METHOD OF REPURPOSING SMALL CUBE COVERED HOPPER RAILCARS AND MODIFIED RAILCARS FORMED THEREBY

Abstract

A method of modification of a railcar to form a modified railcar can be described as comprising the steps of i) providing an existing small cube covered hopper donor railcar supported on a pair of trucks; ii) removing a donor car floor construction including hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floor forming the hopper chutes of the donor railcar; iii) forming a floor construction of the modified railcar which includes one of a) triple hopper independent transverse door floor construction, b) dual hopper independent longitudinal door floor construction, c) flat bottom gondola floor construction, d) dual hopper ballast car floor construction, and e) twin hopper taconite ore car floor construction, and iv) attaching the floor construction to the car to form the modified railcar.

Claims

1. A method of modification of a railcar to form a modified railcar can be described as comprising the steps of i) providing an existing small cube covered hopper donor railcar supported on a pair of trucks; ii) removing a donor car floor construction including hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floor forming the hopper chutes of the donor railcar; iii) forming a floor construction of the modified railcar which includes one of a) triple hopper independent transverse door floor construction, b) dual hopper independent longitudinal door floor construction, c) flat bottom gondola floor construction, d) dual hopper ballast car floor construction, and e) twin hopper taconite ore car floor construction, and iv) attaching the floor construction to the car to form the modified railcar.

2. The method according to claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a triple hopper transverse door floor construction.

3. The method according to claim 2 wherein the doors of a door system of the triple hoppers are independently operated.

4. The method according to claim 1 wherein the step of attaching the floor construction to the car utilizes at least a portion of a donor car center partition.

5. The method according to claim 1 wherein the floor construction is formed of a stainless steel or a copper containing steel construction or copper bearing steel construction.

6. The method according to claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a dual hopper independent longitudinal door floor construction.

7. The method according to claim 6 wherein the dual hopper independent longitudinal door floor construction forms hopper chutes that are steeper than in the donor cars.

8. The method according to claim 6 wherein a front two and a back two doors in the dual hopper independent longitudinal door floor construction can be independently operated.

9. The method according to claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a flat bottom gondola floor construction.

10. The method according to claim 9 wherein in the step of attaching the floor construction to the car the flat bottom gondola floor construction is coupled to the sidewalls and to the bolster web of the donor car to form the modified flat bottom gondola railcar.

11. The method according to claim 10 wherein the bolster web becomes part of the elements defining the interior laden carrying space in the modified railcar.

12. The method according to claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a dual hopper ballast car floor construction.

13. The method according to claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a twin hopper taconite ore car floor construction.

14. The method according to claim 1 wherein the modified railcar utilizes a covered roof.

15. The method according to claim 1 wherein the step of attaching the floor construction to the car utilizes at least a portion of a donor car center partition, and wherein the floor construction is formed of a stainless steel or a copper containing steel construction or copper bearing steel construction.

16. The method according to claim 1 wherein the step of attaching the floor construction to the car utilizes at least a portion of a donor car center partition, and wherein the modified railcar utilizes a covered roof.

17. The modified railcar formed according to the method of claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a triple hopper independent transverse door floor construction, and wherein the step of attaching the floor construction to the car utilizes at least a portion of a donor car center partition.

18. The modified railcar formed according to the method of claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a dual hopper independent longitudinal door floor construction, and wherein the modified railcar utilizes a covered roof.

19. The modified railcar formed according to the method of claim 1 wherein the step of forming a floor construction of the modified railcar which includes forming a triple hopper independent transverse door floor construction, and wherein the modified railcar utilizes a covered roof.

20. The railcar formed according to the method of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a schematic perspective view of an existing small cubed covered hopper railcar acting as a donor car in a method of repurposing small cube covered hopper railcars according to the present invention.

[0014] FIG. 2 is a schematic perspective view of the parts removed from the donor railcar of FIG. 1 in a method of repurposing small cube covered hopper railcars according to one embodiment of the present invention.

[0015] FIG. 3 is a schematic perspective view of an existing prior art triple hopper independent transverse door floor construction intended to be mimicked in a method of repurposing small cube covered hopper railcars according to one embodiment of the present invention.

[0016] FIG. 4 is a schematic side elevational overlay view of a donor car with an overlay of a floor construction to mimic the existing triple hopper independent transverse door railcar according to one embodiment of the present invention.

[0017] FIG. 5 is a schematic perspective view of an independent door system for a triple hopper independent transverse door modified railcar according to one embodiment of the present invention.

[0018] FIGS. 6A and B are schematic perspective views of a triple hopper independent transverse door modified railcars according to two embodiments of the present invention.

[0019] FIG. 6C is a schematic perspective section view of the triple hopper independent transverse door modified railcar of FIG. 6B.

[0020] FIGS. 7A and 7B are schematic perspective views of a triple hopper independent transverse door modified railcar according to one embodiment of the present invention.

[0021] FIGS. 8A, 8B and 8C are schematic perspective view, section view and top plan view, respectively, of an existing prior art dual hopper independent longitudinal door floor construction intended to be mimicked in a method of repurposing small cube covered hopper railcars according to one embodiment of the present invention.

[0022] FIG. 9 is a schematic side elevational view of the donor car with an overlay of a floor construction to mimic the existing prior art dual hopper independent longitudinal door railcar according to one embodiment of the present invention.

[0023] FIG. 10 is a schematic side elevational view of the donor car with an overlay of a floor construction to mimic the existing prior art flat bottom gondola railcar according to one embodiment of the present invention.

[0024] FIG. 11 is a schematic perspective section view of flat bottom gondola modified railcar according to one embodiment of the present invention.

[0025] FIG. 12 is a schematic perspective view of an existing prior art ballast car floor construction intended to be mimicked in a method of repurposing small cube covered hopper railcars according to one embodiment of the present invention.

[0026] FIG. 13 is a schematic side elevational overlay view of the donor with an overlay of a floor construction to mimic the existing prior art ballast railcar according to one embodiment of the present invention.

[0027] FIG. 14 is a schematic side elevational view of the donor car with an overlay of a floor construction to mimic an existing prior art taconite railcar according to one embodiment of the present invention.

[0028] FIG. 15 is a schematic side view of taconite ore modified railcar, according to one embodiment of the present invention.

DESCRIPTION OF THE PREFFERED EMBODIMENTS

[0029] The present invention provides a repurposing small cube covered hopper railcars 10 and the modified railcars 100 formed thereby. FIG. 1 is a schematic perspective view of an existing small cubed covered hopper railcar 10 acting as a donor car 10 in a repurposing program according to the present invention. Within the meaning of this application the terms railcar, car and rail car are used interchangeably representing rolling rail stock. The small cube covered hopper railcars 10 of interest in the present invention may be categorized and defined as about 3000-3500 cubic foot (+?5%), Curved sided, all steel design, covered, twin hopper with center partition. The small cube covered hopper railcars 10 used in this invention may also be referenced as donor cars 10 in the present application.

[0030] In summary the method of modification of a railcar to form a modified railcar can be described as comprising the steps of i) Providing an existing small cube covered hopper donor railcar 10 supported on a pair of trucks 12, such as shown in FIG. 1; ii) Removing a donor car floor construction 14 including hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floor forming the hopper chutes of the donor railcar 10, (and possibly existing roof structure 16) such as shown in FIG. 2; iii) Forming a floor construction of the modified railcar 100 which includes one of i) triple hopper independent transverse door floor construction 110 (with doors 112), ii) dual hopper independent longitudinal door floor construction 120, iii) flat bottom gondola floor construction 130, iv) dual hopper ballast car floor construction 140, and v) twin hopper taconite ore car floor construction 150, and attaching the floor construction (110, 120, 130, 140 or 150) to the car to form the modified railcar 100. Where the modified railcar 100 is a covered hopper car the method further includes the steps of forming roof and coaming construction of the modified railcar.

[0031] Removing a Donor Car Floor and Roof Construction

[0032] FIG. 2 is a schematic perspective view of the parts 14 and 16 removed from the donor railcar of FIG. 1 in a method of repurposing small cube covered hopper railcars 10 according to one embodiment of the present invention. The removing of the donor car floor construction 14 includes removing the hopper discharge gates, and the outside hopper sheets, lower hopper floor and the partition floor forming the hopper chutes of the donor railcar, such as shown in FIG. 2.

[0033] Additionally the roof components 16 are removed when forming an open top modified car 100 design. The material 14 and 16 removed as shown will typically be less than 6800 lbs. The removed steel is scrapped while the specialty components are refurbished and sold or scrapped. Additionally the long hood may be removed as well, although this component may be reused.

[0034] Triple Hopper Independent Transverse Door Floor Construction 110

[0035] The first modified railcar 100 of the present invention is a modified triple hopper independent transverse door railcar 100 having floor construction 110. FIG. 3 is a schematic perspective view of an existing prior art triple hopper independent transverse door floor construction 110 intended to be mimicked by the floor construction 110 in a method of repurposing small cube covered hopper railcars 10 to form the modified triple hopper independent transverse door railcar 100 according to one embodiment of the present invention. The method includes forming a triple hopper independent transverse door floor construction 110 that mimics the arrangement 110 in FIG. 3. This floor construction 110 is shown in FIGS. 6A-C and 7A-B.

[0036] FIG. 4 is a schematic side elevational view of the donor car 10 with an overlay of a floor construction 110 to mimic the existing triple hopper independent transverse door floor construction 110 for the modified railcar 100 according to one embodiment of the present invention. The modified railcar 100 will have a 29-5 truck center to truck center distance and the existing prior art triple hopper independent transverse door floor construction intended to be mimicked in this method has a 31-11? truck center to truck center distance. The car profiles shown demonstrate this is a reasonable alternative for the donor cars 10.

[0037] The doors of the door systems 112 of the triple hoppers are independently operated to give greater flexibility to the discharge capabilities and the laden than may be carried. The individual door systems 112 may be, for representative example, those disclosed in U.S. Pat. No. 7,832,340 which is incorporated herein by reference. The controls for the triple hopper doors of the system 112 may be push button actuation to operate the doors individually or all simultaneously.

[0038] FIG. 5 is a schematic perspective view of an independent door system 112 for the triple hopper independent transverse door modified railcar 100 according to this embodiment of the present invention. Each door of the system 112 includes a pair of doors on opposed sides of the center sill which are connected through a door spreader. The door operating system 112 is connected to the door spreader through an adjustable spreader fulcrum in which the sliding adjustment may add in a proper connection force or tension between the door operating system and the individual doors.

[0039] The main body of the individual pneumatic door operating system 112 can be completely preassembled. The completed assembly is mounted under the bottom surface of the railcar center sill and connected to the spreader fulcrum through a linkage arm. The main body essentially consists of mounting side frame angles, one double acting pneumatic cylinder rotationally mounted in the side frame angles with a slotted cylinder nose clevis applied to the end of the cylinder shaft, one cylinder lever rotationally attached to the side frame angles and to the slotted nose clevis, at least one door spreader lever extending between the cylinder lever and the spreader fulcrum, a secondary lock mounted on the side frame angles at a position that can engage with the door structure when the doors are in a closed position, an indicator on the side frame angles that indicates the status of the secondary door lock, a cylinder fulcrum pin for rotationally mounting the cylinder to the side frame angles, a cylinder lever fulcrum pin for rotationally mounting the door spreader lever to the cylinder lever, and a door fulcrum pin for rotationally mounting the door lever to the spreader fulcrum.

[0040] When air is channeled into the rear of the cylinder, the cylinder piston is extended, rotating the cylinder lever. As the cylinder lever rotates, the door lever rotates about the door spreader fulcrum and extends through the arc of the cylinder lever. The hopper doors pivot about a conventional door pivot (not shown in detail) via the motion of the cylinder lever and the door lever when the cylinder is fully extended, unloading the commodity within the pair of hopper pockets. When the air is directed into the forward end of the cylinder, exhausting the air in the rear end of the cylinder, the cylinder shaft retracts rotating the cylinder lever and pulling the doors closed. When the cylinder lever is fully retracted, the secondary lock is engaged. When the secondary lock is fully engaged, the secondary lock indicator is retracted indicating its engagement.

[0041] The individual automatic door operating system 112 of the present invention can be activated by several different methods, examples of these are, air activated push buttons, electrically charged hot shoe or pads, mechanical linkages, and all known methods of activating the cars auxiliary air or way side air supply. The particular activation and control system is up to the individual user. It is anticipated that multiple door operating cylinders of the modified railcar may be selected to be operated together by the control. The linking of two or more door operating systems of the present invention do not make them less independent in that they can easily be designed for individual operation.

[0042] The independent door system 112 for the triple hopper independent transverse door modified railcar 100 according to this embodiment of the present invention provides an effective efficient door operating system 112 that can control the unloading by an individual hopper pocket (pair of doors), or all hoppers at once. The present system 112 eliminates injury associated with manual individual door actuators. A double hopper door locking system is proposed, with the first being the cylinder and door lever's over center position, and the second being the secondary locking.

[0043] The triple hopper independent transverse door floor construction 110 includes the three independent doors of the door system 112 with two intervening partition floors. The partition floors include apex brace elements extending to the donor car sidewall structure and two supporting gussets. The triple hopper independent transverse door floor construction 110 also includes lower hopper floor that is coupled to the end floor of the donor car 10 as best shown in FIG. 6C.

[0044] The triple hopper independent transverse door floor construction increases the slope of the hoppers from around 40-45 degrees (+/?3 degrees) to about 55-65 degrees (+/?3 degrees). The floor construction 110 is preferably a stainless steel or a copper containing or copper bearing steel construction to inhibit corrosion. Copper containing or copper bearing steel references a copper content of the steel of at least 0.2% within the meaning of this application. In addition to using a corrosion inhibiting steel for the triple hopper independent transverse door floor construction 110, the present invention contemplates supplying a coating to the remaining interior of the donor car 10 with a corrosion inhibiting coating (also called a lining).

[0045] FIGS. 6A and B are schematic perspective views of final triple hopper independent transverse door modified railcars 100 according to two embodiments of the present invention which use an open top in which peripheral coaming elements are added to the modified railcar 100. The difference between these two embodiments is the use of the donor car 10 center partition. Where this is maintained in its entirety it will generally have a coaming member to increase the stiffening characteristics. However it is possible for some or most of the partition or even all of the partition to be removed and no coaming would typically be added.

[0046] FIGS. 7A and B are a schematic perspective views of a final triple hopper independent transverse door modified railcar 100 according to one embodiment of the present invention that utilizes a covered roof as shown. A conventional removable hatch will cover the trough port in the roof to complete the cover. The covered roof can reuse some of the donor car roof components 16 in this modification.

[0047] Dual Hopper Independent Longitudinal Door Floor Construction

[0048] The second family of modified railcar 100 of the present invention is a modified dual hopper independent longitudinal door railcar 100. FIGS. 8A, 8B and 8C are schematic perspective view, section view and top plan view, respectively, of an existing prior art dual hopper independent longitudinal door floor construction 120 intended to be mimicked by a floor construction 120 (which will look the same) in a method of repurposing small cube covered hopper railcars 10 according to one embodiment of the present invention using a dual hopper independent longitudinal door floor construction 120.

[0049] FIG. 9 is a schematic side elevational overlay view of a donor car 10 with an overlay of a floor construction 120 to mimic the existing prior art dual hopper independent longitudinal door railcar according to one embodiment of the present invention. The modified railcar 100 will have a 29-5 truck center to truck center distance and the existing prior art dual hopper independent longitudinal door railcar floor construction intended to be mimicked in this method has a 31-11? truck center to truck center distance. As with the initial modification proposal discussed above these car profiles demonstrate this is a reasonable alternative modification program for the donor cars 10.

[0050] The longitudinal doors of the floor construction 120 are analogous to the transverse doors of the floor construction 110 discussed above other than longitudinal orientation and individual door length. They offer independent operation wherein the front two and back two doors can be independently operated. Independent operation is critical where a dump site can only take one hopper at a time such as due to size restrictions. The dual hopper independent longitudinal door floor construction 120 will form hopper chutes that are steeper than the donor cars 10 and may include use of corrosion inhibiting components. The dual hopper independent longitudinal door floor construction 120 will couple to the sidewalls and end sheets of the donor car 10 to form the modified dual hopper independent longitudinal door railcar 100 as outlined in FIG. 9. Additionally the dual hopper independent longitudinal door floor construction 120 will couple to the existing partition of the donor car. This modified railcar 100 may be an open hopper design or a closed hopper design with a roof as noted above. In other words the roof may be excluded in the modified railcar 100 similar to as shown in FIG. 6A or 6B for the open top design or included as shown in FIG. 7A for the closed top design. An interior coating or liner may be added to the remaining donor car 10 interior space forming parts.

[0051] Flat Bottom Gondola Floor Construction 130

[0052] The third family of modified railcar of the present invention is a modified flat bottom gondola railcar 100. FIG. 10 is a schematic side elevational overlay view of a donor car 10 with an overlay of a floor construction 130 to mimic the existing prior art flat bottom gondola railcar according to one embodiment of the present invention. The modified railcar 100 will have a 29-5 truck center to truck center distance and the existing prior art flat bottom gondola construction intended to be mimicked in this method has a 29-6 truck center to truck center distance. As with the above mentioned modification proposals discussed above these car profiles demonstrate this is a reasonable alternative modification program for the donor cars.

[0053] The flat bottom gondola modified railcar 100 is useful where the car 100 is to be unloaded in an as needed basis by a backhoe or the like, such as when the railcar 100 is being used to sequentially fill a series of dump trucks to carry the laden to a use site.

[0054] FIG. 11 is a schematic perspective section view of a final flat bottom gondola modified railcar 100 according to one embodiment of the present invention. The flat bottom gondola floor construction 130 will couple to the sidewalls and to the bolster web of the donor car 10 to form the modified flat bottom gondola railcar 100 as outlined in FIG. 11. In this modification the bolster web becomes part of the elements defining the interior laden carrying space in the modified railcar 100. This modified railcar 100 will generally be an open hopper design for most applications. It is possible, such as for light weight laden that is unloaded via a suction tube that a roof design, such as shown in FIG. 7A, could be used, but this is not a likely use, but the modification is feasible if desired.

[0055] Dual Hopper Ballast Car Floor Construction 140

[0056] The fourth family of modified railcar of the present invention is a modified dual hopper ballast railcar 100 using floor 140. FIG. 12 is a schematic perspective view of an existing prior art ballast car floor construction 140 intended to be mimicked in a method of repurposing small cube covered hopper railcars 10 according to one embodiment of the present invention.

[0057] For background, track ballast forms the track-bed upon which railroad ties are laid. It is packed between, below, and around the ties. It is used to bear the load from the railroad ties, to facilitate drainage of water, and also to keep down vegetation that might interfere with the track structure. Ballast also holds the track in place as the trains roll over it. A variety of materials have been used as track ballast, including crushed stone, washed gravel, bank run gravel, torpedo gravel, slag, chats, coal cinders, sand, and burnt clay. The term ballast comes from a nautical term for the stones used to stabilize a ship. A ballast railcar is a railroad service vehicle or maintenance vehicle, and is a railcar that delivers ballast material to the railway.

[0058] Ballast railcars include at least one hopper with doors over the rails and discharge diverter/deflector gates that are selected to deliver to the inside of the rail the gate is above, to the outside of the rail the gate is above or simultaneously to both sides. A conventional ballast gate includes fixed deflectors below two guillotine or knife doors. Opening one of the doors will direct ballast to one deflector and to one side of the rail, opening the other of the doors will direct ballast to other deflector and to the other side of the rail, and opening both gates sends ballast to both sides. Conventional ballast doors may be manual or automatic (generally pneumatic or electric) and when not manual they may also be operated remotely. FIG. 13 is a schematic side elevational overlay view of a donor car 10 with an overlay of a floor construction 140 to mimic the existing prior art ballast railcar according to one embodiment of the present invention.

[0059] As best illustrated in FIG. 13 the modified railcar 100 will have a 29-5 truck center to truck center distance while the existing prior art ballast car floor construction intended to be mimicked in this method has a 36-1? truck center to truck center distance. As the modified car 100 is intended as a service vehicle the decreased carrying capacity of the modified car 100 over the mimicked ballast car is less significant in operation and this is a reasonable alternative modification program for the donor cars 10.

[0060] The ballast car floor construction 140 will couple to the sidewalls and end sheets of the donor car to form the modified ballast car railcar 100 as outlined in FIG. 13. The ballast car floor construction 140 will use conventional ballast railcar doors and control systems. Additionally the ballast car floor construction 140 will couple to the existing partition of the donor car 10. This modified railcar 100 may be an open hopper design or a closed hopper design with a roof as noted above. An interior coating or liner may be added to the remaining donor car interior space forming parts.

[0061] Twin Hopper Taconite Ore Car Floor Construction 150

[0062] The fifth family of modified railcar of the present invention is a modified taconite ore railcar 100. FIG. 14 is a schematic side elevational overlay view of a donor car 10 with an overlay of a floor construction 150 to mimic the existing prior art taconite railcar according to one embodiment of the present invention. The modified railcar 100 will have a 29-5 truck center to truck center distance and the existing prior art flat bottom taconite ore railcar floor construction intended to be mimicked in this method has substantially the same 29-5 truck center to truck center distance. As with the above mentioned modification proposals discussed above these car profiles demonstrate this is a reasonable alternative modification program for the donor cars 10.

[0063] The taconite floor construction 150 will couple to the sidewalls and upper end sheets of the donor car 10 to form the modified taconite ore railcar 100 as outlined in FIG. 14. Additionally the taconite ore floor construction 150 will couple to the existing partition of the donor car 10. This modified railcar 100 may be an open hopper design or a closed hopper design. An interior coating or liner may be added to the remaining donor car interior space forming parts.

[0064] Although the present invention has been described with particularity herein, the scope of the present invention is not limited to the specific embodiment disclosed. It will be apparent to those of ordinary skill in the art that various modifications may be made to the present invention without departing from the spirit and scope thereof. The scope of the present invention should be defined by the appended claims and equivalents thereto.