Flange bearing frog crossing

The invention may be described as including a crossing panel assembly for a railway intersection, as well as a rail intersection design and a frog casting therefor. The present invention may be used for single and multiple crossings as will be appreciated from the description and drawings. The invention may be described as including a crossing panel assembly for a railway intersection, as well as a rail intersection design and a frog casting therefor. The present invention may be characterized as a frog containing panel system assembled with an array of castings that form a full flange bearing crossing to provide a rail intersection.

FIELD OF THE INVENTION

The present invention relates to a railroad track and crossing assemblies.

BACKGROUND OF THE INVENTION

The present invention relates to a crossing assembly for a railway crossing panel. A railway crossing is employed where one track crosses another.

Typically, railroad crossing components are some of the highest maintenance portions of a railroad track arrangement as they must endure repetitive impact and stress.

In prior art arrangement, relatively large frog castings are used to lift the wheels to a height necessary to allow the wheels of a train to cross a main line rail. When the wheels cross the gap they generate impacts that adversely affect the frog, wheels, and the track structure. Although each of the foregoing designs is workable, an improved design that further reduces the railroad maintenance would be desirable.

In providing for rail crossing, it is important to accommodate several aspects relating to the main line running and the crossing rail line.

In order to allow the train car wheel set to cross over a main line rail, it must be raised to a height to allow it to cross the near main running rail, maintained securely at that height to cross the far main running rail and then securely returned to the base running height along the rail course and without causing excessive repetitive bounce typically experienced in prior crossing arrangements.

Typically this is accomplished by using a frog casting disposed between and on either side of the main line rails. These castings are designed to lift the wheel, direct it through the transition zone over both main line rails, and capture the wheel, allowing it to relax to the established rail elevation. For these purposes, the dual frogs are specially cast and custom machined to provide the required shaping, such as that to provide the required ramping and channeling for support and capture of the wheel tread and flange, to be able to firmly and accurately provide mechanical action under high strain and impact conditions.

It is advantageous to be able to provide this mechanical action with reduced expense and effort associated with the production of relatively expensive multiple castings that require custom machining that are customary in the industry. In this regard, frog castings typically incorporate ramping in the design of the main body casting that require rather complex post-casting machining, and it is beneficial to reduce or eliminate complex ramping within the body of the casting.

It is also best to provide a uniform, unbroken wheel path that distributes load and reduces wheel and frog wear, such as may be accomplished by providing a horizontal or otherwise linearly regular wheel path that is not interrupted by wheel-to-rail interface.

Typically frog casting systems must incorporate all of the required ramping with the length of the casting, which requires relatively larger castings to distribute the ramping length to reduce inertial bounce as the wheel sets pass over the main line rail. This makes typical frog casting systems relatively large and expensive. Accordingly, it would be beneficial to reduce the overall casting size, and thereby reduce the initial cost of frog production while at the same time reducing the cost of attendant repair and maintenance.

One type of frog casting used for crossings is the so-called full flange bearing frog that operates by engaging the flange of each of the wheels in a wheel set and raising the wheel set as the wheels ride on their flanges (rather than on their treads) to a crossing height, and are maintained at that height. This type of system offers several advantages such as the use of the wheel flanges as the weight-bearing portion of the wheel, which are not subject to as much reduction in outer diameter as the tread bearing surface over the lifetime of the wheel, thus presenting a more regular bearing surface to the casting.

One of the problems associated with full flange bearing frog castings is that they must be incorporated into a system where all or substantially all of the crossing is constructed of interlocking castings such that they form intersecting continuous flange ways. Accordingly, these castings are relatively large and expensive as compared to crossing systems that incorporate rails or other tread bearing structures.

In addition, full flange bearing frog castings must endure very high stress and impact, reducing their lifetime. Because the replacement costs of such large castings are very high, it is desirable to provide a casting and overall panel set-up that accommodates long-term wear while lowering overall costs of use in terms of lengthening the operational lifetime of the casting within the panel.

It is also beneficial to provide a crossing system that may be made and installed simply, while also being adapted for prefabrication and installation, and one that is relatively easy to assemble and repair. In this regard, it is desirable to eliminate multiple castings, make their production easier and less expensive, and provide frog panels that are adapted to reduce overall track and crossing wear associated with long term use, and that accommodate changes in wheel geometry as wheel degradation occurs over the wheel's operational life cycle.

The embodiments of the invention described herein address the shortcomings of the prior art.

SUMMARY OF THE INVENTION

In general terms, the invention may be described as including a crossing panel assembly for a railway intersection, as well as a rail intersection design and a frog casting therefor.

The present invention may be used for single and multiple crossings as will be appreciated from the description and drawings.

The present invention may be characterized as a frog containing panel system, and the frog and rail intersection used therein.

The present invention thus provides several concomitant advantages over the prior art. The system of the present invention allows the required ramping for the approaching wheel set to be presented by the flange way floor while also allowing a substantial portion of the run of the tread-bearing surface of the approaching wheel to be borne by the associated rail, rather than by the corresponding upper surface (i.e., the tread-bearing surface) of the frog casting. In addition, the castings and their arrangement allow the tread-bearing surface of the approaching wheel to be borne by the tread-bearing surface of the associated rail along a substantial portion of the run-up distance such that, as the flange way floor wears over time, the tread-bearing surface of the associated rail astride the worn section will continue to provide tread-borne support for the wheel as it must travel deeper into the flange way until the wheel flange is encountered by a relatively more downstream portion of the flange way floor.

The present invention also includes a crossing panel system which may be assembled as a complete unit at a manufacturing site and transported to its intended installation site. This allows for greater control of manufacturing costs and allows the operator to obtain a completed crossing panel that may be produced using relatively small and simple frog castings that can be installed on site, and castings that can be assembled into a fully flange-bearing crossing arrangement.

In operation, the system of the present invention also provides for an unbroken wheel path that is substantially a horizontal or otherwise linearly regular wheel path and that is not interrupted by wheel to rail interface. Rather, it accepts and allows the wheel set to move through the respective intersecting main line or crossing line flange ways. In this same regard, it will be understood that reference to main line and crossing line, or first line and second line, may be somewhat redundant as the subject crossing arrangement does not feature a classic pass-over main line and crossing line arrangement as in typical tread-bearing crossings.

Rail crossing systems of the present invention may be incorporated with canted rail systems that allow for speeds as high as 50-60 mph where desirable.

The several aspects of the present invention may be summarized as follows.

In general terms the present invention includes castings and a panel arrangement, as well as a crossing constructed thereby.

Full Flange Bearing Rail Crossing Frog and Single Rail Arrangement

In general terms, the invention includes a full flange bearing rail crossing frog and rail arrangement comprising: (a) a frog casting comprising: (i) a main line body portion having a top surface and comprising a main line flange way having: (1) a main line flange way floor, and (2) opposed main line flange way lateral wall portions; (ii) a crossing line body portion having a top surface and comprising a crossing line flange way having: (1) an intersection portion of the crossing line flange way having: (a) a crossing line flange way floor; (b) a crossing line internal lateral wall portion; and (c) a crossing line external lateral wall portion; and (2) a lead portion of the crossing line flange way having: (a) a crossing line flange way floor; (b) a crossing line internal lateral wall portion; and (c) an open crossing line external lateral side; the main line flange way and the crossing line flange way forming an intersection at an intersection level; and a crossing rail having a crossing rail tread bearing surface, the crossing rail disposed along the open crossing line external lateral side, and adjacent the crossing line body portion top surface, such that the crossing rail tread bearing surface is vertically aligned with the crossing line body portion top surface.

The frog casting preferably comprises a first section comprising the main line body portion and the intersection portion of the crossing line flange way, and a second section comprising the lead portion of the crossing line flange way.

The crossing line flange way floor of the lead portion of the crossing line flange way is angled so as to raise the flange of a rail car wheel rolling therethrough from a lower level to a higher level of that of the intersection portion of crossing line flange way.

The present invention may also be considered to include a full flange bearing rail crossing frog and rail arrangement comprising: (a) a frog casting comprising: (i) a main line body portion having a top surface and comprising a main line flange way having a main line flange way floor and opposed main line flange way lateral wall portions; and (ii) a crossing line body portion having a top surface and comprising a crossing line flange way, the crossing line flange way comprising: (1) a crossing line flange way floor and (2) a crossing line internal lateral wall portion; and (3) an open crossing line external lateral side; and wherein the main line flange way and the crossing line flange way forming an intersection at an intersection level; and (b) a crossing rail having a crossing rail tread bearing surface, the crossing rail disposed along the open crossing line external lateral side, and adjacent the crossing line body portion top surface, such that the crossing rail tread bearing surface is vertically aligned with the crossing line body portion top surface. It is preferred that the crossing rail has a terminal end abutting the crossing line tread bearing portion at an angle in the range of from about 50 degrees to about 70 degrees from the crossing line flange way floor.

The crossing line flange way floor typically has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the crossing rail to the intersection level. The rise and run will be determined based upon the desired load and operating speeds, and typically will be in the range of from about 50 degrees to about 70 degrees from the horizontal.

It is also preferred that the open crossing line external lateral side be open through a substantial portion of the overall running length of the flange way from the initially encountered (i.e., distal) end to the intersection point. Preferably, the open-sided external lateral side will represent at least 50 percent, preferably between 60 and 90 percent, and most preferably between 75 and 85 percent of the overall flange way distance.

The frog casting may be manufactured as a single casting, but preferably, owing to manufacturing efficiencies, may be made and assembled from more than one casting, such as in the preferred embodiment which includes a central intersection portion and an extension portion.

Full Flange Bearing Rail Crossing Frog and Single Crossing Rail and Single Main Rail Arrangement

The present invention may also be understood as including a full flange bearing rail crossing frog with a single crossing rail and single main rail arrangement. This aspect of the invention may be described as a full flange bearing rail crossing frog and rail arrangement comprising: (a) a frog casting comprising: (i) a main line body portion having a main line top surface and a main line flange way, the main line flange way comprising: (1) a main line flange way floor and (2) a main line internal lateral wall portion; and (3) a main line open external lateral side; and (ii) a crossing line body portion having a crossing line top surface and a crossing line flange way, the crossing line flange way comprising: (1) a crossing line flange way floor and (2) a crossing line internal lateral wall portion; and (3) a crossing line open external lateral side; the main line flange way floor and the crossing line flange way floor forming an intersection at an intersection level; and (b) a crossing rail having a crossing rail tread bearing surface, the crossing rail disposed along the open crossing line external lateral side, and adjacent the crossing line body portion top surface, such that the crossing rail tread bearing surface is vertically aligned with the crossing line body portion top surface; and (c) a main rail having a main rail tread bearing surface, the main rail disposed along the open main line external lateral side, and adjacent the main line body portion top surface, such that the main rail tread bearing surface is vertically aligned with the main line body portion top surface.

It is preferred that the crossing rail has a terminal end abutting the crossing line tread bearing portion at an angle in the range of from about 50 degrees to about 70 degrees from the crossing line flange way floor, and likewise that the main rail has a terminal end abutting the main line tread bearing portion at an angle in the range of from about 50 degrees to about 70 degrees from the main line flange way floor.

It is preferred that the crossing line flange way floor has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the crossing rail to the intersection level, and likewise that the main line flange way floor has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the main rail to the intersection level.

Both the crossing line flange way floor and the main line flange way floor typically have an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the crossing rail to the intersection level. The rise and run will be determined based upon the desired load and operating speeds, and typically will be in the range of from about 1 to 3 inches in about 4-6 feet, from the horizontal, preferably about 1.5 inches in about 4 feet.

It is also preferred that the open crossing and main line external lateral sides be open through a substantial portion of the respective overall running length of the flange way from the initially encountered (i.e., distal) end to the intersection point. Preferably, the open-sided external lateral side will represent at least 50 percent, preferably between 60 and 90 percent, and most preferably between 75 and 85 percent of the overall flange way distance.

The frog casting may be manufactured as a single casting, but preferably, owing to manufacturing efficiencies, may be made and assembled from more than one casting, such as in the preferred embodiment which includes a central intersection portion and two respective crossing line extension portions.

Full Flange Bearing Rail Crossing Frog and Rail Intersection Arrangement—Two Main Rails and Two Crossing Rails

It is preferred that the crossing rail has a terminal end abutting the crossing line tread bearing portion at an angle in the range of from about 50 degrees to about 70 degrees from the crossing line flange way floor, and likewise that the main rail has a terminal end abutting the main line tread bearing portion at an angle in the range of from about 50 degrees to about 70 degrees from the main line flange way floor.

It is preferred that the crossing line flange way floor has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the crossing rail to the intersection level, and likewise that the main line flange way floor has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the main rail to the intersection level.

Both the crossing line flange way floor and the main line flange way floor typically have an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the crossing rail to the intersection level. The rise and run will be determined based upon the desired load and operating speeds, and typically will be in the range of from about 1 to 3 inches in about 4-6 feet, from the horizontal, preferably about 1.5 inches in about 4 feet.

It is also preferred that the open crossing and main line external lateral sides be open through a substantial portion of the respective overall running length of the flange way from the initially encountered (i.e., distal) end to the intersection point. Preferably, the open-sided external lateral side will represent at least 50 percent, preferably between 60 and 90 percent, and most preferably between 75 and 85 percent of the overall flange way distance.

The frog casting may be manufactured as a single casting, but preferably, owing to manufacturing efficiencies, may be made and assembled from more than one casting, such as in the preferred embodiment which includes a central intersection portion and two respective crossing line extension portions.

Full Flange Bearing Rail Crossing Frog Arrangement

Still another aspect of the present invention is a full flange bearing rail crossing frog casting arrangement comprising a planar arrangement of four adjacent frog castings, each frog casting comprising: (i) a main line body portion having a main line top surface and a main line flange way, the main line flange way comprising: (1) a main line flange way floor and (2) a main line internal lateral wall portion; and (3) a main line open external lateral side; and (ii) a crossing line body portion having a crossing line top surface and a crossing line flange way, the crossing line flange way comprising: (1) a crossing line flange way floor and (2) a crossing line internal lateral wall portion; and (3) a crossing line open external lateral side; the main line flange way floor and the crossing line flange way floor forming an intersection at an intersection level; and wherein each frog casting arranged such that respective adjacent main line flange way floors are aligned and adjacent crossing line flange way floors are aligned.

A full flange bearing rail crossing frog casting arrangement comprising a planar arrangement of four adjacent frog castings, each frog casting comprising: (i) a main line body portion having a top surface and comprising a main line flange way having: (1) a main line flange way floor, and (2) opposed main line flange way lateral wall portions; (ii) a crossing line body portion having a top surface and comprising a crossing line flange way having: (1) an intersection portion of the crossing line flange way having: (a) a crossing line flange way floor; (b) a crossing line internal lateral wall portion; and (c) a crossing line external lateral wall portion; and (2) a lead portion of the crossing line flange way having: (a) a crossing line flange way floor; (b) a crossing line internal lateral wall portion; and (c) an open crossing line external lateral side; the main line flange way floor and the crossing line flange way floor forming an intersection at an intersection level; and wherein each frog casting arranged such that respective adjacent main line flange way floors are aligned and adjacent crossing line flange way floors are aligned.

In a preferred embodiment, the frog casting comprises a first section comprising the main line body portion and the intersection portion of the crossing line flange way, and a second section comprising the lead portion of the crossing line flange way.

Each crossing line flange way floor of the lead portion of each respective crossing line flange way is angled so as to raise the flange of a rail car wheel rolling therethrough from a lower level to a higher level of that of the intersection portion of crossing line flange way. Likewise, it is preferred that each crossing line flange way floor has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the crossing rail to the intersection level.

It is also preferred that each casting has a crossing rail abutting surface at an angle in the range of from about 50 degrees to about 70 degrees from the crossing line flange way floor, and that each casting has a main rail abutting surface at an angle in the range of from about 50 degrees to about 70 degrees from the main line flange way floor.

Preferably each main line flange way floor has an inclined portion adapted to raise the flange of a wheel approaching the frog casting from the main rail to the intersection level.

It will be understood that all disclosed features of the present invention may be utilized to the extent that they are not logically inconsistent with one another.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In accordance with the foregoing summary, the following describes a preferred embodiment of the present invention which is considered to be the best mode thereof. With reference to the drawings, the invention will now be described in detail with regard for the best mode and preferred embodiment.

FIGS. 1-23show, using like reference numerals, a full flange bearing rail crossing frog casting and crossing assembly, in accordance with one embodiment of the present invention.

FIG. 1shows a plan view of a center full flange bearing rail crossing frog casting1in accordance with the preferred embodiment of the present invention.

This frog will be part of a full flange bearing rail crossing frog casting arrangement of the present invention as described herein and comprising a planar arrangement of four adjacent frog castings.

The center crossing frog casting1comprises a crossing line body portion2(that will extend within the main line way, in direction A, and outside the main line way, in direction B, once the arrangement is assembled), having a crossing line top surface2aand a crossing line flange way2b, the crossing line flange way comprising: (1) a crossing line flange way floor2cand (2) a crossing line internal lateral wall portion2d; and (3) a crossing line open external lateral side2e.

The center crossing frog casting1also comprises a main line body portion3(that will extend within the crossing line way, in direction C, and outside the crossing line way, in direction D, once the arrangement is assembled) having a main line top surface3aand a main line flange way3b, the main line flange way comprising: (1) a main line flange way floor3cand (2) a main line internal lateral wall portion3d; and (3) a main line open external lateral side3e.

The crossing line flange way floor2cand the main line flange way floor3cform an intersection4at an intersection level.

The center crossing frog casting1is adapted to be provided with spaces alongside crossing line open external lateral side2eand the main line open external lateral side3ethat accommodate the placement of a respective rail such that such respective rail may be placed astride the respective flange way floors, so as to form an external lateral flange way wall opposite the corresponding internal lateral wall portion.FIG. 1also shows the respective casting faces2fand3fthat conform to the corresponding shape of the terminal end of the rail may be placed astride the respective flange way floors. This angle is typically an angle in the range of from about 45 to 80 degrees, preferably about 60 degrees, as measured from the line of the associated flange way.

FIG. 2shows an elevation view of a center full flange bearing center crossing frog casting1, taken along line2-2ofFIG. 1, in accordance with the preferred embodiment of the present invention. In this Figure, like reference numerals used inFIG. 1refer to the same features. In this view, one can see in more detail the shape and arrangement of the main line top surface3a, the main line flange way3b, the main line flange way floor3c, the main line internal lateral wall portion3d, and the main line open external lateral side3e. From this view one may also appreciate the extent of main line body portion2, and the relative height of main line top surface2a. This view also shows the position of internal joint holes5and external joint holes6that allow the casting to be produced and assembled as two pieces, with an additional extension piece that extends the continuous main line flange way construct from the end of the casting, as shown in the other Figures.

FIG. 3shows an elevation view of a center full flange bearing center crossing frog casting1, taken along line A-A ofFIG. 1, in accordance with the preferred embodiment of the present invention. In this Figure, like reference numerals used inFIG. 1refer to the same features. This Figure shows the extent of main line body portion3with crossing line top surface2aand the crossing line flange way floor2cof the crossing line flange way2b. From this view one may also appreciate the position of internal joint holes7and external joint holes8that allow the casting to be produced and assembled as two pieces, with an additional extension piece that extends the continuous crossing line flange way construct from the end of the casting, as shown in the other Figures.

FIG. 4shows an isomeric perspective view of a center full flange bearing center crossing frog casting1, taken approximately along the direction of line4-4ofFIG. 1. In this Figure, like reference numerals used inFIG. 1refer to the same features. In this view one can appreciate the relative size and orientation of the crossing line body portion2(that will extend within the crossing line way, in direction A, and outside the crossing line way, in direction B, once the arrangement is assembled) having a crossing line top surface2aand a crossing line flange way2b, the crossing line flange way comprising: (1) a crossing line flange way floor2cand (2) a crossing line internal lateral wall portion2d; and (3) a crossing line open external lateral side2e. Also shown is the main line body portion3(that will extend within the crossing line way, in direction C, and outside the crossing line way, in direction D, once the arrangement is assembled) having a main line top surface3aand a main line flange way3b, the main line flange way comprising: (1) a main line flange way floor3cand (2) a main line internal lateral wall portion3d; and (3) a main line open external lateral side3e.

The crossing line flange way floor2cand the main line flange way floor3cform an intersection4at an intersection level.

The center crossing frog casting1is adapted to be provided with spaces alongside crossing line open external lateral side2eand the main line open external lateral side3ethat accommodate the placement of a rail such each may reside astride the respective flange way floors, so as to form an external lateral flange way wall opposite the corresponding internal lateral wall portion.

FIG. 5shows a plan view of an end full flange bearing rail crossing frog casting11in accordance with the preferred embodiment of the present invention.

This frog will be part of a full flange bearing rail crossing frog casting arrangement of the present invention as described herein and comprising a planar arrangement of four adjacent frog castings.

The crossing frog casting11comprises a main line body portion12(that will extend within the crossing line way, in direction A, and outside the crossing line way, in direction B, once the arrangement is assembled) having a crossing line top surface12aand a crossing line flange way12b, the crossing line flange way comprising: (1) a crossing line flange way floor12cand (2) a crossing line internal lateral wall portion12d; and (3) a crossing line open external lateral side12e.

The crossing frog casting11also comprises a main line body portion13(that will extend within the crossing line way, in direction C, and outside the crossing line way, in direction D, once the arrangement is assembled), and having a main line top surface13aand a main line flange way13b, the main line flange way comprising: (1) a main line flange way floor13cand (2) a main line internal lateral wall portion13d; and (3) a main line open external lateral side13e.

The crossing line flange way floor12cand the main line flange way floor13cform an intersection14at an intersection level.

The rail crossing frog casting11is adapted to be provided with spaces alongside the crossing line open external lateral side12eand the main line open external lateral side13ethat accommodate the placement of a rail such that it may reside astride the respective flange way floors, so as to form an external lateral flange way wall opposite the corresponding internal lateral wall portion.

FIG. 5also shows the respective casting faces12fand13fthat conform to the corresponding shape of the terminal end of the rail may be placed astride the respective flange way floors.

FIG. 5ais a cross section view taken along line A-A ofFIG. 5, showing in more detail the shape of an end full flange bearing casting11, and wherein like reference numerals used inFIG. 5refer to the same features.

FIG. 5bis a cross section view taken along line B-B ofFIG. 5, showing in more detail the shape of an end full flange bearing casting11, and wherein like reference numerals used inFIG. 5refer to the same features.

FIG. 5cis a cross section view taken along line C-C ofFIG. 5, showing in more detail the shape of an end full flange bearing casting11, and wherein like reference numerals used inFIG. 5refer to the same features.

FIG. 5dis a cross section view taken along line F-F ofFIG. 5, showing in more detail the shape of an end full flange bearing casting11, and wherein like reference numerals used inFIG. 5refer to the same features.

FIG. 5eis a cross section view of detail E ofFIG. 5a, showing in more detail the shape of an end full flange bearing casting11, and wherein like reference numerals used inFIG. 5refer to the same features.

FIG. 6shows an elevation view of an end full flange bearing rail crossing frog casting11, taken along line6-6ofFIG. 5, in accordance with the preferred embodiment of the present invention. In this Figure, like reference numerals used inFIG. 5refer to the same features. In this view, one can see in more detail the shape and arrangement of the main line top surface13a, the main line flange way13b, the main line flange way floor13c, the main line internal lateral wall portion13d, and the main line open external lateral side13e. From this view one may also appreciate the extent of crossing line body portion12, and the relative height of crossing line top surface12a. This view also shows the position of internal joint holes15and external joint holes16that allow the casting to be produced and assembled as two pieces, with an additional extension piece that extends the continuous crossing line flange way construct from the end of the casting, as shown in the other Figures.

FIG. 7shows an elevation view of a center full flange bearing rail crossing frog casting11, taken along line C-C ofFIG. 5, in accordance with the preferred embodiment of the present invention. In this Figure, like reference numerals used inFIG. 5refer to the same features. This Figure shows the extent of main line body portion13with main line top surface13aand the main line flange way floor13cof the main line flange way13b. From this view one may also appreciate the position of internal joint holes17and external joint holes18that allow the casting to be produced and assembled as two pieces, with an additional extension piece that extends the continuous crossing line flange way construct from the end of the casting, as shown in the other Figures.

FIG. 8shows an isomeric perspective view of a center full flange bearing frog casting11, taken approximately along the direction of line8-8ofFIG. 5. In this Figure, like reference numerals used inFIG. 5refer to the same features. In this view one can appreciate the relative size and orientation of the crossing line body portion12(that will extend within the crossing line way, in direction A, and outside the crossing line way, in direction B, once the arrangement is assembled) having a crossing line top surface12aand a crossing line flange way12b, the crossing line flange way comprising: (1) a crossing line flange way floor12cand (2) a crossing line internal lateral wall portion12d; and (3) a crossing line open external lateral side12e. Also shown is the main line body portion3(that will extend within the crossing line way, in direction C, and outside the crossing line way, in direction D, once the arrangement is assembled) having a crossing line top surface13aand a crossing line flange way13b, the crossing line flange way comprising: (1) a crossing line flange way floor13cand (2) a crossing line internal lateral wall portion13d; and (3) a crossing line open external lateral side3e.

The crossing line flange way floor12cand the crossing line flange way floor13cform an intersection14at an intersection level.

The center full flange bearing frog casting11is adapted to be provided with spaces alongside crossing line open external lateral side12eand the crossing line open external lateral side13ethat accommodate the placement of a rail such that it may be placed astride the respective flange way floors, so as to form an external lateral flange way wall opposite the corresponding internal lateral wall portion.

FIG. 8also shows the respective casting faces12fand13fthat conform to the corresponding shape of the terminal end of the rail may be placed astride the respective flange way floors.

FIG. 9is a cross section view taken along line D-D ofFIG. 6.

FIG. 10is a detailed plan view of a portion of a crossing panel constructed using two end full flange bearing castings11and11a, which are mirror images of one another, as are the respective extension portions110and110athat extend respectively therefrom, and secured to one another, respectively, by bolts112and plate113and by bolts112aand plate113a. The two end full flange bearing castings11and11aare secured to one another by bolts112and plate113.

Alongside these extension portions110and110aare laid crossing rails111and111a. As an example, rail111is laid alongside and secured to end full flange bearing casting11and extension portion110such that it in essence closes the open lateral side of the flange way2b(to form a second side of a completely walled flange way along opposite internal lateral wall portion2dand along open external lateral side2e), and such that its tread bearing surface is at substantially the same height as top surface2a. Rail111is laid alongside and secured to end full flange bearing casting11aand extension portion110ain like manner.

As may be appreciated fromFIG. 10, as the flange way floor wears from repetitive contact with rail wheels sets progressing along path A, the flange way will become progressively worn deeper into the flange way. As this occurs, one of the benefits of the present invention is that the tread bearing surface of the rail adjacent to the worn flange way will be able to bear the wheel in a tread-bearing disposition, rather than the upper surface of the casting itself (as in prior art designs).

In addition, one of the advantages of the multi-piece construction is that the extension portion may be replaced separately, thus further avoiding having to replace an entire large casting. This preferred arrangement thus further extends the lifetime of the crossing panel arrangement through selective replacement of worn extension portions.

The crossing panel typically will be assembled by incorporating the castings into a planar array atop support plates, such as main plate117(which may be comprised of a single plate or multiple plates), and individual tie plates118atop tie119.

FIG. 11is a detailed plan view of a portion of a crossing panel as shown inFIG. 10, and showing in more detail a portion of the panel assembly comprising end full flange bearing casting11, extension portion110, bolts112and plate113, and rail111. Also shown in this view is extension portion116extending along direction D from end full flange bearing casting11along the main line path, and in position to accept a main line rail beside it in a manner similar to the way rail111is positioned and secured.FIG. 12is a cross section view taken along line B-B ofFIG. 11, and showing in more detail the shape of end full flange bearing casting11.

FIG. 13is a cross section view taken along line A-A ofFIG. 11, and showing in more detail the shape and placement of end full flange bearing casting11and extension portion110.

FIG. 14is a cross section view of detail C ofFIG. 12, and showing in more detail the shape of end full flange bearing casting11.

FIG. 15is a plan view of extension portion110aas shown inFIG. 10. In this Figure, like reference numerals used inFIG. 10refer to the same features. This Figure shows top surface110fand a flange way110b, the flange way comprising: (1) a flange way floor110cand (2) an internal lateral wall portion110dand (3) open external lateral side110e; which portions align with and complement the corresponding portions of the end full flange bearing rail crossing frog casting11aas shown inFIG. 10. The extension portion110amay be attached through the bolts112apassing through plate113aand through apertures110g.

FIG. 16is an elevation view of extension portion110aas shown inFIG. 10. In this Figure, like reference numerals used inFIG. 10refer to the same features.

FIG. 17is a cross section view taken along line A-A ofFIG. 15, and showing in more detail the shape of the extension portion110a.

FIG. 18is a cross section view taken along line B-B ofFIG. 15, and showing in more detail the shape of the extension portion110a.

FIG. 19is a cross section view taken along line C-C ofFIG. 15, and showing in more detail the shape of the extension portion110a.

FIG. 20is a cross section view taken along line D-D ofFIG. 15, and showing in more detail the shape of the extension portion110a.

FIG. 21is an upper perspective view of extension portion110a.

FIG. 22is an end elevation view taken along line E-E ofFIG. 15, and showing the relative position of rail111awhen affixed next to extension portion110a. From this view one can appreciate the relative position of the rail111aand how its inboard side serves to close open external lateral side110e. In addition, one can appreciate that, as flange way110cwears through repetitive impact with wheel flanges, that the tread bearing surface of rail111awill bear in-coming wheels deeper into the casting's travel region, thereby allowing the wheels to be borne by the tread bearing surface of rail111athrough regions where the worn flange way has receded by wear. This arrangement thereby extends the overall lifetime of the casting because the upper surface of the casting is not exposed to impact or wear in regions corresponding to those regions where the worn flange way has receded by wear, which would reduce the overall lifetime of the casting, and require its complete replacement. In addition, the fact that the casting may be rendered in and assembled from two or more pieces reduces overall manufacturing costs while allowing maintenance by replacing only the lead portion (i.e., the extension portion as described herein) to maintain the frog crossing assembly in best operative condition.

FIG. 23is an upper perspective view of an assembled dual track crossing of whichFIG. 10is a partial detail and wherein like reference numerals used inFIG. 10refer to the same features.FIG. 23shows a dual track crossing including a crossing rail line along directions A and B (made up of rails111and111a, intermediate rails121and121a, and rails122and122a) intersecting a first main line along directions C and D (made up of rails123and123a, and rails124and124a), and a second main line along directions E and F (made up of rails125and125a, and rails126and126a). It will be appreciated that intermediate rails121and121amaintain the height of flange-borne wheels at a crossing height as they approach—and pass through—the second intersection (crossing path E-F), following which they are returned to the running height by travelling onto the flange way of the downstream end casting pair, mirroring the action of end full flange bearing castings11and11a.

The crossing panel is constructed using two end full flange bearing castings11and11aand respective extension portions110and110athat extend respectively therefrom. It will be appreciated that wheel sets travelling along direction A will first encounter full flange bearing castings11and11a(or their extension portions110and110awhere provided), and be lifted to a crossing height. In operation, a wheel on a rail approaching an intersection with another rail in the first instance will have its flange engaged by the inclined flange way floor which raises the wheel to a crossing level height at which height it is maintained as it crosses one or more pairs of intersecting rails by traversing the guiding flange way path provided by the assembled castings. Following its transition across the last flange way intersection, the wheel will be returned to its running height by following the trailing incline of the end frog casting.

As shown and described further herein, the each frog casting will arranged such that respective adjacent main line flange way floors are aligned and adjacent crossing line flange way floors are aligned.

It will be appreciated that the end full flange bearing castings11and11awill have an angled flange way floor presented to a travelling wheel when approached from two directions (i.e., along direction A and C for end full flange bearing casting11, and along direction A and D for end full flange bearing casting11), while otherwise the flange ways are substantially level. By contrast, the center full flange bearing castings1and1awill have an angled flange way floor only when approached, respectively, along direction C and D. Otherwise the flange ways of these center castings are substantially level to maintain the wheel at a crossing height.

Where a single crossing is desired, one may be constructed by arranging four end full flange bearing castings, essentially duplicating the arrangement of end full flange bearing castings11and11a, such that an approaching wheel set is raised to a crossing height as it approaches the intersecting line, and then is returned to its running height by following the trailing incline of the far side end frog castings.

FIGS. 24-26show in greater detail the arrangement of a portion of a crossing panel frog arrangement as shown inFIG. 11, and showing in more detail a portion of the panel assembly comprising end full flange bearing casting11, extension portion110, bolts112and plate113, and rail111. Also shown in this view is extension portion116extending along direction D from end full flange bearing casting11along the main line path, and in position to accept a main line rail beside it in a manner similar to the way rail111is positioned and secured.

FIG. 24shows a relatively high angle perspective view of an arrangement of a portion of the full flange bearing crossing arrangement in accordance with one embodiment of the present invention.

This Figure shows end full flange bearing casting11adjoined to extension casting110and extension casting116to form the extended flange ways. The extension castings may be affixed and held in place by plates and bolts in accordance with rail or casting joining arrangements that may be appreciated by one of ordinary skill in the art.

This Figure further shows extension casting116as it would appear without a rail disposed alongside, and extension casting110as it would appear with a rail111disposed alongside so as to close the open side of the flange way as it courses through both a portion of the end full flange bearing casting11and the extension casting110.

FIG. 25shows an arrangement of a portion of the full flange bearing crossing arrangement in accordance with one embodiment of the present invention. This Figure shows end full flange bearing casting11adjoined to extension casting110and extension casting116to form the extended flange ways. The extension castings may be affixed and held in place by plates and bolts in accordance with rail or casting joining arrangements that may be appreciated by one of ordinary skill in the art.

FromFIG. 25it will also be appreciated that, in the preferred embodiment, the major portion of the open-sided part of the flange way resides in the extension casting110as compared to that portion of the open-sided part of the flange way resides in the end full flange bearing casting11, wherein the ration of the major portion major portion to the minor portion typically is in the range of from about 10:1 to about 2:1, with the ratio of about 4:1 being preferred.

The overall length of the flange way (and that of the intersection and extension portions where used) full flange bearing casting will be determined by the application parameters, such as load and speed, and the desired rate of incline and decline for the crossing. Other considerations include convenient transport and handling of the constituent parts. As can be appreciated, the described embodiment allows for the convenient on-site assembly, as well as for on-site repair, replacement and/or repositioning of the crossing assembly as required or desired.

FIG. 26shows a relatively low perspective view of the same portion of that arrangement, taken from an opposite side of the intersection point, and wherein like reference numerals are used to refer to portions thereof described herein.

FIG. 27shows a relatively low perspective view, taken along the line of one of the flange ways, of an arrangement of a portion of the full flange bearing crossing arrangement in accordance with one embodiment of the present invention, and wherein like reference numerals are used to refer to portions thereof described herein.

FIG. 28is a top plan view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention.

FIG. 29is a bottom plan view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention.

FIG. 30is a first upper perspective view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant A ofFIG. 28.

FIG. 31is a second upper perspective view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant B ofFIG. 28.

FIG. 32is a first side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken along line32-32ofFIG. 28.

FIG. 33is a second side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken along line33-33ofFIG. 28.

FIG. 34is a third side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken along line34-34ofFIG. 28.

FIG. 35is a third upper perspective view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant C ofFIG. 28.

FIG. 36is a fourth upper perspective view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant D ofFIG. 28.

FIG. 37is a fourth side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant A ofFIG. 28.

FIG. 38is a fourth side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant B ofFIG. 28.

FIG. 39is a fourth side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant C ofFIG. 28.

FIG. 40is a fourth side elevation view of an end full flange bearing casting11used in accordance with one embodiment of the assembly of the present invention, taken from quadrant D ofFIG. 28.

FIG. 41is an upper entrance end perspective view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention.

FIG. 42is a top plan view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention, taken along direction line42ofFIG. 41.

FIG. 43is a bottom plan view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention, taken along direction line43ofFIG. 41.

FIG. 44is a first side elevation view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention, taken along direction line44ofFIG. 41.

FIG. 45is a second side elevation view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention, taken along direction line45ofFIG. 41.

FIG. 46is a third side elevation view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention, taken along direction line46ofFIG. 41.

FIG. 47is a fourth side elevation view of an extension portion casting116used in accordance with one embodiment of the assembly of the present invention, taken along direction line47ofFIG. 41.

As to the crossing specifications, the following parts, specifications and parameters are preferred:

TYPE OF CROSSING: Full Flange Bearing for 10 mph similar to Solid Manganese Steel, AREMA plan 771-02. Flangeways to be ¼″ deep at intersection. Use 1″ raised guards, taper rail joints on exterior arms, anti-creeper bars on internal joints. Explosive harden per ARMEA and CSX specifications.

TRACK ALIGNMENT: Tangent All Tracks. Track centers shown on drawing.

RAIL: 136RE Head Hardened per CSX specification MW-99002A. Rail making up insulated joints must be matched (cut from the same piece).

FLANGEWAYS: AREMA standards ramped to ¼″ deep at intersections for all tracks.

EXTERIOR ARM LENGTHS: As shown on drawing are approximate. All frog throats to be guarded. Guard rail flares and flange bearing ramps to be square to track. Manufacturer to supply all guard rails.

INSULATED JOINTS: Premium bonded L.B. Foster Kevlar (12 total) supported on Foster insulated plate with clips. Each joint is to have 5′ 10″ to 8′ 6″ blind end rail terminating in center of crib. Label length of signal dead section.

TIE LAYOUT: AREMA Plan 700F-01. Manufacturer to supply and pre-plate all ties for diamond. Include all ties where rail is located on both sides of track. Ties to be at least 10′-0″ long. Double ties will be 10″ tall and 12″ wide and bolted together, remaining ties to be 10″×10″. Double ties parallel to CSX route.

TIE PLATES: Large Base plates under castings to be 1½″ thick with ½″ milling and welded filler gage plates. Use track spikes against base of rail or casting perpendicular to grain. All holes to be round 1″ diameter. Countersink holes not at rail base ½″ deep. Milling to have 1/16″ radius. Make surplus screw spike holes show major plate dimensions. Other plates to be 1½″ thick milled seat gage plate with similar construction. Insulated joints shall use IJ manufacturer's plate with clip. Use a 1¼″ milled seat insulated gage plate with Pandrol clips on the next plate beyond the insulated joint bars. Use individual plates with clips beyond that. Manufacturer to supply high strength rectangular head 6½″ long screw spikes per Common Standard Drawing 130800. Pre-drill spike holes. All spike holes to be accessible when rail and castings are installed on plates. All plates are to be installed to ties at proper gage by manufacturer.

TIE PADS: Precut rubber pads, ¼″ thick EDPM 3 ply 14 oz., nylon insert, to be located under all platework, and are commercially available from Cooper Enterprises 770-931-1141.

BODY BOLTS: All body bolts to be 1⅜″ diameter SAE Grade 8 with 3/32″ fillet radius, rolled threats, per SAE J429 specifications and traceable heat and lot numbers. Nuts to be North American standard heavy square fitted with head locks, security lock nuts, and hardened flat steel washers. Torque bolts to 2,200 (+200/−0) ft.-lbs., and lubricated unless bolts are to be field assembled. Provide two containers of anti-seize copper spray lubricant (commercially available from Bowman BD1097 20 oz cans) for bolting. Bolts not fully torqued shall be crated or boxed for shipping; use shop bolts with heads and nuts painted pink for temporary assemblies. All nuts must be accessible to a hydraulic torque wrench or have nut locks applied and torque head.

SPARE PARTS: Manufacturer to supply spare castings, and leg rails (one each type).

OTHER: Manufacturer to make site inspection prior to design. Manufacturer to ship as fully shop assembled and panelized, with bolts torqued, as shipping method will permit. Manufacturer to provide lifting weights for shipped assembles. Match mark assemblies for easy of assembly in the field. Manufacturer to provide annual report of diamond condition for the life of the diamond or 5 years maximum. Report to include digital photographs. Manufacturer to supply hydraulic torque wrench with intensifier (commercially available from Simplex PT-R3, CXS SCN 015.0001681.1, IRS) or equivalent.

The following patent documents generally describe crossing, frog and rail systems with which the present invention may be used, and such references are hereby incorporated herein by reference:

7,377,471Method and system for opening andsecuring a railroad frog7,121,513Cross frog for a set of track points,provided with an end of position-retainingdevice7,083,149Cross frog6,994,299Railroad crossing apparatus havingimproved rail connection and improvedflangeway floor geometry and methodincorporating the same6,732,980Railway frog wear component6,543,728Cross frog6,340,140Railroad frog for switch points andcrossings6,286,791Railroad spring wing frog with hold-openand shock dampening elements6,276,642Railroad spring wing frog assembly6,266,866Frog insert and assembly and method formaking frog assembly6,224,023Railroad spring frog assembly6,177,205Process for producing a permanent waycomponent and such a component6,164,602Railroad frog assembly with multi-positionholdback6,158,697Railroad frog assembly with latch holdback6,138,958Spring rail frog5,810,298Railroad spring frog assembly5,806,810Spring rail frog having switchable magnetfor holding wing rail open5,782,437Spring rail frog having bendable rail withmodified cross-section5,743,496Railroad frog crossing bolt and nutassembly for clamping railroad railsections together5,598,993Pseudo heavy point frog assembly5,595,361Wing rail hold-down5,560,571Reversible wing insert frog5,544,848Railroad spring frog5,531,409Flange bearing bolted rail frog for railroadturnouts and crossings5,522,570Rail section5,375,797Compound geometry rail switch5,184,791Frog tip that can be shifted relative to thewing rails5,082,214Crossing frog with a moving point5,042,755Process for producing a crossing frog witha moving point4,982,919Reversing device for movable parts of arailway switch4,953,814Railway switch comprising a frog having amovable main point and auxiliary point4,948,073Turnout with closing frog4,908,993Grinding machine for reprofiling railheads4,756,477Plate for supporting railway rails and atrack assembly using it4,637,578Railroad frog having movable wing rails4,624,428Spring rail frog4,589,617Frog for switches4,516,504Cross-over track structure for wheeledpallets4,514,235Frog, in particular frog point, for railcrossing or rail switches as well asprocess for producing same4,469,299Railway turnouts4,169,745Method of joining frogs of wear-resistingmanganese steel castings to rails ofcarbon steel4,168,817Rail switch4,159,090Railway switch for vignoles rails4,144,442Process for producing a component part ofa railway switch or a railway crossing andcomponent part of railway switches orrailway crossings produced by suchprocess4,015,805Railway switch or railway crossing20,100,270,436ADJUSTMENT DEVICE IN RAILROADSWITCHES20,070,007,394System, method, and apparatus forrailroad turnout and derail lift frog20,060,202,047Use of k-spiral, bend, jog, and wiggleshapes in design of railroad track turnoutsand crossovers20,050,145,754Cross frog20,050,067,535Cross frog for a set of track points,provided with an end of position-retainingdevice20,040,124,316Railroad crossing apparatus havingimproved rail connection and improvedflangeway floor geometry and methodincorporating the same20,040,065,784Railway frog wear component