CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application Nos. 63/316,614 filed on March 04, 2022 and 63/322,596 filed on March 22, 2022, the contents of which are incorporated by reference in their entirety as if fully set forth herein

TECHNICAL FIELD

This disclosure relates to systems and methods for verifying an open or closed state of a hopper door. In particular, a hopper door indicator is presented that provides an unmistakable indication of an open, closed, or intermediate configuration of a hopper door. The disclosed hopper door indicator can be used, e g., on stationary hoppers, over-the-road grain trailers, rail cars and other transport modalities.

BACKGROUND

A hopper car or hopper wagon is a transport modality for loose bulk commodities such as grain, ore, coal and other flowable substances. Hopper cars are typically used on railways or pulled as trailers for over-the-road transport of goods. Generally, such cars and trailers include a large internal space for storage of the commodity and a door, normally centrally situated at the bottom of the car, that opens and closes to release the contents of the car into or onto a selected location.

Various configurations of hopper doors exist - from doors that translate along a horizontal plane to open and close to louvered systems utilizing one or more doors or slats that translate from a horizontal configuration (closed) to a vertical configuration (open). Hopper doors are usually situated proximal to a large aperture at the bottom of the vessel, the aperture being typically one- to several feet across to allow the contents of the vessel to flow freely and quickly, providing for efficient content drop-offs.

Hopper doors can be manually or automatically (e g., motor-driven) operated between open and closed configurations. Manually actuated hopper doors typically include a handoperated crank attached to a shaft; the shaft is configured to rotate one or more gears or is otherwise configured to slide the door horizontally open and closed, or activate louvers, depending on the type of system used.

As best known, there are no hopper systems that automatically close the hopper door once offloading of the car contents is complete. Thus, it is typically the operator’s responsibility to close the hopper door after the car is emptied, which introduces the possibility of forgetting to close the door before the next load is placed in the car or trailer. If this happens, the contents of the car can quickly flow out of the hopper door, leading to loss and/or destruction of product, a large mess, and lost time and productivity.

While some hopper door indicators exist, they do not provide an unmistakable indication that the door is fully closed. For example, US 8,356,560 to National Steel Car Limited, Hamilton, ON, Canada, discloses a railroad car having a door mechanism. The mechanism includes a rotating-style pointer that rotates to generally indicate if the door is open. However, these types of rotating indicators lack accuracy in their presentation. For example, the indication mechanism is normally attached directly to an axle that opens and closes the hopper door. If the connection between the indicator and axle - usually a collar of some type - becomes loose or is knocked out of alignment, false indications can result. Furthermore, this type of system lacks the ability to indicate if the door is slightly open or not, which could result from a blockage or jam in the door. In such cases, the indicator may generally point to the “closed” position even though the door is not fully closed.

US 2006/0042500 to Fred J. Taylor describes a door position indicating mechanism for a railcar. The mechanism includes a shaft that extends across the longitudinal direction of the car. Indicators are mounted on either end of the shaft to allow an operator to realize the position of the door from either side of the railcar. However, as with the previous example, this disclosure relies again upon a rotating pointer-style indicator that lacks precision in reporting whether the hopper door is fully closed.

Each of these examples rely on an “open/closed” indicator being directly attached to the same mechanism that operates to actuate the hopper door, resulting in reduced precision and the possibility of the indicator being bent, twisted or otherwise thrown out of kilter. A hopper door indicator that operates independently of the hopper door actuating mechanism would provide increased precision, ease of use, unmistakable identification of the door configuration (e.g., being fully closed or at least partially open) and require minimal installation or reconfiguration on a pre-existing railcar or trailer, and is an unmet need in the art.

SUMMARY

In general, a hopper door indicator is disclosed. The hopper door indicator can be used on railcars, trailers or any other type of hauler having a hopper- or similar type of door to quickly, easily and reliably ascertain whether the hopper door is fully closed.

In a first aspect, an assembly for visually indicating an open or closed state of a hopper car door is provided. The assembly includes a visual indicator capable of alternating between first and second indicator states, an actuator in mechanical communication with the visual indicator and configured to cause the visual indicator to shift between the first and the second indicator states, and a support assembly attached to a fixed location on the hopper car and arranged so as to position the actuator at a location where a moveable component of a hopper car door assembly confronts and actuates the actuator when the hopper door is closed.

In one embodiment, the visual indicator includes a first static plate member including at least a first aperture and a rotatable second plate member including at least a second aperture. The first and the second plate members are arranged in a planar-parallel orientation and the actuator is configured to rotate the second plate member relative to the first plate member when the actuator is actuated.

In one embodiment, the movable component of the hopper car is a sled supporting or attached to the hooper car door.

In one embodiment, when the actuator is actuated, the rotatable second plate member rotates so that the first aperture and the second aperture are aligned. In a related embodiment, when the actuator shifts from an actuated state to a de-actuated state, the rotatable second plate member rotates so that the first aperture and the second aperture are not aligned.

In one embodiment, the assembly further includes a rod member, the rod member including a proximal end and a distal end, wherein the actuator is attached to the rod member at the distal end, and the visual indicator is attached to the rod member at the proximal end. In a related embodiment, the assembly further includes a spring member attached to the rod member that applies a torque to the rod member sufficient to urge the rotatable second plate member such that the first aperture and the second aperture are not aligned when the actuator is not actuated.

In one embodiment, the first static plate member and the second rotatable plate member each include four apertures respectively. In one embodiment, the second rotatable plate member is colored, covered with a reflective material or includes indicia sufficient to serve as a visual warning indicator. In one embodiment, the visual indicator includes a swing arm, and wherein the actuator is configured to rotate the swing arm when the actuator is actuated.

In a second aspect, an assembly for visually indicating an open or closed state of a hopper car door is disclosed. In this second aspect, the assembly includes a visual indicator capable of displaying first and second indicator states, an electronic actuator in signal communication with the visual indicator and configured to cause the visual indicator to alternate between the first and the second indicator states, and a support assembly attached to a fixed location on the hopper car and arranged so as to position the electronic actuator at a location where a moveable component of the hopper car door assembly confronts the electronic actuator when the hopper door is in a closed configuration. In one embodiment, when the movable component confronts the electronic actuator, the visual indicator displays the first indicator state, and when the movable component is not in confrontation with the electronic actuator, the visual indicator displays the second indicator state. In a related embodiment, the visual indicator includes one or more light sources. In a related embodiment, the first indicator state correlates with the one or more light sources being deactivated so as not to emit light; and wherein the second indicator state correlates with the one or more light sources being activated so as to emit light.

In one embodiment, the electronic actuator is a proximity sensor.

In one embodiment, the movable component is a plate attached to a sled portion of the hopper car door assembly.

In one embodiment, the visual indicator is located proximal to a user control of the hopper car door.

In a third aspect, an assembly for visually indicating an open or closed state of a hopper car door is disclosed. In this third aspect, the assembly includes an electronic sensor in signal communication with a visual indicator that senses confrontation with a moveable component of a hopper car door assembly. The electronic sensor is positioned at a location where the moveable component of the hopper car door assembly confronts the electronic sensor when the hopper door is in a closed configuration.

In one embodiment, when the moveable component of the hopper door assembly confronts the electronic sensor, the visual indicator is deactivated; and when the moveable component of the hopper door assembly is not in confrontation with the electronic sensor, the visual indicator is activated.

In one embodiment, the visual indicator is a light source.

Certain advantages of the systems and methods described herein include the ability to quickly and easily recognize an open or closed state of a hopper door; the ability to easily adapt an existing hopper car or trailer with an indicator of the type described herein; precision in the indication of a fully closed door state; among others.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of any described embodiment, suitable methods and materials are described below. In addition, the matenals, methods, and examples are illustrative only and not intended to be limiting. In case of conflict with terms used in the art, the present specification, including definitions, will control.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description and claims.

DESCRIPTION OF DRAWINGS

The present embodiments are illustrated by way of the figures of the accompanying drawings, which may not necessarily be to scale, in which like references indicate similar elements, and in which:

FIG. 1 A shows a hopper door indicator according to a first embodiment, wherein the hopper door indicator indicates a ‘closed’ hopper door configuration;

FIG. IB shows the hopper door indicator of FIG. 1A, wherein the hopper door indicator indicates an ‘open’ or ‘partially-open’ hopper door configuration;

FIG. 2 is a hopper door indicator according to one embodiment;

FIG. 3 illustrates components of a hopper door indicator in use, according to one embodiment;

FIGS. 4A and 4B illustrate a hopper door indicator according to a second embodiment;

FIGS. 5 A and 5B illustrate portions of the hopper door indicator according to the second embodiment.

FIG. 6 A shows an electronic sensor of a hopper door indicator according to a third embodiment;

FIG. 6B shows an activated indicator of a hopper door indicator according to the third embodiment;

FIG. 6C shows the electronic sensor of FIG. 6A in contact with a portion of a hopper door component; and

FIG. 6D shows the indicator of FIG. 6B in a deactivated state.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIGS. 1A and IB illustrate a hopper door indicator (hereinafter ‘indicator’) 100 according to one embodiment. In this embodiment, the indicator 100 includes an indication plate 101 exteriorly mounted on a hopper trailer. While the present embodiment is descried with respect to a hopper trailer, it should be understood that the indicator 100 can be utilized on any type of hopper system, including, but not limited to rail cars and the like. The indication plate 101 can be attached, for example, to a portion of the framework or body of the hopper trailer as desired. In this example, the indication plate 101 is preferably mounted proximal to a crank handle CH of the hopper trailer, which itself is mechanically linked to, and operative to open and close the hopper door underneath the hopper trailer. As is common with many hopper trailers, and rail cars, rotation of the crank handle CH causes the hopper door to open or close depending on the direction (clockwise or counter-clockwise) that the crank handle CH is turned.

In this example, the indication plate 101 is securely fastened to an undercarriage portion of the hopper trailer by way of bolts such that it is clearly visible to personnel fdling the trailer. It should be understood that the indication plate 101 can be mounted in an alternative location as preferred; however, disposing the indication plate 101 in proximity to the crank handle CH can be optimal, especially when only one operator is present during onloading and offloading processes.

Referring in part to FIG. 2, in this same embodiment, a rotatable signal plate 110 is mounted behind the indication plate 101 as shown in FIGS. 1 A and IB and coaxially aligned with a circular alert area 115 of the indication plate 101 signified by the dashed circle in FIG. IB. As described in greater detail below, signal plate 110 includes a plurality of apertures 130 matching the number and shape of the apertures 105 of the indication plate 110, and a brightly - colored solid face 135 that exists over the surface of the signal plate 110, exclusive of apertures 130. The signal plate 110 is rotatable between at least two configurations: a first configuration where the apertures 130 of the signal plate 110 align with the apertures 105 of the indication plate 101, representing a non-alert or ‘closed’ hopper door configuration (FIG. 1A); and a second configuration where the signal plate 110 is rotated such that the apertures 130 of the signal plate 110 are not aligned (e.g., are out of phase) with the apertures 105 of the indication plate 101, representing an alert or ‘open’ hopper door configuration (FIG. IB). Said another way, in the example combination of indicator plate 101 and signal plate 110 shown in FIGS. 1A, IB and 2, a ‘door open’ configuration exists when the apertures 130 of the signal plate 110 are rotationally disposed 22.5° from the apertures 105 of the indication plate 110, such that the brightly-colored solid face 135 is visible through the indication plate apertures 1 5.

In this embodiment, the signal plate 110 is connected to a portion of the hopper door by way of a mechanical linkage, such that when the hopper door is fully closed, the signal plate 110 rotates such that apertures 130 of the signal plate 110 align with the apertures 105 of the indicator plate 101, e.g., as shown in FIG. 1A. This configuration provides a visual indication to the operator that the hopper door is closed, and the trailer is ready to be filled.

As explained in greater detail below, in this embodiment, when the hopper door is opened, even slightly, the mechanical linkage causes the signal plate 110 to rotate approximately 22.5 degrees about axis A such that the brightly colored solid face 135 of the signal plate 110 is visible within the apertures 105 of the indicator plate 101 (as shown, e.g., in FIG. IB). This configuration provides a visual alert condition to the operator that the hopper door is open, and contents should not be added to the trailer. In a preferred embodiment the brightly colored solid face 135 of the signal plate 110 is formed of or includes a highly visible surface such as a reflective surface or one that shows a bright color to attract the attention of the operator when the hopper door is in an open configuration, such as bright red, orange, yellow or green.

Referring now to FIG. 3, indicator 100 is show n operably attached to a portion of a hopper car. It should be understood that for the sake of figure clarity, only certain portions of the hopper car that relate to the functioning of the hopper door and indicator 100 are shown. In this example, indicator plate 101 is shown attached to a frame portion J ⁷ of the car. In use, the location of the indicator plate 101 would preferably be close to a handle or other control mechanism that operates opening and closing of a hopper door beneath the car. In this example, the hopper door (not visible in FIG. 3) translates horizontally, e g., on a same or similar plane as the ground beneath the car. In this example, when the hopper door is opened and closed, a sled portion S translates horizontally along a rail R as depicted by the double-headed arrow. For this particular hopper door arrangement, rail R remains fixed in space and allows the sled S to reciprocally translate left and right, according to the convention of the figure. The horizontal translational limits of sled S correspond to fully closed and fully open configurations of the hopper door, respectively. In other words, according to the convention of FIG. 3, when the sled S is in the left-most position, the hopper door is fully closed; when sled is in the right-most position, the hopper door is fully open.

In this embodiment, the indicator 100 includes an actuator 145. The actuator is operably connected with a rotatable shaft 140 and the rotatable shaft 140 is operably connected with the signal plate 110, which is illustrated in dashed line in FIG. 3, being disposed behind the indicator plate 101. In this example, actuator 145 is positioned so as to be engaged by a leading portion 150 of the sled S only when the sled S is in the left-most position, corresponding with the hopper door of the car being in the fully closed position.

In this embodiment, the actuator 145 and rod 140 cooperate to rotate the signal plate 110 when the actuator is actuated through contact, engagement or abutment with the leading portion 150 of sled 5. When the leading edge 150 of sled S engages the actuator 145, signal plate 110 rotates such that the apertures 130 of the signal plate 110 align with the apertures (105) of the indicator plate 101, e.g., as illustrated in FIG. 1 A. As soon as the leading edge 150 of sled S' translates (to the right, according to the convention of FIG. 3) and disengages actuator 145, signal plate 110 rotates approximately 22.5° such that the bnghtly colored solid face 135 of the signal plate 110 is visible through the apertures 105 of the indicator plate. Essentially, signal plate 110 rotates between 0° and 22.5° when the leading edge 150 of sled S engages and disengages actuator 145, respectively. In this embodiment, the indicator 100 can include a spring or similar element that provides a torsional or rotational urging force to the signal plate 110 about axis A (FIG. 3). In such an embodiment, the ‘resting’ or non-urged position of the signal plate 110 can be that where the brightly-colored solid face 135 of the signal plate is shown through the apertures 105 of the indicator plate 101, corresponding to a hopper ‘door-open’ configuration (FIG. IB). When sled translates to confront the actuator 145 - corresponding to a hopper ‘door-closed’ configuration, the sled S can apply the torsional or rotational force to the spring or similar element while also rotating the signal plate 110 such that the apertures (105, 130) are aligned, indicating the ‘door- closed’ configuration (FIG. 1 A). The use of torsional or rotational urging force provided by a spring or similar element can ensure that as soon as the sled S moves from a closed-door configuration towards an open-door configuration, the signal plate 110 immediately and urgently rotates to the ‘door-open’ configuration (FIG. IB). This configuration furthermore provides the ability for the operator to realize that the hopper door is open even slightly; for example, on the order of inches or less.

In this embodiment, actuator 145 can be placed anywhere where a component of the hopper door moves when open and closed and is not limited to engaging and disengaging sled S, which is used as an exemplary structural component of the described hopper car.

Referring now to FIGS. 4A and 4B, a second embodiment of an indicator is shown. In this embodiment, the hopper door indicator includes a swing arm 201 shiftable between a hopper “door-closed” configuration where the swing arm is hidden behind crank plate CP (FIG. 4A) and a hopper “door-open” configuration (FIG. 4B) where the swing arm is visible to the operator of the hand crank H shown. As described in greater detail below, in this embodiment, the swing arm 201 is configured to swing in a vertical plane, according to the convention of FIGS. 4A and 4B, such that it is hidden behind crank plate CP when the hopper door is closed, and visible when the hopper door is open, even slightly. The embodiment of FIGS. 4A and 4B may be considered more rugged and durable than the previously described embodiments and particularly useful for hopper cars and trailers that experience rough terrain, although the use of the present embodiment is not limited thereto.

Referring to FIG. 5A, in this second embodiment, swing arm 201 is connected to a rotatable drive shaft 205. The rotatable drive shaft is supported in part by a support arm 210 that itself is connected to a portion of the hopper car frame body as shown. The swing arm 201 includes a distal end portion 220 that is J-shaped, as shown.

In this embodiment, a strike plate 225 is mounted on a portion of sled S, which is the same sled S referred to previously with respect to the first embodiment. As previously described, sled S translates left and right (according to the convention of FIGS. 5 A and 5B) concurrently with the closing and opening of the hopper door, respectively. Thus, when the hopper door of the car is fully closed, the sled S' is in the left-most position, and when the hopper door of the car is fully open, the sled S is in the right-most position.

In this embodiment, rotatable drive shaft 205 is specifically positioned such that when the sled S is in the left-most position (the hopper door fully closed), strike plate 225 confronts the J- shaped distal end portion 220, thereby causing the drive shaft 205 to rotate clockwise about rotational axis AR as illustrated in FIG. 5 A. As previously mentioned, rotation of the drive shaft 205 causes concurrent motion of the swing arm 201; thus, when the drive shaft 205 rotates clockwise as illustrated in FIG. 5A, swing arm 201 shifts behind the crank plate P as illustrated in FIG. 4A.

Referring now to FIG. 5B, in this example, the sled S' has been translated to the right, according to the convention of FIG. 5B, corresponding to the hopper door being in the open or partially open configuration. Accordingly, strike plate 225 has disengaged from the J-shaped distal end portion 220 of the drive shaft 205 relative to that shown in FIG. 5A, allowing the drive shaft 205 to rotate counter-clockwise. Swing arm 201 will correspondingly shift outwardly to the right, as illustrated in FIG. 4B to indicate to the operator that the hopper door is open or partially open.

In this second embodiment, the indicator can include a spring or other member that applies a torsional or rotational urging to the drive shaft 205 about axis AR. For example, a spring can exert a torsional force unto the drive shaft 205 so that it is constantly urged to rotate in the counter-clockwise direction (e.g., as illustrated in FIG. 5B). When strike plate 225 confronts the J-shaped distal portion 220 of the drive shaft 205, the force of the sled S is sufficient to overcome the rotational urging force of the spring. However, since the spring is constantly urging the drive shaft 205 in the counter-clockwise direction, as soon as the sled ' begins to move to the right (commensurate with the hopper door opening), the drive shaft 205 will rotate and the indicator arm 201 will appear from behind the crank plate CP, alerting the operator of the hopper door configuration.

Referring now to FIGS. 6A-6D, in a third embodiment, an electronic sensor in combination with an electronic indicator can be used for sensing and displaying the state - e.g., open or closed - of the hopper door. In this example, referring first to FIG. 6A, an electronic sensor 302 can be mounted in a fixed location on a selected portion of a hopper car. In this example an arm 301 is attached to a portion of the hopper car frame. A strike plate 225, described previously, is attached to a moveable component of the hopper door assembly such as, but not limited to the previously described sled S which translates horizontally between a door “closed” configuration (left-most sled position) and a door “open” configuration (right-most sled position) according to the convention of the figures. The terminal end portion 303 of the electronic sensor 302 is positioned where strike plate 225 stops when the hopper door is in the fully closed (left-most) position, so that the strike plate 225 confronts the terminal end portion 303 of the electronic sensor when the hopper door is fully closed.

Referring to FIG. 6B, in this third embodiment the sensor 302 can be configured with an electronic indicator, such as light source 304 to illuminate when the strike plate 225 is not confronting the terminal end portion 303 of the sensor 302. In this third embodiment, tight source 304 can be, without limitation, a light bulb, LED, or other light-emitting indicator.

In this third embodiment, a circuit and power source (not illustrated in FIGS. 6A-6D) in electronic communication with the sensor 302 and the light source 304 can be configured to activate the tight source 304 if the strike plate 225 is not touching or in near proximity to the terminal end portion 303 of the sensor 302, as illustrated in FIG. 6B. The terminal end portion 303 of the sensor 302 can be, for example and without limitation, a contact sensor or an electric field sensor.

Referring to FIG. 6C and 6D, in this third embodiment, the circuit can be configured to deactivate the light source 304 when the strike plate 225 contacts, or nearly contacts the terminal end portion 303 of the sensor 302, as illustrated in FIG. 6D. Accordingly, in this embodiment, activation of the hopper door indicator relies on an electronic sensor to alert the operator of the state of the hopper door, in contrast to the mechanical activation methods of the previous embodiments. Nonetheless, the functionality of the hopper door indicator remains the same or similar, in that the operator can be alerted if the hopper door is open - including slightly open - prior to onloading grain or other contents into the hopper trailer or car.

A number of illustrative embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the various embodiments presented herein. For example, any of the components of the indicator embodiments described herein can be adapted or configured to be operable on any type of rail, over-the-road or other type of hopper container. While certain examples of “alerting” devices have been described, such as the rotatable alert described with respect to FIGS. 1A, IB, 2 and 3, and the swing-arm type alert described with respect to FIGS. 4A, 4B, 5A and 5B, it should be understood that other approaches and types of alerting devices can be substituted according to preference or other considerations. The activation or actuation of the indicators described herein may be accomplished by integrating the activation or actuating means with other portions or elements of a hopper trailer, car or other container. Accordingly, other embodiments are within the scope of the following claims.