Patent Publication Number: US-2023159067-A1

Title: Railcar Uncoupling Lever Apparatus and Methods of Using the Same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present invention claims priority to U.S. Prov. Pat. App. No. 63/281,792, titled “Railcar Uncoupling Lever Apparatus and Methods of Using the Same,” filed Nov. 22, 2021, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to improved telescoping railcar uncoupling levers. Specifically, the uncoupling levers have improved bearings that resist damage. Moreover, the uncoupling levers include removable lock lifter linkage hooks. In addition, the uncoupling levers comprise an improved handle loop shape allowing the levers to be more easily installed and/or removed when damaged. Methods of using the same are further provided. 
     BACKGROUND 
     An uncoupling lever is a bar or rod of a specific shape, comprising a handle on one end thereof that is engaged to a bracket on an end of a railcar, a lock lifter linkage hook on a second end thereof that engages the lock lifter linkage of a Janney-type railcar coupler, and an extended, typically telescoping, portion between the first end and the second end thereof. When in use for uncoupling railcars, the handle engaged with the bracket is typically lifted, causing the hook end, engaged with the uncoupling mechanism of the Janney coupler, to rotate causing the Janney coupler to uncouple, causing separation of the railcars. As noted, the uncoupling levers typically have a telescoping extended element between the two ends thereof for precisely engaging the uncoupling lever between the bracket and the uncoupling mechanism of the Janney-type coupler, as different railcars may have different distances between the two. 
     Users of heretofore known uncoupling levers report that the typical service life of an uncoupling lever is about 18 months to about 3 years before the levers require replacement. In that time, the uncoupling levers may be repaired, typically due to wear and loss of bearing material that is used to allow the elongated portion to telescope. The telescoping portion generally comprises at least two lever arms that slide across the bearing material, either extending or contracting/collapsing the elongated portion to fit the needed distance between the bracket and the uncoupling mechanism of the Janney-type coupler. 
     Federal Railroad Administration (FRA) rules dictate that if in-track inspections finds that two of the bearings are missing on the side, or more than two bearings are missing overall, then the lever must be replaced before the railcar can be placed back into service. If the railcar is in the repair in place (RIP) track or service shop, and one or more bearings are missing, the lever must be replaced. Missing bearings can lead to the lever jamming when extended or contracted/collapsed due to the friction of the lever arms and subsequent bending of the lever. Bent levers must be replaced before the railcar can be returned to service. 
     A need, therefore, exists for an improved uncoupling lever apparatus. Specifically, a need exists for an uncoupling lever apparatus having a longer service life than typical heretofore known uncoupling levers. More specifically, a need exists for an uncoupling lever apparatus comprising improved bearings that resist damage, thereby preventing or minimizing bending or damage of the levers during use in the field. 
     The process of replacing an uncoupling lever typically requires the bracket, which is attached to the railcar, to be removed by torching off the colts holding the bracket to the railcar. The lever is then rotated in a way as to remove the hook end from the lifter linkage of the Janney-type coupler. Oftentimes, this is very difficult due to the narrow fit of the hook end into the uncoupling mechanism of the Janney-type coupler, as well as the relatively small space under the railcar. The new coupler is then positioned in the uncoupling mechanism of the Janney-type coupler, which again is difficult due to positioning and the space constraints, and a new bracket is often placed into the handle and then bolted back onto the railcar. 
     A need, therefore, exists for an improved uncoupling lever arm that is more easily removed and/or installed onto a railcar. More specifically, a need exists for an improved uncoupling lever arm that allows a user to remove and/or install the same without removal of the bracket from the railcar, thereby saving time and costs when levers require replacement. 
     SUMMARY OF THE INVENTION 
     The present invention relates to improved telescoping railcar uncoupling levers. Specifically, the uncoupling levers have improved bearings that resist damage. Moreover, the uncoupling levers include removable lock lifter linkage hooks. In addition, the uncoupling levers comprise an improved handle loop shape allowing the levers to be more easily installed and/or removed when damaged. Methods of using the same are further provided. 
     To this end, in an embodiment of the present invention, a railcar uncoupling lever apparatus is provided. The railcar uncoupling lever comprises: a telescoping bar having a first end and a second end; a handle on the first end of the telescoping bar; a hook on the second end of the telescoping bar, wherein the handle is configured to thread through a bracket on a railcar without removal of the bracket, and the hook is configured to be removable from the telescoping bar. 
     In an embodiment, the telescoping bar comprises a first bar portion, a second bar portion, and a third bar portion, wherein the first bar portion is slidably disposed on a first side of the second bar portion and slides relative to the second bar portion, and the third bar portion is slidably disposed on a second side of the second bar portion and slides relative to the second bar portion. 
     In an embodiment, the first bar portion is held to the second bar portion via at least one bearing. 
     In an embodiment, the third bar portion is held to the second bar portion via at least one bearing. 
     In an embodiment, the hook is removably attached to an end of the first bar portion of the telescoping bar. 
     In an embodiment, the hook is configured to engage a lifting linkage of a railcar coupler. 
     In an embodiment, the first bar portion or the third bar portion is held to the second bar portion via at least one bearing, wherein the at least one bearing is held in place by a retaining clip comprising a first plate welded to a first side of the second bar portion, a second plate welded to a second side of the second bar portion, and a third plate extending between the first plate and the second plate, wherein the first, second, and third plates form a space wherein the at least one bearing is held within the space. 
     In an embodiment, the at least one bearing is made from a thermoplastic or a thermoset material. 
     In an embodiment, the at least one bearing is a square tube, wherein the first bar portion or the second bar portion slides therethrough. 
     In an embodiment, the handle comprises a first portion extending roughly perpendicular from the telescoping bar, the handle further having a first straight portion extending from a first bend having a first angle, the handle further having a second straight portion extending from a second bend in the first straight portion having a second angle, the second straight portion extending into a loop forming a first plane that is roughly perpendicular to a second plane formed by the first straight portion and the telescoping bar, the loop extending to a third straight portion that extends back toward the second bend, a third bend extending from the third straight portion having a third angle, the third bend extending into a fourth straight portion, a fourth bend extending from the fourth straight portion having a fourth angle, the fourth bend extending into a fifth straight portion. 
     In an embodiment, the first angle is approximately 45 degrees from the telescoping bar, wherein the second angle is approximately 45 degrees from the first straight portion, wherein the third angle is approximately 90 degrees from the third straight portion, and the fourth bend is approximately 45 degrees from the fourth straight portion. 
     In an alternate embodiment of the present invention, a method of using an uncoupling lever apparatus is provided. The method comprises the steps of: providing a railcar uncoupling lever apparatus comprising a telescoping bar having a first end and a second end, a handle on the first end of the telescoping bar, a hook on the second end of the telescoping bar, wherein the handle is configured to thread through a bracket on a railcar without removal of the bracket, and the hook is configured to be removable from the telescoping bar; threading the handle of the railcar uncoupling lever apparatus through a bracket on railcar; removing the hook from the second end of the telescoping bar; disposing the hook onto a lifting linkage of a railcar coupler; and attaching the hook to the second end of the telescoping bar. 
     In an embodiment, the method further comprises the step of: telescoping the telescoping bar so that the uncoupling lever apparatus extends between the bracket on the railcar through which the handle is threaded and the lifting linkage through which the hook is disposed. 
     In an embodiment, the telescoping bar comprises a first bar portion, a second bar portion, and a third bar portion, wherein the first bar portion is slidably disposed on a first side of the second bar portion and slides relative to the second bar portion, and the third bar portion is slidably disposed on a second side of the second bar portion and slides relative to the second bar portion. 
     In an embodiment, the method further comprises the steps of: sliding the first bar relative to the second bar to extend or contract the telescoping bar or sliding the third bar relative to the second bar to extend or contract the telescoping bar. 
     In an embodiment, the first bar portion or the third bar portion is held to the second bar portion via at least one bearing, wherein the bearing is held in place by a retaining clip comprising a first plate welded to a first side of the second bar portion, a second plate welded to a second side of the second bar portion, and a third plate extending between the first plate and the second plate, wherein the first, second, and third plates form a space wherein the at least one bearing is held within the space. 
     In an embodiment, the at least one bearing is made from a thermoplastic or a thermoset material. 
     In an embodiment, the at least one bearing is a square tube and comprises the step of: sliding the first bar portion or the second bar portion through the square tube of the at least one bearing when extending or contracting the telescoping bar. 
     In an embodiment, the handle comprises a first portion extending roughly perpendicular from the telescoping bar, the handle further having a first straight portion extending from a first bend having a first angle, the handle further having a second straight portion extending from a second bend in the first straight portion having a second angle, the second straight portion extending into a loop forming a first plane that is roughly perpendicular to a second plane formed by the first straight portion and the telescoping bar, the loop extending to a third straight portion that extends back toward the second bend, a third bend extending from the third straight portion having a third angle, the third bend extending into a fourth straight portion, a fourth bend extending from the fourth straight portion having a fourth angle, the fourth bend extending into a fifth straight portion. 
     In an embodiment, the first angle is approximately 45 degrees from the telescoping bar, wherein the second angle is approximately 45 degrees from the first straight portion, wherein the third angle is approximately 90 degrees from the third straight portion, and the fourth bend is approximately 45 degrees from the fourth straight portion. 
     It is, therefore, an advantage and objective of the present invention to provide improved uncoupling lever apparatuses. 
     Specifically, it is an advantage and objective of the present invention to provide uncoupling lever apparatuses having longer service lives than typical uncoupling levers. 
     More specifically, it is an advantage and objective of the present invention to provide uncoupling lever apparatuses comprising improved bearings that resist damage, thereby preventing or minimizing bending or damage of the levers during use in the field. 
     Moreover, it is an advantage and objective of the present invention to provide improved uncoupling lever apparatuses that are more easily removed and/or installed onto railcars. 
     More specifically, it is an advantage and objective of the present invention to provide improved uncoupling lever apparatuses that allow a user to remove and/or install the same without removal of the brackets from the railcars, thereby saving time and costs when levers require replacement. 
     Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments and from the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements. 
         FIG.  1    illustrates a perspective view of a railcar uncoupling lever on a railcar in an embodiment of the present invention. 
         FIGS.  2 A- 2 B  illustrate expanded and collapsed views, respectively, of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  3    illustrates a top view of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  4    illustrates a front view of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  5    illustrates a side view of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  6    illustrates a cross-sectional view along lines VI-VI of  FIG.  4    of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  7    illustrates an exploded view of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  8    illustrates a close-up exploded view of a hook of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  9    illustrates a close-up view of a hook of a railcar uncoupling lever in an embodiment of the present invention. 
         FIG.  10    illustrate a close-up exploded view of a hook of a railcar uncoupling lever in an alternate embodiment of the present invention. 
         FIG.  11    illustrates a close-up view of a hook of a railcar uncoupling lever in an alternate embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS 
     The present invention relates to improved telescoping railcar uncoupling levers. Specifically, the uncoupling levers have improved bearings that resist damage. Moreover, the uncoupling levers include removable lock lifter linkage hooks. In addition, the uncoupling levers comprise an improved handle loop shape allowing the levers to be more easily installed and/or removed when damaged. Methods of using the same are further provided. 
     Referring now to  FIG.  1   , a railcar uncoupling lever  10  is illustrated in an embodiment of the present invention. The railcar uncoupling lever  10  comprises a handle  12  that is engaged on the end of a railcar  1  via a ring bracket  2 . The uncoupling lever  10  generally extends via a telescoping mid portion  14  from the ring bracket  2  on one end thereof to a railcar coupler  3  and is connected to a lifting linkage  4  via a hook  16  on an opposite end of the uncoupling lever  10  from the handle  12 . In use, a user lifts or rotates the handle  12  of the uncoupling lever  10 , which subsequently lifts the hook  16 , which lifts the lifting linkage  4 , thereby opening the railcar coupler  3  and allowing the railcar to disengage from an adjacent railcar. 
       FIGS.  2 A and  2 B  illustrate the railcar uncoupling lever  10  in an extended configuration ( FIG.  2 A ) and in a collapsed or contracted configuration ( FIG.  2 B ). Generally, the handle  12  may extend from a first end  20  of a first bar  22 , and may extend through first and second bearings  24 ,  26 , respectively, which may allow the first bar  22  to slide therethrough. The bearings  24 ,  26  may be held via retaining clips, as described in more detail below with reference to  FIG.  7   , to a central bar  28  on a first side thereof. A cap or plate  29  may be attached to an opposite end  21  of the first bar  22  to prevent the first bar  22  from sliding completely through the first and second bearings  24 ,  26 . 
     The hook  16  may be attached on a first end  30  of a second bar  32 , and may extend through third and fourth bearings  34 ,  36 , respectively, which may allow the second bar  32  to slide therethrough. The bearings  34 ,  36  may be held via retaining clips, as described in more detail below, to the central bar  28  on a second side thereof. A cap or plate  39  may be attached to a second end  31  of the second bar  32  and act as a stopper to prevent the second bar  32  from sliding completely through the third and fourth bearings  34 ,  36 . 
     Thus, both the first bar  22  having the handle  12  thereon and the second bar  32  having the hook  16  thereon may slide relative to the central bar  28 , thereby telescoping between an extended configuration, as illustrated in  FIG.  2 A , and a collapsed or contracted configuration, as illustrated in  FIG.  2 B . 
       FIGS.  6  and  7    illustrate how the bearings  24 ,  26 ,  34 ,  36  are disposed over the first and second bars  22 ,  32 , respectively, and allow the first and second bars  22 ,  32  to slide therethrough. Specifically, as shown in  FIG.  7   , the bearings  24 ,  26 ,  34 ,  36  may each be a square tube of slidable material, such as a thermoplastic or thermoset material that may allow the first and second bars  22 ,  32  to slide therethrough relatively freely. The bearings are held in a fixed relative position to the central bar  28  via clips  124 ,  126 ,  134 ,  136  that may be disposed over the bearings  24 ,  26 ,  34 ,  36 , respectively, and welded to the central bar  28 . 
     As shown in  FIG.  6   , which is a cross-sectional view of the uncoupling lever  10  along lines VI-VI of  FIG.  4   , retaining clip  124  is illustrated. The retaining clip may have a top face  140 , a side face  142 , and a bottom face  144 , each of the faces having tabs  150  on opposite sides thereof extending inwardly, wherein the tabs  150  generally hold the bearing  24  in place prevent the bearing  24  from moving relative to the central bar  28 . The top face  140  may have an extension element  141  that may extend over and may be welded to the central bar  28  on a top thereof, whereas the bottom face  144  may have an extension element  145  that may extend over and may be welded to the central bar  28  on a bottom thereof. Thus, the retaining clips  124 ,  126 ,  134 ,  136  may hold each of the respective bearings  24 ,  26 ,  34 ,  36  in place relative to the central bar  28  and prevent them from sliding along the first and second bars  22 ,  32 . Because the retaining clips encapsulate each of the bearings  24 ,  26 ,  34 ,  36 , the bearings may be relatively more resilient and remain in place after continued use of the uncoupling lever  10 . 
     Although the bearings  24 ,  26 ,  34 ,  36  are shown as square tubes in the embodiments herein, it should be noted that the bearings may conform to the shape of the tubes on which they are disposed. For example, the first and second bars  22 ,  32  may be round in cross-section rather than rectangular or square in cross-section, and therefore the bearings  24 ,  26 ,  34 ,  36  may also be round. The bearings may also be roller bearings, having rolling balls or wheels therein to aid in moving the first and second bars  22 ,  32  therethrough. 
     Referring now to  FIGS.  3 - 5   , various views of the uncoupling lever are shown, mainly to illustrate the arrangement and configuration of the handle  12 . As illustrated, the handle  12  may extend from the first end  20  of the first bar  22 . The handle  12  may comprise a first vertical portion  40  that may be welded to the first bar  22 , or otherwise extend through the first bar  22  and be welded thereto to rigidly hold the first vertical portion  40 . The first vertical portion may have a first bend  42  so that a first straight portion  44  extends at roughly a 135-degree angle from the first vertical portion  40 , or 45 degrees relative to the central bar  28 . The first straight portion  44  may have a second bend  46  forming a second vertical portion  48  extending from the first straight portion at roughly a 45-degree angle relative to the first straight portion  44 . The second vertical portion  48  may extend into a loop  50  forming a plane that is roughly perpendicular to a plane formed by the first straight portion  44  and the central bar  28 . The loop  50  may extend to a third straight portion  52  that extends back toward the second bend  46  within the second plane and may form a third bend  54  that extends into a fourth straight portion  56  from the third bend at roughly 90 degrees relative to the third straight portion  52  that, in turn, extends into a fourth bend  58  that extends into a third vertical portion  59 , wherein the third vertical portion  59  extends at roughly 45 degrees relative to the fourth straight portion  54  at the fourth bend  58 . 
     A user may utilize the configuration and arrangement of the handle  12  to allow the handle to be placed into the bracket  2  of the railcar  1 , as illustrated in  FIG.  1   . Specifically, the uncoupling lever  10  may be turned upside down so that the third vertical portion  59  may be threaded through the bracket  2 , wherein the various bends, vertical portions, and straight portions, may traverse through the bracket  2  until the uncoupling lever  10  is turned right side up as shown in  FIG.  1   . The uncoupling lever  10  may be removed from the bracket  2  by threading the handle  12  therethrough in reverse to the steps disclosed above. 
     To aid in the installation and/or removal of the uncoupling lever  10 , the hook  16  may be removable from the second bar  32 . Removing the hook  16  allows a user to handle and manipulate the remainder of the uncoupling lever  10  in an easier and more efficient manner, without the hook making it difficult to maneuver the same due to the low clearance near the coupler. 
       FIGS.  8 - 11    illustrate embodiments of the removable hook  16 , showing two alternate configurations. It should be noted that although the present invention discloses two alternate configurations, there may be other configurations not shown herein and the present invention should not be limited as disclosed herein. 
       FIGS.  8 - 9    illustrate a first hook configuration, showing the hook  16  having a first vertical element  60  having a first bend  62  extending into a first straight portion  64  which may extend at a greater than 90-degree angle relative to the first vertical element  60 . The first straight portion  64  may extend to a roughly 180-degree bend  66  terminating in a second straight portion  68 . The configuration of the hook  16  may allow the same to be engaged with the lifting linkage of the Janney-type coupler, thereby allowing the coupler to be uncoupled when the uncoupling lever  10  is lifted or rotated via the handle  12 . 
     The first vertical portion  60  may be welded to an insert tube  70  having an aperture  71  therethrough. As shown in  FIGS.  8  and  9   , the insert tube  70  may be inserted into the second bar  32  and secured via a bolt  72  and nut  74  through an aperture  73  within the second bar and the aperture  71  within the insert tube  70 . 
     In an alternate embodiment, illustrated in  FIG.  10 - 11   , the first vertical portion  60  may be inserted into a passage  86  within a tube extension  80  and welded therein for additional strength. The tube extension  80  may further have an aperture  81  therein. As shown in  FIGS.  10 - 11   , the tube extension  80  may be disposed over the second bar  32 , which may have an aperture  83  therein so that a bolt  82  may extend through the aperture  81  within the tube extension  80  and the aperture  83  and secured with a nut  84 . 
     Thus, when installed between a railcar ring bracket and a lifting linkage of a coupler, the hook  16  may be removed from the lever apparatus  10 , the handle may be threaded into and through the ring bracket of the railcar, as described above, and the hook  16  may be reattached thereto and connected to the lifting linkage of the coupler. Therefore, the lever apparatus  10  may be installed and/or removed without removal of the ring bracket. Moreover, handling and manual manipulation of the lever apparatus  10  may be easier than heretofore known, even with the space constraints between adjacent railcars and beneath the coupler. 
     It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to “the invention” are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.