Patent Publication Number: US-2021190300-A1

Title: Railroad crossing gate lamp system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of application Ser. No. 15/872,461 filed Jan. 16, 2018, which application claims the benefit of U.S. Patent Application Ser. No. 62/445,794, filed Jan. 13, 2017, the disclosures of which are hereby incorporated by reference in their entireties. 
    
    
     BACKGROUND 
     Railroad crossing arms are in widespread use as traffic barriers at railroad road crossings. The crossing arms are normally positioned upright and are lowered to a horizontal position when an approaching train is detected. The crossing arms of railroad crossing gates are typically provided with various signal lights that are secured to the crossing arm. 
     Conventionally, three signal lights are used. A first light is disposed at the far end of the crossing arm. The remaining two lights are generally spaced along the crossing arm. It is conventional that the lights be incorporated into an electrical circuit such that the light at the far end is constantly illuminated when the crossing arm is in its horizontal position. The remaining signal lights are configured such that they alternately flash off and on. Other configurations have also been used. 
     The environments in which railroad crossing gates are employed are often harsh. Therefore, from time to time the gate lamps need to be replaced due to damage to the lamps and or damage to the gate arm itself. There is a need for gate lamp systems that are robust, modular, and easy and efficient to install. 
     SUMMARY 
     The present disclosure provides a new gate lamp system and method. The system and method is configured to facilitate the installation of the gate lamp onto a gate arm and to facilitate the replacement of one or more of the gate lamps. The present disclosure provides a system and method of installing gate lamps on a gate arm in the field in a robust manner with relative ease. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is an illustration of a gate arm with a number of gate lamps mounted thereon; 
         FIG. 2  is a top isometric view of three gate lamps electrically connected to each other according to the principles of the present disclosure; 
         FIG. 3  is an exploded isometric view of a portion of  FIG. 2 ; 
         FIG. 4  is a front isometric view of the assembled connector and cord of  FIG. 3 ; 
         FIG. 5  is a rear isometric view of the assembled connector and cord of  FIG. 3 ; 
         FIG. 6  is a rear isometric view of a connector of  FIG. 3 ; 
         FIG. 7  is a cross sectional view of the connector of  FIG. 4  along lines  4 - 4 ; 
         FIG. 8  is a front isometric view of the conductive components within the connector of  FIG. 4  with the insulated housing removed; 
         FIG. 9  is a rear end view of the conductive components of  FIG. 8 ; 
         FIG. 10  is an isometric view of a single conductive component of the connector of  FIG. 4 ; 
         FIG. 11  is a side view of the conductive component of  FIG. 10 ; 
         FIG. 12  is an isometric view of an alternative embodiment of the gate lamp of  FIG. 2 ; 
         FIG. 13  is an exploded view of the gate lamp of  FIG. 12 ; 
         FIG. 14  is a bottom isometric view of the gate lamp of  FIG. 12 ; 
         FIG. 15  is an isometric view of an inline connector connecting two flat cords according to the principles of the present disclosure; 
         FIG. 16  is a side view of the inline connector connecting two assembled connectors and cord of  FIG. 4 ; 
         FIG. 17  is a cross sectional view of a portion of  FIG. 16  along lines  17 - 17 ; 
         FIG. 18  is a cross sectional view of the inline connector of  FIG. 15 ; 
         FIG. 19  is a cross sectional view of an alternative embodiment of the connector of  FIG. 2 ; and 
         FIG. 20  is an exploded assembly view of the connector of  FIG. 19 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the FIGS. generally, the present disclosure is described in further detail below.  FIG. 1  illustrates an example cross gate arm. As is typical, the gate includes an arm  10  that pivots from a generally vertical position (as shown) to a generally horizontal position. The arm typically includes a plurality of lamps  12 ,  14 , and  16  mounted thereon. Typically the gates include three lamps. When a train is near the distal lamp  12 , the lamp lights up and stays on whereas the middle lamp  14  and the proximal lamp  16  flash in an alternating sequence. It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the lamps  12 ,  14  and  16  are EZ Gate® LED Lamps with Light Out Detection (LOD). They are railroad crossing gate arm lamps that adjust their operating current based on whether or not the lamp illuminates. The purpose of such lamps  12 ,  14  and  16  is to provide light at the gate arm  10  and to provide electrical feedback of their state of illumination. It should be understood that although in the depicted embodiment the lamps are EZ Gate® LED lamps with Light Out Detection, the lamps  12 ,  14  and  16  could alternatively be any other type of light emitting diodes (LED) or a non-LED lamp such as an ordinary incandescent bulb. It should be appreciated that the terms “lamp” and “light” are used interchangeably herein. 
     Referring to  FIG. 2 , in the depicted embodiment the lamps  12 ,  14 ,  16  are identical and interchangeable. In the depicted embodiment, what determines whether the particular lamp stays on or flashing according to a particular timing is based on how the lamp is connected and/or configured. Accordingly, only one of the lamps  12 ,  14 ,  16  will be described in further detail below. 
     Referring generally to  FIGS. 2-11 , in the depicted embodiment, the gate lamp  16  includes a lower body portion  18  that is configured to mount to a crossing gate arm  10 . In the depicted embodiment, the lower body portion  18  defines a channel in which can be fitted over the upper edge of a gate arm  10  and screwed, bolted, or clamped to the upper edge of the gate arm  10 . In the depicted embodiment, the lower body portion  18  also includes a plug portion  20 . The plug portion  20  includes at least a first conductive prong  22 , a second conductive prong  24 , and a third conductive prong  26 . It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the gate lamp system includes a connector  28  including a first end  30  that is configured to mate with the plug portion  20  of the gate lamp  16 . In the depicted embodiment, the first end  30  of the connector  28  includes a first conductive receptacle  34 , a second conductive receptacle  36 , and a third conductive receptacle  38 . In the depicted embodiment, the connector  28  is a multi-position connector. In particular, the rotational orientation of the first end  30  of the connector  28  relative to the plug  20  dictates which conductive receptacles  34 ,  36 ,  38  receive which conductive prongs  22 ,  24 ,  26 . In the depicted embodiment, depending on the rotational orientation of the connector  28  and plug  20 , the lamp  16  can be made to stay on when a train is approaching, flash at a first timing sequence, or flash at a second timing sequence. It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the system includes an electrical cord  40  having a non-circular outer profile (e.g., a flat cord as shown). In the depicted embodiment, the electrical cord  40  includes a first conductor  42 , a second conductor  44 , and a third conductor  46  therein. In the depicted embodiment, each of the first, second, and third conductors  42 ,  44 ,  46  are electrically insulated from each other with a known predefined location within the electrical cord  40 . It should be appreciated that the terms “cord” and “cable” are used interchangeably herein. Also it should be appreciated that the electrical cord  40  and conductors  42 ,  44 ,  46  can be used to deliver power and/or a control signal. It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the electrical cord  40  is connected to a second end  32  of the connector  28  such that the first conductor  42  of the electrical cord  40  is electrically connected to the first conductive receptacle  34 , the second conductor  44  of the electrical cord  40  is electrically connected to the second conductive receptacle  36 , the third conductor  46  of the electrical cord  40  is electrically connected to the third conductive receptacle  38 . It should be appreciated that many other alternative configurations are also possible. For example, the connector  28  can be rotated relative to the plug  20  to align different conductors with different receptacles. 
     In the depicted embodiment, the second end  32  of the connector  28  includes an opening  48  that is shaped to axially receive and guide the electrical cord  40  into electrical engagement with conductors within the second end  32  of the connector  28 . In the depicted embodiment, the shape of the opening  48  matches the shape of the external profile of the cord  40 . In some embodiments, the opening  48  is tapered to facilitate insertion of the electrical cord  40 . It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiments, the conductors within the second end  32  of the connector  28  include a first conductive spear  50  that is configured and arranged to axially extend into the first conductor  42  of the electrical cord  40 , a second conductive spear  52  that is configured and arranged to axially extend into the second conductor  44  of the electrical cord  40 , and a third conductive spear  54  that is configured and arranged to axially extend into the third conductor  46  of the electrical cord  40 . In the depicted embodiment, the act of extending the conductive spears  50 ,  52 ,  54  into the conductor  42 ,  44 ,  46  enables electrical connection between the two components. In the depicted embodiment, the spears  50 ,  52 ,  54  are conical in shape and displace the conductor  42 ,  44 ,  46  radially as the spear  50 ,  52 ,  54  is driving axially into the end of the conductor  42 ,  44 ,  46 . It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, a first conductive body  56  connects the first conductive spear  50  to the first conductive receptacle  34 . A second conductive body  58  connects the second conductive spear  52  to the second conductive receptacle  36 . A third conductive body  60  connects the third conductive spear  54  to the third conductive receptacle  38 . In the depicted embodiment, the spear  50 ,  52 ,  54 , the conductive body  56 ,  58 ,  60 , and the receptacle  34 ,  36 ,  38  are integrally formed of a conductive material (e.g., copper, brass, etc.). In the depicted embodiment, the body portions  56 ,  58 ,  60  that connect the spears  50 ,  52 ,  54  to the receptacle  34 ,  36 ,  38  share the same structure which can facilitate their manufacturing of the connector. It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the connector  28  is configured to receive a set screw  62  that is configured to secure the electrical cord  40  within the second end  32  of the connector  28 . It should be appreciated that many other alternative configurations are also possible. For example, the connector  28  can be configured to clamp the end of the cord  40  in place and/or the cord  40  can be potted in place with an adhesive. Referring generally to  FIGS. 19-20 , an alternative embodiment of the connector  28  that secures the electrical cord  40  differently is described. The first end of the connector  100  shares the same features and the first end of the connector  28 . However, the second end of the connector  100  is different than the second end  32  of the connector  28  in that the second end of the connector  100  is configured to secure the electrical cord  40  via a self-locking strain relief system. 
     In the depicted embodiment, the electrical cord  40  is connected to the gate lamp by pushing the cord  40  into engagement with the spears  50 ,  52 ,  54  at the second end of the connector  100  and then tightening the retaining collar  102 . The act of pushing the cord  40  into engagement with the spears  50 ,  52 ,  54  deflects the cable grip plug  104  and causes it to grab the sheathing of the cable to prevent it from being pulled outwardly. In the depicted embodiment, the cable grip plug  104  is a thin sheet of steel with feet that deflect and bite into the cable sheathing. The distance between the teeth and the upper edge of the cable opening is substantially larger than the diameter of the conductors in the electrical cord  40 . The axial location of the cable grip plug  104  is positioned to prevent shorting of the cable (i.e., the teeth are configured to not be able to contact the conductors in the cord  40 . 
     In the depicted embodiment, the connector  100  is weatherproof (waterproof). In the depicted embodiment, the second end of the connector  100  includes a first seal  106 , a second seal  108 , and a washer  110 . When the collar  102  is tightened, the seals  106 ,  108  are compressed and deform, thereby preventing moisture from permeating the connection between the connector body and the electrical cord. In the depicted embodiment, the first seal  106  includes assistive on both primary surfaces, and the second seal  108  is comprised of a soft resilient material (e.g., rubber). In the depicted embodiment, the cable grip plug  104 , the first and second seals  106 ,  108  and the washer  110  all include upper and lower locator notches that align with the outwardly extending tab of the connector body  112 . This configuration prevents these internal components from rotating as the collar  102  is tightened. 
     Referring particularly to  FIG. 9 , in the depicted embodiment, the first conductive receptacle  34 , the second conductive receptacle  36 , and the third conductive receptacle  38 , are spaced apart and positioned equal distance from a central axis CA of the connector  28 . In the depicted embodiment, the distance D 1  between the first conductive receptacle  34  and the second conductive receptacle  36  is the same as the distance D 2  between the first conductive receptacle  34  and the third conductive receptacle  38 . In the depicted embodiment, the receptacles  34 ,  36 ,  38  are positioned 120 degrees relative to each other. It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the electrical cord  40  includes a generally flat top periphery portion  62  and a generally flat bottom periphery portion  64 . In the depicted embodiment, the first conductor  42 , the second conductor  44 , and the third conductor  46  of the electrical cord  40  are arranged linearly with the body of the cord  40 . Likewise, the spears  50 ,  52 ,  54  are also arranged linearly in a row so that they axially align with the conductors  42 ,  44 ,  46  in the cord  40 . In the depicted embodiment, the plug  20  includes a cylindrical housing defining a recess wherein the first, second, and third prongs  22 ,  24 ,  26  are located. The outer surface  66  of the cylindrical housing is threaded. In the depicted embodiment, the cylindrical body of the connector  28  includes an annual flange  78  located between the first and second end of the connector  30 ,  32 . In the depicted embodiment, a cap engages the annular flange  78  configured to engage the threads  66  to secure the connector to the plug  20 . It should be appreciated that many other alternative configurations are also possible. 
     In the depicted embodiment, the system includes an inline connector  68  comprising a first end  70  and a second end  72 . In the depicted embodiment, each end is configured to axially receive and secure a distal end of an electrical cord  74 ,  76 . The inline connector  68  can facilitate installation of a lamp system where the connector and cord are pre-connected. It should be appreciated that many other alternative configurations are also possible. 
     Referring to  FIGS. 12-14 , an alternative embodiment of a gate lamp system is shown. In the depicted embodiment, a gate lamp having an upper portion  80  includes a lamp and a lower portion  82  that is configured to be secured to a crossing gate arm  10 . In the depicted embodiment, the upper portion  80  and the lower portion  82  define a through channel  84 . In the depicted embodiment, the upper portion  80  includes spaced apart staggered conductive spears  86 ,  88 ,  90  that extend downwardly towards the lower portion  82 . In the depicted embodiment, the electrical cord  92  extends through the gate lamp in the through channel  84 . The conductive spears  86 ,  88 ,  90  are arranged and configured to pierce and make electrical connection with spaced apart longitudinal conductors within the electrical cord  92 . 
     The present disclosure also provides a method of installing a gate lamp to a crossing gate arm comprising the steps of securing a gate lamp onto a crossing gate arm, connecting the gate arm to a power source by rotationally orientating a connector to a plug on the gate lamp, axially driving a flat cord into mechanical and electrical engagement with the connector, and securing the flat cord onto the crossing gate arm. It should be appreciated that the method can include more or less steps and that the steps can occur in a number of different sequences. In the depicted embodiment, the step of axially driving a flat cord into mechanical and electrical engagement with the connector occurs before the connector is electrically connected to the plug. 
     The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.