the first
position. Thus, when rail car 20 is connected to a compressed air source, an
operator is free to
open and close discharge doors 64. When rail car 20 is disconnected from the
compressed air
source (e.g., in transit) discharge doors 64 are locked.
FIGURE 12 is a flow diagram illustrating an example method of outfitting a
railcar with
a discharge door locking system, according to some embodiments. In particular
embodiments,
one or more steps of FIGURE 12 may be performed to outfit hopper car 20 with
discharge door
locking system 100, described with respect to FIGURES 1-11.
The method begins at step 1212, where a railcar is provided. The railcar
comprises an
underframe, a hopper coupled to the underframe, a discharge door coupled to
the hopper
proximate the underframe, and an operating beam coupled to the discharge door
and the
underframe.
In some embodiments, the operating beam comprises a lock piston receiving
recess. The
railcar further comprises an operating cylinder coupled to the operating beam.
The operating
cylinder comprises a first input and a second input. The operating cylinder is
configured to
move the operating beam between a first position where the discharge door is
in a closed position
and a second position where the discharge door is in an open position.
Activation of the first
input causes the operating cylinder to move the operating beam to the first
position, and
activation of the second input causes the operating cylinder to move the
operating beam to the
second position.
In some embodiments, the operating cylinder is coupled to the operating beam
with a
mechanical operating beam lock. In these embodiments, the operating beam may
not include a
lock piston receiving recess.
For example, step 1212 may comprise providing hopper car 20 as described with
respect
to any of FIGURES 1-11. In particular embodiments, the railcar may be a new
railcar under
construction, or the railcar may be an existing railcar to be retrofitted with
a discharge door
locking system.
At step 1214, a discharge door locking system is coupled to the underframe of
the railcar.
In some embodiments, the discharge door locking system comprises a lock
piston, a first input,
and a second input. The discharge door locking system may be configured to
move the lock
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Date Recue/Date Received 2021-08-31
piston between a first position where the lock piston is not engaged with the
lock piston
receiving recess and a second position where the lock piston is engaged with
the lock piston
receiving recess. Activation of the first input moves the lock piston to the
first position, and
activation of the second input moves the lock piston to the second position.
For example, discharge door locking system 100 may be coupled to an underframe
of
hopper car 20. Discharge door locking system 100 may be coupled to center sill
34, or any other
suitable mounting location on hopper car 20. Discharge door locking system 100
may be
positioned so that lock piston 76 may engage with lock piston receiving recess
72 of operating
beam 62 when lock piston 76 is in the extended position.
In some embodiments, the discharge door locking system may comprise a lock
block
slidably coupled to the underframe. The lock block may be configured to move
between a first
position where the lock block prevents the mechanical operating beam lock from
moving to the
unlocked position and a second position where the lock block does not prevent
the mechanical
operating beam lock from moving to the unlocked position. For example,
discharge door locking
system 100 may comprise lock block 114 slidably coupled to center sill 34 via
bracket 118 and
track 116.
At step 1216, the inputs of the discharge door locking system are coupled to
the inputs of
the operating cylinder. In particular embodiments, the second input of the
operating cylinder
may be coupled to the first input of the discharge door locking system. The
first input of the
operating cylinder may be coupled to the second input of the discharge door
locking system.
When the second input of the operating cylinder is activated to move the
discharge door to the
open position, the first input of the discharge door locking system is also
activated to disengage
the lock piston from the lock piston receiving recess. When the first input of
the operating
cylinder is activated to move the discharge door to the closed position, the
second input of the
discharge door locking system is also activated to engage the lock piston with
the lock piston
receiving recess.
In particular embodiments, the discharge door locking system includes an
operating
cylinder actuating valve coupled to the lock piston, the first input of the
operating cylinder, and
the second input of the operating cylinder. Coupling the inputs of the
discharge door locking
system to the inputs of the operating cylinder may include coupling the first
and second input of
the operating cylinder to the operating cylinder actuating valve. When the
lock piston is in the
Date Recue/Date Received 2021-08-31
first position, the operating cylinder actuating valve is configured to
activate the second input of
the operating cylinder to move the discharge door to the open position. When
the lock piston is
in the second position, the operating cylinder actuating valve is configured
to activate the first
input of the operating cylinder to move the discharge door to the closed
position.
In some embodiments, the discharge door locking system includes a lock block
and a
lock operating cylinder with an air inlet. The air inlet of the lock operating
cylinder and the first
and second inputs of the operating cylinder may be coupled to a compressed air
source. When
the air inlet of the lock operating cylinder is coupled to the compressed air
source, the lock block
automatically slides to an unlocked position. The first and second inputs of
the operating
cylinder may be used to open or close the discharge doors. When the air inlet
of the lock
operating cylinder is decoupled from the compressed air source, the lock block
automatically
slides to a locked position.
For example, discharge door locking system 100 may be synchronized with the
operation
of operating cylinder 70 by coupling lock air cylinder 74 to operating
cylinder 70. Lock air
cylinder 74 may be coupled to operating cylinder 70 according to any of the
examples described
with respect to FIGURES 5A-11.
In a retrofit application, for example, a 3-way valve may be added to the two
air inputs to
operating cylinder 70 to provide compressed air to the two inputs of lock air
cylinder 74. In
another example, outlet ports may be added to operating cylinder 70, which may
be used in
conjunction with ball valves to provide compressed air to the inputs of lock
air cylinder 74.
In another retrofit example, the two air inputs of operating cylinder 70 may
be coupled to
an operating cylinder actuating valve. The operating cylinder actuating valve
may also be
coupled to lock air cylinder 74 such that the position of lock piston 76
controls the operating
cylinder actuating valve.
In another retrofit example, lock block 114 may be slidably coupled to the
center sill
directly above a mechanical operating beam lock. Lock block 114 prevents the
mechanical
operating beam lock when hopper car 20 is in transit, and automatically slides
out of the way of
the mechanical operating beam lock when compressed air is applied to hopper
car 20.
Modifications, additions, or omissions may be made to method 1200.
Additionally, one
or more steps in method 1200 of FIGURE 12 may be performed in parallel or in
any suitable
order.
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Date Recue/Date Received 2021-08-31
Although the components in FIGURES 1-12 are described with respect to
longitudinal
doors, particular embodiments may include transverse doors, or any other
suitable discharge door
of a railcar.
Although particular embodiments and their advantages have been described in
detail, it
should be understood that various changes, substitutions and alternations can
be made herein
without departing from the spirit and scope of the embodiments.
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Date Recue/Date Received 2021-08-31
