Abstract:
A method and apparatus for loading bulk materials is disclosed. The apparatus of the present invention comprises a track and a frame movable on the track between a retracted and extended position. A first plate is movably mounted on the frame, and a ram is operably connected to the first plate for moving it between a retracted and extended position. A feeder may also secured to the frame. In operating a press such as the one disclosed, the frame and plate are moved within the container, a compressible material is transferred into the container, the compressible material is compressed, and the frame and plate are moved to a position outside the container. The steps of transferring compressible material into the container and compressing it may be repeated as desired. The frame may also be equipped with a second plate in which case one plate may be compressing material while additional compressible material is simultaneously being transferred into another portion of the container. The container may be a rail car, and the compressible material may be selected from the group consisting of cottonseed, cottonseed hulls, rice hulls, rice mill feed, and soy bean hulls.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to a method and apparatus for loading bulk material into a container, and more particularly, to such a method and apparatus for compressing bulk material within a rail car. 
     Bulk materials such as cottonseed, cottonseed hulls, rice hulls, rice mill feed and soybean hulls are sometimes shipped in rail cars. Freight charges for shipping bulk materials via rail cars are typically calculated on a per car basis rather than on the weight of material shipped in the cars. Such bulk materials are sometimes compressed into bales for later transporting and loading onto rail cars. Baling and loading such materials may increase the weight of materials that may be carried in a rail car, but the extra steps and difficulties in baling and loading bales likely outweigh any benefits achieved. In end loaded containers, such as intermodal cargo containers, and in open top style containers, such as gondola style rail cars, equipment such as front-end loaders have sometimes been used to compress bulk material within a container. Such methods slow and disrupt loading and are not practical in rail cars with side doors. As a result, such bulk materials are typically propelled into a rail car using a conveyor belt, auger system, blower system, or some similar bulk material moving equipment and without using any form or method of compressing the material during or after loading. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide a method and apparatus for loading a compressible, bulk material within a container. 
     It is a further object of the present invention to provide a method and apparatus of the above type that quickly and efficiently compresses bulk materials within a container such as a rail car. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that allows for simultaneous loading and compressing of bulk materials within a container. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that allows a press to be situated within a container without interfering with loading of bulk materials. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that allows a press to be quickly and efficiently moved into and out from containers to be loaded with bulk materials. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that allows for repeated loading and compressing of bulk material within a container without repositioning or removing of a press. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that allows for loading and compressing of bulk material within different areas of a container without repositioning or removing of a press. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that reduces the cost of shipping bulk material. 
     It is a still further object of the present invention to provide a method and apparatus of the above type that simplifies the loading of bulk materials within a container. 
     It is a still further object of the present invention to provide a method and apparatus of the above that utilizes a portable press. 
     Toward the fulfillment of these and other objects and advantages, the apparatus of the present invention comprises a track and a frame movable on the track between a retracted and extended position. A first plate is movably mounted on the frame, and a ram is operably connected to the first plate for moving it between a retracted and extended position. A feeder may also secured to the frame. In operating an apparatus such as the one disclosed, the frame and plate are moved within the container, a compressible material is transferred into the container, the compressible material is compressed, and the frame and plate are moved to a position outside the container. The steps of transferring compressible material into the container and compressing it may be repeated as desired. The frame may also be equipped with a second plate in which case one plate may be compressing material while additional compressible material is simultaneously being transferred into another portion of the container. The container may be a rail car, and the compressible material may be selected from the group consisting of cottonseed, cottonseed hulls, rice hulls, rice mill feed, and soy bean hulls. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above brief description, as well as further objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of the presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein: 
     FIG. 1 is an elevation view of a press of the present invention adjacent a rail car, with portions omitted for clarity of presentation; 
     FIG. 2 is a schematic, overhead view of a press of the present invention with a frame in an extended position within a rail car, with portions omitted for clarity of presentation; and 
     FIG. 3 is an elevation view of a frame of the present invention; 
     FIG. 4 is an elevation view of a plate of the present invention; 
     FIG. 5 is a schematic view of a portion of the hydraulic system for powering rams operably connected to the plates; 
     FIG. 6 is a side view of a press of the present invention with a plate partially extended, with portions omitted for clarity of presentation; 
     FIG. 7 is a schematic view of a portion of the hydraulic system for powering locks of the present invention; and 
     FIG. 8 is a schematic, overhead view of an apparatus and method of loading rail cars according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, the reference numeral  10  refers in general to a press of the present invention, comprising a frame  12 , one or more plates  14  movably secured to the frame  12 , and one or more rams  16  operably connected to each plate  14 . The press  10  may include a feeder  18 , secured to the frame  12 , a platform  20 , such as a trailer, having one or more tracks  22 , and a ram  24  operably connected to the frame  12  and trailer  20  for moving the frame between a retracted and extended position. 
     The platform  20  is preferably a trailer, such as a flatbed trailer. As best seen in FIG. 2, the trailer  20  is equipped with hydraulic cylinders  26  for raising and leveling the trailer, the cylinders being powered by a separate hydraulic system  28 , including a separate hydraulic tank, motor, pump and controls. Chains  30  may be used to secure the trailer  20  to the ground for greater stability. A hydraulic tank  32 , pump  34 , motor  36 , and controls  38  are positioned on the platform  20 , with hydraulic lines providing hydraulic fluid to the hydraulic cylinders or rams and other hydraulic components. The tracks  22 , formed by angle irons, are secured to a rear portion of the trailer bed, extending substantially parallel with each other on opposite sides of the bed. The feeder  18  is formed by a feed pipe having first, second, and third portions,  18   a,    18   b,  and  18   c,  respectively. The first portion of the feed pipe  18   a  is secured to the trailer  20 , and the first portion is telescopically nested within the second portion  18   b.  A front portion of a hydraulic cylinder or ram  24  is secured to a front portion of the trailer  20 , and a rear portion of the ram  24  is secured to the frame  12 . The ram  24  is aligned substantially parallel to the tracks  22  and is operably connected to the hydraulic system. Although the frame  12  is preferably mounted on a trailer  20 , it is understood that it may be mounted on a fixed platform or no platform at all. Similarly, although the hydraulic tank  32 , pump  34 , motor  36  and controls  38  are shown positioned on the platform  20  or trailer, it is understood that they could be mounted on the frame  12  or different combinations could be mounted on the frame  12 , on the platform  20 , or at a location adjacent where the press  10  would be used. 
     The frame  12  is movably mounted on the tracks  22 . As best seen in FIG. 3, the frame  12  is generally box shaped having a front, a rear, and two sides and is preferably formed by steel structural members such as square tubular members. Each side is a mirror image of the other, so only one side is be described in detail. Each side has two vertical members  40 . Horizontal members or feet  41  are secured to the bottom of vertical members  40 , and bushings  42  formed from UHMW plastic are secured to the bottom of the feet  41  to allow the frame  12  to more easily move along the tracks  22  and along a floor of a rail car  44 . The foot  41  on the trailer side of the frame  12  is preferably long enough so that at least a portion of the foot  41  remains on the track  22  when the frame  12  is positioned within the rail car  44 . A top member  46  extends between and is secured to the top of the vertical members  40 . A bottom member  48  extends between the vertical members  40  at a lower portion of the vertical members. For reasons to be described, the bottom member  48  extends between the vertical members  40  at a point raised from the bottom of the vertical members  40 . It is understood that the frame  12  may take any number of shapes, sizes, and configurations and may be formed from any number of known structural members, including but not limited to different combinations of beams, pipes and tubes. It is also understood that bushings may or may not be used, different types of bushings may be used, and any number of combinations of bearings, rollers, and bushings may be used to facilitate movement of the frame  12 . 
     The front of the frame  12  is a mirror image of the back, so only the front is described in detail. A pair of upper members  50 ,  52  and a pair of lower members  54 ,  56  extend between corresponding vertical members  40  of the two sides. Bushings formed from UHMW plastic are secured to inner portions of members  50 ,  54  to facilitate moving the plates  14  between retracted and extended positions. It is understood that any number of front and back frame members may be used, and the members may be aligned in a wide variety of configurations to provide the desired strength, stability, and weight. Also, the front and back members may be formed from any number of known structural members, including but not limited to different combinations of beams, pipes and tubes. It is also understood that bushings may or may not be used, different types of bushings may be used, and any number of combinations of bearings, rollers, and bushings may be used to facilitate movement of the plates relative to the frame  12 . 
     As best seen in FIG. 4, the plate has a planar member  58 , horizontally disposed upper and lower members  60 , and a plurality of vertically disposed members  62 ,  64 , and  66 . Slide members  68  are secured to the outermost vertical members  62 , extending substantially horizontally and substantially perpendicular to the planar member  58 . The upper slide members  68  are sized to fit within one of the upper frame members  50  and the lower slide members  68  are sized to fit within one of the lower frame members  54 . Bushings allow the slide members  68  to glide readily within the upper and lower members  50  and  54 . Each slide member  68  is aligned to glide along an axis that is substantially perpendicular to the axes of the tracks  22  and the axis over which the ram  24  moves. Two pairs of vertical members  64  extend between the upper and lower members  60  at intermediate portions thereof. Plates  70  are secured to opposing faces of the members  64 , and holes pass through corresponding portions of the members  64  and plates  70  to provide four ready locations for securely connecting the rams  16  to the plates  14 . Each ram  16  is aligned to provide movement along an axis that is substantially perpendicular to the axes of the tracks  22  and the axis over which the ram  24  moves. Each plate is a mirror image of the other, so only one plate is be described in detail. It is understood that any number of plates  14  may be used. Also, although the plate is described as being formed by a planar member  58  secured to a number of vertical and horizontal members, it is understood that the plate may take any number of shapes or configurations. For example, the portion that contacts and compresses the compressible material need not be planar and, in fact, need not be a single piece. Further, even though the plate is described as having slide members  68  that fit telescopically within frame members, it is understood that the plates  14  may be attached to the frame  12  in any number of ways. Also the plates  14  may be aligned to move along axes disposed in any number of ways, so that the axes need not be perpendicular to the tracks  22  or ram  24  and need not be parallel with rams  16 . 
     In one embodiment, four rams or hydraulic cylinders  16  are secured at opposite ends to each plate, with pins passing through corresponding sets of holes for securing the rams to the plates  14 . Because each ram  16  is secured to both plates  14  rather than being secured to a plate  14  at one end and to the frame  12  at the other end, fewer rams may be used to move both plates  14 . For example, if one wants to use four rams  16  to move a plate, and if one secures each ram to both plates, with an appropriate locking system, a total of only four rams would be needed to move both plates. If, however, one wants to use four rams to move a plate, and if one secures one end of each ram to a plate and the other end of that ram to the frame  12 , a total of eight rams would be needed to move both plates. Although any number of rams may be used, for durability and ease of design and use, the configuration using eight rams is preferred. The hydraulic tank  32 , pump  34  and motor  36  are secured to the trailer  20 . Referring to FIG. 5, hydraulic lines  72  are provided for evenly routing hydraulic fluid to the rams  16 . Lines  72  extend from the pump  34  to a flow divider  74  secured to the frame  12 , from the flow divider  74  to the rams  16  and from the rams  16  to the pump  34 . It is understood that fewer or more rams  16  may be used and that the rams  16  may be secured to the plates or frame in any number of combinations and configurations. Further any number of different types and combinations of equipment may be used for applying force to move the plates between retracted and extended positions. 
     As best seen in FIG. 6, locks  76  are provided to secure each plate to the frame  12  as desired. Each lock is substantially identical, so only one lock is described in detail. Upper and lower pairs of metal sheets  78  are secured to an outermost vertical member  62  of a plate, each sheet having a generally hook shaped recess  80  formed in a lower side thereof. A pair of substantially vertical guide members  82  is secured to the vertical member  62  of the frame  12 . Two horizontally disposed bars  84 , connected by a rigid member  86 , are disposed between the vertical guide members  82  and the vertical frame member. A hydraulic cylinder  88  is secured to the frame  12 , and a piston  90  of the hydraulic cylinder  88  is secured to one of the bars  84 . The bars  84  are aligned with the sheets  78  so that when the piston is in an extended position, the upper bar is received within the recesses  80  of the upper pair of sheets  78  and the lower bar is received within the recesses  80  of the lower pair of sheets  78 . Similarly, when the piston is in a retracted position, the upper bar is below the recesses  80  of the upper pair of sheets  78  and the lower bar is below the recesses  80  of the lower pair of sheets  78 . Referring to FIG. 7, hydraulic lines  72  are provided for evenly routing hydraulic fluid to the cylinders. Lines  72  extend from the pump  34  to the hydraulic cylinders and back from the hydraulic cylinders to the pump  34 . It is understood that fewer or more locks  76  may be used. It is understood that the press  10  may be used with or without locks  76  and that a wide variety of different locking mechanisms may be used if desired. In the preferred embodiment, in which eight cylinders  16  are used, locks are not needed or used since each of the two sets of four cylinders  16  is attached at one end to a plate  14  and at another end to the frame  12 . 
     Referring to FIG. 6, the second and third portions of the feed pipe,  18   b  and  18   c,  are secured to the frame. The second portion of the feed pipe  18   b  is telescopically nested within the third portion of the feed pipe  18   c,  and the third portion of the feed pipe  18   c  may be raised, lowered, and rotated relative to the second portion. A pair of hydraulic cylinders  92  is operably connected to the third portion of the feed pipe  18   c  for raising and lowering the third portion relative to the second portion of the feed pipe  18   b  and frame  12 . The cylinders  92  move the third portion  18   c  between a lowered and raised position. In the lowered position, the third portion of the feed pipe  18   c  is low enough to fit through a door of a rail car  44 , and in the raised position, the third portion of the feed pipe  18   c  is high enough to allow it to transfer compressible material over the plates. A hydraulic motor  94  drives a chain or belt  96  that is operably connected to the third portion of the feed pipe  18   c  for rotating the third portion of the feed pipe relative to the second portion of the feed pipe  18   b  and frame  12 . It is understood that a feeder  18  need not be provided as part of the press  10  and that a wide variety of different feed mechanisms may be used. Further, it is understood that the feeder  18  need not be movable between raised and lowered positions, need not transfer compressible material over the plates, and need not be rotatable. 
     Referring to FIG. 8, in operation, a press  10  of the present invention is moved to a desired location for loading rail cars. The trailer  20  is aligned substantially perpendicular to the rail cars  44  and railroad tracks  98 . The rear portion of the trailer  20  is positioned near the railroad tracks  98 , allowing sufficient clearance for rail cars to move along the railroad track past the press  10 . Hydraulic cylinders  26  are used as desired to level the trailer  20  and to raise the trailer, if necessary. The trailer  20  is secured to the ground, such as by using chains  30 , to provide added stability. A feed pipe  100  from a blower  102  is secured to the first portion of the feed pipe  18   a  to provide a source of compressible material  104  such as cottonseed. A second feed pipe  106  and blower  108  are provided for reasons to be described. The trailer  20  is disposed at a distance from the second feed pipe  106  selected to allow the press feeder  18  to transfer compressible material into one rail car  44  while the second feed pipe  106  simultaneously transfers compressible material into an adjacent rail car  44 . 
     An open door of a rail car  44  is aligned with the press  10 . With the third portion of the feed pipe  18   c  in a lowered position and the plates in a retracted position, the ram  24  is actuated to move the frame  12  along the tracks  22  from a first position outside of the rail car  44  to a second position inside the rail car  44 . Bushings  42  help the frame  12  glide along the tracks  22  and along the floor of the rail car  44 . With the frame  12  in an extended position within the rail car  44 , hydraulic cylinders  92  are actuated to move the third portion of the feed pipe  18   c  from the lowered position to the raised position. If needed, the third portion of the feed pipe  18   c  is rotated to a position for transferring compressible material into a first portion of the rail car  44 . 
     The blower  102  is activated to transfer compressible material through the feed pipe  100 , through the three portions of the feed pipe  18   a,    18   b,  and  18   c,  and into a first portion of the rail car  44 . After a desired amount of compressible material is transferred into the first portion of the rail car, the flow of compressible material is interrupted, and the hydraulic motor  94  is actuated to rotate the third portion of the feed tube to a position for transferring compressible material into a second portion of the rail car  44 . The flow of compressible material is then resumed so that a second portion of compressible material is transferred into the second portion of the rail car  44 . If locks are used, the locks  76  on the first plate are put in the unlocked position, and the locks  76  on the second plate are put in the locked position. In that regard, if the locks  76  on the first plate are in the locked position, the cylinders  88  are actuated to move the bars  84  from the raised position to the lowered position so that the first plate is not locked against movement relative to the frame  12 . Similarly, if the locks  76  on the second plate are in the unlocked position, the cylinders  88  are actuated to move the bars  84  from the lowered position to the raised position so that the second plate is locked against movement relative to the frame. 
     The rams  16  are actuated to move the first plate from the retracted position to the extended position to compress the compressible material in the first portion of the rail car  44 . This step of compressing the material in the first portion of the rail car  44  is preferably performed while the compressible material is being transferred into the second portion of the rail car. The flow divider  74  is used in an effort to have each ram  16  extending and retracting at the same rate as the other rams  16  so that the plate is maintained in a substantially vertical position as it moves from the retracted position to the extended position, and vice versa. The rams  16  may however be extended and retracted at different rates for different positioning and movement of the plate. For example, the upper rams  16  may extend at a slightly faster rate than the lower rams  16 , so that the plate is slanted at an angle of approximately 15 degrees from vertical as it moves from the retracted position to the extended position. 
     After the compressible material in the first portion of the rail car  44  is compressed to a desired amount, the first plate  14  is moved from the extended position to the retracted position. Because the bottom members  48  of the frame sides are raised from the bottom, any compressible material that may have fallen between the plate  14  and frame  12  will not be wedged between the plate  14  and frame  12  and will therefore not prevent the plate from returning to a fully retracted position. After moving the first plate  14  to the retracted position, the locks  76  of the first plate  14  are then moved to the locked position, and the locks  76  of the second plate  14  are moved to the unlocked position. 
     After a desired amount of compressible material is transferred into the second portion of the rail car  44 , the flow of compressible material is interrupted, and the motor  94  is actuated to rotate the third portion of the feed pipe  18   c  back to a position for again transferring compressible material into the first portion of the rail car  44 . The flow of compressible material is then resumed so that a third portion of compressible material is transferred into the first portion of the rail car  44 . The rams  16  are actuated to move the second plate  14  from the retracted position to the extended position to compress the compressible material in the second portion of the rail car  44 . This step of compressing the second portion of compressible material in the second portion of the rail car  44  is preferably performed while a third portion of compressible material is being transferred into the first portion of the rail car  44 . After the second portion of compressible material in the second portion of the rail car  44  is compressed to a desired amount, the second plate  14  is moved from the extended position to the retracted position. The steps of loading material in one portion of the rail car  44  and compressing material in another portion of the rail car  44  may be repeated until a desired amount of material has been transferred into the rail car  44  and compressed. The amount loaded and compressed is selected based upon the size, strength, and load rating of the rail car  44 . Care is taken to avoid exceeding the structural limitations of the rail car  44  and to avoid damaging the rail car. 
     After a desired amount of material has been transferred into the rail car  44  and compressed, the plates  14  are moved to the retracted position, the third portion of the feed pipe  18   c  is moved to the lowered position, and the ram  24  is actuated to move the frame  12  from an extended position inside the rail car  44  to a retracted position outside of the rail car  44 . The locks  76  may or may not be placed in the locked position. The rail car  44  is then moved along the railroad track  98  to a second station aligned with the second feed pipe  106 . Additional compressible material  104  is transferred into the rail car  44  to fill the central portion that was occupied by the frame  12  during the first stages of loading. In the preferred embodiment, the press  10  is preferably being used to load and compress material within a second rail car  44  at the same time that the second feed pipe  106  is being used to transfer compressible material  104  into the central portion of the first rail car  44 . 
     Other modifications, changes and substitutions are intended in the foregoing, and in some instances, some features of the invention will be employed without a corresponding use of other features. For example, although the press  10  has been described as having a large number of hydraulic components, hydraulic components need not be used or may be used in different combinations with other known pieces of equipment. Also the press  10  of the present invention offers great flexibility in loading methods. For example, the second feed pipe  106  need not be used. Further, compressible material  104  may be transferred into the rail car  44  before the frame  12  is moved into the rail car. Similarly, the frame  12  may be moved into and out of the rail car  44  any number of time during loading. Also, both plates may be moved at the same time to compress material  104  in different portions of the rail car  44  simultaneously. Further, although the press  10  has been described for use in connection with a rail car  44  having side doors, the press  10  may be used in connection with any number of different rail cars and containers including, but not limited to, rail cars and containers having one or more end doors and rail cars and containers having open tops. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.