Railcar end door support

An apparatus includes a transfer ball, a rod, a first bracket, a second bracket, a lock nut, an elastic element, and a threaded collar. The rod is coupled to the transfer ball and extends vertically from the transfer ball. The second bracket is positioned above the first bracket. The rod extends vertically through the first bracket and the second bracket. The lock nut engages to the rod and is positioned above the first bracket and below the second bracket. The elastic element is positioned above the lock nut and below the second bracket. The rod extends vertically through the elastic element. The threaded collar is positioned above the elastic element and below the second bracket. The threaded collar is engaged to the rod. The rod extends through the threaded collar.

TECHNICAL FIELD

This disclosure relates generally to configuring railroad freight cars (also referred to as “railcars”).

BACKGROUND

Railcars are configured to store and transport freight across long distances. Some types of railcars have end doors that close to secure the contents of the railcars.

SUMMARY

Railcars are configured to store and transport freight across long distances. For example, an autorack car is configured with one or more decks that carry automobiles. The railcars typically include doors at the ends of the railcars that protect the freight as the railcar is traveling. The doors can be opened to access the freight and closed during transport.

It is typically desirable for there to be some mechanism to support the weight of the end doors but allow easy lateral movement. In one example, railcar end enclosures (doors) may rotate or move laterally from their closed to their open position to allow access into the interior of the railcar. These end doors can weigh several hundred pounds, but their movement force should be low enough for a person to control its movement. In some cases, the end doors may be fully supported by rollers under the end doors, but if the floor of the railcar is uneven, the rollers may not contact the floor and thus fail to support the weight of the doors. In other cases, the end doors may be attached to the railcar structure with hinges, but when the weight of the end doors is fully supported by the hinges, the weight may impart significant loads onto the hinges during normal operation of the railcar due to vibrations and impact loads. These loads may be excessive and can lead to premature hinge failure or require the hinges to be oversized to account for the loads.

This disclosure contemplates a rolling support that provides vertical support to reduce loads on other components, such as end doors. The rolling support allows for adjustment of height independent of the adjustment for how much support is desired. The rolling support generally includes a transfer ball that rolls along the floor of the railcar. The transfer ball is coupled to a rod that extends vertically upwards from the transfer ball. The rod couples to a door of the railcar. Various components engaged with the rod allow adjustment of the height of the rolling support and how much support is provided by the rolling support. Three embodiments are described below.

According to an embodiment, an apparatus includes a transfer ball, a rod, a first bracket, a second bracket, a lock nut, an elastic element, and a threaded collar. The rod is coupled to the transfer ball and extends vertically from the transfer ball. The second bracket is positioned above the first bracket. The rod extends vertically through the first bracket and the second bracket. The lock nut engages to the rod and is positioned above the first bracket and below the second bracket. The elastic element is positioned above the lock nut and below the second bracket. The rod extends vertically through the elastic element. The threaded collar is positioned above the elastic element and below the second bracket. The threaded collar is engaged to the rod. The rod extends through the threaded collar.

According to another embodiment, a railcar includes a floor, an end door, and a rolling support. The end door is positioned at an end of the floor. The rolling support is coupled to the end door and supports the end door on the floor. The rolling support includes a transfer ball, a rod, a first bracket, a second bracket, a lock nut, an elastic element, and a threaded collar. The transfer ball rolls on the floor. The rod is coupled to the transfer ball and extends vertically from the transfer ball. The first bracket is coupled to the end door. The second bracket is positioned above the first bracket and is coupled to the end door. The rod extends vertically through the first bracket and the second bracket. The lock nut is engaged to the rod and is positioned above the first bracket and below the second bracket. The elastic element is positioned above the lock nut and below the second bracket. The rod extends vertically through the elastic element. The threaded collar is positioned above the elastic element and below the second bracket. The threaded collar is engaged to the rod. The rod extends through the threaded collar.

According to yet another embodiment, a method includes turning a lock nut of a rolling support to adjust a vertical distance between a transfer ball and a first bracket. The transfer ball is coupled to a rod that extends vertically from the transfer ball. The method also includes turning a threaded collar engaged to the rod to adjust a vertical force applied downward on an elastic element. The elastic element is positioned above the lock nut and below the threaded collar. The threaded collar, elastic element, and lock nut are positioned between the first bracket and the second bracket. The rod extends through the first bracket and the second bracket. The lock nut and the threaded collar are engaged to the rod.

Certain embodiments may provide one or more technical advantages. For example, an embodiment allows an end door to be supported while open or closed. As another example, an embodiment allows an end door of a railcar to be supported by a floor of the railcar even if the railcar floor is uneven. 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 claims included herein.

DETAILED DESCRIPTION

Railcars are configured to store and transport freight across long distances. For example, an autorack car is configured with one or more decks that carry or support the weight of one or more automobiles. The railcars typically include doors at the ends of the railcars that protect the freight as the railcar is traveling. The doors can be opened to access the freight and closed during transport.

FIG. 1Aillustrates an example railcar100. As shown inFIG. 1A, railcar100includes an end door110. End door110can close to protect the freight within railcar100during transport.

FIG. 1Billustrates an example end door110of the railcar100ofFIG. 1A. As shown inFIG. 1B, end door110is coupled to railcar100using one or more hinges135. End door110is positioned above floor115of railcar100. End door110opens and closes by swinging or rotating on hinges135. This disclosure contemplates railcar100including any number of hinges to couple railcar100to end door110. In existing railcars, end door110can weigh several hundred pounds and its weight should be supported. In some railcars, a support is added to the bottom of end door110so that the support can support the weight of end door110on the floor115of railcar100. However, this support may fail to contact floor115if floor115is uneven or if door110is opened all the way such that the support is positioned beyond the side of railcar100. In some railcars, additional hinges or sturdier hinges are used to support the weight of end door110. However, during transport, vibrations and impact loads increase the strain on these hinges and may result in premature hinge failure or deformation.

In certain embodiments, end door110is a folding door and includes one or more panels. In the example ofFIG. 1B, end door110includes three panels120,125, and130. Panel120is coupled to panel125. Panel125is coupled to panel120and panel130. Panel120rotates or folds towards and away from panel125to extend or retract the length of end door110. Likewise, panel125rotates or folds towards and away from panel130to extend or retract the length of end door110. Panel130is coupled to railcar100by the one or more hinges135. Panel130rotates or swings about hinges135to open and close end door110.

Although the example illustrated inFIG. 1Bpresents a railcar100in which end door110is a folding door, this disclosure may be applied to a variety of other types of doors, such as radial doors, or any other types of structures or objects that require support that is adjustable for both height and force.

FIG. 1Cillustrates an example end door110of the railcar100ofFIG. 1A, in which the various panels of end door100have been folded together and end door110is rotated open on hinges135. As seen inFIG. 1C, the end door110of railcar100is completely open. Additionally, end door110hangs off the side of floor115such that a support140at the bottom of door110does not support the weight of end door110on floor115. As a result, all of the weight of end door110is supported by the hinges135, which could result in premature hinge failure.

This disclosure contemplates an end door assembly that includes a rolling support that provides vertical support to reduce loads on other components, such as end doors and hinges. The rolling support allows for adjustment of height independent of the adjustment for how much support is desired. The rolling support generally includes a transfer ball that rolls along the floor of the railcar. The transfer ball is coupled to a rod that extends vertically upwards from the transfer ball. The rod couples to a door of the railcar. Various components engaged with the rod allow adjustment of the height of the rolling support and how much support is provided by the rolling support. The end door assembly will be described in more detail usingFIGS. 2A, 2B, 3, and 4.

Although this embodiment describes a transfer ball, other types of rolling or sliding elements may be applied to the end of the adjustable rod.

FIG. 2Aillustrates an example end door assembly200. As seen inFIG. 2A, the end door assembly200includes an end door110coupled to railcar100by one or more hinges135. A rolling support205is coupled to end door110near a bottom edge of end door110. A platform210is coupled to a side of floor115and extends beyond the edge of floor115. Rolling support205is configured to rest on platform210such that rolling support205supports the weight of end door110on platform210when end door110is open and extends beyond the side of floor115. Additionally, rolling support205is configured to rest on floor115when end door110is closed, such that rolling support205supports the weight of end door110on floor115when end door110is closed and when end door110is open but does not extend beyond the side of floor115. In this manner, hinges135do not support all the weight of end door110.

FIG. 2Billustrates a view of the end door assembly200ofFIG. 2A. As seen inFIG. 2B, end door assembly200includes end door110, rolling support205, and platform210. Rolling support205is coupled to end door110near a bottom edge of end door110. Rolling support205supports the weight of end door110on platform210when end door110is open and extends beyond a side of floor115. When end door110is closed, or when end door110is open but does not extend beyond a side of floor115, rolling support205supports the weight of end door110on floor115.

Platform210is coupled to a side of floor115and extends beyond the side of floor115. Platform210includes a groove215cut into platform210. Groove215allows for rolling support205to contact platform210and support the weight of end door110on platform210. Groove215also sets the boundaries for rolling support205so that rolling support205does not travel beyond the walls of groove215. The extent of groove215in the direction away from the side of floor115determines the angular amount by which end door110can rotate open on hinges135.

In certain embodiments, groove215is curved to accommodate the movement of rolling support205along an arc on which rolling support205travels as end door110rotates open on hinges135. In certain other embodiments, groove215is rectangular in shape, with a width measured along the direction parallel to the side of floor115that is large enough to accommodate the movement of rolling support205along the arc on which rolling support205travels as end door110rotates open on hinges135.

In certain embodiments, platform210rises above floor115and groove215is level with floor115. In this manner, there is little to no vertical displacement when rolling support205moves between floor115and platform210when end door110opens and closes. In certain embodiments, platform210allows for rolling support205to support the weight of end door110even though end door110extends beyond the side of floor115when open.

FIG. 2Cillustrates the example end door assembly200ofFIG. 2A. As seen inFIG. 2C, end door assembly200includes an end door110coupled to hinges135. Rolling support205is coupled to end door110using brackets310and330. Rolling support205supports the weight of end door110on floor115and/or platform210. In certain embodiments, rolling support205allows for the independent adjustment of height and the amount of support provided by rolling support205. By adding vertical support to end door110while also allowing lateral movement, loads in other support components may be reduced. Adjustment is provided for height as well as the amount of support desired.

Rolling support205includes a transfer ball305at the bottom of rolling support205. In certain embodiments, transfer ball305is a ball bearing. Transfer ball305is designed to contact and roll along floor115and/or platform210. As a result, transfer ball305supports the weight of end door110and allows end door110to open and close. A vertical rod308is coupled to transfer ball305. Rod308extends vertically upwards from transfer ball305and extends through brackets310and330. Rod308may be allowed to slide laterally along brackets310and330towards and away from end door110. Rod308may also slide vertically through brackets310and330.

Brackets310and330are angled brackets that couple to end door110. Bracket310is positioned beneath bracket330. This disclosure contemplates brackets310and330being coupled to end door110in any suitable manner. For example, brackets310and330may be bolted, screwed, glued, or welded onto end door110. Brackets310and330transfer the weight of end door110down into transfer ball305. Bracket330is coupled to the side of end door110that faces the inside of railcar100, when end door110is closed, and extends towards the inside of railcar100, when end door110is closed. In certain embodiments, bracket310is similarly coupled to the side of end door110that faces the inside of railcar100, when end door110is closed, and extends towards the inside of railcar100, when end door110is closed. In other embodiments, bracket310is coupled to the side of end door110that faces outside when end door110is closed and extends towards the inside of railcar100, when end door110is closed.

A lock nut315is engaged to rod308by a threaded connection. Lock nut315is positioned above bracket310and below bracket330. In certain embodiments, lock nut315directly contacts bracket310and is allowed to slide with respect to bracket330. By turning nut315, the distance between transfer ball305and bracket310is adjusted. As a result, rolling support205can be adjusted to accommodate any suitable height of end door110. In other words, rolling support205can be adjusted to accommodate any suitable distance between end door110and floor115. Thus, even if floor115is uneven, the vertical position of rolling support205can be set so that rolling support205contacts even the uneven surfaces of floor115. In certain embodiments, the length that the transfer ball305extends past bracket310is adjusted by turning rod308with respect to lock nut315or by turning lock nut315with respect to rod308. Adjustment may account for tolerance between the hinge135locations and the floor115to maintain contact between the transfer ball305and the floor115.

An elastic element320is positioned above lock nut315and between brackets310and330. Rod308extends through elastic element320. This disclosure contemplates elastic element being any suitable elastic element such as a spring or an elastomer. Elastic element320provides support for the weight of end door110. The compression of elastic element320can be adjusted to allow for elastic element320to support more or less of the weight of end door110. For example, elastic element320can be compressed more so that it supports more of the weight of end door110. As another example, elastic element320can be less compressed so that it supports less of the weight of end door110.

A threaded collar325is positioned above elastic element320and between brackets310and330. Rod308extends through threaded collar325. Threaded collar325may engage bracket330through a threaded connection. In certain embodiments, threaded collar325directly contacts bracket330. Threaded collar325provides a downward force onto elastic element320. By turning threaded collar325, more or less downward force is applied to elastic element320. As a result, the compression of elastic element320can be adjusted so that elastic element320supports more or less of the weight of end door110. In certain embodiments, an additional lock nut340is engaged to threaded collar325by a threaded connection on the exterior of threaded collar325. In certain embodiments, the lock nut340may be integral with threaded collar325or it may be connected to threaded collar325via a threaded connection. The lock nut340directly contacts elastic element320and applies a downward force onto elastic element320. Turning threaded collar325or the lock nut adjusts the amount of downward force applied to elastic element320.

In certain embodiments, threaded collar325is attached to bracket330via a threaded connection. The rod308protrudes through the threaded collar325, and therefore the bracket330, via a sliding interface. By adjusting the threaded collar325with respect to the bracket330, the height of the elastic element320is adjusted. Adjusting the height of the elastic element320determines the force required to be applied to the transfer ball305to move the transfer ball305and rod308vertically. This determines the amount of vertical support permitted by the transfer ball305and the reduction in support required by the hinges135.

In particular embodiments, the vertical position of rolling support205is adjusted independent of the support provided by rolling support205. For example, turning lock nut315adjusts the vertical position of rolling support205while turning threaded collar325adjusts the support provided by rolling support205.

Lock nut335is positioned above bracket330. Threaded collar325extends through lock nut335and rod308extends through threaded collar325. Lock nut335directly contacts bracket330and in some embodiments, prevents rolling support205from moving downwards past a particular point set by lock335. In certain embodiments, the top of the threaded collar325is attached to lock nut335to prevent the threaded collar325from inadvertently rotating and changing the force applied to elastic element320. In certain such embodiments, lock nut335is attached to threaded collar325through a threaded connection.

From bottom to top the relative positions of the various components of rolling support205along vertical rod308, in certain embodiments, are as follows. Transfer ball305is coupled to the bottom of vertical rod308. Next, rod308extends through bracket310. Above bracket310, lock nut315is engaged to rod308by a threaded connection. Rod308then passes through elastic element320, which is positioned above lock nut315. Next, rod308passes through threaded collar325, where an additional lock nut340is engaged to a lower portion of threaded collar325by a threaded connection on the exterior of threaded collar325. Rod308and threaded collar325then extend through bracket330, with threaded collar325engaged to bracket330through a threaded connection. Finally, lock nut335is positioned above bracket330, and is attached to threaded collar325.

FIG. 3is a flowchart illustrating a method300of adjusting an end door assembly. In particular embodiments, an operator performs method300. By performing method300, the operator can adjust a vertical position of a rolling support independent of the support provided by the rolling support. The operator begins in step305by turning a lock nut315of a rolling support to adjust a vertical distance between a transfer ball and a first bracket in step305. This adjustment allows the rolling support to contact uneven surfaces of a floor of a railcar and to accommodate any distance between the end door and the floor of the railcar. In step310, the operator turns a threaded collar325engaged to a rod308to adjust a vertical force applied downward on an elastic element320. This adjustment allows the rolling support to accommodate different weights of end doors110and different types of floors115. Then lock nut335is tightened to maintain the position of threaded collar325.

Modifications, additions, or omissions may be made to method300depicted inFIG. 3. Method300may include more, fewer, or other steps. For example, steps may be performed in parallel or in any suitable order. While discussed as an operator performing the steps, any suitable person may perform one or more steps of the method.