Abstract:
An air hose hanger for supporting flexible air hoses of a trainline braking system of a rail car includes a head including a mounting plate for mounting the hanger to a coupler of a rail car, the mounting plate including first and second apertures for receiving first and second bolts for attaching the mounting plate to the coupler, and an arm removably attached to the head. The arm includes a first arm removably attached to the head extending in a substantially vertical direction away from the head, and a second arm integral with the first arm and extending in a horizontal direction substantially parallel to an axis of the coupler. The head is attached to the coupler at three preformed holes formed in the coupler, the three preformed holes including two lightener holes preformed in the coupler, and an aperture preformed in a tab on an underside of the coupler.

Description:
FIELD OF THE INVENTION 
     The present invention is directed generally towards hangers/couplers for supporting flexible air (i.e., brake) hoses between adjacent rail cars and, in particular, towards hangers/couplers for supporting flexible air (i.e., brake) hoses between adjacent rail cars known as “cushioned cars” which include cushioned couplers for shock absorption. 
     BACKGROUND OF THE INVENTION 
     A brake system for a rail car, and preferably a cushioned car, generally includes a pipe which is attached to the rail car, and which pipe terminates in a valve at the end of the rail car. The valve is connected to a flexible hose which connects to a flexible hose on an adjacent car via a glad hand to connect the brake line pipe of adjacent cars together for proper operation of the braking system. The flexible hose on each car is supported by a hanger bracket, which is designed to maintain the hose a specified distance from the ground. Typically, this distance is set by Association of American Railroads (“AAR”) standards. Such a connection permits the rail cars (in addition to the flexible hoses) to be readily connected to, and disconnected from, each other. Further, the flexible nature of the hose helps support the brake system through turns when the axes of the rail cars are angled with respect to one another. 
     However, a problem with cushioned couplers (used extensively on autorack train cars—i.e., cushioned cars) is the issue of needing brake hose supports that will move in tandem with the couplers to hold up hose slack while preventing air hose separations at the glad hand connections. It is estimated that air hose separation is one of the largest causes of train stoppage for cushioned cars. Additionally, the AAR standard distance from the trainline support casting to the end of the coupler, as well as the distance of the air hose above the ground, also need to be maintained. 
     Since the geometries of the various rail cars differ, it is difficult to provide a hanger/coupler that will maintain the above-identified distances for the various rail cars. 
     The present invention is directed toward overcoming one or more of the above-mentioned problems. 
     SUMMARY OF THE INVENTION 
     The air hose hanger of the present invention is designed for applications in the rail industry, specifically dealing with long-travel, cushioned couplers (which are used extensively on autorack train cars, also referred to as “cushioned cars”), and the issue of needing brake hose supports that will move in tandem with the couplers to hold up hose slack while preventing air hose separations at the glad hand connections. The inventive air hose hanger is designed to mount to the area of the coupler head that includes the lightener holes. The inventive air hose hanger includes an arm that will extend a certain distance downward and toward the centerline of the rail car in a plane generally perpendicular to the longitudinal center plane of the car. The arm then turns and extends down the centerline of the rail car away from the coupler head a predetermined distance. At the end of the arm, a hose connection is provided which suspends the air hose above the track/ground (e.g., at a distance within AAR standards). The hose connection is allowed to rotate 360°. Once the air hose is connected thereto, the hose connection will rotate, or swivel, to accommodate the taking up and letting out of slack in the semi-rigid (yet still flexible) rubber air hose as the coupler moves in and out, or as the cars move through curves, causing the couplers to angle with respect to each other. Rotation of the hose connection will be limited by the air hose itself. This rotation, or swiveling, will also isolate the glad hand connections from any forces on the hose itself, as they will be transferred into the hose connection at the end of the arm extension, which is not susceptible to hose separation issues. 
     The inventive air hose hanger includes a bolt-on, or otherwise attached, head which will mount directly to the coupler, and an arm extension which will bolt, or otherwise attach, to the head. The arm extension and the head are in separate pieces to account for different coupler types (e.g., E, F, etc.), as well as to allow the arm extension to be interchangeable between bolt-on type mounting heads and/or a welded-on mounting head, depending on customer preference or specific/unique applications. Thus, the air hose hanger of the present invention has the advantage in that it can be used on a different variety of rail cars with different geometries by simply changing the head mounting design coupler. This allows the arm extension to be used with different head designs to be able to attach to the different types of couplers. 
     In one embodiment, the method by which the bolt-on head mounts to the coupler relies on exploiting a feature of all couplers, namely, the lightener holes (named as such because they reduce the total casting weight of the coupler by removing material therefrom in an area of the coupler where it is typically not needed). The lightener holes are thru-holes extending into the coupler, and span from the front to the rear of the coupler. The lightener holes have a larger opening at the front end of the coupler head than at the rear end of the coupler head. This change in the size of the lightener hole allows inserts to be used which can pass through the front lightener hole opening, but cannot pass through the rear lightener hole opening. Since two lightener holes are typically provided in the coupler, it is contemplated to utilize two inserts. The inserts can have a single threaded hole in the center of them that will allow them to receive a bolt from the bolt-on head and act as a solid connector therefore. 
     The bolt-on head of the inventive air hose hanger can also take advantage of a third mounting point to ensure correct orientation. This third mounting point is a small tab with a hole in it formed on the underside of the coupler, which tab/hole is normally used to attach a rubber, stretchy air hose hanger with S-hooks, much like a bungee cord. The bolt-on head of the inventive air hose hanger includes a small “thumb-like” extension that extends down from the head and outward to the tab on the coupler to allow a single bolt to secure the thumb-like extension to the tab on the coupler. All three of the connection points of the bolt-on head (e.g., at the two lightener holes and at the thumb-like extension) can be considered solid connections, meaning that with proper securement and using common unthreading prevention methods (e.g., cotter pins, bolt-locking tabs, etc.) the head will not come off or come loose due to vibration or shock forces, as well as normal operating forces. 
     In accordance with one aspect of the present invention, an air hose hanger for supporting flexible air hoses of a trainline braking system of a rail car is provided. The air hose hanger includes a head including a mounting plate for mounting the air hose hanger to a coupler of a rail car, the mounting plate including first and second apertures for receiving first and second bolts for attaching the mounting plate to the coupler, and an arm removably attached to the head. The arm includes a first arm removably attached to the head and extending in a substantially vertical direction away from the head, and a second arm integral with the first arm and extending in a horizontal direction substantially parallel to an axis of the coupler. The air hose hanger further includes first and second inserts received in first and second lightener holes which are preformed in the coupler, the first and second lightener holes extending from a front opening in the coupler to a rear opening in the coupler, wherein the front opening is larger than the rear opening, and wherein the first and second inserts are sized such that they are received in the front opening and are displaceable in the first and second lightener holes, but are larger than the rear openings such that they cannot pass there through, and wherein the first and second inserts are disposed in the lightener holes adjacent the rear openings and each include a threaded aperture for receiving the first and second bolts, respectively, for securing the head of the hanger to the coupler. 
     In one form, a hose connection is rotatably attached to an end of the second arm for rotatably supporting a flexible air hose attached to the hose connection. 
     In another form, the end of the second arm includes a hollow cylindrical member configured for receiving a cylindrical member of the hose connection, wherein the cylindrical member of the hose connection is attached to the hollow cylindrical member for rotatable movement of the hose connection with respect to the hollow cylindrical member. 
     In a further form, an extension extends from the head in a direction generally away from the second arm, the extension including an aperture configured for alignment with an aperture preformed in an underside of the coupler and attached to the coupler via a bolt passing through both apertures. 
     The arm can include a “+” or “x” shaped cross-section. Further, the rail car can include a cushioned car and, accordingly, the coupler can include a cushioned coupler. 
     While various materials can be used for the head and the arm, in a preferred form the head and arm can be made from, for example, ductile iron, heat treated ductile iron, or austempered ductile iron or steel for weldable designs. 
     In accordance with another aspect of the present invention, an air hose hanger for supporting flexible air hoses of a trainline braking system of a rail car is provided. The air hose hanger includes a head including a mounting plate for mounting the air hose hanger to a coupler of a rail car, the mounting plate including first and second apertures for receiving first and second bolts for attaching the mounting plate to the coupler, and an arm removably attached to the head. The arm includes a first arm removably attached to the head and extending in a substantially vertical direction away from the head, and a second arm integral with the first arm and extending in a horizontal direction substantially parallel to an axis of the coupler. The head is attached to the coupler at three preformed holes formed in the coupler, the three preformed holes comprised of first and second lightener holes preformed in the coupler, and a third aperture preformed in a tab on an underside of the coupler. 
     In one form, the air hose hanger further includes first and second inserts received in the first and second lightener holes which are preformed in the coupler, the first and second lightener holes extending from a front opening in the coupler to a rear opening in the coupler. The front opening is larger than the rear opening, and the first and second inserts are sized such that they are received in the front opening and are displaceable in the first and second lightener holes, but are larger than the rear openings such that they cannot pass there through. The first and second inserts are disposed in the lightener holes adjacent the rear openings and each include a threaded aperture for receiving the first and second bolts, respectively, for securing the head of the hanger to the coupler. 
     In another form, the air hose hanger further includes an extension extending from the head in a direction generally away from the second arm, the extension including an aperture configured for alignment with the third aperture preformed in the underside of the coupler and attached to the coupler via a bolt passing through both apertures. 
     In a further form, the air hose hanger further includes a hose connection rotatably attached to an end of the second arm for rotatably supporting a flexible air hose attached to the hose connection. 
     In yet a further form, the end of the second arm includes a hollow cylindrical member configured for receiving a cylindrical member of the hose connection, wherein the cylindrical member of the hose connection is attached to the hollow cylindrical member for rotatable movement of the hose connection with respect to the hollow cylindrical member. 
     The arm can include a “+” or “x” shaped cross-section. Further, the rail car can include a cushioned car and, accordingly, the coupler can include a cushioned coupler. 
     While various materials can be used for the head and the arm, in a preferred form the head and arm can be made from, for example, ductile iron, heat treated ductile iron, or austempered ductile iron or steel for weldable designs. 
     While the head and arm are described herein in the form of a two-piece design, it should be appreciated that a one-piece design is also contemplated where the head and arm are integral with each other. 
     It is an object of the present invention to provide an air hose hanger that solidly connects to a coupler using connections inherent to a typical coupler. 
     It is a further object of the present invention to provide a universal air hose hanger that may be utilized with rail cars of different geometries. 
     It is yet a further object of the present invention to provide a two-piece air hose hanger consisting of a head and arm extension, which allows for different arm extensions to be utilized with the same head to account for different geometries of rail cars. 
     It is still a further object of the present invention to provide an air hose hanger that exploits common features of couplers for each of installation. 
     Other objects, aspects and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various features, details and advantages of the present invention arise from the following description in which different exemplary embodiments are illustrated in more detail by means of the attached drawings. In the figures: 
         FIG. 1  is a perspective view of an air hose hanger in accordance with the present invention; 
         FIG. 2  is a perspective view of an air hose hanger in accordance with the present invention connected to a rail car coupler and having a flexible air (i.e., brake) hose connected thereto; 
         FIG. 3  is a cross-sectional detailed view showing inserts provided in the lightener holes in the coupler for attachment of the air hose hanger head thereto taken along line  3 - 3  in  FIG. 4 ; 
         FIG. 4  is a sectional detailed view illustrating the head of the inventive air hose hanger mounted to a rail car coupler; 
         FIG. 5  is a perspective detailed view showing the third connection point of the inventive air hose hanger to the rail car coupler; 
         FIG. 6  is a perspective detailed view showing inserts provided in the lightener holes in the coupler for attachment of the air hose hanger head thereto; 
         FIG. 7  is an exploded perspective view of the inventive air hose hanger; and 
         FIG. 8  is a perspective view illustrating rotation of the hose connection. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in  FIGS. 1-2 and 7 , an air hose hanger in accordance with the present invention is shown at  10 . The air hose hanger is designed to be mounted to a rail car coupler  12  and rotatably support the flexible air/brake hose  14  connected between the rail cars as part of the train brake system, as will be described in more detail hereafter. As shown and described herein, the air hose hanger  10  is of a two-piece construction, and includes a head portion, or head,  16  having an arm extension, or arm,  18  extending therefrom. The arm  18  includes two portions, or arms, extending approximately 90° relative to each other such that the arm  18  is substantially “L” shaped. With the hanger  10  attached to the rail way coupler  12  (see e.g.,  FIG. 2 ), the arm  18  includes a first arm  20  that extends a certain distance downward and toward the centerline of the rail car (not shown) in a plane perpendicular to the longitudinal center plain of the rail car, and a second arm  22  that extends down the centerline of the rail car away from the coupler head a certain distance. As previously noted, the first  20  and second  22  arms are approximately 90° apart such that the arm  18  is substantially “L” shaped. 
     It is contemplated herein that the head  16  and arm  18  can be made of, for example, ductile iron, heat treated ductile iron, or austempered ductile iron or steel for weldable designs. However, one skilled in the art will appreciate that other materials may be used without departing from the spirit and scope of the present invention. One skilled in the art will further appreciate that while the head  16  and arm  18  are described herein in the form of a two-piece design, one-piece design is also contemplated where the head  16  and arm  18  are integral with each other, without departing from the spirit and scope of the present invention. 
     At the end of the arm  18  (specifically second arm  22 ), a hose connection  24  is provided for suspending the air (brake) hose  14  above the track and allowing the hose  14  to swivel, or rotate, (see arrow  26  in  FIGS. 1 and 8 ) to accommodate the taking up and letting out of slack in the semi-rigid, yet still flexible, air hose  14  as the coupler  12  moves in and out. When the coupler  12  is installed in a rail car, it will generally move in front and back directions as well as left to right directions around turns. The hose connection  24  will rotate to accommodate for the slack in the coupling system. 
     Specifically, as shown in  FIGS. 1-2 and 8 , the end of the second arm  22  includes a hollow cylindrical member  28  which receives a cooperating cylindrical member  30  of the hose connection  24 . A cotter pin (not shown) is extended through the top portion of the cylindrical member  30  to maintain the rotational relationship of cylindrical members  28  and  30  (see arrow  26  in  FIGS. 1 and 8 ), as will be appreciated by one skilled in the art. Further, the angle of rotation of the hose connection  24  may be adjusted to be limited, or may rotate freely 360° and be limited by the air hose itself, as will be appreciated by one skilled in the art. 
     The hose connection  24  generally includes a first threaded aperture  32  which is connected to the air (brake) hose  14  (see  FIGS. 1-2 and 8 ) and generally faces away from the rail car body when the hanger  10  is connected to the coupler  12 . A flanged aperture  34  is opposite, and in communication with, the threaded aperture  32 , and is also typically threaded. The flanged aperture  34  connects a flexible air (brake) hose between the hanger  10  and the angle cock valve (not shown) on the rail car body. 
     The head  16  is connected to the arm extension  18  via bolts  36  which extend through cooperating connector plates  38 ,  40  formed on the end of the head  16  and the arm extension (specifically first arm  20 ), respectively, and are fastened, for example, using lock nuts or other fastening means. The head  16  is connected to the rail way coupler via two bolts  42  which are connected to inserts provided in the lightener holes of the rail way coupler  12 , as will be described hereafter. Providing the hanger  10  in a two-piece construction (head  16  and arm  18 ) allows the hanger to be used with different coupler types (e.g., E, F, etc.) by simply changing the head mounting design coupler. This allows the arm extension to be used with different head designs to be able to attach to the different types of couplers. Additionally, should the arm  18  or the hose connection  24  become damaged, they can be readily replaced without having to remove the entire hanger  10  from the coupler, resulting in cost savings in maintenance operations. 
     As shown in  FIGS. 1-2 and 7 , the arm  18  has a generally “+” or “x” shaped cross-section. Such a cross-section adds strength to the arm  18  against lateral and/or longitudinal forces, and helps to facilitate connection of the arm  18  to the head  16  via the bolts  36  and connector plates  40 ,  38 , respectively. For ease of connection, the head  16  also has a generally “+” or “x” shaped cross-section at an area directly adjacent the connector plate  38 . However, one skilled in the art will appreciate that the cross-section of the arm  18  (and also the head  16  in general and directly adjacent the connector plate  38 ) is/are not critical to the present invention, and the arm  18  (and head  16 ) may have any cross-sectional shape without departing from the spirit and scope of the present invention. 
     Referring to  FIGS. 2-4 and 6 , the head  16  of the hanger  10  is connected to the coupler  12  utilizing the lightener holes provided in the coupler  12 . As previously noted, the lightener holes are provided in the coupler  12  to reduce the total casting weight of the coupler  12  by removing material from the coupler  12  where it is generally not needed. As shown in  FIGS. 2-4 and 6 , the lightener holes generally include an upper lightener hole  44  and a lower lightener hole  46 . The upper and lower lightener holes  44 ,  46  extend into the coupler  12  from a front opening  48 ,  50  to a rear opening  52 ,  54 , respectively. The front opening  48 ,  50  is generally larger than the rear opening  52 ,  54 . 
     Inserts  56  and  58  are inserted into the lightener holes  44  and  46  at the front openings  48  and  50  thereof, respectively. The inserts  56 ,  58  are sized such that they are smaller than the front openings  48 ,  50 , but larger than the rear openings  52 ,  54 . The inserts  56 ,  58  are inserted in the front openings  48 ,  50  and moved through lightener holes  44 ,  46  in the direction of dotted arrows (see  FIGS. 4 and 6 ) until they sit adjacent the rear openings  52 ,  54 . Since the inserts  56 ,  58  are larger than the rear openings  52 ,  54 , they will not pass through the rear openings  52 ,  54 . 
     The inserts  56 ,  58  include threaded apertures  60  formed therein. Preferably, the threaded apertures  60  are centered, but may be placed at any convenient point on the inserts  56 ,  58 . The inserts  56 ,  58  are aligned with the rear openings  52 ,  54  and the bolts  42  pass through corresponding apertures formed in a mounting plate  62  of the head  16  and are threaded into the apertures  60  formed in the inserts  56 ,  58 . The bolts  42  are tightened to pull the inserts  56 ,  58  up against the edges of the coupler  12  that define the rear openings  52 ,  54  to fasten the head  16 , and thus the hanger  10 , securely to the coupler  12 . By using the lightener holes  44 ,  46  that are already formed in the coupler  12 , no additional holes or fastening means need formed in the coupler  12 . Additionally,  FIGS. 4 and 7  show a lock washer  64  utilized in securing the bolts  42  to the inserts  56 ,  58 . However, the lock washer  64  may be omitted. 
     Referring to  FIGS. 1-2, 5 and 7 , to provide added stability and securement of the hanger  10  to the coupler  12 , a third connection point on the coupler  12  is used to fasten the hanger  10  thereto. In this regard, the head  16  includes an extension (e.g., a thumb-like extension)  66  which extends from the head  16  in a direction generally away from the rail car body. This third connection point attaches to a small tab  68  generally provided on the underside of the coupler  12  body, which tab  68  includes a hole for attaching an elastic air support hanger  72  with an S-hook  73  (see e.g.,  FIGS. 2 and 5 ), much like a bungee cord. The air support hanger  72  supports the air hose  14 . The end of the extension  66  includes an aperture  70  which is aligned with the aperture in the tab  68  and secured with a bolt  74  extending there through. A lock nut  76  and cotter pin  78  (see  FIG. 5 ) are shown for securing the bolt  74  in place; however, one skilled in the art will appreciate that any means of securing the bolt  74  to effectuate this third connection point may be implemented without departing from the spirit and scope of the present invention. Since the extension  66  is secured using the aperture in the tab  68  typically used for attaching the elastic air support hanger  72  with the S-hook  73 , the extension  66  may include an additional aperture (not shown) to which the S-hook  73  may attach. Alternately, the S-hook  73  may hook over the extension  66  so that the air support hanger  72  may support the air hose  14  (see  FIG. 2 ). The three connection points, namely the two lightener holes  44  and  46  and the tab  68 , provide secure and stable connection of the hanger  10  to the coupler  12 , such that the head  16  (and thus the hanger  10 ) will not come off or come loose due to vibration or shock forces, as well as normal operating forces. 
     While the present inventive hanger  10  has particular utility for use with cushioned cars having cushioned couplers that move in a horizontal plane, it should be understood that the inventive hanger  10  may be implemented and attached to any coupler to support the air hose. For example, the hanger  10  may be attached to a rail way coupler that does not move in a generally horizontal plane. 
     While the present invention has described herein with particular reference to the drawings, it should be understood that various modifications could be made without departing from the spirit and scope of the present invention. Those skilled in the art will appreciate that various other modifications and alterations could be developed in light of the overall teachings of the disclosure. The presently preferred embodiments described herein are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof. Additionally, the disclosure of a range of values is a disclosure of every numerical value within that range.