Modular Lubrication Unit

Abstract

A modular lubrication unit for a rail lubrication distribution system includes a tank, a pump assembly, and a controller. The pump assembly is in fluid communication with the tank and the controller is in communication with the pump assembly for controlling the pump assembly. The controller is enclosed within a panel and the tank is self-contained and movable relative to the panel.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/158,418, filed Mar. 9, 2009, the entire content of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to lubrication of railroad tracks and, more particularly, to a modular lubrication unit for supplying lubricant, such as grease, to railroad rails.

2. Description of Related Art

In the operation of railroads, it has long been the practice to apply lubricant or friction modifier materials onto railroad rails, such as to the top of the rails or sides of the rails at curves, turnouts, switches, and in some cases, the section of a track immediately before a switch, and periodically spaced along the length of the track. Such lubricants and friction modifier materials, such as grease, can either reduce or increase the friction where necessary to improve train performance and reduce wear on both the rails and the train wheels. Lubricant is typically pumped from a nearby central pump station to a rail applicator device for applying lubricant to the railroad rails. Such rail applicator devices are disclosed in U.S. Pat. No. 5,394,958, which is hereby incorporated by reference. The pump station, which is typically housed in a small enclosure, generally includes a tank and at least one pump that draws lubricant from the tank. The pump is typically mounted to a wall of the enclosure, wherein access to the pump for maintenance purposes is easily attainable.

In the railroad industry, railroads typically have different priorities and solutions to their specific problems. Oftentimes lubricant may be needed at different locations along the railroad track that was not contemplated during the design stage of the railroad. Because the prior art pump stations are integrated as one complete unit, a new pump station along with an enclosure would have to be provided. If more lubricant is required at another location of a railroad track or even at the same location, a second complete lubrication unit may have to be installed. Either another small enclosure would have to be installed, or an additional lubrication pump would have to be positioned within the limited space of the one enclosure.

SUMMARY OF THE INVENTION

In one embodiment, a modular lubrication unit for a rail lubrication distribution system includes a tank, a pump assembly, and a controller. The pump assembly is in fluid communication with the tank and the controller is in communication with the pump assembly for controlling the pump assembly. The controller is enclosed within a panel and the tank is self-contained and movable relative to the panel.

The pump assembly may be attached to the tank via a connector. The pump assembly may include a pump and a motor with the pump assembly being positioned within an enclosure. The pump assembly may be attached to a side of the tank and the panel may be spaced from the tank. The panel may also be positioned on a pair of spaced apart legs with a bottom of the tank defining a recess. The tank may be positioned on a support and the support and the bottom of the tank defining a recess. The pump assembly may be positioned within an enclosure with the enclosure being attached to the bottom of the tank within the recess. The enclosure may be supported via bracket.

In a further embodiment, a modular lubrication unit for a rail lubrication distribution system includes first and second tanks, first and second pump assemblies, and a controller. The first tank is spaced from the second tank and the first pump assembly is in fluid communication with the first tank and the second pump assembly is in fluid communication with the second tank. The controller is in communication with the first and second pump assemblies for controlling the first and second pump assemblies. The controller is enclosed within a panel, where the first and second tanks are self-contained and movable relative to the panel.

The first pump assembly may be attached to the first tank via a connection and the second pump assembly may be connected to the second tank via a connector. Each pump assembly may include a pump and a motor with each pump assembly being positioned within an enclosure. The first pump assembly may be attached to a side of the first tank and the second pump assembly may be attached to a side of the second tank. The panel may be positioned between the first and second pump assemblies, where the first and second pump assemblies are supported by first and second brackets. The panel may be positioned on a pair of spaced apart legs.

In another embodiment, a method includes: providing a tank, a pump assembly, and a controller; positioning a pump and a motor within an enclosure to define the pump assembly; connecting the pump assembly to the tank such that the pump assembly is in fluid communication with the tank; positioning the controller within a panel; positioning the panel at a location that is adjacent to and spaced from the tank; and actuating the pump assembly via the controller to supply lubricant from the tank to a rail lubrication distribution system. The method may further include removing the pump assembly and replacing the pump assembly with a different pump assembly and removing the tank by moving the tank relative to the panel and replacing the tank with a different tank.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular lubrication unit according to one embodiment of the present invention;

FIG. 2 is a top view of the modular lubrication unit shown in FIG. 1;

FIG. 3 is a side view of the modular lubrication unit shown in FIG. 1;

FIG. 4 is a front view of the modular lubrication unit shown in FIG. 1;

FIG. 5 is a perspective view of the modular lubrication unit shown in FIG. 1, showing a door in the closed position;

FIG. 6 is a perspective view of a pump assembly of the modular lubrication unit shown in FIG. 1;

FIG. 7 is a side view of the pump assembly shown in FIG. 6;

FIG. 8 is a front view of the pump assembly shown in FIG. 6;

FIG. 9 is top view of the pump assembly shown in FIG. 6;

FIG. 10 is a side view of the pump assembly shown in FIG. 6, showing the interior of an enclosure;

FIG. 11 is a front view of the pump assembly shown in FIG. 6, showing the interior of an enclosure;

FIG. 12 is top view of the pump assembly shown in FIG. 6, showing the interior of an enclosure;

FIG. 13 is a perspective view of a modular lubrication unit according to a further embodiment of the present invention;

FIG. 14 is a side view of the modular lubrication unit shown in FIG. 13;

FIG. 15 is a front view of the modular lubrication unit shown in FIG. 13;

FIG. 16 is a top view of the modular lubrication unit shown in FIG. 13;

FIG. 17 is a perspective view of a pump assembly of the modular lubrication unit shown in FIG. 13;

FIG. 18 is a side view of the pump assembly shown in FIG. 17;

FIG. 19 is a front view of the pump assembly shown in FIG. 17;

FIG. 20 is a top view of the pump assembly shown in FIG. 17;

FIG. 21 is a is a side view of the pump assembly shown in FIG. 17, showing the interior of an enclosure;

FIG. 22 is a front view of the pump assembly shown in FIG. 17, showing the interior of an enclosure;

FIG. 23 is a top view of the pump assembly shown in FIG. 17, showing the interior of an enclosure;

FIG. 24 is a perspective view of a modular lubrication unit according to another embodiment of the present invention;

FIG. 25 is a top view of the modular lubrication unit shown in FIG. 24;

FIG. 26 is a front view of the modular lubrication unit shown in FIG. 24;

FIG. 27 is a side view of the modular lubrication unit shown in FIG. 24;

FIG. 28 is a side view of modular lubrication unit according to yet another embodiment of the present invention, showing the interior of an enclosure;

FIG. 29 is a front view of the modular lubrication unit shown in FIG. 28;

FIG. 30 is a perspective view of a modular lubrication unit according to a further embodiment of the present invention; and

FIG. 31 is a side view of the modular lubrication unit shown in FIG. 30.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of the description hereinafter, spatial orientation terms, if used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following detailed description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and embodiments. It is also to be understood that the specific devices illustrated in the accompanying drawing figures and described herein are simply exemplary and should not be considered as limiting.

Referring to FIGS. 1-12, one embodiment of a modular lubrication unit 10 for supplying pressurized lubricant, such as grease or friction modifying material, is provided. The modular lubrication unit 10 supplies lubricant to an applicator device (not shown) for application of the lubricant onto the railroad rails. The lubrication unit 10 includes a lubricant tank 12, a pump assembly 14 attached to and in fluid communication with the tank 12 and a controller 16 in communication with the pump assembly 14 for supplying the lubricant to the railroad rails. The controller 16 is electronically connected to the pump assembly 14 via a cable 17 for controlling the pump assembly 14. The tank 12 has spaced-apart legs 18 beneath a bottom 19 of the tank 12 defining a recess 20 therebetween, although the tank 12 may also have a flat bottom or other suitable bottom configurations. The recess 20 enables the tank 12 to be easily moved, such as via the forks of a forklift truck received within the recess 20. The tank 12 may also be positioned on a support 22, such as channel bars, having channels 24 (shown in FIGS. 13-16) for receiving the forks of a forklift truck within the channels 24. The bottom 19 of the tank 12 and the support 22 also define a recess 26. The tank 12 may also be a tote. Such tanks or totes may have various sizes and shapes. The tank 12 may also include a funnel-shaped insert (not shown) received therein for funneling lubricant toward a bottom outlet of the tank. Further, a tank enclosure (not shown) may also be used to house the tank. The tank 12 is self-contained and movable relative to the panel 42, such that the tank 12 can be readily replaced with a different tank for containing a different type of lubricant, if required. The different tank may be a different shape or size than the tank 12 to hold a different volume of lubricant than the tank 12. The tank 12 may be readily separated from the panel 42 and pump assembly 14 by, for example, removing a mechanical fastener arrangement that secures the tank 12 relative to the panel 42 and the pump assembly 14.

Referring to FIGS. 6-12, the pump assembly 14 may include a pump 30 and a motor 32 attached thereto. The pump assembly 14 is shown housed in an enclosure 34 having openings O therein for receiving inlet and outlet tubing or piping (not shown). The enclosure 34 may be attached to a holding bracket 38 with the holding bracket 38 supporting the enclosure 34. The bracket 38 may also be attached directly to the tank 12 using any suitable fastening arrangement, such as mechanical fastening, for easy removal from the tank 12. The pump assembly 14 is in fluid communication with the tank 12 via a connector 36 that attaches the pump assembly 14 to the tank. The present invention permits different pump assemblies 14 to be utilized with the tank 12. The connector 36 is attached to a side 40 of the tank 12, although the connector may be attached to other portions of tank or may be attached to the tank 12 through piping. The pump assembly 14 is protected from the environment via the enclosure 34, which may provide protection against corrosion, moisture and other hazards that can damage or reduce the normal life cycle of the pump assembly 14. For example, the enclosure 34 can be made of a polymeric material or corrosion-resistant metal.

Referring to FIGS. 1-5, the controller 16 is typically housed in an electrical box or panel 42 having an access door 44 therein for easy access to the controls by an operator. The access door 44 has an open position (shown in FIG. 1) and a closed position (shown in FIG. 5). The lubrication unit 10 may include timers, flow meters, level sensors, manifolds, flow dividers and microprocessors, and the like, for controlling the amount and frequency of lubricant supplied to the railroad rails via the controller 16. The panel 42 is positioned adjacent to and spaced from the tank 12, although the panel 42 may also be directly attached to the tank 12. The panel 42 includes channels or legs L whereby the forks of a forklift truck can be inserted therein thus lifting and/or transporting the panel 42. The present invention permits different controllers to be used with pump assemblies 14 and tanks 12 creating a modular design, where the present invention creates a true modular arrangement.

In operation, lubricant from the tank 12 is pumped out of the tank 12 from a bottom side thereof via the pump assembly 14 thus supplying pressurized lubricant to a rail applicator device and onto railroad rails. An operator (not shown) can program the controller 16 via the access door 44 and control the flow rates and/or frequency of application. The controller 16 may be attached to the tank 12 or adjacent to and spaced from the tank 12. The panel 42 and controller 16 are self-contained and may be readily separated from the tank 12. When transporting the unit 10, the un-attached panel 42 and controller 16 can be transported separately from the tank 12.

FIGS. 13-23 show a further embodiment of a modular lubrication unit 10A that is similar the lubrication unit 10. Like reference numerals are used for like parts. The lubrication unit 10A also includes a lubrication tank 12, a pump assembly 14 and controller 16 which is similar to lubrication unit 10. However, the pump assembly 14 of lubrication unit 10A is attached to the bottom 19 of the tank 12. In particular, the pump assembly 14 is positioned within the enclosure 34 with the enclosure 34 being secured to the bottom 19 of the tank 12. Typically, this type of arrangement will be used with highly viscous liquids such as grease. Although not shown, a holding bracket may be used to support the pump assembly 14 or to attach the pump assembly 14 to the bottom of the tank 12. The support 22, such as channel bars, positioned beneath the bottom 19 of the tank 12 raises the tank 12 off of the ground level and defines the recess 26 such that the pump assembly 14 is also spaced away from the ground level and positioned within the recess 26. Access to the pump assembly 14 for maintenance purposes may be accomplished by lifting the unit 10A with the forks of a forklift truck. In this embodiment, the tank 12 can also have a cone-shaped insert (not shown) for funneling lubricant to the bottom of the tank 12 into an inlet of the pump assembly 14.

FIGS. 24-27 show another embodiment of a modular lubrication unit 10B that is similar to lubrication unit 10A. Like reference numerals are used for like parts. Lubrication unit 10B includes first and second tanks 12 with the tanks 12 being spaced from each other. First and second pump assemblies 14 are attached to the sides 40 of the respective tanks 12 with the first and second pump assemblies being in fluid communication with the respective tanks 12. A controller 16 is in communication with the first and second pump assemblies 14 for controlling the first and second pump assemblies 14. The controller 16 is enclosed within a panel 42. The first and second tanks 12 are self-contained and movable relative to the panel 42 such that the tanks 12 can be readily replaced with different tanks for containing different types of lubricant if required. The first and second pump assemblies 14 may be supported by brackets 38. The panel 42 and controller 16 are positioned between the first and second pump assemblies 14 and are positioned on spaced-apart legs L. The controller 16 controls the first and second pump assemblies 14, although the controller may control one or more pump assemblies for distribution of lubricant from one or more tanks.

In particular, one of the tanks 12 may contain a first lubricant and the other tank 12 may include a second lubricant. For example, the first lubricant may be a summer-formulated lubricant and the second lubricant may be a winter-formulated lubricant. The controller 16 may be in communication with various temperature sensors (not shown) to determine the temperature conditions. During colder weather, the controller 16 may actuate the pump assembly 14 connected to the tank 12 that contains the winter-formulated lubricant for distribution to the rail lubrication equipment. During warmer weather, the controller 16 may actuate the pump assembly 14 connected to the tank that contains the summer-formulated lubricant for distribution to the rail lubrication equipment. The pump assemblies 14 may be similar, but can be operated differently based on the lubricant the pump assemblies 14 are pumping. For instance, the pump assemblies 14 may have different pumping intervals and cycles depending on the type of lubricant being pumped. Accordingly, the controller 16 can selectively distribute a suitable lubricant from the plurality of tanks 12 based on the particular temperature conditions.

FIGS. 28 and 29 show yet another embodiment of a modular lubrication unit 10C that is similar to the lubrication units 10, 10A, and 10B. Like reference numerals are used for like parts. Lubrication unit 10C includes a tank 12, which is shown as a tote, a pump assembly 14, and a controller 16. The controller 16 and the pump assembly 14 are positioned within a panel 42 rather than providing a separate enclosure for the pump assembly 14. The pump assembly 14 is connected to and in fluid communication with the tank via piping 48. The controller 16 is connected to the pump assembly 14 to allow the controller 16 to control the operation of the pump assembly 14.

FIGS. 30 and 31 show a further embodiment of a modular lubrication unit 10D that is similar to the lubrication units 10, 10A, 10B, and 10C. Like reference numerals are used for like parts. Lubrication unit 10C includes a tank 12, a pair of pump assemblies 14, and a controller 16. The controller 16 is positioned within a panel 42 as discussed above in connection with lubrication units 10, 10A, 10B, and 10C. The panel 42 is secured to the upper portion of the tank 12 to define a space 50 beneath the panel 42. Although not shown, the controller 16 is connected to the pump assemblies 14 to allow the controller 16 to control the operation of the pump assemblies 14. Each of the pump assemblies 14 are positioned within separate enclosures 34 with the pump assemblies 14 being connected to and in fluid communication with the tank 12 via a connector 36. In particular, the connector 36 of the lubrication unit 10D is a T-shaped piping assembly that is secured to a single outlet O of the tank 12 with each pump assembly 14 being separately connected to the connector 36. The single tank 12 of the lubrication unit 10D may feed multiple tracks of lubrication equipment with one of the pump assemblies 14 supplying lubricant to a first set of lubrication equipment and the other pump assembly 14 supplying lubricant to a second set of lubrication equipment.

Although not shown, the modular lubrication units 10, 10A, 10B, 10C may be powered via a DC solar power arrangement, through connection via cabling to an AC or DC power source, or through any other suitable power source options.

In a further embodiment, a method includes providing a tank, a pump assembly, and a controller; positioning a pump 30 and a motor 32 within an enclosure 34 to define the pump assembly 14; connecting the pump assembly 14 to the tank 12 such that the pump assembly 14 is in fluid communication with the tank 12; and positioning the controller 16 within a panel 42. The method also may include positioning the panel 42 at location adjacent to and spaced from the tank 12 and actuating the pump assembly 14 via the controller 16 to supply lubricant from the tank 12 to a rail lubrication distribution system. The method may also include removing the pump assembly 14 and replacing the pump assembly with a different pump assembly 14 and removing the tank 12 by moving the tank 12 relative to the panel 42 and replacing the tank with a different tank 12. In particular, the pump assembly 14 and tank 12 may be readily removed and replaced with different pump assemblies or tank to accommodate various types of lubricants.

The advantage of having self-contained tanks with pump assemblies mounted thereto is that the tank and/or pump assembly can be switched out for another self-contained tank and pump assembly having different grade lubricants therein. Hence, a modular design is provided that allows a lubrication system to be customized based upon the customer's needs. The present invention provides a modular arrangement with a tank 12, pump assembly 14, and controller 16 creating a modular lubrication unit, where the controller 16, pump assembly 14, and tank 12 can be formed from different size tanks, size pumps, and controllers depending on the requirements at the point of application. By ensuring that the customer can optimize the lubrication unit to suit their specific needs, the modular unit will increase the effectiveness of the system. That is, specific tanks, pumps and controllers can be connected together to result in a specific lubrication system. As a result, inventory can be minimized via the present modular system. Further, the self-contained lubrication units can be easily transported or shipped anywhere on a railroad line and then easily installed at the site where the lubrication system is to be installed.

This invention has been described with reference to the preferred embodiments. Obvious modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.

Claims

1. A modular lubrication unit for a rail lubrication distribution system comprising:

a tank;

a pump assembly in fluid communication with the tank; and

a controller in communication with the pump assembly for controlling the pump assembly, the controller being enclosed within a panel, wherein the tank is self-contained and movable relative to the panel.

2. The modular lubrication unit of claim 1, wherein the pump assembly is attached to the tank via a connector.

3. The modular lubrication unit of claim 2, wherein the pump assembly comprises a pump and a motor, the pump assembly being positioned within an enclosure.

4. The modular lubrication unit of claim 1, wherein the pump assembly is attached to a side of the tank.

5. The modular lubrication unit of claim 1, wherein the panel is spaced from the tank.

6. The modular lubrication unit of claim 5, wherein the panel is positioned on a pair of spaced apart legs.

7. The modular lubrication unit of claim 1, wherein a bottom of the tank defines a recess.

8. The modular lubrication unit of claim 1, wherein the tank is positioned on a support, the support and the bottom of the tank defining a recess.

9. The modular lubrication unit of claim 8, wherein the pump assembly is positioned within an enclosure, the enclosure being attached to the bottom of the tank within the recess.

10. The modular lubrication unit of claim 3, wherein the enclosure is supported via a bracket.

11. A modular lubrication unit for a rail lubrication distribution system comprising:

first and second tanks, the first tank being spaced from the second tank;

first and second pump assemblies, the first pump assembly being in fluid communication with the first tank and the second pump assembly being in fluid communication with the second tank;

a controller in communication with the first and second pump assemblies for controlling the first and second pump assemblies, the controller being enclosed within a panel, wherein the first and second tanks are self-contained and movable relative to the panel.

12. The modular lubrication unit of claim 11, wherein the first pump assembly is attached to the first tank via a connector and the second pump assembly is connected to the second tank via a connector.

13. The modular lubrication unit of claim 12, wherein each pump assembly comprises a pump and a motor, each pump assembly being positioned within an enclosure.

14. The modular lubrication unit of claim 11, wherein the first pump assembly is attached to a side of the first tank, and the second pump assembly is attached to a side of the second tank.

15. The modular lubrication unit of claim 14, wherein the panel is positioned between the first and second pump assemblies.

16. The modular lubrication unit of claim 15, wherein the first and second pump assemblies are supported by first and second brackets.

17. The modular lubrication unit of claim 16, wherein the panel is positioned on a pair of spaced apart legs.

18. A method comprising:

providing a tank, a pump assembly, and a controller;

positioning a pump and a motor within an enclosure to define the pump assembly;

connecting the pump assembly to the tank such that the pump assembly is in fluid communication with the tank;

positioning the controller within a panel;

positioning the panel at a location that is adjacent to and spaced from the tank;

actuating the pump assembly via the controller to supply lubricant from the tank to a rail lubrication distribution system.

19. The method of claim 18, further comprising:

removing the pump assembly and replacing the pump assembly with a different pump assembly.

20. The method of claim 19, further comprising:

removing the tank by moving the tank relative to the panel and replacing the tank with a different tank.