Abstract:
The present disclosure relates to brake control systems for the control of air brakes on rail vehicles. More particularly, the present disclosure relates to a unitized brake assembly including a pipe bracket coupled to a combined brake cylinder-empty/load reservoir and a control valve mounted on the pipe bracket.

Description:
[0001]    This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 61/006,137, filed Dec. 26, 2007, which is expressly incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates to brake control systems for the control of air brakes on rail vehicles. More particularly, the present disclosure relates to a unitized brake assembly including a pipe bracket coupled to a brake cylinder and a control valve mounted on the pipe bracket. 
         [0003]    In a “single-sided” type pipe bracket and control valve arrangement, it is known to mount an emergency and a service portion of a control valve to a common or front face of a pipe bracket and have ports for the brake cylinder, brake pipe and reservoirs on the opposing or back face of the pipe bracket, as noted in U.S. Pat. No. 5,478,142. A retainer valve is mounted to the front face of the pipe bracket between the service and emergency portions and a cut-off cock is mounted to the brake pipe port on the back face. The pipe bracket is mounted to the rail vehicle by cantilevered flanges. 
         [0004]    Each of the various known mounting options requires a great deal of piping between the pipe bracket and, for example, the brake cylinder, empty-load device and auxiliary and emergency reservoirs. The combination of the mountings on the pipe bracket and the piping requirements make for a crowded or cramped arrangement for maintenance and operations purposes. Moreover, mounting of the components and connection of all the piping leads to excessive labor and parts inventory costs. 
         [0005]    It is known, for example, from U.S. Pat. No. 4,058,348 to mount a control valve and a brake cylinder to a pipe bracket and to have this unitized assembly mounted to a rail vehicle using bolts to mount both the pipe bracket and the brake cylinder to the rail vehicle. The unitized assembly disclosed does not provide a provision for an empty-load device. 
         [0006]    It is also known, for example, from U.S. Pat. No. 4,498,712, to connect a separate empty-load device to a brake cylinder-control valve arrangement via piping connections. 
       SUMMARY 
       [0007]    In accordance with the present disclosure, a unitized brake assembly for operating the brakes on a rail vehicle comprises a pipe bracket including at least a brake cylinder port, a brake pipe port, a reservoir port and control valve ports. The unitized brake assembly also includes a control valve mounted on the pipe bracket and further includes a plurality of ports mated with the control valve ports on the pipe bracket. 
         [0008]    In an illustrative embodiment, the unitized brake assembly includes a combined brake cylinder-empty/load reservoir having a plurality of ports and also including at least one mounting flange configured to mount the unitized brake assembly directly to the rail vehicle. 
         [0009]    In this illustrative embodiment, the unitized brake assembly includes the pipe bracket mounted on and supported by the combined brake cylinder-empty/load reservoir with the brake cylinder port of the pipe bracket mating with the brake cylinder port of the combined brake cylinder-empty/load reservoir and the empty/load reservoir port of the pipe bracket mating with the empty/load reservoir port of the combined brake cylinder-empty/load reservoir. And, the brake cylinder-empty/load reservoir mounting flange is the only mounting of the unitized brake assembly to the rail vehicle. 
         [0010]    In another illustrative embodiment, the unitized brake assembly includes a pipe bracket including at least a brake cylinder port, a brake pipe port, a reservoir port, control valve ports and empty-load ports. A control valve is mounted to the pipe bracket and includes a plurality of ports mated with the control valve ports on the pipe bracket. A combined brake cylinder-empty/load reservoir is mounted to the pipe bracket and includes a brake cylinder port mated with the brake cylinder port on the pipe bracket and an empty/load reservoir port mated with a reservoir port on the pipe bracket. An empty-load device is mounted to the pipe bracket and includes a plurality of ports mated with the empty-load ports on the pipe bracket. 
         [0011]    In the illustrative embodiments of the unitized brake assembly, the coupling of components, such as the empty-load device, the control valve and the brake cylinder directly to the pipe bracket, may be provided by a sealable port or other connection between surfaces of the pipe bracket and surfaces of the components, thereby eliminating the need for piping connections between the pipe bracket and the components. In the illustrative embodiments of the unitized brake assembly, the unitized brake assembly may also include additional components such as a retainer valve mounted to the pipe bracket via a sealable port connection between surfaces of the pipe bracket and the retainer valve. 
         [0012]    Other aspects of the present disclosure will become apparent from the following descriptions when considered in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    The detailed description particularly refers to the accompanying figures. 
           [0014]      FIG. 1  is a perspective view of a unitized brake assembly, in accordance with the present disclosure. 
           [0015]      FIG. 2  is a top view of the unitized brake assembly of  FIG. 1 . 
           [0016]      FIG. 3  is another perspective view of the unitized brake assembly of  FIG. 1 . 
           [0017]      FIG. 4  is an exploded view of the unitized brake assembly of  FIG. 1 . 
           [0018]      FIG. 5  is another exploded view seen from the rear of the unitized brake assembly of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    It is within the scope of the present disclosure that a unitized brake assembly  10  includes components such as a combined brake cylinder-empty/load reservoir  12 , a control valve  14 , and a pipe bracket  20 , and may include one or more additional components such as a retainer valve  24  and an empty-load proportioning valve  26 . The unitized brake assembly  10  is configured such that the included components are packaged on a framework as an integrated unit including direct coupling via sealable fluid connections between one or more surfaces of the pipe bracket  20  and the surfaces of the combined brake cylinder-empty/load reservoir  12 , control valve  14 , empty-load proportioning valve  26 , and retainer valve  24 . A piping connection exists between a combined auxiliary/emergency reservoir and the pipe bracket  20  and a brake pipe connection to the pipe bracket  20 . 
         [0020]    Such a unitized brake assembly  10  is designed to provide a pre-assembled, pre-tested brake assembly to the customer or rail vehicle builder. Elimination of piping connections between, for example, components such as the pipe bracket  20  and the combined brake cylinder-empty/load reservoir  12 , the empty-load proportioning valve  26 , and the retainer valve  24  reduces the potential for fluid leakage from piping connections. And, co-location of all brake equipment on the rail vehicle would provide for easier maintenance and service operations. 
         [0021]    A unitized brake assembly  10  is shown in  FIGS. 1-5 . Unitized brake assembly  10  comprises the combined brake cylinder-empty/load reservoir  12 , pipe bracket  20  and the control valve  14  mounted on opposite sides or faces or surfaces of and coupled directly to pipe bracket  20 . The brake cylinder portion of the combined brake cylinder-empty/load reservoir  12  is identified as  12 X and the empty/load reservoir portion is identified as  12 Y. Brake cylinder  12 X and empty/load reservoir  12 Y may be formed integrally, monolithically or otherwise combined to form the combined brake cylinder-empty/load reservoir  12 . 
         [0022]    Pipe bracket  20  is configured as a single-sided pipe bracket, in that the control valve  14  is mounted on only one side or surface of pipe bracket  20 . Control valve  14  includes a service portion  16  with manual release valve  17  and an emergency portion  18  mounted to matching ports on a front surface  22  of pipe bracket  20 , as suggested in  FIGS. 1 ,  2 ,  4  and  5 . Service portion  16  is mounted to pipe bracket  20  via bolts  520  extending from pipe bracket  20  and via nuts  520 A. 
         [0023]    Manual release valve  17  is mounted to service portion  16  via bolts  17 A. Emergency portion  18  is mounted to pipe bracket  20  via bolts  620  extending from pipe bracket  20 , mounting holes  620 A on emergency portion  18  and nuts  620 B. 
         [0024]    Unitized brake assembly  10  also includes a retainer valve  24  mounted to pipe bracket  20  via bolts  124  and threaded openings  320 A on integral extension  320  extending upwardly from top surface  52  and being flush with front surface  22  of pipe bracket  20 . Retainer valve  24  mates with pipe bracket  20  via sealable port  224  on retainer valve  24  and sealable port  420  on extension  320  of pipe bracket  20 . 
         [0025]    Combined brake cylinder-empty-load reservoir  12  includes sealable ports  13  and  13 A configured to mate with sealable ports  21  and  21 A, respectively, on pipe bracket  20  using O-rings  23  and  29 , respectively, therebetween. 
         [0026]    Unitized brake assembly  10  further includes an empty-load proportioning valve  26  mounted to pipe bracket  20  via bolts  126  and threaded openings  128  on a left surface  28  of pipe bracket  20 . Empty-load valve  26  mates with pipe bracket  20  via three sealable ports  120 ,  121  and  122  on pipe bracket  20  connecting the empty-load valve to the brake cylinder  12 X, empty/load reservoir  12 Y and control valve  14 . Empty-load valve  26  also includes sealable port  226  configured to function as an empty-load sensing port. 
         [0027]    Mounting of an empty-load device on a face of a pipe bracket, which pipe bracket is different from a pipe bracket to which a control valve is mounted, is known in the rail industry. However, as disclosed herein, integrating the empty/load reservoir  12 Y with brake cylinder  12 X to form combined brake cylinder-empty-load reservoir  12  and mating it to pipe bracket  20  via sealable ports  13 ,  13 A,  21  and  21 A is an innovative variation of and improvement from what is known. 
         [0028]    Pipe bracket  20  is mounted on combined brake cylinder-empty/load reservoir  12  via bolts  212  extending from brackets  112 , as shown in  FIGS. 4 and 5 . Bolts  212  are inserted into and through mounting holes  220 A on brackets  220 , which brackets  220  are coupled to or integrally or monolithically formed with and extend from pipe bracket  20  and face toward combined brake cylinder-empty/load reservoir  12 . Bolts  220  are secured by nuts  220 B. 
         [0029]    Combined brake cylinder-empty/load reservoir  12  includes a rail vehicle mounting foot or flange  31  extending from a longitudinal side  12 A of combined brake cylinder-empty/load reservoir  12  facing towards a rear surface  42  of pipe bracket  20 , as shown in  FIGS. 2 and 4 . Mounting flange  31  extends outwardly from an end  12 B of combined brake cylinder-empty/load reservoir  12  and from a right surface  58  of pipe bracket  20 . Mounting flange  31  includes rail vehicle mounting holes  34 A and  34 B to couple combined brake cylinder-empty/load reservoir  12  to the rail vehicle. 
         [0030]    Combined brake cylinder-empty/load reservoir  12  further includes another rail vehicle mounting foot or flange  33  extending outwardly from an opposite longitudinal side  12 C and from end  12 B of combined brake cylinder-empty/load reservoir  12 , as shown in  FIGS. 3 ,  4  and  5 . Mounting flange  33  includes rail vehicle mounting holes  35  to couple combined brake cylinder-empty/load reservoir  12  to the rail vehicle, as shown in  FIGS. 2 ,  3  and  5 . 
         [0031]    Mounting flanges  31  and  33  extend past end  12 B for stability and mounting holes  34 A and  34 B are offset or displaced from one another to provide access for installation and/or maintenance, as shown in  FIGS. 2 ,  4  and  5 . Mounting holes  34 A,  34 B and  35  are located outside a center of gravity of the mounted control valve  14 . However, the center of gravity of unitized brake assembly  10  is located between the mounting holes  34 A and  34 B for stability. The mounting of the combined brake cylinder-empty/load reservoir  12  to the rail vehicle is accomplished via bolts (not shown) extending through mounting holes  34 A,  34 B and  35 . 
         [0032]    The mounting of the pipe bracket  20  on the combined brake cylinder-empty/load reservoir  12  via bolts  212 , brackets  220  and nuts  220 B makes for rigid connections in order to reduce vibrations that may be transmitted from the rail vehicle to the service and emergency portions  16 ,  18 , of control valve  14 , (which may be constructed of aluminium) and to the retainer valve  24  (which may be made of plastic). Vibrations are also reduced because the combined brake cylinder-empty/load reservoir  12  is made of or includes cast iron which has natural vibration damping properties. These rigid connections help to protect vibration-susceptible components. 
         [0033]    As noted, pipe bracket  20  is connected to combined brake cylinder-empty/load reservoir  12  by four connections via bolts  212 . The combined brake cylinder-empty/load reservoir  12  is connected to the rail vehicle by a plurality of bolts (not shown) via mounting flanges  31  and  33  and mounting holes  34 A,  34 B and  35 . Previously in the art, the pipe bracket  20  was connected by brackets to the rail vehicle. The present disclosure provides for a different footprint and for a more stable connection. 
         [0034]    The fluid connection between combined brake cylinder-empty/load reservoir  12  and pipe bracket  20  is provided via a sealable ports  13 ,  13 A,  21  and  21 A via O-rings  23  and  29 , as shown in  FIGS. 4 and 5 , thereby eliminating a need for a piping connection between pipe bracket  20  and combined brake cylinder-empty/load reservoir  12 . 
         [0035]    The coupling or fluid connection between retainer valve  24  and pipe bracket  20  is provided via a sealable port  420  on extension  320  of pipe bracket  20  and a sealable port  224  on retainer valve  24 , as suggested and shown in  FIGS. 4 and 5 . 
         [0036]    The fluid connection between combined brake cylinder-empty/load reservoir  12  and pipe bracket  20  via sealable ports  13 ,  13 A,  21  and  21 A eliminates a need for a piping connection between the empty-load proportioning valve  26  and the empty/load reservoir  12 Y in that the empty/load reservoir  12 Y would normally be connected to the empty-load proportioning valve  26  and not to the pipe bracket  20 . 
         [0037]    The fluid connection between the empty-load proportioning valve  26  and the pipe bracket  20  is provided via the three sealable ports  120 ,  121 ,  122  on pipe bracket  20 , as shown in  FIGS. 4 and 5 , and corresponding sealable ports (not shown) on empty-load valve  26 , thereby eliminating a need for a piping connection between pipe bracket  20  and empty-load valve  26 . The three sealable ports  120 ,  121  and  122  are for the brake cylinder  12 X, control valve  14 , and empty/load reservoir  12 Y. An example of the ports and their relationship, as well as an example of a combined load sensing and proportioning valve, are shown in U.S. Pat. No. 6,206,483. The empty-load proportioning valve  26  include a means (not shown) to proportion fluid to brake cylinder  12 X via the pipe bracket  20  as a function of the load of the rail vehicle. Two connections of a separate empty-load sensor (not shown) may be connected at port  46  on pipe bracket  20  for the brake cylinder connection and at port  54  on the empty/load reservoir  12 Y for the empty/load reservoir connection, as shown in  FIGS. 1 ,  2  and  4 . An example of the separate proportioning valve and load sensor is shown in U.S. Pat. No. 6,666,528. 
         [0038]    The pipe bracket  20  includes a plurality of pipe flange connectors  44 ,  46 ,  48 ,  50 , shown, for example, on top surface  52  (see  FIG. 2 ), to allow for installation of selected piping connections. Pipe flange connectors  44 ,  46 ,  48  and  50 , and possibly additional pipe flange connectors on other surfaces of the pipe bracket  20  (not shown), are configured to receive fluid piping connections from one or more of a brake pipe, an auxiliary reservoir, and an emergency reservoir (not shown), and the empty-load sensor. The emergency and auxiliary reservoirs may be combined in a two-compartment reservoir having separate auxiliary and emergency piping connections for connection to the pipe bracket  20 . 
         [0039]    Thus, for example, the pipe flange connector  44  is for the brake pipe via cutoff-valve and dirt collector. The connector  46  is for the empty-load sensor (not shown). The connector  48  is for the auxiliary reservoir and the connector  50  is for the emergency reservoir. Pipe bracket  20  may also include lifting provisions  40 , as shown, for example, in  FIGS. 1 ,  3 ,  4  and  5 , for ease of movement and/or installation of the unitized brake assembly  10 . Pipe bracket  20  may also include a brake cylinder pressure tap or test port  56  mounted, for example, on front surface  22 , as shown, for example, in  FIG. 4 . 
         [0040]    Although the present disclosure has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The scope of the present disclosure is to be limited only by the terms of the appended claims.