FOLDING STEP FOR AUTORACK DOOR

This disclosure generally relates to railcars, and more particularly to an autorack railcar with doors including a folding step.

An autorack railcar (also referred to as an auto carrier or car transporter) is a railcar for transporting automobiles and light trucks. For example, an autorack railcar may transport vehicles from a manufacturing facility to a distributorship, or transport vehicles for passengers of a passenger train service.

An autorack railcar generally includes two or three decks for transporting vehicles. Some autorack railcars are convertible between two and three decks. The cars are typically fully enclosed with continuous side panels, end doors, and roofs to protect the vehicles from severe weather, theft/vandalism, or other in-transit damage.

To load an autorack railcar, a skilled driver drives the vehicle up a ramp and onto one of the decks. The driver or another crew member then secures the vehicle to the deck with tie down straps, chains, etc. The process is reversed to unload the autorack railcar.

After loading a vehicle, or before unloading a vehicle, the driver or other crew members may enter or exit the autorack railcar via the end doors. In some conventional autorack railcars, the driver or other crew members may use a ladder mounted to the end door to facilitate entry or exit of the autorack railcar.

According to some embodiments, a railcar comprises a door configured to provide access to an interior of the railcar. The door comprises an inside panel that faces the interior of the railcar when the door is in a closed position, and a plurality of ladder rungs coupled to the inside panel of the door in a vertical sequence. The railcar further comprises a folding ladder apparatus comprising a first ladder rung and a second ladder rung in a vertical sequence. The folding ladder apparatus is pivotally coupled to the inside panel of the door and operable to pivot in a vertical direction between an up position and a down position. The folding ladder apparatus is configured such that when the door is in an open position and the folding ladder apparatus is in the down position, the second ladder rung extends below a bottom of the door facilitating access to the railcar; and when the folding ladder apparatus is in the up position, the first ladder rung and the second ladder rung are vertically offset from the plurality of ladder rungs coupled to the inside panel of the door.

In particular embodiments, the folding ladder apparatus is pivotally coupled to the inside panel of the door below the bottom-most rung of the plurality of ladder rungs coupled to the inside panel of the door. When the folding ladder apparatus is in the up position, the first ladder rung is positioned below, and the second ladder rung is positioned above, the bottom-most rung of the plurality of ladder rungs coupled to the inside panel of the door.

Particular embodiments comprise a latch coupled to the inside panel of the door operable to secure the folding ladder apparatus in the down position. The latch may be positioned to secure the first ladder rung to the door. The folding ladder apparatus may comprise at least one vertical support that couples the first ladder rung to the second ladder rung, and the latch may be positioned to secure the at least one vertical support to the door.

In particular embodiments, the railcar comprises an autorack car or a box car. According to some embodiments, a folding ladder apparatus comprises a first ladder rung and a second ladder rung in a vertical sequence, and a pivotal coupling operable to pivotally couple the first ladder rung and the second ladder rung to a door panel. The door panel comprises a plurality of ladder rungs arranged in a vertical sequence. The folding ladder apparatus is operable to pivot in a vertical direction between an up position and a down position. When the folding ladder apparatus is in the down position, the second ladder rung extends below a bottom of the door. When the folding ladder apparatus is in the up position, the first ladder rung and the second ladder rung are vertically offset from the plurality of ladder rungs coupled to the door.

In particular embodiments, the folding ladder apparatus is pivotally coupled to the door panel below the bottom-most rung of the plurality of ladder rungs coupled to the door. When the folding ladder apparatus is in the up position, the first ladder rung is positioned below, and the second ladder rung is positioned above, the bottom-most rung of the plurality of ladder rungs coupled to the door.

Particular embodiments comprise a latch coupled to the door, the latch operable to secure the folding ladder apparatus in the down position. The latch may be positioned to secure the first ladder rung to the door. The folding ladder apparatus may comprise at least one vertical support that couples the first ladder rung to the second ladder rung, and the latch may be positioned to secure the at least one vertical support to the door.

According to some embodiments, a method of manufacturing a railcar comprises providing a door configured to provide access to an interior of the railcar. The door comprising a plurality of ladder rungs arranged in a vertical sequence. The method further comprises coupling a folding ladder apparatus to the door. The folding ladder apparatus comprises a first ladder rung and a second ladder rung in a vertical sequence. The folding ladder apparatus is operable to pivot in a vertical direction between an up position and a down position. When the folding ladder apparatus is in the down position, the second ladder rung extends below a bottom of the door. When the folding ladder apparatus is in the up position, the first ladder rung and the second ladder rung are vertically offset from the plurality of ladder rungs coupled to the door.

In particular embodiments, the folding ladder apparatus is pivotally coupled to the door panel below the bottom-most rung of the plurality of ladder rungs coupled to the door. When the folding ladder apparatus is in the up position, the first ladder rung is positioned below, and the second ladder rung is positioned above, the bottom-most rung of the plurality of ladder rungs coupled to the door.

In particular embodiments, the method further comprises coupling a latch to the door. The latch is operable to secure the folding ladder apparatus in the down position. The latch may be positioned to secure the first ladder rung to the door. The folding ladder apparatus may comprise at least one vertical support that couples the first ladder rung to the second ladder rung, and the latch may be positioned to secure the at least one vertical support to the door.

In particular embodiments, the railcar comprises an autorack car or a box car.

As a result, particular embodiments of the present disclosure may provide numerous technical advantages. For example, the folding ladder apparatus prevents pinch points present in other ladder types. The ladder rungs of the folding apparatus are offset from the fixed ladder rungs on the railcar door when the folding ladder apparatus in the up or stored position. The folding operation of the ladder apparatus is more ergonomic than other ladder types that may include sliding or other mechanisms for storing the ladder. Particular embodiments provide a latch that stabilizes the steps when the folding ladder apparatus is in the down position. Particular embodiments of the present disclosure may provide some, none, all, or additional technical advantages.

Railcars, such as autorack railcars, may include doors for accessing an interior of the railcar. The doors may include ladder systems that facilitate a rail operator to enter and exit the railcar. The ladder systems are typically located on the interior of the door, such that when the door is open a rail operator may access the ladder. When the door is closed, such as when the railcar is underway, the ladder closed within the railcar.

When the railcar is stationary and the door is open, the bottom of the door may be too high above ground for a rail operator to access the ladder. Because the ladder is mounted on the inside of the door, a rail operator may not be able to use the sill step to access the ladder. Some ladder systems include swinging or sliding portions that may extend below the bottom of the door and closer to the ground so that a rail operator may comfortably and safely access the ladder system. The ladder system may swing or slide upward for storage so that the door may be closed without interference from the ladder and, for example, the end sill.

Particular embodiments obviate the problems found in conventional ingress and egress ladder systems. Particular problems are illustrated with respect to FIGS. 1-3.

FIG. 1 is a schematic perspective diagram illustrating an example interior of an autorack railcar door. Autorack railcar 10 includes a pair of end doors 12. End doors 12 include a plurality of ladder rungs 14. When end doors 12 are open, a rail operator may enter or exit railcar 10 using ladder rungs 14.

Ladder rungs 14c-14j are fixed to end door 12. Ladder rungs 14a and 14b are coupled to end door 12 via pivot couplings 16. Pivot couplings 16 facilitate moving ladder rungs 14a and 14b from an extended position (illustrated) to a stored position. In the illustrated example, pivot coupling 16 includes a ring coupling ladder rung 14b to end door 12.

In this example of a stirrup-style ladder system, the bottom step or tread (i.e., ladder rung 14a) swings up by rotating around the second step or tread (i.e., ladder rung 14b and pivots 16) for storage. Federal Railroad Administration (FRA) rules require that the vertical space between ladder rungs are within two inches of each other (i.e., the vertical spacing between ladder rung 14a and 14b is within 2 inches of the vertical spacing between ladder rung 14b and 14c, etc.). Thus, in the illustrated example, when a rail operator rotates the stirrup-style ladder system up for storage, because the spacing between ladder rungs is approximately the same, the rail operator risks pinching a finger between ladder rung 14a and ladder rung 14c (arrow illustrated in FIG. 1). Such a pinch point is dangerous for the rail operator. Another example is illustrated in FIG. 2.

FIG. 2 is a schematic perspective diagram illustrating another example interior of an autorack railcar door. Autorack railcar 10 includes a pair of end doors 12 with a plurality of ladder rungs 14, similar to those described with respect to FIG. 1. End door 12 includes slotted bracket 18. Slotted bracket 18 is arranged with a vertical slot so that ladder rungs 14a and 14b may slide up vertically for storage.

In this example of a stirrup-style ladder system, the second step or tread (i.e., ladder rungs 14b) is retained in the vertical slot of slotted bracket 18. The first and second steps or treads (i.e., ladder rungs 14a and 14b) slide straight up slotted bracket 18 for storage (arrow illustrated in FIG. 2). A problem with the illustrated example is that if the step (i.e., ladder rung 14a) is lifted off center (i.e., offset either in front of or behind the vertical plane of the slot in slotted bracket 18), then the ladder system easily jams. Another problem is that a rail operator may pinch a finger between ladder rung 14b and ladder rung 14c when storing the ladder system.

Other railcars may include fixed steps. These examples also include particular problems. An example is illustrated in FIG. 3.

FIG. 3 is a schematic perspective diagram illustrating an example interior of an autorack railcar door and an end sill step. Autorack railcar 10 includes a pair of end doors 12 with a plurality of ladder rungs 14, similar to those described with respect to FIGS. 1 and 2. Railcar 10 also includes sill step 20.

Sill step 20 is mounted to the end sill of railcar 10. Still step 20 includes fixed ladder rungs 14a and 14b. Ladder rungs 14a and 14b do not move up down for storage. A particular problem with the end sill mounted ladder is that a rail operator must take a large and potentially dangerous step from ladder rung 14b mounted on the end sill to ladder rung 14c mounted on door 12. Another problem is that the location of ladder rungs 14a and 14b on the end sill place the rail operator directly in line with vehicles being loaded or unloaded from the A-deck of railcar 10, which is dangerous for the rail operator.

Particular embodiments described herein include improved lower steps for autorack doors by reducing or eliminating pinch points and by improving the ergonomics and safety of the rail operator using the ladder. Particular embodiments avoid sliding parts that may easily jam. Particular embodiments locate the pivot point between the second and third ladder treads so that the ladder treads do not come close enough to each other to create a pinch point. Particular embodiments include the benefits of the swinging stirrup-style ladder system without the potentially dangerous pinch points. Particular embodiments and their advantages are best understood by reference to FIGS. 4-8, wherein like reference numbers indicate like features.

FIG. 4 is a schematic diagram of an autorack door with a folding ladder apparatus in a down position, according to some embodiments. Door 12, such as the interior of autorack door 12 illustrated in FIGS. 1-3, includes a plurality of ladder rungs 14 in a vertical sequence. A rail operator may enter or exit a railcar, such as railcar 10, using ladder rungs 14. Ladder rungs 14c-14e are fixed to door 12. Folding ladder apparatus 24 is also coupled to door 12.

In particular embodiments, folding ladder apparatus 24 comprises ladder rungs 14a and 14b in a vertical sequence. Folding ladder apparatus 24 is coupled to door 12 via pivot couplings 22. Pivot couplings 22 facilitate moving folding ladder apparatus 24 from an extended position (illustrated in FIG. 4) to a stored position (illustrated in FIG. 5). In other embodiments, folding ladder apparatus may include one, two, three, or any suitable number of ladder rungs. FIGS. 8 and 9, described below, illustrate an example with a single rung.

In particular embodiments, pivot couplings 22 may be located on door 12 vertically between ladder rung 14b and ladder rung 14c. In particular embodiments, pivot coupling 22 may comprise a pair of tabs coupled to door 12 with a pin pivotally coupling the tabs to a support member of folding ladder apparatus 24. In some embodiments, pivot coupling 22 may include any suitable coupling so that folding ladder apparatus 24 may rotate between the extended and stored positions.

When a rail operator rotates folding ladder apparatus 24 up for storage, because pivot couplings 22 are between ladder rung 14b and 14c, ladder rungs 14a and 14b will be vertically offset from the other fixed ladder rungs, such as bottom-most fixed ladder rung 14c or ladder rung 14d. In some embodiments, pivot couplings 22 may be located at any vertical position on door 12 such that the rungs of folding ladder apparatus 24 (e.g., ladder rungs 14a and 14b) do not contact the rungs fixed to door 12 (e.g., ladder rungs 14c-14e) when folding ladder apparatus 24 is in the upright stored position. A particular advantage is that the location of pivot couplings 22 reduces or eliminates the danger of pinch points, as illustrated in FIG. 5.

FIG. 5 is a schematic diagram of an autorack door with a folding ladder apparatus in an up position, according to some embodiments. Door 12 includes ladder rungs 14 and folding ladder apparatus 24 as described with respect to FIG. 4.

Folding ladder apparatus 24 is in an up or stowed position. The ladder rungs of folding ladder apparatus 24 are offset from ladder rungs 14c-e fixed to door 12. For example, in the up position, ladder rung 14a is above the bottom-most rung fixed to door 12 (i.e., ladder rung 14c), and ladder rungs 14b is below the bottom-most rung fixed to door 12. As described with respect to FIG. 4, in some embodiments pivot couplings 22 may be located at any vertical position on door 12 such that the rungs of folding ladder apparatus 24 do not contact the rungs fixed to door 12 when folding ladder apparatus 24 is in the up position. Although folding ladder apparatus 24 is illustrated with two vertical supports coupling ladder rungs 14a and 14b, other embodiments may include any suitable number of supports. For example, particular embodiments may include a single vertical support in the middle of ladder rungs 14a and 14b (i.e., an “I” or “T” configuration) and a single pivot coupling 22.

Folding ladder apparatus 24 is illustrated having the same width as the fixed ladder rungs, such as ladder rungs 14c-14e. In other embodiments, folding ladder apparatus 24 may be wider or narrower than the fixed ladder rungs. For example, in particular embodiments folding ladder apparatus 24 may be wider than the fixed ladder rungs so that folding ladder apparatus 24 may lay flat against door 12 when in the up position.

Another advantage of particular embodiments is that the folding ladder apparatus may be secured in the extended or down position. Securing the ladder in the down position stabilizes the ladder for a rail operator. Particular examples are illustrated in FIGS. 6 and 7.

FIG. 6 is a schematic diagram of an autorack door with a folding ladder apparatus and securing mechanism in a down position, according to some embodiments. The components of door 12 and folding ladder apparatus 24 are the same as those described with respect to FIGS. 4 and 5. Door 12 further comprises one or more latches, such as latches 26 and 28. Latches 26 and/or 28 secure folding ladder apparatus 24 to door 12 when folding ladder apparatus 24 is in the down or extended position.

In particular embodiments, folding ladder apparatus 24 may include one or more vertical supports, such as vertical supports 30. Latch 26 may secure vertical support 30 to door 12 to reduce or prevent movement of folding ladder apparatus 24 when a rail operator is climbing folding ladder apparatus 24. In particular embodiments, latch 26 may comprise a spring or tension latch for securing folding ladder apparatus 24. Latch 26 may include removable mechanical fasteners (e.g., bolts, cotter pins, gravity actuated swing arms, etc.) for securing folding ladder apparatus 24. In particular embodiments, latch 26 may comprise any suitable securing mechanism.

In particular embodiments, latch 28 may secure a ladder rung (e.g., ladder rung 14b) of folding ladder apparatus 24 to door 12. In particular embodiments, latch 28 may comprise any suitable latch, such as those described with respect to latch 26. Particular embodiments provide advantages over other ladder systems, such as the ladder system illustrated in FIG. 1, that are not able to be secured in the down position.

FIG. 7 is a schematic diagram an autorack door with a folding ladder apparatus and securing mechanism in an up position, according to some embodiments. The components of door 12 and folding ladder apparatus 24 are the same as those described with respect to FIGS. 4-6. Door 12 further comprises one or more latches, such as latches 32 and 34. Latches 32 and/or 34 secure folding ladder apparatus 24 to door 12 when folding ladder apparatus 24 is in the up or stored position.

In particular embodiments, one or more latches 32 secure vertical supports 30 to door 12 and one or more latches 34 secure ladder rungs (such as ladder rungs 14a and/or 14b) to door 12. Latches 32 and 34 may comprise any suitable type of latch, such as those described with respect to latches 26 and 28.

Although FIGS. 6 and 7 illustrate latches for securing folding ladder apparatus 24 in the down and up positions, respectively, other embodiments may include any combination of latches 26, 28, 32 and/or 34.

Although FIGS. 4-7 illustrate a folding ladder apparatus with two ladder rungs, other embodiments may include any suitable number of ladder rungs. FIGS. 8 and 9 illustrate a folding ladder apparatus with a single ladder rung.

FIG. 8 is a schematic diagram of an autorack door with another example folding ladder apparatus in a down position, according to some embodiments. Door 12, such as the interior of autorack door 12 illustrated in FIGS. 1-3, includes a plurality of ladder rungs 14 in a vertical sequence. Ladder rungs 14b-14e are fixed to door 12. Folding ladder apparatus 24 is also coupled to door 12.

In particular embodiments, folding ladder apparatus 24 comprises ladder rung 14a. Folding ladder apparatus 24 is coupled to door 12 via pivot couplings 22. Pivot couplings 22, similar to those described with respect to FIGS. 4 and 5, facilitate moving folding ladder apparatus 24 from an extended position (illustrated in FIG. 8) to a stored position (illustrated in FIG. 9).

In particular embodiments, pivot couplings 22 may be located on door 12 vertically between ladder rung 14b and ladder rung 14c. When a rail operator rotates folding ladder apparatus 24 up for storage, because pivot couplings 22 are between ladder rung 14b and 14c, ladder rung 14a will be vertically offset from the other fixed ladder rungs, such as bottom-most fixed ladder rung 14b, or ladder rungs 14c or 14d. In some embodiments, pivot couplings 22 may be located at any vertical position on door 12 such that the rung of folding ladder apparatus 24 (e.g., ladder rung 14a) does not contact the rungs fixed to door 12 (e.g., ladder rungs 14b-14e) when folding ladder apparatus 24 is in the upright stored position.

FIG. 9 is a schematic diagram of an autorack door with another example folding ladder apparatus in an up position, according to some embodiments. Door 12 includes ladder rungs 14 and folding ladder apparatus 24 as described with respect to FIG. 8.

Folding ladder apparatus 24 is in an up or stowed position. The ladder rung of folding ladder apparatus 24 is offset from ladder rungs 14b-e fixed to door 12. For example, in the up position, ladder rung 14a is between fixed ladder rungs 14c and 14d.

A particular advantage of a single ladder rung is reduced weight of folding ladder apparatus 24. A lighter apparatus may be easier for a rail operator to move between the stored and extended positions.

The embodiments described with respect to FIGS. 8 and 9 may include the latches described with respect to FIGS. 6 and 7. Accordingly, a particular advantage of the folding ladder apparatus of embodiments of FIGS. 8 and 9 is that the folding ladder apparatus may be secured in the down or extended position.

A folding ladder apparatus, such as folding ladder apparatus 24, may be included with a new railcar or may be retrofitted to an existing railcar. An example is illustrated in FIG. 10.

FIG. 10 is a flow diagram illustrating an example method of manufacturing an autorack railcar, according to some embodiments. . In particular embodiments, one or more steps of method 1000 may be performed to manufacture a railcar, such as the autorack railcars described with respect to FIGS. 4-9.

The method begins at step 1010 by providing a door configured to provide access to an interior of the railcar, the door comprising a plurality of ladder rungs arranged in a vertical sequence (e.g., ladder rungs 14c-14e). For example, the door may comprise any of doors 12 described with respect to FIGS. 4-9.

At step 1012, a folding ladder apparatus is coupled to the door. For example, the folding ladder apparatus may comprise any of the folding ladder apparatus 24 described with respect to FIGS. 4-9. The folding ladder apparatus may be pivotally coupled to the door according to any of the coupling methods described above such that the folding ladder apparatus is operable to pivot in a vertical direction between an up and down position (e.g., pivot between the positions illustrated in FIGS. 4 and 5, FIGS. 6 and 7, or FIGS. 8 and 9).

In particular embodiments, the folding ladder apparatus may be coupled to the door below the bottom-most rung (e.g., ladder rung 14c) of the plurality of ladder rungs coupled to the door. When the folding ladder apparatus is in the up position, the first ladder rung (e.g., ladder rung 14b) and the second ladder rung (e.g., ladder rung 14a) are vertically offset from the plurality of ladder rungs coupled to the door. In particular embodiments, when the folding ladder apparatus is in the up position (e.g., FIG. 5 or 7), the first ladder rung (e.g., ladder rung 14b) is positioned below, and the second ladder rung (e.g., ladder rung 14a) is positioned above, the bottom-most rung (e.g., ladder rung 14c) of the plurality of ladder rungs coupled to the door.

At step 1014, in particular embodiments a latch may be coupled to the door. For example any of latches 26, 28, 32 and/or 34 described with respect to FIGS. 6 and/or 7 may be coupled to the door.

For example, latches 26 and 32 may secure a vertical support of folding ladder apparatus 24 to door 12. Latches 28 and 30 may secure a rung of folding ladder apparatus 24 to door 12.

Modifications, additions, or omissions may be made to the method of FIG. 10. Additionally, one or more steps in method 1000 of FIG. 10 may be performed in parallel or in any suitable order.

Although particular embodiments are described with respect to an autorack railcar, other embodiments may include other railcars, such as box cars, or other vehicles, such as over the road trailers.

Some embodiments of the disclosure may provide one or more technical advantages. As an example, the folding ladder apparatus prevents pinch points present in other ladder types because the ladder rungs of the folding apparatus are offset from the fixed ladder rungs on the railcar door when the folding ladder apparatus in the up or stored position. The folding operation of the ladder apparatus is more ergonomic than other ladder types that may include sliding or other mechanisms for storing the ladder or end sill mounted ladders. Particular embodiments provide a latch that stabilizes the steps when the folding ladder apparatus is in the down position.

Modifications, additions, or omissions may be made to the systems and apparatuses disclosed herein without departing from the scope of the invention. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. Features of one embodiment may be combined with features of another.

Modifications, additions, or omissions may be made to the methods disclosed herein without departing from the scope of the invention. The methods may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.

Although embodiments of the present disclosure and their advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the claims below.