Abstract: A railway vehicle, a coupler, and a coupler body thereof. The coupler body comprises an upper traction platform, a lower traction platform, a lock chamber, and a pin hole. A traction surface of an upper traction platform and/or a lower traction platform is divided into a contact area and a yielding area along the direction approaching the lock chamber, an extension face of the end of the contact area close to the lock chamber is an M2 face, and the yielding area is positioned at the side of the M2 face close to the pin hole. The yielding area is positioned on the side of the contact area next to the lock chamber and there is a gap and no contact between the yielding area and a traction platform of a coupler knuckle.

Abstract: A railroad car coupler assembly knuckle pin including an elongated cylindrical tubular body having an upper end portion, a lower end portion spaced apart from the upper end portion, and an intermediate portion between and connecting the upper end portion and the lower end portion, the body including an elongated cylindrical wall that defines an elongated cylindrical central opening and an elongated slot that extends the length of the wall, a first ring integrally connected to and outwardly extending from a first area of the upper end portion of the body, a second ring integrally connected to and outwardly extending from a second area of the upper end portion of the body, the second ring spaced apart from the first ring along the body, the first ring defining a plurality of first stress relief slots, and the second ring defining a plurality of second stress relief slots.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A railcar coupler having a head portion extending from a shank portion, the coupler head portion is configured to couple to a first coupler knuckle for coupling the railcar coupler to a second railcar coupler of an adjacent railcar. The coupler has weight reduction features that also are configured to provide strength to the coupler when handling forceloads. The coupler may have a head with a front face with bores provided in the front face a cavity extending through the coupler, a guard arm with cavities formed therein, and a shank having a plurality of longitudinal cavities and adjacent ribs separating the cavities. Preferred embodiments may be constructed from an austempered metal.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: The coupler system of a railway car truck is constructed such that basic overall appearance may be maintained, but the actual material of which it is constructed is changed. According to one embodiment, the coupler is constructed from cast austempered ductile iron; whereas cast iron has a density, 0.26 lbs/in^3, which is approximately 8% less than steel, 0.283 lbs/in^3, thereby allowing for a reduction in weight over steel. A suitable austempering process is used to produce the austempered metal coupler and components thereof. A second benefit of embodiments of the present invention provides for a more efficient use of materials, meaning less metal is used to make the same final shape, as a way of reducing the coupler weight. Both factures combined allow for a lighter weight coupler, while utilizing the standard designs. Alternate coupler configurations are disclosed for further reducing coupler weight.

Abstract: Disclosed is a front installed suspension system having overload protection. The system comprises a mounting seat (1), a centring apparatus (2), a support apparatus (3) used for supporting a coupling buffer and a coupling end pin (4), wherein the mounting seat (1) is connected to a railway vehicle body, and the centring apparatus (2) and the support apparatus (3) are both installed on the mounting seat (1). The system further has a coupling connection seat (5) and an overload protection element (6), wherein the coupling connection seat (5) comprises a base and a coupling connection part connected as one with the base. The base is connected to a rear face of the mounting seat (1) by means of the overload protection element (6). The coupling connection part passes through a through hole (7) provided in the middle of the mounting seat (1) and is connected with the coupling buffer by means of the coupling end pin (4). The coupling connection part is closely fitted with the through hole (7).

Abstract: A railroad coupler assembly having at least a body and a knuckle both formed in a no-bake manufacturing process, the body and the knuckle having dimensional tolerances of distances between features that wear during operation that are about half those obtained from a body and a knuckle manufactured by a green sand process, resulting in increased fatigue life compared to the body and the knuckle manufactured by a green sand process.

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: A railcar coupler having a head portion extending from a shank portion, the coupler head portion is configured to couple to a first coupler knuckle for coupling the railcar coupler to a second railcar coupler of an adjacent railcar. The coupler has weight reduction features that also are configured to provide strength to the coupler when handling forceloads. The coupler may have a head with a front face with bores provided in the front face a cavity extending through the coupler, a guard arm with cavities formed therein, and a shank having a plurality of longitudinal cavities and adjacent ribs separating the cavities. Preferred embodiments may be constructed from an austempered metal.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A process for producing a coupler knuckle and an improved coupler knuckle design are provided. The process produces a coupler knuckle by constructing a mold having the shape of the coupler knuckle. The mold is coated with a material that is resistant to melting at the molten melt temperatures of the molten metal used to form the knuckle. With the mold coated, the cavities in the mold interior are filled by placing an inert material therein. The molten metal used for forming the knuckle contacts the mold and consumes it, while the coating serves to provide a shape for the knuckle.

Abstract: An improved coupler knuckle with an improved interior configuration for handling forces imparted on the knuckle and transferring said imparted forces through the knuckle and improving handling of linear force loads and their transmission the interior having a force handling structure that includes spaced apart layers and cavities, with a cavity extending between the nose section and the tail section of the coupler knuckle.

Abstract: A knuckle may include a throat portion having a throat side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section. The throat portion may also include a tail stop side wall with at least three sections, a first section closest to the knuckle tail, a third section closest to the knuckle pulling face, and a second section between said first and third sections. The wall thickness of said first section may be less than 10% different than the wall thickness of said second section.

Abstract: A core assembly for creating interior spaces in a railcar coupler knuckle is designed to be set in a cavity with cope and drag sections. The cavity is shaped to form a railcar coupler knuckle and includes a first wall that forms the substantially vertical outside wall of the tail of the knuckle. The core includes a kidney section with a rear core support section that extends at least 0.5? outside the first wall of the cavity when the core is set in the drag.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing a first mold section having internal walls defining at least in part perimeter boundaries of a first coupler knuckle mold cavity. The method includes providing a second mold section having internal walls defining at least in part perimeter boundaries of a second coupler knuckle mold cavity. The second coupler mold cavity of the second mold section is offset from the first coupler mold cavity of the first mold section. The method includes closing the first and second mold sections and at least partially filling the first and second coupler knuckle mold cavities with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

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 core assembly for forming the interior spaces of a railcar coupler knuckle has a first transition section between the C-10 portion of the core and the finger portion of the core. The first transition section has a first side, a second side, a third side and a fourth side and the first and second sides form the vertical axis of the first transition section and the third and fourth sides form the horizontal axis of said first transition section. The vertical axis of the first transition section has a height along a horizontal plane of the vertical axis of at least 2.5? and the horizontal axis of said first transition section has a width along a vertical plane of the horizontal axis of at least 0.925?.

Abstract: A railroad coupler knuckle includes a single, solid rib at a horizontal centerline of the knuckle that passes through a pivot pin hub thereof. The single, solid rib extends generally from a flag hole of a finger cavity of the knuckle to an opposite side of the knuckle from the flag hole. In another aspect, a railcar coupler knuckle includes a tail section, a hub section, and a nose section. The tail, hub, and nose sections define internal cavities including (i) a combined void that defines a pivot pin hub cavity and a kidney cavity and (ii) an isolated finger cavity. The combined void is formed using a first internal core during manufacturing of the coupler knuckle. The isolated finger cavity is formed using a second internal core during manufacturing of the coupler knuckle, such that molten alloy substantially separates the combined void and the isolated finger cavity.

Abstract: A railcar coupler knuckle includes a tail section, a hub section, and a nose section. The tail, hub, and nose sections define internal cavities including (i) a kidney cavity, (ii) a pivot pin cavity, and (ii) a finger cavity. The kidney and pivot pin cavities are formed using at least one internal core during manufacturing of the coupler knuckle. The finger cavity is formed from a finger section of cope and drag mold portions of a mold used during manufacturing of the coupler knuckle, wherein the finger section of the mold defines the entirety of the finger cavity of the coupler knuckle.

Abstract: An improved knuckle pin for use in a railway car coupling is illustrated and described. In one example, the pin comprises a shank extending along a longitudinal axis and having a first end. A head is positioned on the first end of the shank, and includes an abutment surface and a top surface opposite the abutment surface. At least one lug extends from the top surface of the head along the longitudinal axis to provide a point of engagement for a hand or hand tool to allow rotation of the pin about the longitudinal axis.

Abstract: A method for manufacturing a railcar coupler knuckle, said method includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls that define at least in part perimeter boundaries of a coupler knuckle mold cavity. At least one chill core is positioned within one of the cope mold portion and the drag mold portion. The cope and drag mold portions are closed, with the at least one core therebetween, and the closed cope and drag mold portions and the chill core define a parting line. The mold cavity is filled with a molten metal, which solidifies after filling to form a casting. The casting includes a pulling face portion defined by the chill core, and a central section of the pulling face portion does not contain the parting line and requires no finish grinding upon its formation.

Abstract: A knuckle for a railway coupler system is made without internal voids or cores. Instead, external pockets are formed on the front face and tail portion surface to reduce weight. The knuckle is formed by investment casting, which permits a pulling face to be provided without a draft angle or parting line typical of a cast part. As a result of these innovations, the knuckle according to the invention has an improved fatigue life.

Abstract: A method of casting a core includes the steps of preparing a first half of a corebox, preparing a second half of a corebox such that the parting line of a core formed from the first and second coreboxes runs along the vertical axis of the core.

Abstract: A core assembly for forming the interior spaces of a railcar coupler knuckle has a first transition section between the C-10 portion of the core and the finger portion of the core. The first transition section has a first side, a second side, a third side and a fourth side and the first and second sides form the vertical axis of the first transition section and the third and fourth sides form the horizontal axis of said first transition section. The vertical axis of the first transition section has a height along a horizontal plane of the vertical axis of at least 2.5? and the horizontal axis of said first transition section has a width along a vertical plane of the horizontal axis of at least 0.925?.

Abstract: A core assembly for creating interior spaces in a railcar coupler knuckle is designed to be set in a cavity with cope and drag sections. The cavity is shaped to form a railcar coupler knuckle and includes a first wall that forms the substantially vertical outside wall of the tail of the knuckle. The core includes a kidney section with a rear core support section that extends at least 0.5? outside the first wall of the cavity when the core is set in the drag.

Abstract: Railway coupler knuckle apparatus are described herein. An example railway coupler knuckle includes a tail portion, a hub portion and a transition portion joining the tail portion and the hub portion. The hub portion includes a generally cylindrical pivot pin passage having a longitudinal axis. The railway coupler knuckle has a cavity formed inside the tail portion and at least a portion of the transition portion and a first wall extends between surfaces of the cavity adjacent the transition portion.

Abstract: A knuckle for a railway coupler system is made without internal voids or cores. Instead, external pockets are formed on the front face and tail portion surface to reduce weight. The knuckle is formed by investment casting, which permits a pulling face to be provided without a draft angle or parting line typical of a cast part. As a result of these innovations, the knuckle according to the invention has an improved fatigue life.

Abstract: A railroad coupler knuckle includes a single, solid rib at a horizontal centerline of the knuckle that passes through a pivot pin hub thereof. The single, solid rib extends generally from a flag hole of a finger cavity of the knuckle to an opposite side of the knuckle from the flag hole. In another aspect, a railcar coupler knuckle includes a tail section, a hub section, and a nose section. The tail, hub, and nose sections define internal cavities including (i) a combined void that defines a pivot pin hub cavity and a kidney cavity and (ii) an isolated finger cavity. The combined void is formed using a first internal core during manufacturing of the coupler knuckle. The isolated finger cavity is formed using a second internal core during manufacturing of the coupler knuckle, such that molten alloy substantially separates the combined void and the isolated finger cavity.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity, wherein the mold cavity includes a finger section; positioning at least one internal core within either the cope mold portion or the drag mold portion, the at least one internal core configured to define a kidney cavity and a pivot pin cavity within a coupler knuckle; closing the cope and drag mold portions with the single core therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle, wherein the at least one core defines the kidney and pivot pin cavities, and the finger section of the mold cavity defines at least one finger cavity of the coupler knuckle.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a knuckle mold cavity; positioning a first internal core within either the cope mold or the drag mold portions, the first internal core configured to define a kidney cavity and a pivot pin hub as a single void within the knuckle; positioning a second internal core within either the cope mold portion and the drag mold portion, the second internal core configured to define a finger cavity; closing the cope and drag mold portions with the two internal cores therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the knuckle, wherein the first internal core defines the kidney cavity and the pivot pin hub of the coupler knuckle, and wherein the second internal core defines the finger cavity of the knuckle.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity, wherein the mold cavity includes a finger section; positioning at least one internal core within either the cope mold portion or the drag mold portion, the at least one internal core configured to define a kidney cavity and a pivot pin cavity within a coupler knuckle; closing the cope and drag mold portions with the single core therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle, wherein the at least one core defines the kidney and pivot pin cavities, and the finger section of the mold cavity defines at least one finger cavity of the coupler knuckle.

Abstract: Railway coupler knuckle apparatus are described herein. An example railway coupler knuckle includes a tail portion, a hub portion and a transition portion joining the tail portion and the hub portion. The hub portion includes a generally cylindrical pivot pin passage having a longitudinal axis. The railway coupler knuckle has a cavity formed inside the tail portion and at least a portion of the transition portion and a first wall extends between surfaces of the cavity adjacent the transition portion.

Abstract: A method for manufacturing a railcar coupler knuckle, said method includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls that define at least in part perimeter boundaries of a coupler knuckle mold cavity. At least one chill core is positioned within one of the cope mold portion and the drag mold portion. The cope and drag mold portions are closed, with the at least one core therebetween, and the closed cope and drag mold portions and the chill core define a parting line. The mold cavity is filled with a molten metal, which solidifies after filling to form a casting. The casting includes a pulling face portion defined by the chill core, and a central section of the pulling face portion does not contain the parting line and requires no finish grinding upon its formation.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing a first mold section having internal walls defining at least in part perimeter boundaries of a first coupler knuckle mold cavity. The method includes providing a second mold section having internal walls defining at least in part perimeter boundaries of a second coupler knuckle mold cavity. The second coupler mold cavity of the second mold section is offset from the first coupler mold cavity of the first mold section. The method includes closing the first and second mold sections and at least partially filling the first and second coupler knuckle mold cavities with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

Abstract: A knuckle for a railway coupler system is made without internal voids or cores. Instead, external pockets are formed on the front face and tail portion surface to reduce weight. The knuckle is formed by investment casting, which permits a pulling face to be provided without a draft angle or parting line typical of a cast part. As a result of these innovations, the knuckle according to the invention has an improved fatigue life.

Abstract: A knuckle pin retainer for a railroad car coupler adapted for disposition in an aperture formed by a knuckle coupler assembly for connecting adjacent railroad car. The pin retainer includes a pivot pin with a retaining member installed within the pivot pin. The retaining member extends diametrically from a slot in the elongate shaft and is spring-loaded and rotatable within a slot in the shaft. A spring member is disposed within the slot between a back wall of the slot and the retaining member. The spring member is biased to expose the retaining member outside of the slot.

Abstract: Yokes utilized in railway coupling apparatus are designed according to the invention to have improved stress profiles and increased service life. Investment casting techniques used to make the yokes and other components of the coupling apparatus yield improved surface finishes and tighter dimensional tolerances of the parts without requiring hammering, coating or other post-casting treatment.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity, wherein the mold cavity includes a finger section; positioning at least one internal core within either the cope mold portion or the drag mold portion, the at least one internal core configured to define a kidney cavity and a pivot pin cavity within a coupler knuckle; closing the cope and drag mold portions with the single core therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle, wherein the at least one core defines the kidney and pivot pin cavities, and the finger section of the mold cavity defines at least one finger cavity of the coupler knuckle.

Abstract: A method for manufacturing a railcar coupler knuckle includes providing cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a knuckle mold cavity; positioning a first internal core within either the cope mold or the drag mold portions, the first internal core configured to define a kidney cavity and a pivot pin hub as a single void within the knuckle; positioning a second internal core within either the cope mold portion and the drag mold portion, the second internal core configured to define a finger cavity; closing the cope and drag mold portions with the two internal cores therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the knuckle, wherein the first internal core defines the kidney cavity and the pivot pin hub of the coupler knuckle, and wherein the second internal core defines the finger cavity of the knuckle.

Abstract: The KNUCKLE PIN LOCK is designed to fit an American Association of Railroads articulated locklift assembly's connector and up the bottom part of the attached toggle to a point where it would contact the bottom of the lock of the rail car knuckle. When the knuckle is in the closed or locked position, the knuckle pin lock when applied, would make opening the knuckle to separate a rail car from another rail car impossible. The Knuckle Pin Lock blocks the accidental or malicious disconnection of rail cars by blocking the ability of anyone or anything pulling up on the operating lever to open the knuckle. This mechanism can be made from plastic, metal, wood or any other rigid material. The thickness of the material depends on the type of material used. For instance, a plastic unit would be approx. 1/8? thick. The larger “key” shaped holes are where fastening devices such as multi-purpose zip-ties would be threaded through and around the toggle and tightened.

Abstract: A railroad car (18) uses a coupling system (10) to couple to other railroad cars. The coupling system includes a coupler (12), a knuckle (14), a knuckle pin (16) and a lock (30). When two railroad cars are coupled to each other, the knuckles of the two railroad cars are engaged and the forces produced during buff and draft movement of the railroad cars are transmitted through the knuckles, the coupler and the locks. Under normal operation, the knuckle pin should experience minimal forces during the buff and draft movement of the railroad cars. However, over time the various components that make up the coupler system may fall out of tolerance due to usage, wear and other factors. As the various components of the coupler system fall out of tolerance, increasing bending forces are applied to the knuckle pin. A knuckle pin with a slot (52) and a hollow body (50) is capable of withstanding bending forces applied to the knuckle pin by out-of-tolerance coupling systems.

Abstract: A lightweight knuckle weighing substantially less than an AAR Standard Knuckle, is described for use in a railroad car coupler. This lightweight knuckle can be used, for example, to replace AAR Standard knuckle which becomes broken or otherwise damaged during operation and requires replacement in the field. Both the contouring and inner coring of an AAR Standard knuckle are radically changed to produce this lightweight knuckle which has all the functioning features of the standard knuckle, so as not to adversely effect the coupling and uncoupling operations of a coupler in which the lightweight knuckle is used.

Abstract: An improved lightweight knuckle is described for use in an AAR Standard E or F type railroad car coupler. The outer contouring and inner voids of the improved lightweight knuckle are radically changed without compromising the integrity or operability of the knuckle during conventional coupling and uncoupling operations with, and from, an existing AAR Standard knuckle. The nose of the improved lightweight knuckle is provided with a pair of parallel, coplanar flat surfaces between which is a projection which extend outwardly from the flat surfaces and terminates at an outer curved surface which has the same curvature as the corresponding curvature of an existing AAR Standard knuckle. Also, twin sets of reinforcement ribs are provided within the improved lightweight knuckle to strengthen the knuckle and make it more durable.