Modular coil railcar

A modular railcar includes a modular top system that is configured to hold one or more coils of material, and a railcar underframe that supports the modular top system. The modular top system includes a pair of side sills and one or more troughs disposed between the pair of side sills. Each side sill of the pair of side sills extends a longitudinal length of the modular top system. Each trough of the one or more troughs is configured to hold a coil of the one or more coils of material. The underframe includes one or more coupling apparatuses that are configured to detachably engage the modular top system when the modular top system is positioned on top of the underframe.

TECHNICAL FIELD OF THE INVENTION

This disclosure relates generally to railcars, and more particularly to a modular coil railcar.

BACKGROUND

Railcars designed specifically to transport coils of material are known as coil railcars. Coil railcars are typically designed either to transport coils of material positioned with their axes of rotation parallel to the longitudinal axis of the railcar, or to transport coils of material positioned with their axes of rotation perpendicular to the longitudinal axis of the railcar. While coil cars typically transport coils of sheet metal, such as steel or aluminum, they may be used to transport any type of coiled material, including plastic.

SUMMARY

According to an embodiment, a modular railcar includes a modular top system that is configured to hold one or more coils of material, and a railcar underframe that supports the modular top system. The modular top system includes a pair of side sills and one or more troughs disposed between the pair of side sills. Each side sill of the pair of side sills extends a longitudinal length of the modular top system. Each trough of the one or more troughs is configured to hold a coil of the one or more coils of material. The underframe includes one or more coupling apparatuses that are configured to detachably engage the modular top system when the modular top system is positioned on top of the underframe.

According to another embodiment, a method includes removing a first modular top system that is configured to hold one or more coils of material from a railcar underframe. The first modular top system includes a pair of side sills and one or more troughs disposed between the pair of side sills. Each side sill of the pair of side sills extends along a longitudinal length of the first modular top system. Each trough of the one or more troughs is configured to hold a coil of the one or more coils of material. The railcar underframe includes one or more coupling apparatuses that are configured to detachably engage the first modular top system. Removing the first modular top system from the railcar underframe includes disengaging the first modular top system from the one or more coupling apparatuses of the railcar underframe. The method also includes placing a second modular top system on the railcar underframe. The one or more coupling apparatuses of the railcar underframe are further configured to detachably engage the second modular top system. Placing the second modular top system on the railcar underframe includes engaging the second modular top system with the one or more coupling apparatuses of the railcar underframe.

According to a further embodiment, a modular top system that is configured to hold one or more coils of material includes a pair of side sills, one or more troughs disposed between the pair of side sills, and one or more coupling apparatuses configured to detachably couple to a railcar underframe. Each trough of the one or more troughs is configured to hold a coil of the one or more coils of material.

Certain embodiments of the modular coil railcar provide one or more technical advantages. For example, an embodiment transfers coil loads to the middle of the railcar and into the center sill rather than the side sills, thereby enabling the modular coil car to use shorter side sills and/or side sills of alternate designs (e.g., scalloped), as compared with conventional coil railcars. The use of such side sills may improve the efficiency of the coil loading and unloading processes, by permitting unencumbered access to the central axes of the coils during these processes. Additionally, the use of shorter and/or scalloped side sills may lead to an overall weight reduction, as compared with conventional coil railcars, thereby improving the efficiency of coil transport by rail. As another example, an embodiment enables a modular top system that is configured to transport coils to be easily replaced with a modular top system of another design, thereby changing the railcar from a coil railcar into a railcar of another type. In this manner, use of the railcar may be maximized, despite changing market conditions. Certain embodiments may include none, some, or all of the above technical advantages. One or more other technical advantages may be readily apparent to one skilled in the art from the figures, descriptions, and example embodiments included herein.

DETAILED DESCRIPTION

Railcars designed specifically to transport coils of material are known as coil railcars. While coil railcars are typically considered a sub-type of gondola railcars, they are generally much more specialized. For example, while gondola railcars may transport a wide variety of different materials in different forms, such as gravel aggregate or scrap metal, coil cars are designed either as longitudinal coil cars, configured to transport coils of material positioned with their axes of rotation parallel to the longitudinal axis of the railcar, or as transverse coil cars, configured to transport coils of material positioned with their axes of rotation perpendicular to the longitudinal axis of the railcar. Both longitudinal and transverse coil cars transport coils positioned in one or more troughs. This helps to prevent the coils from rolling while the railcars are in motion. While coil cars typically transport coils of sheet metal, such as steel or aluminum, they may be used to transport any type of coiled material, including plastic.

In conventional transverse coil railcars, the troughs that support the coils are attached to the side sills of the railcars. This results in a transfer of the vertical weight of the coils, as well as lateral and longitudinal reaction loads from the coils, to the side sills. Accordingly, the side sills of conventional transverse coil cars are relatively large in order to withstand such loads and transfer them to the underframe of the railcar. However, when small coils are loaded into the troughs of such coil cars, the large side sills may obscure all or part of the area from which the coils are to be lifted, making it difficult to unload the coils from the railcar.

Another issue with conventional coil cars relates to the fact that such cars are specifically built as either longitudinal coil cars or transverse coil cars and generally cannot be adapted for other purposes. Accordingly, any decrease in the demand for a particular type of coil car, or a decrease in the demand for coil transport by rail, in general, may result in coil railcars being taken out of service prematurely. This may lead to significant inefficiency and waste, given that a large portion of the railcar (for example, the truck assemblies, underframe, and braking system) may remain useable for purposes other than longitudinal and/or transverse coil transport.

This disclosure contemplates a modular coil railcar that addresses one or more of the above issues. Certain embodiments of the modular coil car include a common underframe that may be coupled to a plurality of different top portions. For example, this disclosure contemplates that the common underframe may be coupled to a modular top configured to transport coils transversely and/or a modular top configured to transport coils longitudinally. The use of such a modular top portion offers several advantages over conventional coil cars. As an example, in contrast to conventional transverse coil cars, the modular transverse coil car top of the present disclosure is designed to transfer a majority of the vertical coil loads into the underframe, rather than the side sills of the car. This allows the side sills of the modular railcar to be smaller than those of conventional transverse coil cars, providing unencumbered access to any loaded coils, thereby enabling easy loading and/or unloading. As another example, the modular top may easily be decoupled from the common underframe and replaced with a different top, of a different design and/or for a different purpose. For example, the common underframe be coupled to a modular top configured to transport coils transversely, a modular top configured to transport coils longitudinally, and/or a modular top configured for an entirely different purpose than transporting coils. By enabling one modular top to be swapped for another, the modular coil car may easily adapt to changing market conditions, avoiding the waste associated with otherwise taking the car out of service.

Embodiments of the present disclosure and its advantages are best understood by referring toFIGS.1through14of the drawings, like numerals being used for like and corresponding parts of the various drawings.

FIG.1is a schematic side view of a conventional transverse coil railcar100. Railcar100includes open top115, which is supported by truck assemblies105aand105b. Open top115includes underframe110and side sills130. As illustrated inFIG.1, open top115includes nine transverse troughs120that are each configured to transport a coil125positioned such that the axis of rotation of coil125is perpendicular to the longitudinal axis of railcar100. Conventional transverse coil railcars may be configured to transport coils125of various diameters. For example, as illustrated inFIG.1, railcar100is configured to transport large coils125a, medium coils125b, and smaller coils125c. In some conventional transverse coil cars100, coils125of different diameters may be transported within troughs120of the same width, because the coils125are supported by the sides of troughs120(rather than resting on the bottom of troughs120). Accordingly, in such transverse coil cars, large diameter coils125awill rest higher up in troughs120than small diameter coils125c.

In conventional transverse coil cars100, troughs120are attached to side sills130. Accordingly, both the vertical weight of coils125, as well as the lateral and longitudinal reaction loads experience by coils125, are transferred from coils125to side sills130. As a result, side sills130on conventional transverse coil cars100are typically quite large, in order to withstand such loads and transfer them to underframe110of railcar100. When coils125of different diameters are transported within fixed-width troughs120, the large side sills130, which are present to withstand and transfer the loads from coils125, may lead to issues when loading and unloading railcar100. For example, because troughs120are fixed-width, when smaller coils125care loaded into top115, the center of these coils is lower with respect to side sills130than the center of larger coils125a. As a result, on some transverse coil railcars100, side sills130may cover all or a portion of the centers of smaller coils125c. Given that coils125are typically handled at their centers, this may make loading and unloading smaller coils125cdifficult.

Additionally, because open top115is integrally connected to underframe110and truck assemblies105aand105b, any change in market conditions may lead a rail operator to take the entire railcar100out of service, if the design of railcar100is no longer efficient for the current conditions. However, given that many parts of railcar100—including truck assemblies105aand105b, underframe110, and other components of the railcar, such as brake systems—may be common amongst other types of railcars (e.g., boxcars, flatcars, gondola cars, etc.), removing the entire railcar100from service simply because top portion115does not match current market demand may result in considerable inefficiency and waste.

This disclosure contemplates a modular coil railcar that addresses one or more of the above issues. Certain embodiments of the modular coil car include a modular coil car top that may be coupled to a common underframe. Some embodiments of the modular coil car top are configured to transport longitudinally aligned coils, and some embodiments are configured to transport transversely aligned coils. In contrast to conventional transverse coil cars100, the modular transverse coil car top of the present disclosure is designed to transfer a majority of the vertical coil loads into the underframe, rather than the side sills of the car. This allows the side sills of the modular railcar to be smaller than those of conventional transverse coil cars, providing, in certain embodiments, unencumbered access to any loaded coils, thereby enabling easy loading and unloading. Additionally, the modular top may easily be decoupled from the common underframe and replaced with a different top, allowing the railcar to adapt to changing market conditions.

FIGS.2A through2Dpresent examples of a modular transverse coil car top200of the present disclosure.FIG.2Aillustrates a bottom-up view of a modular coil car top200that includes nine troughs210,FIG.2Billustrates a side view of a modular coil car top200that includes nine troughs210,FIG.2Cillustrates an isometric view of the top of a modular coil car top200that includes seven troughs210, andFIG.2Dillustrates an isometric view of the underside of a modular coil car top200that includes seven troughs210. As illustrated inFIGS.2A through2D, in certain embodiments, modular coil car top200includes (1) a plurality of I-beams220, which extend in a transverse direction between side sills240, (2) a plurality of gussets215coupled to I-beams220, and (3) a plurality of floor sections225, supported by I-beams220and gussets215, which define a number of transverse troughs210. While illustrated inFIGS.2A and2Bas including nine transverse troughs210, and inFIGS.2C and2Das including 7 transverse troughs210, this disclosure contemplates that modular coil car top200may include any number of troughs210. For example, a first modular coil car top200may include 5 troughs210, a second modular coil car top200may include 7 troughs210, and a third modular coil car top200may include 9 troughs210. Additionally, while illustrated inFIGS.2A through2Das including transverse troughs210, this disclosure contemplates that modular coil car top200may include longitudinal troughs, and/or a mixture of both transverse and longitudinal troughs. An example of a modular longitudinal coil car top is described below, in the discussion ofFIGS.8A and8B.

In certain embodiments, each trough210is formed from an angled floor sheet225positioned between a pair of I-beams220aand220b. As illustrated inFIG.2B, each angled floor sheet225includes (1) a first angled portion225a, which slopes downward, away from the top of support member220a, (2) a horizontal portion225b, which defines the lowest position of trough210, and (3) a second angled portion225c, which slopes upward, toward the top of support member220b. Each angled floor sheet225extends in a transverse direction between side sills240and may be formed from one or more sheets of metal, as described in further detail below, in the discussion ofFIGS.4A and4B.

A plurality of gussets215are coupled to each I-beam220. As illustrated inFIGS.2B and2D, each gusset215may be formed as a metal plate of any suitable thickness. Gussets215may be positioned substantially parallel to one another and extend in a direction parallel to the longitudinal axis of modular transverse coil car top200(the direction generally perpendicular to support members220). Gussets215are configured to support angled floor sheets225. Accordingly, a side of each gusset215is configured to slope downwards, away from I-beam220, with angled floor sheet225configured to rest on top of this side. This disclosure contemplates that any number of gussets215may extend from I-beams220to floor sheet225, on either side of I-beam220.

While illustrated inFIGS.2B and2D, as including I-beams220, this disclosure contemplates that I-beams220may be replaced by any suitable vertical load carry members, which extend in a transverse direction between side sills240. The use of alternative geometries in place of I-beams220is described in further detail below, in the discussion ofFIGS.5through7.

Modular coil car top200is configured to couple to a common underframe using one or more coupling apparatuses205, as described in further detail below, in the discussion ofFIGS.9through11. Modular coil car top200may include any number of coupling apparatuses205. For example, as illustrated inFIGS.2A through2D, modular coil car top200may include two pairs of coupling apparatuses205-afirst pair of coupling apparatuses205located near a first end of modular coil car top200and a second pair of coupling apparatuses205located near a second end of modular coil car top200. When coupled to the common underframe, I-beams220of modular coil car top200are supported by center sill235of the common underframe. Because I-beams220are located on top of center sill235, troughs210may be located lower on the modular coil railcar than in conventional coil railcars, thereby lowering the overall center of gravity for the loaded car.

In certain embodiments, coils125rest in troughs210on top of angled floor sheets225. In particular, coils125may rest on angled portions225aand225cof angled floor sheets225. Angled floor sheets225are configured to distribute the loads from coils125to gussets215. Gussets215in turn transfer these loads to I-beams220and into the common underframe at the center of the railcar and the side sills. In this manner, modular coil car top200is configured to transfer a majority of the vertical loads from coils125into the common underframe of the modular coil railcar, rather than into side sills240(while longitudinal and transverse coil loads transfer to side sills240, consistent with conventional transverse coil cars). This enables side sills240to be smaller than side sills130of conventional transverse coil cars. As a result, in certain embodiments, side sills240may permit unencumbered access to the centers of small diameter coils125, facilitating loading and unloading of the coils from modular coil car top200.

As an example,FIG.3illustrates a side view of an example modular coil car top300that includes scalloped side walls305that facilitate loading and unloading of coils125from the modular top. As illustrated inFIG.3, each side wall305includes indentations310at locations on the side wall adjacent to troughs210. In certain embodiments, and as illustrated inFIG.3, indentations310may be concave shaped; however, this disclosure contemplates that indentations310may be of any suitable shape. In certain embodiments, indentations310may provide improved access to coils125, when loaded in modular coil car top300. For example, indentations310may provide improved access to coils125when using a forklift to unload the coils from modular coil car top300. In some embodiments, indentations310may help to reduce the weight of modular coil car top300.

FIGS.4A and4Bpresent cross-sections of a trough210aof modular coil car top200, illustrating example constructions that may be used for the angled floor sheets225of troughs210.FIG.4Apresents an example in which each angled floor sheet225of trough210ais formed from a single sheet of metal, whileFIG.4Bpresents an example in which each angled floor sheets225of trough210ais formed from two sheets of metal.

As illustrated inFIG.4A, in certain embodiments, the angled floor sheet225, defining a given trough210, may be formed from a single sheet of metal405.FIG.4Apresents a cross-section of this single sheet of metal405. This disclosure contemplates that each sheet of metal410and415extends in a transverse direction between side sills240from a first side of modular coil car top200to a second side of modular coil car top200, opposite the first side. As illustrated inFIG.4A, single sheet of metal405includes four bends, which define five portions of the sheet of metal: (1) a first horizontal portion405a, which is coupled to the top of I-beam220a, (2) a first angled portion405b, which slopes downward, away from the top of I-beam220a, (3) a second horizontal portion405c, which defines the lowest position of trough210, (4) a second angled portion405d, which slopes upward, from horizontal portion405band toward the top of the adjacent I-beam220b, and (5) a third horizontal portion405e, which is coupled to the top of I-beam220b. In certain embodiments, the use of a single sheet of metal405to form each trough210may be desirable, as it may help to ensure that no debris from under the modular coil railcar can contaminate or damage coils125during transport. Sheet of metal405may be coupled to the tops of I-beams220aand/or220bin any suitable manner. For example, in certain embodiments, sheet of metal405is welded to the tops of I-beams220a

As illustrated inFIG.4A, the third horizontal portion405eof a first angled floor sheet225ais coupled to the top of the same I-beam220bas the first horizontal portion405aof a second angled floor sheet225b. In certain embodiments, a space420separates third horizontal portion405eof first angled floor sheet225afrom first horizontal portion405aof second angled floor sheet225b. Space420may account for manufacturing tolerances and may allow for adjustment of angular floor sheets225. This disclosure contemplates that space420may be of any suitable size. In certain embodiments, rather than including space420, third horizontal portion405eof first angled floor sheet225aand first horizontal portion405aof second angled floor sheet225bmay overlap one another on top of I-beam220b. In some embodiments, third horizontal portion405eof first angled floor sheet225amay be coupled to first horizontal portion405aof second angled floor sheet225b.

As illustrated inFIG.4B, in certain embodiments, each angled floor sheet225, defining each trough210, may be formed from two sheets of metal-first sheet of metal410and second sheet of metal415.FIG.4Bpresents a cross-section of sheets of metal410and415. This disclosure contemplates that each sheet of metal410and415extends in a transverse direction between side sills240from a first side of modular coil car top200to a second side of modular coil car top200, opposite the first side. As illustrated inFIG.4B, first sheet of metal410includes two bends, which define three portions of the sheet of metal: (1) a first horizontal portion410a, which is coupled to the top of I-beam220a, (2) an angled portion410b, which slopes downward, away from the top of I-beam220a, and (3) a second horizontal portion410c, which defines the lowest position of trough210, and extends part way along the bottom of trough210. Similarly, second sheet of metal415includes two bends, which define three portions of the sheet of metal: (1) a first horizontal portion415a, which is coupled to the top of I-beam220b, (2) an angled portion415b, which slopes downward, away from the top of I-beam220b, and (3) a second horizontal portion415c, which defines the lowest position of trough210, and extends part way along the bottom of trough210. Second horizontal portion410cof first sheet of metal410and second horizontal portion415cof second sheet of metal415define the bottom of trough210. In certain embodiments, and as illustrated inFIG.4B, second horizontal portion410cof first sheet of metal410and second horizontal portion415cof second sheet of metal415overlap one another. In some embodiments, the joint where second horizontal portion410cof first sheet of metal410and second horizontal portion415cof second sheet of metal415overlap one another may be sealed to prevent unwanted debris from damaging coils125during transport. In certain embodiments, the use of two sheets of metal410and415to form each trough210may be desirable to provide a greater ability to account for manufacturing tolerances as compared with the single sheet construction ofFIG.4Aand/or to facilitate certain manufacturing processes.

While illustrated inFIGS.4A and4Bas being formed from either a single sheet of metal405, or two sheets of metal410and415, this disclosure contemplates that each angled floor sheet225of trough210may be formed from any number of sheets of metal. As an example, angled floor sheet225may be formed from sheets of metal that do not extend the full transverse distance between side sills240. Additionally, this disclosure contemplates that in certain embodiments, a single sheet of metal may be used to form more than one trough210. For example, a single sheet of metal may be used to form the floors of a pair of adjacent troughs.

WhileFIGS.2B through4Billustrate the use of I-beams220, this disclosure contemplates that any suitable vertical load carrying member configured to span the width between side sills240and to transfer vertical coil loads into center sill235of the common underframe may be used in place of I-beams220. For example,FIG.5presents an example modular coil car top500that includes a box structure505for use in place of I-beams220. As illustrated inFIG.5, box structure505may be defined by a pair of vertical plates510aand510b, separated from one another by a distance d. This disclosure contemplates that d may be any suitable distance. For example, in certain embodiments, d may be the width of a conventional I-beam at its widest extent. Each vertical plate510aand510bis configured to extend in a transverse direction between side sills240. In certain embodiments, the space between vertical plates510aand510bmay be empty. In some embodiments, the space between vertical plates510aand510bmay be filled. As another example,FIG.6presents an example modular coil car top600that includes channels605for use in place of I-beams220. Each channel605includes a top portion, a side portion and a bottom portion, such that a cross-section of channel605forms a C-shape. Each channel605is configured to extend in a transverse direction between side sills240. In addition to I-beams220, box structures505, and channels605, this disclosure contemplates that any suitable geometry may be used for the vertical load carrying members configured to span the width between side sills240and to support angled floor sections235. The particular geometry chosen for such members may be chosen to maximize the strength of the modular coil car top and/or to achieve various manufacturing advantages.

As illustrated inFIGS.7A through7C, in certain embodiments, rather than including an integral vertical member, such as an I-beam220, box structure505, and/or channel605, angled floor sections225may be supported by monocoque frame structures705.FIG.7Aillustrates a side view of modular coil car top700with monocoque frame structures705installed to support angled floor pieces235, whileFIG.7Billustrates a cross-section of monocoque frame structure705prior to installation in modular rail car top700. A cross-section of monocoque frame structure705is generally triangular shaped such that the sloped portions of angled floor pieces235are configured to rest against sloped sides of structure705. A number of gussets230may be installed inside monocoque frame structure705to provide added support. Gussets230may be installed at various spacings within structure705.FIGS.7B and7Cillustrate an example geometry for such gussets230.

In addition to modular coil car tops that can be used to transport coils positioned in the transverse direction, the modular coil car tops of the present disclosure may also be used to transport coils positioned parallel to the longitudinal axis of railcar100.FIGS.8A and8Bpresent an example modular longitudinal coil car top800configured to transport coils positioned parallel to the longitudinal axis of the modular railcar.

FIG.8Aillustrates the underside of the example modular longitudinal coil car top800, whileFIG.8Billustrates the top of modular longitudinal coil car top800. As illustrated inFIGS.8A and8B, modular longitudinal coil car top800includes a pair of sidewalls805and a trough820positioned between the sidewalls. Trough820is formed from floor sheet815, which is supported by a plurality of gussets810. Floor sheet815includes a pair of sloped portions and a horizontal portion, located between each sloped portion. Each sloped portion of the pair of sloped portions slopes downwards from a sidewall805towards the horizontal portion. The horizontal portion defines the bottom of trough820. Floor sheet815may be formed from any number of sheets of metal. For example, in certain embodiments, floor sheet815may be formed from a single sheet of metal. As another example, in certain embodiments, floor sheet815may be formed from a pair of sheets of metal, with each sheet of metal of the pair of sheets of metal forming a sloped portion of floor sheet815. In some such embodiments, the pair of sheets of metal may be configured to overlap one another at the horizontal bottom of trough820. As another example, in certain embodiments, floor sheet815may be formed from any number of sheets of metal, with each sheet of metal spanning a portion of the longitudinal extent of trough820.

As illustrated inFIG.8A, each gusset810may be formed as a metal plate of any suitable thickness. Gussets810may be positioned substantially parallel to one another and extend in a direction perpendicular to the longitudinal axis of modular longitudinal coil car top800. Each gusset810is coupled at a first side to a sidewall805and may support a portion of one of the sloped portions of floor sheet815. Accordingly, a second side of each gusset810is configured to slope downwards, away from sidewall205, with one of the sloped portions of floor sheet815resting on top of this second side. Gussets810may transfer the vertical load of coils125, transported within trough820, into sidewalls805. While illustrated as including nineteen gussets810on each side of trough820, this disclosure contemplates that modular longitudinal coil car top800may include any number of gussets810.

Similar to the modular transverse coil car tops described above, modular longitudinal coil car top800may couple to a common underframe using coupling apparatuses205, as described in further detail below, in the discussion ofFIGS.9through11. Modular longitudinal coil car top800may include any number of coupling apparatuses205. For example, as illustrated inFIG.8A, modular longitudinal coil car top800may include two pairs of coupling apparatuses205-afirst pair of coupling apparatuses205located near a first end of modular longitudinal coil car top800and a second pair of coupling apparatuses205located near a second end of modular coil car top800.

While illustrated inFIGS.8A and8Bas including one longitudinal trough820, this disclosure contemplates that modular longitudinal coil car top800may include any number of longitudinal troughs820. Additionally, in certain embodiments, modular coil car top800may include a combination of longitudinal and transverse troughs.

As described above, modular coil car tops200,500,600,700, and800may couple to a common underframe.FIGS.9A and9Bpresent example embodiments of common underframe900. As illustrated inFIGS.9A and9B, common underframe900includes center sill235. As described above, in certain embodiments, center sill235is configured to receive vertical loads from coils125transported in the modular coil car tops.

As illustrated inFIG.9A, in certain embodiments, common underframe900includes coupling apparatuses910alocated on bolsters905. For example, common underframe900includes coupling apparatuses910alocated near each end of each bolster905. As illustrated inFIG.9A, the coupling apparatuses910aon first bolster905aare separated from the coupling apparatuses910aon second bolster905bby a longitudinal distance X. Each coupling apparatus910aon underframe900may be configured to couple with a corresponding coupling apparatus205of the modular coil car top of the present disclosure, as described in further detail below, in the discussion ofFIGS.10and11.

In certain embodiments, in addition to or instead of locating coupling apparatuses910aon bolsters905, in certain embodiments, coupling apparatuses may be located on cross-bearers915of common underframe900.FIG.9Billustrates a common underframe900that includes coupling apparatuses910aon bolsters905as well as coupling apparatuses910bon cross-bearers915. For example, common underframe900includes coupling apparatuses910blocated near each end of each cross-bearer915. As illustrated inFIG.9B, the coupling apparatuses910bon first cross-bearer915aare separated from the coupling apparatuses910bon second cross-bearer915bby a longitudinal distance Y, where distance Y is shorter than distance X. Including coupling apparatuses910at multiple locations on common underframe900may enable common underframe900to couple to a variety of different modular tops. For example, a first modular top may be configured to couple to modular underframe900using coupling apparatuses910a, while a second modular top (e.g. a modular top that is shorter than the first modular top) may be configured to couple to modular underframe900using coupling apparatuses910b. Coupling apparatuses910bmay go unused when common underframe900is coupled to a modular top using coupling apparatuses910a. Similarly, coupling apparatuses910amay go unused when common underframe900is coupled to a modular top using coupling apparatuses910b. This disclosure contemplates that common underframe900may include any number of coupling apparatuses910. For example, additional coupling apparatuses910may be added to underframe900by adding additional cross-bearers815to underframe900, with a coupling apparatus910installed near either end of each additional cross-bearer915. In certain embodiments, the positions of coupling apparatuses910may vary transversely across common underframe900to accommodate modular tops of various widths.

This disclosure contemplates that a modular top may be coupled to common underframe900in any suitable manner. As an example, in certain embodiments, the modular top may include one or more apparatuses that are each designed to couple to a corresponding apparatus on the common underframe. For example, in certain embodiments, the modular top may include one or more apparatuses in the form of female portions (e.g., recessed portions), each of which is configured to couple to a corresponding apparatus on common underframe900in the form of a male portion (e.g., protruding portion), coupled to the underframe. In some embodiments, the modular top may include one or more apparatuses in the form of male portions (e.g., protruding portions), each of which is configured to couple to a corresponding apparatus on common underframe900in the form of a female portion (e.g., recessed portion), coupled to the underframe. In such embodiments, the modular top may be configured to be lifted off of/lowered onto common underframe900. When the modular top is lowered onto common underframe900, the male portions of the coupling apparatus slide into the female portions of the coupling apparatus.FIGS.10A through10Dpresent an example coupling apparatus that includes a female coupler portion andFIGS.11A through11Cpresent an example coupling apparatus that includes a male coupler portion, for use in such embodiments.

FIG.10Ais an overhead schematic of a female portion1005of a coupling apparatus, according to some embodiments. Female coupler portion1005includes recessed portion1010for receiving a corresponding male coupler portion. Recessed portion1010is positioned on a surface1015. In certain embodiments in which the coupling apparatus that includes female portion1005is coupled to common underframe900, surface1015includes a surface on common underframe900and/or is coupled to common underframe900. As an example, surface1015may include a surface on a bolster910and/or a cross-bearer915and/or surface1015may be coupled to a bolster910and/or a cross-bearer915. For example, in certain embodiments, female portion1005may be installed, mechanically or otherwise, onto a surface of a bolster910and/or a cross-bearer915. For instance, in certain embodiments, female portion1005may be welded to a surface of a bolster910and/or a cross-bearer915. In some embodiments, a bolster910and/or a cross-bearer915may be formed to integrally include female portion1005. In some embodiments in which the coupling apparatus that includes female portion1005is coupled to modular top200, surface1015includes a surface on the underside of modular top200and/or is coupled to a surface on the underside of modular top200. For example, in certain embodiments, female portion1005may be installed, mechanically or otherwise, onto a surface of the underside of modular top200. For instance, in certain embodiments, female portion1005may be welded to a surface of the underside of modular top200. In some embodiments, female portion1005may be integrally formed together with modular top200.

Female coupler portion1005may be formed from a metal, such as steel, or any other suitable material. For example, in certain embodiments, female coupler portion1005may be formed from the same material as a surface of underframe900. In some embodiments, female coupler portion1005may be formed from the same material as a surface of the underside of modular top200. In certain embodiments, female coupler portion1005may be formed from a different material from the material forming the surface of underframe900and/or the surface forming the underside of modular top200.

FIG.10Bis a cross-section schematic of the female portion1005of the coupling apparatus illustrated inFIGS.10A through10D. The illustrated cross-section is viewed from the line labeled A-A inFIG.10A.FIG.10Cis a side view schematic of the female portion1005of the coupling apparatus illustrated inFIGS.10A through10D.FIG.10Dis another cross-section schematic of the female portion1005of the coupling apparatus illustrated inFIGS.10A through10D. The illustrated cross-section ofFIG.10Dis viewed from the line labeled B-B inFIG.10C.

As illustrated inFIGS.10A through10D, recessed portion1010of female portion1005is of a length l at its longest dimension, a width w at its widest dimension, and a depth d at its deepest dimension. This disclosure contemplates that recessed portion1010of female coupling portion1005may include any recessed geometry. For example, in certain embodiments, recessed portion1010may include a rectangular recessed portion of length l, width w, and uniform depth d. As another example, in certain embodiments (and as illustrated inFIGS.10A through10D), recessed portion1010may include a stadium-shaped recessed portion of uniform depth d, wherein the stadium-shape includes a rectangle of length l−2r, and width w=2r, in which the sides of the rectangle along the direction of its length are capped with semicircles of radius r. In certain other embodiments, recessed portion1010may include a rectangular geometry or a stadium-shaped geometry, with non-uniform depth d. For example, in certain such embodiments, recessed portion1010may include a taper in the direction away from surface1015, such that a length of recessed portion1010, measured at depth d (e.g., the bottom of recessed portion1010), and a width of recessed portion1010, measured at depth d, are smaller that length l and width w, measured at surface1015.

FIG.11Ais an overhead schematic of a male portion of a coupling apparatus, according to some embodiments. Male coupler portion1105includes protruding portion1110for fitting into a corresponding recessed portion1010of female coupler portion1005. Protruding portion1110is positioned on a surface1115. In certain embodiments in which the coupling apparatus that includes male portion1105is coupled to common underframe900, surface1115includes a surface on common underframe900and/or is coupled to common underframe900. As an example, surface1115may include a surface on a bolster910and/or a cross-bearer915and/or surface1115may be coupled to a bolster910and/or a cross-bearer915. For example, in certain embodiments, male portion1105may be installed, mechanically or otherwise, onto a surface of a bolster910and/or a cross-bearer915. For instance, in certain embodiments, male portion1105may be welded to a surface of a bolster910and/or a cross-bearer915. In some embodiments, a bolster910and/or a cross-bearer915may be formed to integrally include male portion1105. In some embodiments in which the coupling apparatus that includes male portion1105is coupled to modular top200, surface1115includes a surface on the underside of modular top200and/or is coupled to the underside of modular top200. For example, in certain embodiments, male portion1105may be installed, mechanically or otherwise, onto a surface of the underside of modular top200. For instance, in certain embodiments, male portion1105may be welded to a surface of the underside of modular top200. In some embodiments, male portion1105may be integrally formed together with modular top200.

Male coupler portion1105may be formed from a metal, such as steel, or any other suitable material. For example, in certain embodiments, male coupler portion1105may be formed from the same material as a surface of common underframe900. In some embodiments, male coupler portion1105may be formed from the same material as a surface of the underside of modular top200. In certain embodiments, male coupler portion1105may be formed from a different material from the material that forms the surface of common underframe900and/or the surface forming the underside of modular top200.

The protruding portion1110of male coupler portion1105is sized to fit within the recessed portion1010of female coupler portion1005. In particular embodiments, protruding portion1110may be sized somewhat smaller than recessed portion1010. For example, in certain embodiments, protruding portion1110may be between 1/16 to 1 inch smaller than recessed portion1010. The use of a smaller protruding portion1110, as compared to the corresponding recessed portion1010, may help to facilitate slippage (longitudinally and/or transversely) between modular top200and underframe900. This slippage may prevent or reduce action loads from transferring to modular top200from underframe900and/or lading loads from transferring from modular top200to underframe900. In certain embodiments, the use of a smaller protruding portion1110, as compared to the corresponding recessed portion1010, may also help to enable easy installation of modular top200onto underframe900.

FIG.11Bis a side view schematic of the male coupler portion1105of the coupling apparatus illustrated inFIGS.11A through11C.FIG.11Cis a cross-section schematic of the male coupler portion1105of the coupling apparatus illustrated inFIGS.11A through11C. The illustrated cross-section ofFIG.11Cis viewed from the line labeled A-A inFIG.11B.

As illustrated inFIGS.11A through11C, protruding portion1110is of a length L at its longest dimension, a width W at its widest dimension, and a height H at its tallest dimension. This disclosure contemplates that protruding portion1110of male coupler portion1105may include any protruding geometry capable of fitting into recessed portion1010of female portion1005. For example, in certain embodiments, protruding portion1110may include a rectangular-shaped protruding portion of length L, width W, and uniform height H, where L is somewhat less than l, W is less than w, and H is less than d, where l, w, and d define dimensions of recessed portion1010, as described above, in the discussion ofFIGS.10A through10D. As another example, in certain embodiments, protruding portion1110may include a stadium-shaped protruding portion of uniform height H, wherein the stadium-shape includes a rectangle of length L−2R, and width W=2R, in which the sides of the rectangle along the direction of its length are capped with semicircles of radius R, and R is less than r, where r defines a dimension of recessed portion1010, as described above, in the discussion ofFIGS.10A through10D. In certain embodiments, protruding portion1110may include a rectangular geometry or a stadium-shaped geometry, with non-uniform height H. For example, in certain such embodiments, protruding portion1110may include a taper in the direction away from surface1115, such that a length of protruding portion1110, measured at height H (e.g., the top of protruding portion1110), and a width of protruding portion1110, measured at height H, are smaller than length L and width W, measured at surface1115.

Under normal operating conditions, the weight of modular top200may be enough to keep the male portion1105of a coupling apparatus that is installed on modular top200coupled to the female portion1005of a corresponding coupling apparatus installed on underframe900and/or to keep the female portion1005of a coupling apparatus that is installed on modular top200coupled to the male portion1105of a corresponding coupling apparatus that is installed on underframe900. Particular embodiments may include one or more fasteners configured to keep male portion1105coupled to female portion1005. Each fastener may include a nut and bolt, or any other suitable fastener. One or more fasteners prevent or resist separation of modular top200from common underframe900under particular conditions including, for example, an emergency condition such as a derailment.

In operation, a railyard operator may use a crane, hoist, or any other suitable equipment or machinery to couple or decouple modular top200to/from common underframe900.FIGS.12A and12Billustrate the use of a hoist1205to lift modular coil car top200. As illustrated inFIGS.12A and12B, hoist1205may be coupled to modular top200at attachments1210. Attachments1210are coupled to side sills240. For example, a first attachment1210may be coupled to side sill240near a first end of side sill240and a second attachment1210may be couple to side sill240near a second end of side sill240. In certain embodiments, modular tops200may be loaded with coils125prior to being lifting onto common underframe900. Similarly, loaded modular tops200may be decoupled from common underframe900and lifted off of common underframe900prior to being unloaded. In this manner, when a modular coil railcar arrives at a loading station a hoist1205may be used to lift a first loaded modular top200off of common underframe900, and a hoist1205may be used to lift a second loaded modular top200onto common underframe900. In certain embodiments, this may increase the efficiency of the loading/unloading process, by reducing the time used to load the coil railcar.

FIG.13presents an example method1300(described in conjunction withFIGS.2A through2D,8A,8B,9A,9B,10A through10D, and11A through11C) for operating the modular coil railcar of the present disclosure. In step1302a first modular coil car top200/800is removed from a common underframe900. In certain embodiments, first modular coil car top200/800is holding a first set of coils. Removing the first modular coil car top from the common underframe includes disengaging one or more coupling apparatuses (e.g., male coupler portion1105and/or female coupler portion1005) of first modular coil car top200/800from one or more coupling apparatuses (e.g., female coupler portion1005and/or male coupler portion1105). In certain embodiments, a crane and/or hoist may be used to remove first modular coil car top200/800from common underframe900. In certain embodiments in which first modular top is transporting the first set of coils, the coils may be removed from first modular top200/800prior to removing the top from underframe900. In some embodiments, the coils are removed from first modular top200after the top is removed from underframe900.

In step1304one or more coils of material are loaded into a second modular coil car top200/800. For example, a forklift or other equipment may be used to load coils into second modular coil car top200/800. In step1306second modular coil car top200/800is placed on top of common underframe900. Placing second modular coil car top200/800on top of common underframe900may include engaging one or more coupling apparatuses (e.g., male coupler portion1105and/or female coupler portion1005) of second modular coil car top200/800with one or more coupling apparatuses (e.g., female coupler portion1005and/or male coupler portion1105). In certain embodiments, a crane and/or hoist may be used to lift second modular coil car top200/800onto common underframe900. In some embodiments, steps1304and1306are performed in the opposite order. For example, coils may be loaded into second modular coil car top200/800after the top has been placed on top of common underframe900.

Second modular coil car top200/800may be the same or a different type of top as first modular coil car top200/800. For example, first modular coil car top may be a transverse coil car top200that is configured to hold N coils, or a longitudinal coil car top800that is configured to hold M coils. Similarly, second modular coil car top may be a transverse coil car top200that is configured to hold P coils, or a longitudinal coil car top800that is configured to hold R coils, where P is the same or a different number than N, and R is the same or a different number than M.

Modifications, additions, or omissions may be made to method1300depicted inFIG.13. Method1300may include more, fewer, or other steps. For example, steps may be performed in parallel or in any suitable order. One or more steps may be performed by an individual, a machine, any other device, or a combination of the preceding.

FIG.14presents an example method1400(described in conjunction withFIGS.2A through2D,9A,9B,10A through10D, and11A through11C) for manufacturing modular coil car top200. In step1402a set of support members220are installed between a pair of side sills240. When modular coil car top200is placed onto common underframe900, support members220are configured to transfer vertical coil loads into center sill235of common underframe900. In step1404a trough210is installed between each pair of adjacent support members220. Each trough210may be formed from one or more angled sheets of metal225. For example, in certain embodiments, a trough210is formed from a single sheet of metal225that is coupled to a first support member220at a first end and to a second support member220that is adjacent to the first support member at a second end, and includes: (1) a first sloped portion that slopes down and away from the first support member; (2) a horizontal portion which defines the lowest position of the trough; and (3) a second sloped portion that slopes up and towards the second support member. In some embodiments, a trough210is formed from two sheets of metal that overlap one another at the bottom of the trough. Each sheet of metal225may be coupled to one or more support members220in any suitable manner. For example, in certain embodiments, the sheet of metal is welded to the top of support member220.

In step1406support gussets230are installed on modular coil car top200. Each gusset230is coupled to a support member220, and extends from support member220in a generally perpendicular direction. Gussets230may be coupled to support members220in any suitable manner. For example, in certain embodiments, gussets230are welded to support members220. Installing gussets230in modular coil car top200after installed metal floor sheets225may be desirable to taking into account various manufacturing tolerances. For example, installing gussets230after metal floor sheets225may help to ensure that the gussets230are able to fully support floor sheets225while at the same time being securely attached to support members220.

In step1408one or more coupling apparatuses are installed on the underside of modular top200. Each coupling apparatus is configured to engage a corresponding coupling apparatus of common underframe900. For example, each coupling apparatus may include a female portion1005and/or a male portion1105that is configured to engage a corresponding male portion1105and/or a female portion1005of a coupling apparatus of underframe900. In certain embodiments, installing the one or more coupling apparatuses includes welding the coupling apparatuses to the underside of modular coil car top200.

Modifications, additions, or omissions may be made to method1400depicted inFIG.14. Method1400may include more, fewer, or other steps. For example, steps may be performed in parallel or in any suitable order. One or more steps may be performed by an individual, a machine, any other device, or a combination of the preceding.

Although the present disclosure includes several embodiments, a myriad of changes, variations, alterations, transformations, and modifications may be suggested to one skilled in the art, and it is intended that the present disclosure encompass such changes, variations, alterations, transformations, and modifications as falling within the scope of the appended claims.