Abstract:
A method designed to replace a compromised instrument case with a new case without the need to disconnect any wire, relay or any other electric equipment is described herein. The instrument panel is supported for example by a temporary support frame during the dismantling of the old case and the assembly of the new case. The new case is therefore assembled on site around the instrument panel. The new instrument case includes a floor which is made of at least two parts, one on each side of the wiring. The instrument case therefore remains in a normal working mode during the entire replacement procedure thus preventing downtime. As well, the amount of manpower required for the replacement of an instrument case is drastically reduced.

Description:
This application is a Continuation of PCT/CA2010/001539, filed 27 Sep. 2010, which claims benefit of Ser. No. 2,680,941, filed 29 Sep. 2009 in Canada and which applications are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications. 
    
    
     The present invention generally relates to instrument cases such as those used in the railroad industry. More specifically, the present invention is concerned with a method to replace such an instrument case and a replacement case therefor. 
     BACKGROUND 
     Railroad track electrical equipments are often located in cases and bungalows along the railroad track. These electrical equipments are primarily used to control rail traffic and crossing gates. 
     Many of these units were installed more than 50 years ago using either painted steel or galvanized metal. Over time, the environment has caused many of them to rust and corrode creating a potential safety hazard. 
     This compromised metal may allow insects, rodents, rain, and/or snow to penetrate the cases which can cause the electrical components to malfunction. 
     Some cases must also be replaced by bigger cases or bungalows to accommodate new, updated or additional equipments. 
     The current replacement procedure for the instrument cases in the railroad track industry is as follows: 
     1) The traffic on the track is slowed down or stopped; 
     2) All wiring, relays and other electrical components within the compromised instrument case are disconnected and removed; 
     3) The compromised instrument case is cut up and removed; 
     4) A new instrument case is installed on top of the new base; 
     5) The wiring, relays and other electrical equipment are reinstalled inside the new instrument case; 
     6) All the electrical connections are tested; 
     7) The old instrument case and components are discarded; 
     8) The track is re-opened for operation. 
     This procedure involves a tremendous labor cost, risks of misconnection and reduced track speed for a relatively long period of time. 
     SUMMARY 
     The method to replace an instrument case and replacement case therefor according to embodiments described herein are designed so that instrument cases can be replaced without the disconnection of any wire, relay or any other electric equipment. The instrument cases remain in operation during the entire replacement procedure thus preventing downtime, and, more specifically in the railroad industry, alleviating the need for train slowdown. As well, the amount of manpower is drastically reduced. 
     The method to replace an instrument case and replacement case therefor according to embodiments of the present invention are adaptable to any instrument case, cabinet or bungalow which uses one or multiple doors located on either side of the unit. It is also applicable to pole mount cabinets. More generally, the method to replace an instrument case according to illustrative embodiments of the present invention can be used to replace cases, cabinets or bungalows in many industries in addition to the railroad industry including, without limitations, the telecommunication industry and the energy distribution industry. 
     More specifically, in accordance with an embodiment of the present invention, there is provided a method for replacing an old instrument case with a new instrument case, the old instrument case including at least one instrument panel, the method comprising: 
     supporting each of the least one instrument panel; 
     removing the old instrument case; 
     installing the new instrument case and securing each of the at least one instrument panel thereto; 
     removing support from each of the at least one instrument panel. 
     According to another embodiment of the present invention, there is provided a new instrument case for replacing an old instrument case, the old instrument case including at least one instrument panel connected from outside the old instrument case through wiring, wherein the new instrument case comprising: 
     a peripheral wall including at least one opening; the peripheral wall having top and bottom ends; 
     at least one door, each to be movably mounted in a respective one of the at least one opening; 
     a roof for mounting to the peripheral wall at the top end thereof for closing the top end; and 
     a floor for mounting to the peripheral wall at the bottom end thereof for closing the bottom end; 
     the improvement wherein: 
     the floor being assembled from at least two sections and including at least one aperture for allowing passage to the wiring. 
     The expression “instrument panel” is to be construed herein as comprising any board, panel, sheet or support that includes electrical or electronic components or a combination thereof including without limitation circuitries, wirings, etc, used for any application including control, command, statistics, etc. 
     The expression “instrument case” is to be construed herein as including any case, casing, housing, bungalow, or any similar construction that includes an instrument panel. 
     Other objects, advantages and features of the present invention will become more apparent upon reading the following non restrictive description of embodiments thereof, given by way of example only with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the appended drawings: 
         FIG. 1  is a flowchart of a method for replacing an old instrument case with a new instrument case; 
         FIG. 2  is a perspective view of a temporary holding structure being mounted to the electric panel of an existing instrument case (not shown); 
         FIG. 3  is a perspective view of the floor of the old instrument case, illustrating the cutting of the floor on both sides of the wiring protective tube; 
         FIG. 4  is a perspective view similar to  FIG. 2 , showing the temporary holding structure mounted to the electric panel, and replacement anchor plates being mounted to the concrete base; 
         FIG. 5  is a perspective view similar to  FIG. 2 , showing a replacement two-door instrument case subfloor being installed; 
         FIG. 6  is a perspective view of a replacement instrument case wall and roof being installed; 
         FIG. 7  is a perspective view of a replacement instrument case insulated floor being installed; 
         FIG. 8  is a perspective view of a replacement instrument case door gasket being installed; 
         FIG. 9  is a perspective view of a replacement instrument case doors being applied; 
         FIG. 10  is a perspective view of a replacement instrument case wall and ceiling insulation being installed; 
         FIG. 11  is a perspective view of a replacement instrument case sealant being applied; 
         FIG. 12  is an exploded view of a four-door replacement instrument case according to a second embodiment of the present invention; 
         FIG. 13  is a perspective view of the four-door replacement case from  FIG. 12 ; and 
         FIG. 14  is a perspective view of a replacement bungalow according to a third embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one”, but it is also consistent with the meaning of “one or more”, “at least one”, and “one or more than one”. Similarly, the word “another” may mean at least a second or more. 
     As used in this specification and claim(s), the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “include” and “includes”) or “containing” (and any form of containing, such as “contain” and “contains”), are inclusive or open-ended and do not exclude additional, non-recited elements or process steps. 
     The term “about” is used to indicate that a value includes an inherent variation of error for the device or the method being employed to determine the value. 
     With reference to  FIG. 1 , a method  100  for replacing an old instrument case (not shown) with a new instrument case  10  (see  FIG. 11 ) will now be described. The new instrument case  10  will also be referred to herein as the replacement case  10  or the new replacement case  10 . 
     The old instrument case includes an instrument panel  12  that is part of one or more networks and that is connected thereto through wires  14  and  16  (see  FIG. 3 ). Depending on the functions of the instrument panel  12 , the wires  14  and  16  can be of the electric, optical, coaxial or power type or else. As will be described further in more detail, the method  100  allows the instrument panel  12  to remain in operation throughout the replacement of the old case with the new case  10 , i.e. during steps  102  to  110 . 
     It is to be noted that the configuration and nature of the wires  14  and  16  are provided for illustration purposes only and as an example and should not be used to limit the scope of the present invention. 
     In the first step  102 , a temporary holding structure  18  is removably mounted to the instrument panel  12 . 
     In cases where the old instrument case is provided with two or more instrument panels accessible through a corresponding number of doors on each side of the case, a temporary holding structure  18  is used for each instrument panel as will be described hereinbelow in more detail. 
     In step  104 , the old instrument case is removed. 
     Many means and tools can be used to remove the old case, depending on its configuration, construction and on whether or not some parts thereof are to be recycled. The removing of the old case may include part or total dismantling or destruction thereof. Great care is given however to not disconnect the wires  14  and  16 . 
     In step  106 , the replacement case  10  is installed and, in step  108 , the instrument panel  12  is secured thereto. 
     The temporary holding structure  18  can then be removed from the instrument panel  12 . 
     Alternatively, in some application, the panel holding structure  18  is omitted and the instrument panel is supported for example by workers, adapted machinery or else. 
     Each of the steps  102  to  108  will now be described in more detail with references to  FIGS. 2 to 11 . 
     Prior to step  102 , the front and back doors of the compromised instrument case are removed or at least open (not shown), any batteries are removed and placed on the side of the instrument case while leaving them connected. 
     The front and rear surfaces of the instrument panel  12  are thus exposed. It is to be noted that, for clarity purpose, the compromised instrument case is not illustrated in the appended figures. Also, the wires  14  and  16  connected thereto will be omitted on most figures, also for clarity purpose. 
     Once the instrument panel  12  is exposed, the panel holding structure  18  is installed (step  102 ). 
     With reference to  FIG. 2 , the panel holding structure  18  includes four diagonal arms  20  for mounting to the instrument panel  12  and four upright legs  22 , each for a receiving respective diagonal arm  20  and to be positioned on the ground. Each leg  22  includes a foot  26  in the form of a rectangular plate. 
     The instrument panel  12  receives the four diagonal arms  20  via respective brackets  24  secured to the diagonal arms  20  for example via welding. According to the illustrated embodiment, the brackets  24  of facing diagonal arms  20  are bolted together through the central panel  12 . 
     According to the illustrated embodiment, the diagonal arms  20  and the legs  22  are made of angle-iron provided with a plurality of mounting holes  28  and  30  allowing the interconnection of the arms  20  to the legs  22  notwithstanding the height at which each arm  20  is mounted to the instrument panel  12 . Fasteners  25  are used to mount the arms  20  to the legs  22 . As will now appear obvious to a person skilled in the art, each arm  20  can be positioned at a different height relative to its respective leg  22  allowing stabilizing the panel  12  on an uneven ground. 
     Each pair of legs  22  on a same side of the panel  12  are interconnected by a respective cross-bar  29 . 
     The configuration of the holding structure  18  is not limited to the embodiment illustrated in  FIG. 2 . For example, the diagonal arms  20  can be replaced by an L-shaped member. Other means can also be provided to adjustably assemble the frame members. Clamps, brackets, etc. or simply other fastening means may replace the fasteners. Also, the foot  26  can be replaced by a pile stake. The mounting position of the brackets  24  on the panel  12  may also be different than the one illustrated depending on the available space thereon. It is also not necessary that a pair of brackets  24  be positioned on opposite side faces of the panel  12  so as to face and be secured together. 
     The panel holding structure  18  is adapted to the configuration of the instrument case and more specifically to the number and configuration of the doors thereof. For example, two pairs of facing panel holding structures as shown in  FIG. 2  can be used for instrument cases having four doors, i.e. two on each side, and two panels  12 . If the instrument case includes a single door (not shown), a holding structure wherein the lower end of the instrument panel  12  is supported can be provided (not shown). 
     Once the arms  20  are mounted to the instrument panel  12  and to the legs  24 , and once the plates  26  are all properly seated on the ground, the compromised instrument case can be dismantled (step  104 ), leaving the instrument panel  12  untouched and all the electrical interconnections intact. 
     As described hereinabove, the removal of the old case is similar to the corresponding step from the instrument case replacement method from the prior art. A difference with the corresponding step from the prior art will now be described with reference to  FIG. 3 . 
     Indeed, as illustrated in  FIG. 3 , great care should be taken during removal of the old case so as to not disconnect the wires  14  and  16 . For example, to dismantle the old floor  29  a cut is practiced on both side of the protector/isolator tube  31 , and the floor  29  is then removed in two parts or more. 
       FIG. 4  illustrates the instrument panel  12  being supported by the temporary holding structure  18 . 
       FIG. 4  also illustrates the beginning of step  106  with the installation of four (4) anchor plates  34  (only three shown) to a base  36  using anchors. The anchor plates  34  are used to fixedly receive the floor  40  assembly of the replacement case  10  onto the base  36 . The concrete base  36  is the base that was used for the old case. It is to be noted that the base  36  and anchor plates  34  are not limited to the illustrated embodiments as will be described further. The base  36  can also be replaced by a new base. 
       FIG. 5  illustrates the installation of the subfloor assembly  40  of the new instrument case  10 . This sub-floor  40  includes a front half portion  42  and a rear half portion  44 . The front half  42  includes a U-shaped structure  46 , a plate  48  mounted to the structure  46  inside thereof and a pair of brackets  50  secured to the structure  46  outside thereof along a respective one of the two parallel members. Similarly, the rear half  44  includes a U-shaped structure  51  and a plate  54  mounted therein. The bracket  50  and a bottom plate  52  interconnect the front and rear halves  42  and  44 . The plates  48 ,  52  and  54  include half-circle shaped recesses  55 . 
       FIG. 6  shows the subfloor  40  assembled. The subfloor assembly  40  is achieved by joining the front and rear half  42  and  44  and more specifically by telescopically sliding the parallel members of the U-shaped structure  51  within the parallel members of the U-shaped structure  46 . The protecting tube  31  (not shown in  FIG. 6 ) is then moved in the nearest recess  55  and the bottom plate  52  is fixed in place using screws or fasteners (not shown). The recesses  55  of the bottom plate  52  complete the recesses  55  of the front and rear plates  48  and  54  to form circular holes  58 , including one that is used to allow passage to the tube  31 . Therefore, providing a floor or subfloor assembly in at least two sections, wherein one section includes a recess allows its mounting around the live wires  14  and  16 . 
     Even though the recesses are illustrated herein as being semi-circular, they can have any other shape and size allowing passage for the wires and/or other network link. 
     The walls  60 ,  62  and the roof  64  of the replacement case  10  are then mounted to the subfloor  40 , as can also be seen on  FIG. 6 . It is to be noted that once the walls  60 ,  62  and the roof  64  are securely assembled, the instrument panel  12  can be secured at least to the walls  60  and  62  (step  108 ). Accordingly, once this is done, the temporary frame support  18  may be removed from the instrument panel  12  (step  110 ) and stored for a subsequent use. 
     According to another embodiment, steps  108  and/or  110  are performed after the replacement case  10  is completely mounted. The order of the steps  102  to  110  of the method  100  may then differ then the one presented in  FIG. 1 . 
       FIG. 7  illustrates the installation of the insulated floor assembly  66  on top of the subfloor assembly  40 . Similarly to the subfloor  40 , the floor  66  is assembled from two half sections  68  to facilitate the installation, considering the presence of wires  14  and  16 . 
     Each section  68  is symmetrically identical and includes an isolator sheet  70  and a base plate  72  secured to the isolator  70  using fasteners or another fastening means such as cement. The plates  72  include recesses  74  positioned so as to be registered with the recesses  55  of the plates  48 ,  52  and  54  of the subfloor assembly  40 . The isolator sheets  70  include either recesses (not shown) or score lines  76  to ease the creation of a recess in the sheet  70  to allow passage for the wires  14  and  16 . Cover plates  78  can be mounted to the base plates  72  using for example fasteners to cover the unused recesses  74  and  55 . 
       FIG. 7  also illustrates the securing of the brackets  50  to a further embodiment of a base  82 . Similarly to the base  36 , the metal frame base  82  can be base used for the old case or a new replacement base install with the new case  10 . 
       FIG. 7  further illustrates the mounting of a base stiffer channel  80  under the floor  66  and secured thereto to reinforce the floor  66 , and the securing of the brackets  50  of the subfloor  40  to the base frame  82  through fasteners  84  or other fastening means. 
     According to other embodiments of a method for replacing an old instrument case with a new instrument case and of a new instrument case used therefore, the plates  48 ,  52 ,  54  and  72  and isolator sheets  70  do not include recesses or holes. After taking measurements on site, a worker cut the plates  48  or  54  and  72  and isolator sheet  70  that are on the side of the wires  14  and  16  so as to create a passage for the wires  14  and  16  and tubing  31  or other wire containment (not shown) therethrough. 
     In preparation for door installation, a gasket  86  is installed around the edge of both door openings  88  (see  FIG. 8 ). The doors  90  are then hingedly mounted to the walls  60 ,  62  (see  FIG. 9 ). A replacement case according to an embodiment of the present invention is of course not limited to such an illustrated configuration of door mounting. 
     In  FIG. 10 , the walls  60  and  62  and the roof  64  are insulated using conventional insulation sheets  92  and  94  cut to the proper sizes. An adhesive (not shown) may be used to mount the insulation sheets  92  and  94  to the walls  60  and  62  and roof  64 . 
     Caulking is then installed ( FIG. 11 ) to all the joints of the new instrument case  10 . 
     Finally, the batteries are repositioned in the new instrument case in their respective places (not shown). 
     A replacement case according to another embodiment of the present invention does not include insulation and/or caulking. 
     As will easily be understood by one skilled in the art, the compromised instrument case can be removed and the new instrument case  10  installed using a limited number of general purpose tools such as:
         Ratchet set;   Cutting discs;   Gas powered cutting saw;   Grinder with grinding discs;   Sawzall; and   Drill and drill bits.       

     It has been found that by using the above described method and kit of parts, it is possible to drastically reduce the number of man-hours required to replace a compromised instrument case with a new case compared to the method from the prior art. For example, it has been found that a SS-5 cabinet can be replaced by a crew of three (3) people in four (4) hours. Furthermore, during the present instrument case replacement, there is no downtime, no equipment disconnected, no service interruption and no retesting necessary. 
     By replacing all the existing contaminated metal cases with an all new aluminum base, frame, walls, doors and roof, maintenance costs are reduced since no painting and patching/plastering has to be done. 
     According to embodiments of the present invention, the replacement cabinet is manufactured in marine quality aluminum 5052-H32 corrosive resistant. Of course, other adequate materials could be used. 
     All the parts required can be supplied as a kit including the temporary holding structure, all necessary parts and hardware, in a cardboard box and further including step by step instructions of how to dismantle the old case and assemble the replacement case. 
     Moreover, the cardboard box may then be used to store all the parts of the old case. 
     As mentioned hereinabove, the method for replacing an old instrument case with a new instrument case is not limited to the illustrated two door case  10 . 
     Another example of a case than can be installed using the present method is shown in  FIGS. 12 and 13 . The case  96  includes four (4) doors, two on each side. Returning briefly to  FIG. 2 , a pair of side by side temporary support frames  18  can be used to support the two instrument panels (not shown) during the removal of the old case. 
       FIG. 14  shows a new bungalow  98  that can also be used to replace an old case (not shown). It is to be noted the two portions  99  of the floor to help position the wiring as described hereinabove.  FIG. 14  further illustrates the use of a two-part rectangular sleeve  97  to define a passage for the wiring through the floor. Since the method for replacing the old case with the new bungalow is similar to what has been described hereinabove using the case  10  as an example, it will not be described further in more detail. 
     While the replacement cases described herein are all fully assembled on site, a replacement case according to another embodiment of the present invention (not shown) can be partly assembled prior to arrival on site and prior to step  104  of the method  100 . The floor of the replacement case is however assembled on site after the old case is dismantled. 
     It is to be understood that the invention is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The invention is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, the present invention has been described hereinabove by way of illustrative embodiments thereof; it can be modified, without departing from the spirit, scope and nature of the subject invention.