Sensor assembly for tank cars

• US 20070120665A1
• Filed: 11/28/2005
• Published: 05/31/2007
• Est. Priority Date: 11/28/2005
• Status: Active Grant

• Current Assignee: Asset Intelligence LLC (PowerFleet, Inc.)
• Original Assignee: General Electric Company
• Inventors: Martin, Michael, Hawkins, Roger
• Granted Patent: US 7,498,530 B2
• Time in Patent Office: Days
• US Class Current: 340/545.100
• CPC Class Codes: B60P 3/226 Arrangements of access openings or covers therefor
• CPC Class Codes: B60P 3/227 Methods for tracing the load
• CPC Class Codes: H01H 13/183 for actuation by moving a closing member, e.g. door, cover H01H13/186, H01H27/002 take precedence; the switch controlling enclosed equipment H01H9/226
• CPC Class Codes: H01H 15/102 comprising cam devices

Abstract

A sensor assembly, system and method for using a sensor assembly is disclosed making use of a sealed switch and an actuator that converts linear motion in a plane to linear motion in a perpendicular plane. The motion of the actuator in the perpendicular plane actuates the switch which signals that hatch is in an open position.

Claims

1. A sensor assembly for use in a hatch position notification system on a tank car, the sensor assembly comprising:

a hollow rod sleeve having a top end, a bottom end, and a side, wherein the side of the hollow rod sleeve has a hole through which an actuating member can pass;

an actuator rod within the hollow rod sleeve, the actuator rod having a top end, a bottom end, and an engagement notch, wherein the engagement notch is located proximate to the hole in the hollow rod sleeve;

a spring within the hollow rod sleeve, the spring having a top end and a bottom end, wherein the bottom end of the spring is adjacent to a fixed surface, and the top end of the spring is adjacent to the bottom end of the actuator rod;

a 2-position electrical switch, the switch having an actuating member substantially perpendicular to the actuator rod, wherein the actuating member extends from the electrical switch through the hole in the hollow rod sleeve and wherein the actuating member has a curved end that contacts the actuator rod,

wherein, when the hatch is in the open position, the spring is extended and the actuator rod is positioned such that the curved end of the actuating member of the 2-position electrical switch makes contact with the actuator rod at a point other than the engagement notch, which places the 2-position electrical switch in a first position indicating that the hatch is opened; and

wherein, when the hatch is in a closed position, the hatch causes the actuator rod to move and compress the spring, which causes the actuator rod to be positioned such that the curved end of the actuating member of the 2-position electrical switch makes contact with actuator rod at the engagement notch, which places the 2-position electrical switch in a second position indicating that the hatch is closed.

2. The sensor assembly of claim 1 further comprising a baseplate, wherein the baseplate has a first planar region for mounting the baseplate to the tank car and a second planar region for mounting the an electrical switch to the baseplate, wherein the bottom of the hollow rod sleeve is connected substantially perpendicular to the first planar region of the baseplate, and wherein the bottom of the spring is adjacent to the first planar region of the baseplate.

3. The sensor assembly of claim 2 further comprising a retaining mechanism for preventing the actuator rod from exiting the hollow rod sleeve, the retaining mechanism comprising a fastener which passes through a hole in the side of the hollow rod sleeve, and which is in movable contact with a longitudinal retaining notch on the actuator rod.

4. The sensor assembly of claim 3 further comprising an alignment plate having a bottom and a side for aligning the hollow rod sleeve substantially perpendicularly relative to the baseplate, wherein the bottom of the alignment plate is connected to the first planar region of the baseplate and the side of the alignment plate is connected to the hollow rod sleeve.

5. The sensor assembly of claim 1 wherein the actuator rod is substantially cylindrical.

6. The sensor assembly of claim 1 wherein the engagement notch on the actuator rod consists of full circumference notch in the actuator rod, wherein the notch has a beveled upper section, a cylindrical center section, and a beveled lower section.

7. The sensor assembly of claim 2 wherein the first planar region of the baseplate has at least one hole for mounting the baseplate to an adjacent surface on the tank car.

8. The sensor assembly of claim 2 wherein the first planar region of the baseplate has at least one slot for mounting the baseplate to an adjacent surface on the tank car.

9. The sensor assembly of claim 2 wherein the second planar region of the baseplate has at least one hole for mounting the electrical switch to the baseplate.

10. The sensor assembly of claim 1 further comprising an extender movably connected to the top end of the actuator rod, wherein the extender has a curved head for contacting the hatch and wherein the length of the extender can be adjusted relative to the top end of the actuator rod.

11. The sensor assembly of claim 1 wherein the curved end of the actuating member of the 2-position electrical switch comprises a rotatable wheel.

12. A monitoring system for a tank car having a protective housing and a hatch covering the protective housing, comprising:

a sensor for monitoring the position of the hatch on the protective housing of the tank car; and

a communications device for transmitting the position of the hatch on the protective housing of the tank car.

13. The system of claim 12, further comprising a tracking device for determining the location of the tank car and wherein said communications device also transmits the location of the tank car.

14. The system of claim 13, further comprising at least one sensor for measuring a condition of the tank car and wherein said communications device also transmits the condition measured by said at least one sensor.

15. The system of claim 14, wherein the sensor is selected from the group of railcar temperature sensor, pressure sensor, weight sensor, valve condition sensor, impact sensor, hatch sensor, and bearing temperature sensor.

16. The system of claim 12, further comprising at least one sensor for measuring a condition of the tank car and wherein said communications device also transmits the condition measured by said at least one sensor.

17. The system of claim 16, wherein the sensor is selected from the group of sensors consisting of a temperature sensor, pressure sensor, weight sensor, valve condition sensor, impact sensor, hatch sensor, and bearing temperature sensor.

18. The system of claim 12, wherein the transmitting by the communications device is performed wirelessly.

19. The system of claim 12, wherein the sensor comprises a sensor assembly having:

a hollow rod sleeve having a top end, a bottom end, and a side, wherein the side of the hollow rod sleeve has a hole through which an actuating member can pass;

an actuator rod within the hollow rod sleeve, the actuator rod having a top end, a bottom end, and an engagement notch, wherein the engagement notch is located proximate to the hole in the hollow rod sleeve;

a spring within the hollow rod sleeve, the spring having a top end and a bottom end, wherein the bottom end of the spring is adjacent to a fixed surface, and the top end of the spring is adjacent to the bottom end of the actuator rod;

a 2-position electrical switch, the switch having an actuating member substantially perpendicular to the actuator rod, wherein the actuating member extends from the electrical switch through the hole in the hollow rod sleeve and wherein the actuating member has a curved end that contacts the actuator rod,

wherein, when the hatch is in the open position, the spring is extended and the actuator rod is positioned such that the curved end of the actuating member of the 2-position electrical switch makes contact with the actuator rod at a point other than the engagement notch, which places the 2-position electrical switch in a first position indicating that the hatch is opened; and

wherein, when the hatch is in a closed position, the hatch causes the actuator rod to move and compress the spring, which causes the actuator rod to be positioned such that the curved end of the actuating member of the 2-position electrical switch makes contact with actuator rod at the engagement notch, which places the 2-position electrical switch in a second position indicating that the hatch is closed.

20. The system of claim 19, wherein said sensor assembly further comprises a baseplate, wherein the baseplate has a first planar region for mounting the baseplate to the tank car and a second planar region for mounting the an electrical switch to the baseplate, wherein the bottom of the hollow rod sleeve is connected substantially perpendicular to the first planar region of the baseplate, and wherein the bottom of the spring is adjacent to the first planar region of the baseplate.

21. A method for monitoring the hatch on a tank car, the method comprising:

determining the open or closed position of the hatch with a sensor; and

transmitting the position of the hatch of the tank car to a remote location with a communications device.

22. The method of claim 21, wherein the step of transmitting by the communications device is performed each time the position of the hatch changes from closed to open and each time the position of the hatch changes from open to closed.

23. The method of claim 21, wherein transmitting by the communications device is performed periodically.

24. The method of claim 21, wherein the transmitting by the communications device is performed wirelessly.

25. The method of claim 21, further comprising determining the location of the tank car with a tracking device and transmitting the location of the tank car to a remote location with the communications device.

26. The method of claim 25, wherein transmitting the location of the tank car is performed whenever the hatch position is transmitted.

27. The method of claim 25, wherein transmitting the location of the tank car is performed periodically.

28. The method of claim 25, wherein the transmitting by the communications device is performed wirelessly.

29. The method of claim 21 further comprising determining when the tank car is in motion and when the tank car is stationary using a motion sensor and wherein transmitting the position of the hatch is performed when the motion sensor senses that the tank car is in motion and the sensor senses that the hatch is in an open position.

30. The method of claim 29, wherein the transmitting by the communications device is performed wirelessly.

31. The method of claim 21 further comprising determining when the tank car is in motion and when the tank car is stationary using a motion sensor and wherein transmitting the position of the hatch is performed when the motion sensor senses that the tank car has started motion or when the motion sensor senses that the tank car has stopped motion.

32. The method of claim 31, wherein the transmitting by the communications device is performed wirelessly.

33. The method of claim 21, further comprising measuring at least one additional condition of the tank car with a sensor selected from the group of railcar temperature sensor, pressure sensor, weight sensor, valve condition sensor, impact sensor, hatch sensor, and bearing temperature sensor, and further comprising transmitting the condition of the additional sensor.

34. The method of claim 31, wherein the transmitting by the communications device is performed wirelessly.

35. The method of claim 25, further comprising measuring at least one additional condition of the tank car with a sensor selected from the group of railcar temperature sensor, pressure sensor, weight sensor, valve condition sensor, impact sensor, hatch sensor, and bearing temperature sensor, and further comprising transmitting the condition of the additional sensor.

36. The method of claim 35, wherein the transmitting by the communications device is performed wirelessly.

37. The method of claim 21, wherein the sensor comprises a sensor assembly having:

a hollow rod sleeve having a top end, a bottom end, and a side, wherein the side of the hollow rod sleeve has a hole through which an actuating member can pass;

an actuator rod within the hollow rod sleeve, the actuator rod having a top end, a bottom end, and an engagement notch, wherein the engagement notch is located proximate to the hole in the hollow rod sleeve;

a spring within the hollow rod sleeve, the spring having a top end and a bottom end, wherein the bottom end of the spring is adjacent to a fixed surface, and the top end of the spring is adjacent to the bottom end of the actuator rod;

a 2-position electrical switch, the switch having an actuating member substantially perpendicular to the actuator rod, wherein the actuating member extends from the electrical switch through the hole in the hollow rod sleeve and wherein the actuating member has a curved end that contacts the actuator rod,

wherein, when the hatch is in the open position, the spring is extended and the actuator rod is positioned such that the curved end of the actuating member of the 2-position electrical switch makes contact with the actuator rod at a point other than the engagement notch, which places the 2-position electrical switch in a first position indicating that the hatch is opened; and

wherein, when the hatch is in a closed position, the hatch causes the actuator rod to move and compress the spring, which causes the actuator rod to be positioned such that the curved end of the actuating member of the 2-position electrical switch makes contact with actuator rod at the engagement notch, which places the 2-position electrical switch in a second position indicating that the hatch is closed.

38. The method of claim 33, wherein said sensor assembly further comprises a baseplate, wherein the baseplate has a first planar region for mounting the baseplate to the tank car and a second planar region for mounting the an electrical switch to the baseplate, wherein the bottom of the hollow rod sleeve is connected substantially perpendicular to the first planar region of the baseplate, and wherein the bottom of the spring is adjacent to the first planar region of the baseplate.