Abstract:
A ballast load device for increasing a tractive effort of a railcar mover having a coupler includes a side member and a bottom attached to the side member. The bottom is adapted to support a weight. A primary coupler is attached to the side member and is adapted to removably connect to the coupler of the railcar mover such that the railcar coupler may lift the ballast load device.

Description:
CLAIM OF PRIORITY 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/556,567, filed Nov. 7, 2011, the contents of which are hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to mobile railcar movers and, more particularly, to a ballast load device and method for mobile railcar movers. 
       BACKGROUND 
       [0003]    As is known in the art, mobile railcar movers are used in rail yard switching operations and to shunt railcars around rail yards. Railcar movers are typically equipped with hydraulically-powered couplers on each end that lilt up on the attached railcars&#39; couplers to transfer additional eight from the railcars to the railcar mover to increase the traction of the railcar mover. 
         [0004]    As an example, if the railcar mover has a dead weight of 50.000 lbs., and transfers an additional 50,000 lbs. via the hydraulically-powered couplers on each end from attached loaded railcars (i.e. the railcar mover is “double-coupled”) the effective total weight of the railcar mover for purposes of traction is 150,000 lbs. This would typically create approximately 49,500 lb of tractive effort (150,000 lbs. ×0.33 coefficient of friction). 
         [0005]    A railcar mover, however, typically operates 90-95% of the time coupled to a single railcar. In other words, only one of the railcar mover&#39;s hydraulically-powered couplers is being used. This is because most plant switching applications cannot efficiently operate with railcar movers being double-coupled due to either space or safety concerns. Furthermore, in a railcar switching yard, when a railcar mover is double-coupled, a ground man is required at both distal ends of the joined railcars to safely move the cars. For a single railcar, this only allows 50% of the maximum traction available for the railcar mover. 
         [0006]    A need exists for a device and method of using the device that addresses the above issues. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a side elevational view of the a railcar mover equipped with an embodiment of the ballast load device of the present invention; 
           [0008]      FIG. 2  is a perspective view of the ballast load device of  FIG. 1 ; 
           [0009]      FIG. 3  is a perspective section view of the ballast load device taken along line  3 - 3  of  FIG. 2  illustrating horizontal adjustment of the coupler of the ballast load device of  FIGS. 1 and 2 ; 
           [0010]      FIG. 4  is a side elevational view of a railcar mover equipped with an alternative embodiment of the ballast load device of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0011]    In accordance with the present invention, providing a ballast load device on a railcar mover, such as the one indicated in general at  8  in  FIG. 1 , increases the tractive effort of the railcar mover wheels  10   a  and  10   b  (and the corresponding wheels on the opposite side of the railcar mover) on a track  12  when only one of the railcar mover couplers  16  is being used to move a railcar—indicated in phantom at  18 . When such a ballast load device is used in accordance with the invention, the tractive effort of the railcar mover  8  can approach the double coupled tractive effort performance level. 
         [0012]    While the present invention is described below in terms of a box, it may take any form by which weight may be supported and lifted by a railcar mover coupler. 
         [0013]    An embodiment of the ballast load device of the present invention is indicated in general at  20  in  FIGS. 1 and 2 . The ballast load device or box includes four side members or walls  22   a - 22   d,  a bottom  23  and an open top  25 . Side wall  22   b  is constructed of a panel portion  24  and is reinforced by a framework consisting of vertical struts  26 , horizontal struts  27  and a diagonal strut  28 . The other side walls feature a similar construction. The panels, struts and side walls may be secured together by welding, fasteners, brackets or any other secure fastening arrangement known in the art. The bottom  23  of the ballast load box includes a panel reinforced by a pair of support beams  31   a  and  31   b  running along the front and rear edges of the bottom. The support beams  31   a  and  31   b  feature open ends that are sized and spaced so as to accept lift truck forks to move the ballast load box to and from the rail. Of course any side wall and bottom construction known in the art that will support and contain the contents of the ballast load box may be used. Examples include, but are not limited to, one inch thick steel plating or simply a framework consisting of struts such as  26 ,  27  and  23  (without panels). 
         [0014]    The struts  26 ,  27  and  28  and support beams  31   a  and  31   b  are preferably constructed of steel bars or tubing, while panel  24  is preferably one quarter inch thick steel plating. 
         [0015]    As illustrated in  FIGS. 1 and 2 , a AAR profile coupler  30  is provided on the sidewall  22   a  of the ballast load box. In addition, a pair of rollers  32   a  and  32   b  is provided on support beam  31   a  of the ballast load box bottom, the purpose for which will be explained below. 
         [0016]    The ballast load box is loaded with weights  33   a  and  33   b  ( FIG. 2 ). Weights  33   a  and  33   b  may be replaced by a single weight or an additional number of weights. Indeed, the weight placed in the ballast load box may take any number of forms including, but not limited to, bags containing sand or the like, bags or other containers filled with water and lead, concrete or steel plates or blocks. Of course, the weight of the ballast load box contributes to the total weight provided by the device. 
         [0017]    As an example only, for a ballast load box having a shell (i.e. the box  20  without the weights  33   a  and  33   b ) constructed of one half inch thick steel wall tubing having dimensions 7.5 ft. wide by 5 ft. high by 4.5 ft. deep and weighing 4,500 lbs., the following approximate total weights by material were obtained during testing: 
         [0000]      4,500 lbs+43,660 lbs=48,160 lbs   Steel plates
 
         [0000]      4,500 lbs+10,800 lbs=15,300 lbs   Concrete
 
         [0000]      4,500 lbs+4,600 lbs=9,100 lbs   Water
 
         [0000]      4,500 lbs+8,600 lbs=13,100 lbs   Sand
 
         [0000]      4,500 lbs+51,000 lbs=55,500 lbs   Lead
 
         [0018]    Of course the ballast load box may be constructed with alternative dimensions as dictated by the application and the weight used. 
         [0019]    As illustrated in  FIGS. 1 and 3  the coupler  30  is mounted on an elongated member  40 . As shown in  FIG. 3 , the elongated member  41  passes through an opening in side wall  22   a,  through the interior of the ballast load box  20  and guide  41  and exits through a collar  42  positioned on side wall  22   c.  The elongated member  40  is free to slide in the horizontal direction (as indicated by arrow  43  in  FIG. 3 ) between positions. As a result, the coupler  30  may be extended or retracted to fit different models of railcar movers. Locking holes are formed through the elongated member  40  and the collar  42 . When the desired position of coupler  30  is determined and selected, a locking pin, illustrated at  45  in  FIG. 1  and  FIG. 3  is inserted through the aligned corresponding holes in elongated member  40  and collar  42  to lock the coupler in place. Alternative locking arrangements known in the art could be used instead of the locking pin and hole arrangement described. 
         [0020]    In operation, a hydraulically-powered coupler  36  of the railcar mover is placed in a lowered position, and the coupler  30  of the ballast load box  20  is connected thereto. With referenced to  FIG. 1 , the coupler  36  is then raised so that the ballast load box is raised to increase the effective weight, and thus tractive force, of the railcar mover  8 . As the ballast load box  20  is raised, rollers  32   a  and  32   b  engage the bumper surfaces of the railcar mover  8  so as to guide and stabilize the ballast load box. 
         [0021]    As illustrated in  FIGS. 1-3 , a semi round tube  70  preferably is mounted to the bottom support beam  31   b  of the ballast load box, while a channel-shaped stand  72  (such as an inverted U-shape) preferably is mounted to the bottom support beam  31   a.  The semi-round tube  70  provides a rounded Surface When setting the ballast load box onto the rail. The channel-shaped stand  72  acts as a guide to laterally position on to the rail  12  in  FIG. 1  when the mobile car mover sets the ballast load box down to connect or disconnect from the ballast load box. 
         [0022]    As noted previously, a railcar mover may couple and move cars from either end or both ends of the railcar mover. When adding the ballast load box described above to the rail car mover, however, that end of the rail car mover cannot be used for coupling railcars. In accordance with a second embodiment of the ballast load box of the invention, indicated in general at  50  in  FIG. 4 , an auxiliary AAR coupler  52  is secured to the opposite side of the ballast box that is coupled to the railcar mover  53 . The auxiliary AAR coupler  52  may be connected to the coupler  54  of a railcar and thus would regain the use of both ends of the railcar mover. An additional airline  56  is designed into the ballast load box  50  for actuating the air brakes of the railcar coupled to the ballast load box and operating the auxiliary coupler release  58  from the railcar mover cab. The remainder of the ballast load box  50  of  FIG. 4  features the same construction as ballast load box  20  of  FIGS. 1-3 . 
         [0023]    In summary, the ballast load box is a structure that may weigh, for example, up to approximately 48,000 lbs, and incorporates an AAR profile coupler that can be extended or retracted to fit different models of railcar movers. The ballast load box is equipped with two rollers below the coupler to guide the ballast load box as it is raised and lowered by the railcar mover hydraulically-powered coupler. Using the ballast load box, the operator finds it is easier to accomplish railcar moves as compared to having an additional fifty or sixty foot loaded railcar coupled to the front of the railcar mover to get additional weight transfer for added traction. 
         [0024]    While the preferred embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the spirit of the invention, the scope of which is defined by the appended claims.