METHOD OF CONVERTING RAILCARS

Abstract

A method of increasing the height of an autorack railcar comprising replacement of a conventional roof with an increased height roof assembly that includes integrated vertical side wall extensions, which avoid any need to provide side wall post extensions or additional side screens. The method may be used in conjunction with conversion of bi-level autorack railcars to tri-level autorack railcars, as well as with other conversions involving addition or removal of decks.

Claims

1. A method of converting a bi-level auto-rack railcar to a tri-level autorack railcar, the bi-level autorack railcar comprising a first deck, a second deck above the first deck, a roof, side walls extending from the first deck to the roof, and end doors extending between the first deck and the roof, the side walls comprising series of posts arranged along each side of the railcar with vertical screens arranged between adjacent posts, the method comprising: removing the roof structure; removing the second deck using an overhead crane; installing a new second deck using an overhead crane; installing a new third deck above the second deck using an overhead crane; and replacing the roof structure with a new roof structure comprising a horizontal top center portion, inner intermediate portions extending downward and outward on each side of the top center portion, outer/lower intermediate portions extending downward and outward from the inner intermediate portions on each side of the roof structure, and vertical side wall extension portions extending downward from the outer/lower intermediate portions on each side of the roof structure to increase the height of the railcar without increasing the height of the side wall posts, and without adding side screens.

2. The method of claim 1 wherein the bi-level autorack car has a height of about 19 ft., 0 in. ATR, and is converted into a tri-level autorack car having a height of about 20 ft., 2 in., and wherein the vertical side wall extension portions have a vertical dimension of at least 12 in.

3. The method of claim 2 wherein the new roof structure comprises a series of corrugated sheets of galvanized steel joined by fasteners, and a pair of roof rails extending longitudinally along bottom edges of the vertical side wall extension portions and joined thereto, and wherein each of the roof rails consists of an angle member comprising a horizontal base portion and a vertical flange extending upward therefrom, and wherein the corrugated sheets are welded to the roof rails.

4. The method of claim 3 further comprising removing the end doors of the bi-level autorack railcar, and replacing them with end doors of increased height.

5. The method of claim 4 wherein replacing the roof with a new roof structure comprises removably attaching the new roof structure to the side walls.

6. The method of claim 4 wherein replacing the roof with a new roof structure comprises bolting the roof rails to upper ends of side wall posts.

7. The method of claim 6 wherein the tri-level railcar has a fully enclosed interior and an empty weight of no more than 116,000 lbs., and when fully loaded at up to about 24,000 lbs. per deck, has a Cg no greater than 98 in. ATR.

8. The method of claim 7 wherein the new roof structure is secured to the side walls by removable fasteners that are accessible from the interior but not from the exterior of the railcar.

9. A method of converting a bi-level auto-rack railcar to a tri-level autorack railcar, the bi-level autorack railcar comprising a first deck, a second deck above the first deck, a roof, side walls extending from the first deck to the roof, and end doors extending between the first deck and the roof, the side walls comprising series of posts arranged along each side of the railcar with vertical screens arranged between adjacent posts, the method comprising: removing the roof structure; lowering the second deck; installing a new third deck above the second deck using an overhead crane; and replacing the roof structure with a new roof structure comprising a horizontal top center portion inner intermediate portions extending downward and outward on each side of the top center portion, outer/lower intermediate portions extending downward and outward from the inner intermediate portions on each side of the roof structure, and vertical side wall extension portions extending downward from the outer/lower intermediate portions on each side of the roof structure to increase the height of the railcar without increasing the height of the side wall posts, and without adding side screens.

10. The method of claim 9 wherein the bi-level autorack car has a height of about 19 ft., 0 in. ATR, and is converted into a tri-level autorack car having a height of about 20 ft., 2 in., and wherein the vertical side wall extension portions have a vertical dimension of at least 12 in.

11. The method of claim 10 wherein the new roof structure consists of a series of corrugated sheets of galvanized steel joined by fasteners, and a pair of roof rails extending longitudinally along bottom edges of the vertical side wall extension portions and joined thereto, and wherein each of the roof rails consists of an angle member comprising a horizontal base portion and a vertical flange extending upward therefrom, and wherein the corrugated sheets are welded to the roof rails.

12. The method of claim 11 further comprising removing the end doors of the bi-level autorack railcar, and replacing them with end doors of increased height.

13. The method of claim 12 wherein replacing the roof with a new roof structure comprises removably attaching the new roof structure to the side walls.

14. The method of claim 13 wherein replacing the roof with a new roof structure comprises bolting the roof rails to upper ends of side wall posts.

15. The method of claim 14 wherein the tri-level railcar has a fully enclosed interior and an empty weight of no more than 116,000 lbs., and when fully loaded at up to about 24,000 lbs. per deck, has a Cg no greater than 98 in. ATR.

16. The method of claim 15 wherein the new roof structure is secured to the side walls by removable fasteners that are accessible from the interior but not from the exterior of the railcar.

17. A method of increasing the height of an autorack railcar comprising a first deck, a second deck above the first deck, a roof, side walls extending from the first deck to the roof, and end doors extending between the first deck and the roof, the side walls comprising series of posts arranged along each side of the railcar with vertical screens arranged between adjacent posts, the method comprising: removing the roof structure; and replacing the roof structure with a new roof structure comprising a horizontal top center portion, inner intermediate portions extending downward and outward on each side of the top center portion, outer/lower intermediate portions extending downward and outward from the inner intermediate portions on each side of the roof structure, and vertical side wall extension portions extending downward from the outer/lower intermediate portions on each side of the roof structure to increase the height of the railcar without increasing the height of the side wall posts, and without adding side screens; wherein the autorack railcar initially has a height of about 19 ft., 0 in. ATR, and is converted into an autorack car having a height of about 20 ft., 2 in.

18. The method of claim 17 wherein the vertical side wall extension portions have a vertical dimension of at least 12 in., and wherein the new roof structure comprises a series of corrugated sheets of galvanized steel joined by fasteners, and a pair of roof rails extending longitudinally along bottom edges of the vertical side wall extension portions and joined thereto, and wherein each of the roof rails consists of an angle member comprising a horizontal base portion and a vertical flange extending upward therefrom, and wherein the corrugated sheets are welded to the roof rails.

19. The method of claim 18 further comprising removing the end doors of the bi-level autorack railcar, and replacing them with end doors of increased height.

20. The method of claim 18 wherein replacing the roof structure with a new roof structure comprises bolting the roof rails to upper ends of side wall posts; and wherein the tri-level railcar has a fully enclosed interior and an empty weight of no more than 116,000 lbs., and when fully loaded at up to about 24,000 lbs. per deck, has a Cg no greater than 98 in. ATR; and wherein the new roof structure is secured to the side walls by removable fasteners that are accessible from the interior but not from the exterior of the railcar.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0042] FIG. 1 is an end view of a prior art tri-level autorack railcar.

[0043] FIG. 2 is a sectional view of a tri-level autorack railcar made from the railcar of FIG. 1.

[0044] FIG. 3 is a sectional view of a prior art bi-level autorack railcar.

[0045] FIG. 4 is a sectional view of an increased height bi-level autorack railcar made from the railcar of FIG. 3.

[0046] FIG. 5 is a sectional view of an increased height tri-level autorack railcar made from the railcar of FIG. 3.

DETAILED DESCRIPTION

[0047] The embodiments described herein comprise a method of shipping automobiles, a railcar for shipping automobiles, and methods of manufacturing and converting railcars for shipping automobiles.

[0048] FIG. 1 illustrates a prior art tri-level autorack railcar that may be converted into the increased height tri-level railcar of FIG. 2. The railcar of FIG. 2 comprises a flat car 12 having a rack structure constructed thereon. The flat car has a deck 14 that functions as the A deck of the railcar. The A deck may be at substantially at the same elevation along its entire length. The rack structure comprises a plurality of vertical posts 16, and B and C decks 18 and 20 respectively supported by the posts. Side screens 44 are supported between adjacent pairs of posts on each side of the railcar.

[0049] Each of the decks is connected directly to the posts to be supported thereby. Knee braces 24 add strength and stiffness. Tire guides 26 and a chock track 28 are provided on each deck. Longitudinal members 36 such as roof rails and/or top chords tie the vertical posts together at their upper ends.

[0050] A corrugated increased height roof structure 32 encloses the top of the car. The increased height roof structure comprises a horizontal top center portion 40, inner intermediate portions 42 extending downward and outward on each side of the top center portion, outer/lower intermediate portions 43 extending downward and outward from the inner intermediate portions 42 on each side of the roof structure, and vertical side wall extension portions 30 extending downward from the outer/lower intermediate portions 43 on each side of the roof structure.

[0051] A pair of radial end doors enclose each end of the car. One end door is shown at 34 in FIG. 2. Minimum clearances of h.sub.a, h.sub.b and h.sub.c, measured 30 off center, are maintained above the A, B and C decks respectively. The minimum clearances may be equal or approximately equal, and may be, e.g., between 64 and 66 in.

[0052] The railcar may be based on a low-level flat car, a conventional flat car, an upsill flat car, or a flat car having a 39 ATR (above top of rail) running surface. To facilitate maintenance of appropriate clearances, high cambered decks may be employed at both the B and C level. The overall height of the railcar is preferably equal to the maximum height permissible in North America under applicable AAR regulations, i.e., about 20 2.

[0053] In some embodiments, when the railcar is in a bi-level configuration, a third deck may be added by first removing the roof of the bi-level car, then lowering the upper deck or B deck of the bi-level car, then lowering an additional deck into position as the C deck using an overhead crane or other suitable equipment, and thereafter replacing the original roof with an increased height roof structure as shown at 32 in FIG. 2.

[0054] In some embodiments, a bi-level autorack car may be built to the maximum allowed height with an upper deck bolted in place. The upper deck of the bi-level car may have hinged end sections locked in the level position. That is, the B deck of the bi-level railcar may have pivotable end sections of the type normally used on the B deck of tri-level railcars, with the pivotable end sections being secured in place and not pivoted during normal operation of the bi-level railcar. The car may have a bolt-on roof. The car may be converted to a tri-level configuration by removing the bolt-on roof, repositioning the B deck downward from the bi-level B deck position to the tri-level B deck position and enabling the end sections of the B deck to pivot up and down, adding a third deck by lowering it through the open top into the tri-level C deck position, fixing it in place, e.g., by bolting or welding, and replacing the original roof with an increased height roof structure having vertical side wall extensions 30 as shown in FIG. 2.

[0055] FIG. 3 illustrates a prior art bi-level railcar that may be converted to an increased height autorack car such as that of FIG. 4 or FIG. 5 by replacing its roof with an increased height roof structure 116. The increased height roof structure comprises a horizontal top center portion 40, inner intermediate portions 42 extending downward and outward on each side of the top center portion, outer/lower intermediate portions 43 extending downward and outward from the inner intermediate portions 42 on each side of the roof structure, and vertical side wall extension portions 30 extending downward from the outer/lower intermediate portions 43 on each side of the roof structure.

[0056] FIG. 4 illustrates an increased height bi-level autorack car 108 having a first deck 110, a plurality of posts 114 extending upward on opposite sides thereof, a second deck 112 supported on the posts 114 above the first deck, and a roof 116. Braces 118 extend upward and inward from the posts to the second deck 112. The lower/outer ends of the braces are joined to plates 120 which extend upward from the braces to the sides of the deck. The plates 120 are preferably removably attached to posts 114 by bolts or other means to facilitate adjustment of deck position.

[0057] The bi-level car of FIG. 3 may be converted to the increased height tri-level car of FIG. 5 by removing the roof, disconnecting the upper deck 112 from the posts, lowering it and securing it in the position shown in FIG. 5, securing a new C deck 122 above it, and replacing the original roof with an increased height roof structure 116.

[0058] The new C deck 122 may have braces 118 and connecting plates 120, attached thereto prior to installation. The braces and connecting plates may be bolted or otherwise fastened to the posts or other structure to secure the deck 122.

[0059] The bi-level car of FIG. 20 may alternatively be converted to the tri-level car of FIG. 22 by other methods described herein. The tri-level car of FIG. 22 may be converted to the bi-level car of FIG. 20 by reversing the steps of any of the methods described herein for converting bi-level cars to tri-level cars.

[0060] One additional method of converting railcars comprises converting a bi-level or tri-level auto-rack railcar to a unilevel railcar by removing the roof structure to facilitate crane access to the railcar interior; removing one or more decks from the railcar using a crane; and replacing the original roof with an increased height roof structure as described herein to provide an interior space that is capable of accommodating and enclosing vehicles of a height greater than the spacing between the decks of the bi-level or tri-level car.

[0061] Another additional method comprises building a mixed use bi-level railcar in which the B deck is mounted much higher than in conventional bi-level railcars, e.g., at the height of the C deck in a tri-level railcar. A bi-level car with this configuration may be used to transport tall vans such as Sprinter vans or other tall vehicles on its A deck while transporting conventional vehicles on its B deck. This type of bi-level car can be built by removing the B deck from a tri-level railcar by any of the methods described in this application without other major structural changes.

[0062] Another additional method comprises building a mixed use bi-level railcar in which the B deck is mounted lower than in conventional bi-level railcars, e.g., at the height of the B deck in a conventional tri-level car. A bi-level car with this configuration may be used to transport tall vans such as Sprinter vans or other tall vehicles on its B deck while transporting conventional vehicles on its A deck. This type of bi-level car can be built by removing the C deck from a tri-level railcar by any of the methods described in this application without other major structural changes.

[0063] A method of installing a removable roof on an autorack railcar may comprise installing removable longitudinal roof supports 140 on upper portions of the side walls, and thereafter attaching the increased height roof structure 116 to the removable longitudinal roof supports. Installing removable longitudinal roof supports on upper portions of the side walls may comprise bolting them to upper ends of side wall posts. The increased height roof structure 116 may comprise a plurality of sections, or may be one piece, end to end, with no transitions. The roof structure 116 may have offsets at its ends for radial end doors.

[0064] The roof supports 140 may comprise generally L-shaped angle members extending the entire length of the railcar along each side. Each roof support may comprise a horizontal bottom portion and a vertical portion. The roof structure 116 may be welded to the vertical portion of the roof support 140 with an inner bead and/or an outer bead along the entire length of the roof or along portions thereof. The roof supports 140 may be attached to the side wall posts by fasteners. The fasteners are preferably easily removable from the inside of the railcar only. Each fastener may comprise, e.g., a bolt that engages a nut which may be welded to the roof support 140. In other embodiments, cap screws may be employed with their heads on the outside of the car, and nuts secured to them on the inside of the railcar. In some embodiments, other fasteners may be used. When replacing the roof, new fasteners may be used to secure it in place, with the fasteners, such as cap screws, bolts or the like, being loosely secured first, then torqued as required.

[0065] The invention is not limited to the embodiments described above. The invention is further described in the following claims.