Abstract:
A wheel flange lubrication system for rail vehicles is described consisting of a rigid lubrication block, which is forced against a wheel flange to provide lubrication to the wheel flange. The block or stick is maintained in position to reduce flange wear, to minimize the movement of lubricant to undesirable locations, such as the crown of the rails and the tread of the wheel, and to provide a lubrication system which is environmentally safe. Preferably the lubrication block is arc shaped and spring-forced laterally and radially into the flange. The lubrication system is designed to stay in contact with the wheel flange and apply the desired amount of lubrication in the flange area using the side contact surface of the block. This adjustable position control is provided by applying independent forces which are directed radially towards the crotch of the wheel and laterally towards the wheel flange. The lubrication system is applicable to single or two flange wheels.

Description:
RELATED APPLICATION  
       [0001]     This patent application is based on and claims priority of provisional patent application Ser. No. 60/585984, filed on Jul. 7, 2004. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates in general to systems for lubricating wheel flanges on railroad vehicles, overhead cranes, trolleys and other equipment traveling on rails. In particular, the system relates to lubrication of wheel flanges using a rigid lubricant block or stick.  
       BACKGROUND OF THE INVENTION  
       [0003]     Friction between rails and wheels is known to increase the wear on the wheel flange and increase fuel consumption. It has long been known to apply lubricant to a wheel flange to reduce the friction and wear between a vehicle wheel and a rail. Lubricants which are not solid (greases and liquids) have many disadvantages including; storing and refilling the lubricant container, controlling the amount applied and dealing with environmental concerns with lubricant on the track. Most of these systems also rely on the lubricant rubbing from the wheel flange onto the rail and carrying back to subsequent cars. The amount of lubricant being shared with subsequent wheel flanges is not easily controlled.  
         [0004]     It is well known that misalignment will occur between the rail and wheel flange due to the vertical and horizontal movements of the wheel. Rail alignment will also contribute to wheel flange wear. Since there will always be alignment problems, it is important that the wheel flange lubrication system can track the position of the wheel flange relative to the rail to maintain constant contact of the lubricant with the flange.  
         [0005]     The use of a lubricant block or stick has eliminated some of these problems but still has not been completely successful. Lubricant sticks are usually rigid blocks of lubricant which gradually wear with contact and must be replaced over time. The sticks must be held against the flange to maintain contact and this is usually accomplished with springs. It has been difficult to mount these devices on board a rail vehicle or crane and control where the lubricant stick is positioned to insure the lubrication is applied to the flange. Previous sticks have had their tips pushed against the wheel flange and have not had their position controlled to compensate for the normal wheel movement and curvature of the track. The tip of the lubricating stick is used to contact the wheel flange. The capability to adjust the forces and direction on the stick has been lacking.  
         [0006]     The rail and crane industries are still in need of a flange lubrication system which applies lubricant in the desired amount and location while also being easily mounted to the vehicle. Applying lubricant to a wheel flange which is subject to a great range of movement has created a need not solved by previous lubricant stick or block application systems.  
       SUMMARY OF THE INVENTION  
       [0007]     A rigid block of lubricant is provided with a holder for directing a contact side of the block against the wheel flange. A method and means are provided to force the contact side of the lubricant block laterally against the wheel flange and radially into the crotch of the wheel. The rigid block has independent radial and lateral force means for improved control of the position of the block. A significant improvement in lubrication control is achieved by providing means to adjust the forces used to position and direct the lubrication block. Improved control minimizes lubricant contact on the tread of the wheel or on the rail. A preferred design is the use of a curved block or segment blocks to provide an arc length of at least 5 degrees relative to the wheel radius.  
         [0008]     The lubrication system of the present invention includes a lubrication block or block segments supported by a spine which holds the lubricant block around the wheel. The spine provides a radial flexing action to provide force towards the crotch of the wheel. The spine will be connected to metallic holders which are used to attach side springs for lateral force. The tensioning means keep the lubricant block in direct contact with the wheel flange to distribute lubricant to the wheel flange. The spine(s) and metallic holders are normally held in place while the lubricant material is cast, extruded, injection molded, etc., around them.  
         [0009]     Support means are included to keep the lubrication system in position for proper lubrication and to compensate for vertical and horizontal movement of the wheels relative to the rails.  
         [0010]     The present invention is applicable to a wheel lubrication system for a wheel with two flanges where two lubrication blocks (or two connected segments of blocks) are mounted with side springs to push the blocks against the two wheel flanges or on a single wheel flange design where only one lubrication block (or one connected segments of blocks) is forced against the one wheel flange. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]      FIG. 1  is a vertical sectional view of a lubricant system of the prior art.  
         [0012]      FIG. 2  is a perspective view of the invention of the spine support for the rigid lubricant block of the invention showing the wire springs and side spring holders.  
         [0013]      FIG. 3  is a perspective view of the invention of the spine support showing the lubricant block around the spine.  
         [0014]      FIG. 4  is a perspective view of the invention of a pair of lubricant blocks with side springs mounted within on a wheel.  
         [0015]      FIG. 5  is a perspective view of the mounting brackets and holders for the lubricant blocks of the invention.  
         [0016]      FIG. 6  is a perspective view of the invention of the mounting brackets and holders connected to the lubricant blocks.  
         [0017]      FIG. 7  is a perspective view of the invention showing the mounting system for a single wheel flange lubrication system.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     The following description is a preferred embodiment by way of example only and without any limitation to the combination of features for carrying out the invention.  
         [0019]     The present invention relates to a system for lubricating wheel flanges using a rigid lubrication block. Various lubricants may be used including microporous polymeric lubricants, graphite, molybdenum disulfide, impregnated polymers, solid grease, sponge, sintered bronze, impregnated felt, PTFE (PolyTetraFluoroEthylene) and UHMWPE (UltraHighMolecularWeightPolyEthylene). Other lubricants may also be used. A preferred lubricant is the microporous polymeric lubricant which has excellent wear characteristics and provides a controlled release of the lubricant from the block. This type of material is taught in U.S. Pat. Nos. 3,541,011; 3,547,819; and 3,729,415.  
         [0020]     The lubricant block or stick is composed of at least 30% solids. The lubricant block may have various shapes. The shape, amount of surface contact, type of lubricant, force, surface characteristics of the flange, etc., determine the amount of lubricant being provided to the flange. A major improvement provided by the invention is the increased surface area provided by the contact surface of the arc shaped lubricant block contrasted to the tips of previously mentioned sticks. By providing an arc shape, the lubricant blocks provide a contact surface of at least 5 degrees of arc and preferably at least about 10 degrees up to the point where the blocks do not cause interference between the wheel and rail. The contact surface of the lubricant block may be a single surface or composed of segments which are connected or spaced apart. A typical lubricant block would be an arc shape of about 45-315 degrees and preferably about 90-135 degrees relative to the wheel. An arc shape of greater than about 315 degrees would not provide much improved lubrication and would begin to cause difficulties with the installation.  
         [0021]     Mounting means must be provided in order to support the lubricant block in position. Any mounting means may be used which provides a stable support which maintains the block in the desired position regardless of distance between the wheel flange and the rail. The mounting means provide a way of increasing the contact surface area with the wheel flange and means to adjust the forces. The mounting means also provide the desired force vectors for directing the lubricant block into the flange. The force is preferably provided by springs which provide radial and lateral forces which maintain the desired position and compensates for variations in distance between the rail and wheel flange.  
         [0022]     The lubricant blocks, including the mounting means, must also be supported by means which attach the lubricating system to the vehicle. Various bracket designs have been taught in the past. It is important that the lubricating system be kept stationary relative to the wheel. The brackets or support means used in the present invention are not novel in and of themselves and numerous designs may be used.  
         [0023]     The lubrication system of the present invention has solved the problems with previous designs by providing lubrication blocks which have adjustable radial and lateral forces to ensure the blocks are maintained in a position which lubricates only the wheel flange. The amount of surface contact area provided by the controllable positioning of the high surface area arc shaped lubrication blocks provides a method of controlling the amount of lubricant supplied to the wheel flange. The invention will now be discussed in more detail and in reference to the figures.  
         [0024]      FIG. 1  shows a prior art lubricator where a stick is spring fed into position. The pressure is applied to the back end of the stick and the lubricant is applied from the front end of the stick. This approach does not allow the end of the lubricant stick to remain in contact with the wheel flange during normal wheel movement since there are no independent radial and lateral forces.  
         [0025]     The lubrication support system  8  of the present invention for casting, injecting, molding or extruding lubricant blocks  23  (shown in  FIG. 3 ) includes a wire  11  of any cross section shape formed into a circular arc fed through holders  12  are shown in  FIG. 2 . Although the preferred lubrication support system  8  utilizes a circular arc wire support for the lubricant, an external support, such as, a circular arc shaped C-channel, U-channel and angle bracket, could be used as an alternative support system while providing the same functional characteristics. Any number of holders  12  may be used depending on the length of the lubricant blocks  23 . The desired thickness of the lubricant blocks  23  will also determine if multiple wires  11  are threaded through the holders  12  which may have openings at various locations for multiple wires. Bolts  13  are used to secure the springs  14  to the holders  12 . Springs  14  supply lateral force to the lubricant blocks  23  as shown in  FIG. 4 . Mounting brackets  15  are used to support the lubrication support system  8  attached by retaining bolts  16  in addition to the tensioning rod  18 . It is important to note that the thickness of the rigid lubricant blocks  23  and the lubrication support system  8 (wire diameter, number of wires and wire composition) will be selected for providing the desired rigidity. The size of the rigid blocks  23  must allow space for the springs which minimizes the contact side  23   a  of the lubricating blocks  23  with the tread areas  10  of the wheel  9 , as well as, the rail  40 . Although springs  14  may be the preferred method of supplying lateral and radial forces, other methods, such as, metal clips, air; gas or hydraulic actuated cylinders via pumps, compressors and/or motor driven servo devices are also capable of producing said forces.  
         [0026]     One or more tensioning devices  17  may be used to provide radial force and adjust the amount of contact between the lubricant blocks  23  and the wheel flange  24  shown in subsequent figures. The tensioning devices  17  may include one or more rods  18  having loops  18   a  for attaching to the mounting brackets  15 . The use of more than one rod  18  will provide an added measure of safety. The tension adjustment bolts  19  are positioned in the loops  18   a  and connected by upper and lower tensioning nuts  20  and  21 . Bracket nuts  22  are used to connect the tensioning device to the mounting brackets  15 . Washers may also be included. The amount of tightening on the upper and lower tensioning nuts  20  and  21  will position the rod  18  and thus the lubricant blocks  23  correctly. As will be explained in more detail later, this influences the amount of the contact side  23   a  of the blocks  23  in contact with the wheel flange and the amount of lubricant and its distribution.  
         [0027]      FIG. 3  is basically the same as  FIG. 2  except the lubricant block  23  is shown with the lubrication support system  8  which includes the circular arc wire  11  and holders  12 . It is important to understand that the amount of tightening of the upper and lower tension nuts  20  and  21  controls the contact side  23   a  of the lubricant block  23 . This insures the lubricant being applied to the tread of the wheel is minimized and the wheel flange  24  is lubricated with the desired control. The importance of arc shaped block  23  (or segments of blocks which are connected) will now become clearer. This allows the bending of the arc at the lubricant block tips for a contact side  23   a  length which is easily adjusted for control of the amount of lubricant and location of the lubricant on the wheel flange  24 . The radius r of the lubrication block assembly  42  shown in  FIG. 3  should approach the radius of the wheel tread  10 , such that the contact area of the rigid lubrication blocks  23  to the wheel flange  24  is maximized. The radius r of lubrication block assembly can be increased to conform to the radius of the wheel tread  10 , if less than optimum, by adjusting nuts  20 , and thereby, positioning rod  18  to apply a radial force to increase the lubrication block assembly radius. The length of the arc shaped lubricant block  23 , or segments, should be at least about 5 degrees, preferably at least about 10 degrees, and more preferably, about 90 to 135 degrees relative to the wheel radius. Longer lengths of the lubricant block  23  in the shape of an arc will provide more lubrication surface area but are also limited to a length which permits easy installation. As stated previously, it is important to understand that the amount of lubricant must also be controlled to avoid lubrication on the tread of the wheel and on the rail  40 .  
         [0028]     The present invention is not limited to a single block of rigid lubricant  23 . If segments of lubricant blocks  23  are employed, one must include connection means with springs between the segments (not shown). This is important for installation purposes and control of the surface area of contact. It is the sum of the arc shaped segments which compares with the arc length of a single block  23  in order to provide the same levels of lubrication and control of the lubricant distribution. Numerous forms of rigid lubricant blocks may be used. Those skilled in the art will appreciate that different materials will require different lengths of surface contact to provide the same amount of lubrication.  
         [0029]     It is a further feature of the present invention that solid, wear resistant spacers  31  in  FIG. 3  may be used to improve the spacing control of the arc shaped lubricant blocks  23  above the wheel tread  10 . Considerable radial forces may be applied and still a gap is provided between the lubricant blocks  23  and the tread. This will also prevent the lubricant from depositing onto the wheel tread  10  thus allowing adequate braking of the rail vehicle or crane Altering the geometry of the cross section of the lubricant, such as, adding features like a relief angle between the lubricant and the tread will further increase control of the amount of lubricant deposited on the tread. The use of a microporous polymer for the lubricant block  23  has several advantages. This material has a controlled release of the lubricant from within the rigid lubricant block. The rigidity of the block is maintained to provide improved service life. The lubrication block  23  provides a supply of lubricant that is available over a considerable time period and reduces the rate at which lubrication blocks  23  need to be replaced. The present invention has provided over  8  months of continuous lubrication on a  2 -flange wheel application with a single microporous block of lubricant produced by PhyMet, Inc. under the trade name, MicroPoly®. The amount of wheel flange  24  wear has been drastically reduced using the rigid block of lubricant  23  with adjustable radial and lateral forces for improved lubricant control. See Tables 1 and 2 below.  
                                           TABLE 1                           Wear rate and life of 24″ (610 mm)       diameter double flange crane wheel            Lubrication   Wear rate (mm/week)   Crane wheel life (weeks)                    None   0.9   24       Stick lubricator with   0.3   76       MicroPoly ®       Present Invention with   0.2   108       MicroPoly ®                  
 
         [0030]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                   
               
               
                 Wheel life of a 27″ (686 mm) diameter double flange crane wheel 
               
             
          
           
               
                 Lubrication 
                 Wear rate (mm/week) 
                 Crane wheel life (weeks) 
               
               
                   
               
             
          
           
               
                 None 
                 0.45 
                 52 
               
               
                 Present Invention with 
                 0.10 
                 &gt;156 
               
               
                 MicroPoly ® 
               
               
                   
               
             
          
         
       
     
         [0031]     It is preferable that the height of the lubricant blocks  23  should be at least the height of the wheel flange  24 . The amount of lubricant provided will depend on the height and length of the lubricant blocks  23 .  
         [0032]     The present invention may also be applied to single flange applications. As shown in  FIG. 7 , it is not possible to provide the lateral force from springs  35  which push in both directions as in the two flange designs. In order to provide the lateral force, a different support system is required. One way of providing this support is with the use of multiple rod design wherein rods  25  are connected to an outer race  26  of a bearing  27  that does not rotate as the inner race of the bearing  33  rotates with wheel. The rods  25  are threaded and fasten to nuts,  28  and  29  which fix the rods  25  to brackets  30  which are connected to spring anchor bolts  32  which allow the springs  35  to push against the lubrication block  23 , thereby, forcing the contact side  23   a  of the lubrication block  23  against the wheel flange  24 , not shown, held in proper alignment by alignment bolts  34  and bracket slot  36 . This modification, which may be done in other manners, provides a rigid lubrication block  23  which pushes the contact side  23   a  laterally and radially without the use of springs  14  acting in opposed directions.  
         [0033]     The invention has significant advantages. The lubrication system may be easily produced and has great flexibility in application to a wide range of operating conditions. It is easily applied to all wheel flange designs. The wheel flanges are lubricated with a control not previously obtainable. The system is easily installed and avoids the maintenance concerns of other systems. There are also no environmental issues with the present invention. While the present invention has been shown in several embodiments, it should be apparent to those skilled in the art that it is not so limited and numerous changes may be made without departing from the scope of the invention.