Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: A method of forming a mold for use in the casting of a steel railway freight car truck component is provided. A cope mold is formed by providing a near net shape oversize impression of a cope pattern of a product to be cast in a flask. A cope pattern of the product to be cast is then placed on the flask forming a spacing between the cope pattern and the oversize impression. A resin coated sand is then blown to form a sand layer between the oversized impression in the flask and the cope pattern. The resin sand is set to form a mold of a thickness between the oversized impression in the flask and the cope pattern of the product to be cast. The drag mold is formed in a similar manner.

Abstract: A railcar handbrake wheel of polymeric composition including an outer ring connected to a hub by at least two spokes. The hub containing an insert or core molded into the hub. The core is a shaft member having a first end and a second end, with a head connected to the first end. The head on the first end of the core having a greater cross-sectional area than the second end of the core. The core containing an opening extending from the first end to the second end.

Abstract: A brake beam assembly for a railway car truck includes a brake beam mounted between opposed side frames of the railway car truck with opposite right hand and left hand ends. A strut is coupled to the brake beam and has opposite right hand and left hand ends coupled to the brake beam. Brake heads are coupled to the brake beam and struts proximate to the right hand and left hand ends thereof. Each brake head holds a brake shoe configured to engage a wheel of the railway car truck. Paddles extend from the brake heads. The paddles have distal ends configured to be received in wear liners in corresponding side frames of the railway car truck.

Abstract: A brake beam assembly for a railway car truck includes a brake beam configured to be mounted between opposed side frames of the railway car truck, a strut extending from the brake beam and brake heads coupled to the brake beam proximate to right hand and left hand ends thereof. Each brake head holds a brake shoe configured to engage a wheel of the railway car truck. Paddles extend exterior of the brake heads. The paddles have distal ends received in corresponding guide brackets of the side frames to guide movement of the brake beam. Paddle caps cover the distal ends of the paddles. The paddle caps are configured to be received in brake beam wear liners in corresponding side frames of the railway car truck. The paddle caps have a lower coefficient of friction than the paddles.

Abstract: An improved coupler-knuckle assembly is comprised of a coupler body, a knuckle, and at least two knuckle retainer plugs. The knuckle has an internal coring geometry that increases the cross-sectional area of the throat portion of the knuckle compared to previous designs. The present invention's knuckle design includes a top and a bottom tapered holes in the knuckle with a locking groove at the bottom of each tapered hole for the knuckle retainer plugs to snap into. The knuckle retainer plugs are inserted through the coupler body and into the tapered holes in the knuckle. The improved coupler-knuckle assembly of the present invention reduces fatigue on the coupler, knuckle, and knuckle pin, prevents misalignment of the coupler-knuckle assembly, and prevents knuckle pin breakage.

Abstract: An improved polymeric knuckle pin with at least one indented area that elastomer rings rest in. The indented area is strategically placed in an area on the shaft of the pin where the coupler-knuckle connection exerts impact, force, and stress on the pin. The elastomer rings in the indented area provide cushion to the pin from the impact, force, and stress, allow the pin to avoid hard contact with the coupler and knuckle, distribute the loads exerted by the coupler and knuckle more evenly, realign the coupler and knuckle positions, and protect the pin itself from surface cuts and scratches. The elastomer rings on the shaft of the pin improve the life of both the coupler-knuckle assembly and the pin.

Abstract: A railcar sensing system is provided that in particular provides a system for sensing the orientation of a hatch of a railway tank car. The railcar sensing system includes an accelerometer for sensing the orientation of the hatch, a position sensing device for detecting the global position of the railcar, and a processing unit. The accelerometer sends a first signal to the processing unit when the orientation of the hatch changes more than a predetermined angle. The processing unit also senses whether the railway tank car is outside one of the preselected safe zones. If the railway tank car is located outside one of the preselected safe zones, and the accelerometer senses that the hatch orientation has been changed more than a predetermined angle, an alert signal is sent to a receiver indicative of such event.

Abstract: A novel assembly for a railcar axle bearing is presented. The assembly includes a backing ring affixed to the fillet of the journal of an axle and a locking ring for further affixing the backing ring the journal. The locking ring has an inboard end affixed to the dust guard of the axle and an outboard end for engaging the backing ring. The looking ring may include a resilient sealing ring.

Abstract: A device for monitoring the status of a railcar handbrake having a hand operated handle, which device has a magnet configured to he inserted in the linkage of a railcar handbrake system. A sensing component is mounted on the railcar to sense the proximity of the magnet when the handbrake is applied. A system and method using the monitoring device to provide communication of an alarm when the handbrake is applied and the railcar is moving.

Abstract: A system for monitoring operation of a railcar having one or more sensing units, mounted on the railcar, for monitoring operating parameters and or conditions of the railcar, and a communication management unit, in wireless communication with the sensing units, wherein the system can make a determination of an alarm condition based on data collected the sensing units. A temperature sensor device for use in such a system is also provided.

Abstract: A brake beam wear plate assembly for a railway car truck sideframe is provided. A brake beam wear plate is provided and adapted to be inserted in a brake beam guide which is typically an integral component of a railway car truck sideframe. The brake beam wear plate itself is comprised of a channel shaped body having an upper wall, a lower wall, and a bottom wall. The brake beam wear plate is typically comprised of a polymer or a high density plastic. The brake beam wear plate also includes a projecting locating tab and the brake beam guide itself includes a complimentary cutout section.

Abstract: A bearing assembly is presented having a novel bearing seal design that, in one embodiment, combines the sealing advantages of both a labyrinth-like seal in combination with a contact seal. The seal is held perpendicularly to the sealing surface, and in one embodiment, substantially divides the sealing forces equally between the lubricant seal portion and the dust seal portion of the seal by virtue of the symmetry of the seal geometry and the application of the resisting force substantially along the seal body's centerline. The seal departs from the cantilever geometry of prior art seal designs, and in one embodiment, provides an inherently stiffer seal.

Abstract: A method and apparatus for collecting ultrasonic test data from a railway wheel with an ultrasonic testing apparatus is described. The railway wheel is supported by two drive rollers, each having an indentation which engages with and rotates the wheel. An indexing transducer moves across the rotating wheel, collecting ultrasonic test data while a fixed transducer correlates a reference position on the wheel to the collected test data. To maintain the accuracy of the reference position to the collected test data, it is desirable to maintain the rotational stability of the wheel, minimizing any dynamic instability caused by dimensional tolerances in the wheel. To mitigate instabilities resulting from dimensional tolerances, the indentation of the drive rollers, which engage and drive the flange of the wheel, is adjustable by the flexing design of the drive rollers to maintain frictional contact between the wheel and the drive roller.

Abstract: A method and apparatus for collecting ultrasonic test data from a railway wheel with an ultrasonic testing apparatus is described. The railway wheel is supported by two drive rollers, each having an indentation which engages with and rotates the wheel. An indexing transducer moves across the rotating wheel, collecting ultrasonic test data while a fixed transducer correlates a reference position on the wheel to the collected test data. To maintain the accuracy of the reference position to the collected test data, it is desirable to maintain the rotational stability of the wheel, minimizing any dynamic instability caused by dimensional tolerances in the wheel. To mitigate instabilities resulting from dimensional tolerances, the indentation of the drive rollers, which engage and drive the flange of the wheel, are variably spaced using a resilient member to maintain frictional contact between the wheel and the drive roller.

Abstract: An improved railway car truck is provided that includes two sideframes and a bolster. The bolster has laterally opposite ends, each end extending into and supported within a sideframe opening on a spring group. Each sideframe also has a pedestal opening at each end to receive a bearing adapter assembly. The railway car truck also includes a transom extending into and supported within a sideframe opening. The spring group is supported at each transom end. A lateral damping cylinder is connected between the bolster and the transom. A vertical damping cylinder is connected between the bolster and the sideframe.

Abstract: A method of manufacturing bearing seal for use in a roller bearing is provided. A steel coil of a preselected width is fed into a ring rolling machine to form a closed coil ring. The closed coil ring is then welded along the butted joint. The welded closed coil ring is then fed to a series of pre-forming machines wherein the desired profiles of the final bearing seal are formed.

Abstract: A novel assembly for a railcar axle bearing is presented. The assembly includes a backing ring affixed to the fillet of the journal of an axle and a locking ring for further affixing the backing ring the journal. The locking ring has an inboard end affixed to the dust guard of the axle and an outboard end for engaging the backing ring. The looking ring may include a resilient sealing ring.

Abstract: A railcar cushioning device has a hydraulic cylinder holding pressurized fluid. The cylinder has a cylinder body with an inner chamber and a reservoir chamber. A piston is movably positioned in the inner chamber. The cylinder body has a bleed opening allowing bleed flow from the inner chamber to the reservoir chamber. A bleed orifice valve in the bleed opening has a valve housing and a poppet received in the valve housing that moves to allow and restrict fluid flow through a bleed flow path based on the pressure of the fluid. The poppet has an orifice channel allowing a restricted fluid flow through the valve housing when the pressure in the inner chamber is greater than the pressure in the reservoir chamber.

Abstract: A cast steel railway wheel includes a hub that has an axial bore. A rim is concentric with the bore. A plate extends substantially radially from the hub to the rim. The plate has a front face and a rear face. The plate has a plurality of spokes that extend between the hub and the rim. Adjacent spokes have different thicknesses defined between the front face and the rear face.