Railcar coupler

• US 9,701,323 B2
• Filed: 04/06/2015
• Issued: 07/11/2017
• Est. Priority Date: 04/06/2015
• Status: Active Grant

• Current Assignee: Bedloe Industries LLC
• Original Assignee: Bedloe Industries LLC
• Inventors: Smerecky, Jerry R., Manibharathi, Roshan N., Hudson, Corey M., Nibouar, F. Andrew
• Primary Examiner(s): MCCARRY JR, ROBERT J
• Application Number:
  US14/679,709
• Publication Number:
  US 20160288806A1
• Time in Patent Office: 827 Days
• CPC Class Codes: B61G 3/06 Knuckle-locking devices
• CPC Class Codes: B61G 3/08 Control devices, e.g. for uncoupling

Abstract

A railcar coupler may include a coupler head comprising a shank and a head portion, the head portion defining a cavity for receiving a knuckle, a thrower, and a lock. The cavity can include a top pulling lug, a bottom pulling lug, and a thrower retaining lug. The top pulling lug can be configured to engage an upper knuckle pulling lug, and the bottom pulling lug being can be configured to engage a lower knuckle pulling lug. During operation of the railcar coupler, the ratio of the stress between the top pulling lug and the bottom pulling lug can be configured to be better balanced to help extend the life of the railcar coupler assembly.

Claims

1. A railcar coupler comprising:

a knuckle having an upper knuckle pulling lug and a lower knuckle pulling lug;

a pin extending through the knuckle and wherein the knuckle is configured to rotate about the pin;

a thrower configured to rotate the knuckle from a locked position to an unlocked position and a thrower retaining lug, the thrower comprising a lower trunnion and an upper trunnion, the upper trunnion defining a pivot for the thrower defining an outer circumference and wherein the thrower retaining lug is configured to guide the upper trunnion at a contact portion of the outer circumference through a range of motion of the thrower and wherein the contact portion of the outer circumference is less than 90 degrees, wherein the thrower retaining lug and the thrower define an overlapping area such that the thrower is maintained in position in the coupler head regardless of an orientation of the coupler head including when the coupler head is in an upright position and when the coupler head is in an inverted position regardless if the knuckle is an open or closed position, wherein an overlapping distance between the thrower retaining lug and the thrower is approximately 0.4 in. or more and wherein the overlapping area is approximately 0.4 in² or more the thrower retaining lug comprising a first surface and a second surface wherein the first surface and the second surface form an angle of less than 70°

;

a lock comprising a head and a leg configured to maintain the knuckle in either a locked position or an unlocked position;

a lock lift assembly configured to move the lock from a locked position to an unlocked position; and

a coupler body comprising a shank and a head portion, the head portion defining a cavity for receiving the knuckle, the thrower, the lock lift assembly, and the lock, the cavity comprising a top pulling lug, a bottom pulling lug, a knuckle side lock guide, and the thrower retaining lug, wherein the coupler body top pulling lug is configured to engage the upper knuckle pulling lug and the coupler body bottom pulling lug is configured to engage the lower knuckle pulling lug and to help balance the loads from the upper knuckle pulling lug and the lower knuckle pulling lug, wherein during operation of the railcar coupler a ratio between the loads on the coupler body top pulling lug and the coupler body bottom pulling lug is approximately equal to or less than 1.5;

wherein the top pulling lug comprises a non-contact side and a contact side, the top pulling lug having a substantially uniform thickness from the non-contact side to the contact side, wherein the top pulling lug defines a first end thickness and a second end thickness and the first end thickness is substantially equal to the second end thickness, wherein the non-contact side and the contact side define first and second arcuate paths in a common plane at a predetermined height and wherein the first and second arcuate paths are substantially parallel;

wherein the top pulling lug defines a top pulling lug contact patch area configured to engage the upper knuckle pulling lug and the bottom pulling lug defines a bottom pulling lug contact patch area configured to engage the lower knuckle pulling lug and wherein a ratio of the top pulling lug contact patch area to the bottom pulling lug contact patch area is equal to or less than 1.5;

wherein the top pulling lug has a top pulling lug base defining a cross-sectional area larger than a top pulling lug cross-sectional area adjacent to a distal end and wherein the ratio of the top pulling lug base cross-sectional area to the top pulling lug cross-sectional area adjacent to the distal end is greater than 2.5 and the bottom pulling lug has a bottom pulling lug base defining a cross-sectional area larger than a bottom pulling lug cross-sectional area adjacent to a distal end and wherein the ratio of the bottom pulling lug base cross-sectional area to the bottom pulling lug cross-sectional area adjacent to the distal end is greater than 2.5 and the bottom pulling lug base cross-sectional area ranges from 8 in² to 12 in²;

wherein the bottom pulling lug converges in the longitudinal direction from the bottom pulling lug base cross-sectional area to the bottom pulling lug distal end, wherein a base fillet radius extends around a majority of the bottom pulling lug base cross-sectional area and extends to a drain hole, an opening for the lock, a bottom buffing shoulder, and a bottom front face;

wherein a contact side of the bottom pulling lug contacting the lower knuckle pulling lug defines a top contact-side fillet radius, a contact-side lock-side fillet radius, and a contact-side thrower-side fillet radius that form a substantially continuous fillet radius in the range of 0.1 in. to 0.5 in. extending along the contact side along outer edges of the bottom pulling lug, which starts at the base of the bottom pulling lug on a lock side and continues up in a substantially vertical direction, then in a substantially horizontal direction, then in a substantially vertical direction and ends at the start of a drain hole, and a substantially continuous fillet radius at the base of the bottom pulling lug that bridges the contact-side lock-side fillet radius and the contact-side thrower-side fillet radius;

wherein the thrower is configured to be removed from the coupler head without interference from the bottom pulling lug when aligned up against the bottom pulling lug, the thrower lug and the knuckle side lock guide and wherein the knuckle side lock guide is positioned at or more than 2.75 in. above a thrower support surface on the coupler head;

wherein when the railcar coupler is in the unlocked position, the thrower overlaps with the bottom pulling lug such that the thrower extends over the bottom pulling lug at an area starting from a thrower side of the bottom pulling lug at a base of the bottom pulling lug and extending over a slope starting at a first fillet at the base of the bottom pulling lug and ending at an intersection of a second fillet adjacent the top of the bottom pulling lug and a vertical tangent.

2. The railcar coupler of claim 1 wherein during operation of the railcar coupler a ratio of stresses between the top pulling lug and the bottom pulling lug is approximately equal to or less than 1.5.

3. The railcar coupler of claim 2 wherein the ratio of the top pulling lug contact patch area to the bottom pulling lug contact patch area is equal to or less than 1.5.

4. The railcar coupler of claim 1 wherein top pulling lug contact patch area for contacting the upper knuckle pulling lug is greater than 1.0 in² and the bottom pulling lug contact patch area is greater than 1.0 in².

5. The railcar coupler of claim 1 wherein the top pulling lug defines a top pulling lug length and the bottom pulling lug defines a bottom pulling lug length and wherein the ratio of the top pulling lug length to the bottom pulling lug length is less than or equal to 1.3.

6. The railcar coupler of claim 1 wherein the top pulling lug base cross-sectional area is approximately 10.5 in² to 11.5 in² and the top pulling lug cross-sectional area adjacent to the distal end is approximately 2.5 in² to 3.5 in².

7. The railcar coupler of claim 1 wherein the bottom pulling lug base cross-sectional area is approximately 9.5 in² to 10.5 in² and the bottom pulling lug cross-sectional area adjacent to the distal end is approximately 2.5 in² to 3.5 in².

8. The railcar coupler of claim 1 wherein the first fillet radius of the bottom pulling lug is approximately 0.7 in. and the second fillet radius of the bottom pulling lug is approximately 1.125 in.

9. The railcar coupler of claim 1 wherein the upper knuckle pulling lug and the lower knuckle pulling lug are configured to receive equal reacting loads from the coupler body top pulling lug and the coupler body bottom pulling lug to help increase fatigue lives of the coupler body and the knuckle.

10. The railcar coupler of claim 1 wherein the coupler body bottom pulling lug has a bottom pulling lug cross-sectional area at the base and the coupler body top pulling lug has a top pulling lug cross-sectional area at the base and wherein a ratio of the top pulling lug cross-sectional area to the bottom pulling lug cross sectional area is less than 1.5.

11. The railcar coupler of claim 10 wherein the bottom pulling lug cross sectional area at the base is equal to the top pulling lug cross sectional area at the base.

12. A railcar coupler comprising:

a knuckle having an upper knuckle pulling lug and a lower knuckle pulling lug;

a thrower configured to move the knuckle from a locked position to an unlocked position;

a lock comprising a head and a leg configured to maintain the knuckle in either a locked position or an unlocked position; and

a coupler body comprising a shank and a head portion, the head portion defining a cavity for receiving the knuckle, the thrower, and the lock, the cavity comprising a top pulling lug, a bottom pulling lug, a knuckle side lock guide and a thrower retaining lug, wherein the coupler body top pulling lug is configured to engage the upper knuckle pulling lug and the coupler body bottom pulling lug is configured to engage the lower knuckle pulling lug and to help balance the loads from the upper knuckle pulling lug and the lower knuckle pulling lug;

wherein the top pulling lug comprises a non-contact side and a contact side, the top pulling lug having a substantially uniform thickness from the non-contact side to the contact side, wherein the top pulling lug defines a first end thickness and a second end thickness and the first end thickness is substantially equal to the second end thickness, and wherein the non-contact side and the contact side define first and second arcuate paths and wherein the first and second arcuate paths are substantially parallel;

wherein the top pulling lug has a top pulling lug base defining a cross-sectional area larger than a top pulling lug cross-sectional area adjacent to a distal end and wherein the ratio of the top pulling lug base cross-sectional area to the top pulling lug cross-sectional area adjacent to the distal end is greater than 2 and the bottom pulling lug has a bottom pulling lug base defining a cross-sectional area larger than a bottom pulling lug cross-sectional area adjacent to a distal end and wherein the ratio of the bottom pulling lug base cross-sectional area to the bottom pulling lug cross-sectional area adjacent to the distal end is greater than 2;

wherein the thrower is configured to be removed from the coupler head without interference from the bottom pulling lug when aligned up against the bottom pulling lug, the thrower lug, and the knuckle side lock guide, and wherein when the railcar coupler is in the unlocked position, the thrower overlaps with the bottom pulling lug such that the thrower extends over the bottom pulling lug.

13. The railcar coupler of claim 12 wherein during operation of the railcar coupler a ratio of stresses between the top pulling lug and the bottom pulling lug is less than 3 to 2.

14. The railcar coupler of claim 12 wherein the thrower comprises a lower trunnion and an upper trunnion, the upper trunnion defining a pivot for the thrower defining an outer circumference and wherein thrower retaining lug is configured to guide the upper trunnion at a contact portion of the outer circumference through a range of motion of the thrower and wherein the contact portion of the outer circumference is less than 90 degrees, the thrower retaining lug and the thrower define an overlapping area such that the thrower is maintained in position in the coupler head regardless of an orientation of the coupler head including when the coupler head is in an upright position and when the coupler head is in an inverted position and regardless if the knuckle is an open or closed position, the thrower retaining lug comprising a first surface and a second surface wherein the first surface and the second surface form an angle of less than 70°

.

15. The railcar coupler of claim 12 wherein the top pulling lug base cross-sectional area is approximately 10.5 in² to 11.5 in² and the top pulling lug cross-sectional area adjacent to the distal end is approximately 2.5 in² to 3.5 in².

16. The railcar coupler of claim 12 wherein the bottom pulling lug base cross-sectional area is approximately 9.5 in² to 10.5 in² and the bottom pulling lug cross-sectional area adjacent to the distal end is approximately 2.5 in² to 3.5 in².

17. The railcar coupler of claim 12 wherein the ratio of the top pulling lug base cross-sectional area to the top pulling lug cross-sectional area adjacent to the distal end is greater than 2.5 and wherein the ratio of the bottom pulling lug base cross-sectional area to the bottom pulling lug cross-sectional area adjacent to the distal end is greater than 2.5.

18. The railcar coupler of claim 12 wherein during operation the ratio of stresses between the top pulling lug and the bottom pulling lug is approximately 1 to 1.

19. The railcar coupler of claim 12 wherein the top pulling lug defines a top pulling lug contact patch area for engaging the upper knuckle pulling lug and the bottom pulling lug defines a bottom pulling lug contact patch area configured to engage the lower knuckle pulling lug and wherein a ratio of the top pulling lug contact patch area to the bottom pulling lug contact patch area is less than 1.5.

20. The railcar coupler of claim 19 wherein the ratio of the top pulling lug contact patch area to the bottom pulling lug contact patch area is approximately 1 to 1.

21. The railcar coupler of claim 19 wherein the top pulling lug contact patch area is greater than 1.0 in² and the bottom pulling lug contact patch area is greater than 1.0 in².

22. The railcar coupler of claim 12 wherein the bottom pulling lug defines a bottom pulling lug contact patch area configured to engage the lower knuckle pulling lug, the bottom pulling lug contact patch area having a length and a height and wherein a ratio of the length to the height is greater than or equal to 3 to 1.

23. The railcar coupler of claim 12 wherein the knuckle side lock guide is positioned at or more than 2.75 in. above a thrower support surface on the coupler head.

24. The railcar coupler of claim 12 wherein a base fillet radius extends around a majority of the bottom pulling lug base and extends to a drain hole, an opening for the lock, a bottom buffing shoulder, and a bottom front face.

25. A railcar coupler comprising:

a knuckle having an upper knuckle pulling lug and a lower knuckle pulling lug;

a thrower configured to move the knuckle from a locked position to an unlocked position;

a lock configured to maintain the knuckle in a locked position; and

a coupler body comprising a shank and a head portion, the head portion defining a cavity for receiving the knuckle, the thrower, and the lock, the cavity comprising a top pulling lug, a bottom pulling lug, a thrower retaining lug, and a knuckle side lock guide, the top pulling lug being configured to engage the upper knuckle pulling lug and the bottom pulling lug being configured to engage the lower knuckle pulling lug and to help balance the loads from the upper knuckle pulling lug and the lower knuckle pulling lug, wherein during operation of the railcar coupler a ratio of the loads between the coupler body top pulling lug and the coupler body bottom pulling lug is approximately equal to or less than 1.5;

wherein the top pulling lug has a top pulling lug base defining a cross-sectional area larger than a top pulling lug cross-sectional area adjacent to a distal end and wherein the ratio of the top pulling lug base cross-sectional area to the top pulling lug cross-sectional area adjacent to the distal end is greater than 2 and the bottom pulling lug has a bottom pulling lug base defining a cross-sectional area larger than a bottom pulling lug cross-sectional area adjacent to a distal end and wherein the ratio of the bottom pulling lug base cross-sectional area to the bottom pulling lug cross-sectional area adjacent to the distal end is greater than 2.

26. The railcar coupler of claim 25 wherein the thrower retaining lug and the thrower define an overlapping area such that the coupler can be oriented upside down without the knuckle moving from the locked position to the unlocked position or from the unlocked position to the locked position.

27. The railcar coupler of claim 25 wherein the thrower is configured to be removed from the coupler head without interference from the bottom pulling lug when aligned up against the bottom pulling lug, the thrower lug, and the knuckle side lock guide, and wherein when the railcar coupler is in the locked position, the thrower overlaps with the bottom pulling lug.