REFURBISHMENT OF LOAD-BEARING LOWER SURFACES OF ARTICULATED CONNECTORS

Abstract

A method is provided for semi-automatically reconditioning a railcar articulated connector comprising a male portion (10) including a parent casting material; the method comprises applying welding material to a male portion (10) of an articulated connector, mounting a housing defining an interior space to the male portion, the male connector within the interior space, centering and stabilizing the fitting laterally on the male portion, inserting a clamping mechanism (218) attached to the housing within an opening (32) of the male connector (10) to fix the housing to the male portion, securing the clamping mechanism (218) to a surface of the male portion, and automatically turning at least a portion of the welding and / or parent casting material.

Description

REFURBISHMENT OF LOAD-BEARING LOWER SURFACES OF ARTICULATED CONNECTORS RELATED APPLICATIONS This application claims priority over U.S. Provisional Application No. 61 / 590,675, filed on January 25, 2012, entitled “Reconditioning of Articulated Connector Load Bearing Bottom Surfaces”; U.S. Non-Provisional Application No. 13 / 749,190, filed on January 24, 2013, entitled “Method for Semi-Automatically Reconditioning a Railcar Articulated Connector”; U.S. Non-Provisional Application No. 13 / 749,229, filed on January 24, 2013, entitled “Application of Wear Plate to Articulated Connector Load Bearing Bottom Surface”; and U.S. Non-Provisional Application No. 13 / 749,305, filed on January 24, 2013, entitled “Gauge for Measuring a Portion of a Railcar Articulated Connector”; US Non-Provisional Application No. 13 / 749,325, filed on January 24, 2013 and entitled, “Fixture for Use in Semi-Automatic Reconditioning Process of a Railcar Articulated Connector”; and US Non-Provisional Application No.13 / 749,364, submitted on January 24, 2013 and entitled, “Method for Reconditioning a Railcar Articulated Connector”, the full descriptions of which are incorporated herein by reference nQrnnn / Q7n7 / e / YiAi. BACKGROUND OF THE INVENTION Multi-unit railroad cars are typically interconnected using couplings, such as hinge connectors, to link one unit to the next. Most often, the connectors include a male casting mounted to the end structure of one car unit that joins with a female casting located on the end structures of the adjacent car unit. The joining of the male and female portions results in a hinged connection between the car units. American Steel Foundries, Inc. (ASF) of Granite City, IL, and Meridian Rail, Inc. (formerly and hereafter National Castings) of Lombard, II, manufacture connectors of this type that are very commonly used in the U.S. industry. The freight portion of a railway comprises a plurality of multi-unit cars linked in this manner. As such, the driving locomotive is only acting directly on the car adjacent to it, which is then coupled to the next unit, and so on. The attraction, or push, of the car units by the locomotive creates a significant level of stress on each connector, as each one bears the full force of the other cars. Any contact between the male and female casting portions and their associated components results in wear on those contact areas of the connectors. nocnnn / rznz / E / YiAi The tension placed on the connectors results in metal wear at various contact points between the male and female portions of the connectors, or their respective components, due to impact and frictional contact. Particular wear points include the lower ring surface and front surfaces of the bores on the female connector portion, the lower bearing surface, the spherical inner surface of the opening 32 (as shown in Figure 1), and the front spherical surface of the male connector portion. Jointly owned U.S. Patents Nos. 7,490,363 and 6,944,925 describe processes for reconditioning the front surface 30 of the male connector portion and the front surfaces of the bores on the female connector portion, as well as the front surfaces of the bores on the female connector portion. Since articulated connector castings are an integral part of the railcar structure and are difficult and expensive components to replace, it is preferable to repair or recondition the connectors rather than replace them or the entire railcar. Connector castings can commonly travel 1,931,212.8 km (1,200,000 miles) or more without significant maintenance. In the past, reconditioning most railcar components has involved removing various parts of the railcar and reattaching them after reconditioning. Some couplers have been reconditioned in this way, especially those removable by design. However, articulated connectors are not suitable for such removal and repair since they are integrated into the railcar, and such repair would be inefficient, time-consuming, and expensive. Therefore, it is an objective of the present invention to provide a method for reconditioning railcar connectors such that the reconditioning occurs while the connectors are still attached to the railcars. It is a further objective of this invention to simplify the measurement of portions of the connectors, ensuring that the connectors are reconditioned to the appropriate dimensions, including the use of suitable calipers. It is yet another objective of this invention to provide a method for reconditioning railcar connectors using calipers to take measurements of the connectors while they are still attached to the railcar. It is also another objective of this invention to provide a method for reconditioning railcar connectors using less laborious processes, eliminating the need to invert a railcar in order to perform connector reconditioning, although the process can be used on inverted railcars as well. BRIEF DESCRIPTION OF THE INVENTION In a first embodiment, a method is provided for semi-automatically reconditioning a railcar articulated connector comprising a male portion including a parent casting material. The method comprises applying welding material to a male portion of an articulated connector, mounting a housing that defines an interior space to the male portion, the male connector within the interior space, centering and stabilizing the fitting laterally on the male portion, inserting a clamping mechanism fixed to the housing within an opening of the male connector to secure the housing to the male portion, securing the clamping mechanism to a surface of the male portion, and automatically turning at least a portion of the welding and / or parent casting material. In a second embodiment, a method is provided for semi-automatically reconditioning a railcar articulated connector. The method comprises attaching a welding fixture to a male portion of an articulated connector, automatically applying welding material within a welding device to at least a portion of the lower bearing surface of the male portion, allowing the male portion to cool, removing the male portion from the welding fixture, attaching a turning fixture to the male portion, and turning at least a portion of the welding material. In a third embodiment, a method is provided for semi-automatically reconditioning a wagon connector. The method comprises attaching a welding accessory to a male connector, attaching a welding device to the welding accessory, placing a torch nozzle of the welding device along an outer portion of a lower bearing surface of the male connector, and forming an intermittent welding pattern along the lower bearing surface. In a fourth embodiment, a method is provided for semi-automatically reconditioning a railcar connector. The method comprises attaching a welding fitting to a male connector, attaching a welding device to the welding fitting, placing a torch nozzle of the welding device along an inner portion of a lower bearing surface of the male connector, and forming a weld pattern along the lower bearing surface. In a fifth embodiment, an apparatus is provided for measuring a portion on a hinged connector relative to a reference point on said connector. The apparatus comprises a base mountable to the connector against the reference portion of the connector, an arm pivotally mounted to the base that can be extended toward the portion of the connector, the arm having a measuring portion, the measuring portion being movable through at least a section of the connector portion, and a rotating component connected to a mounting piece. In a sixth embodiment, a method for reconditioning a railcar connector is provided. The method comprises turning a portion of a casting to create a wear plate application surface, placing a wear plate onto the wear plate application surface, and welding the wear plate to the wear plate application surface. In a seventh embodiment, a method for reconditioning a railcar connector is provided. The method comprises turning a portion of a casting to create a wear plate application surface, placing a wear plate onto the wear plate application surface, and mechanically clamping the wear plate to the wear plate application surface. In an eighth embodiment, a turning accessory is provided for semi-automatically reconditioning a hinged connector. The accessory comprises a housing having at least two side walls, a top plate having a first opening connecting the side walls, and a bottom plate connecting the side walls, top plate, and bottom plate, defining an interior space. The accessory also includes a clamping mechanism fixed to at least one of the side walls. The clamping mechanism comprises a curved hook portion, which is laterally adjustable. In a ninth embodiment, an assembly is provided for semi-automatically reconditioning a hinged connector. The assembly comprises a welding fixture including an accessory shaft extending upward from the welding fixture and a plurality of clamps for securing the welding fixture to a male casting, a welding device including a torch nozzle assembly for applying welding material, a control unit for indicating the flow of welding material to the torch nozzle, an opening for attachment to the accessory shaft, and a welding cam having at least one brake, wherein an uninterrupted welding pattern is formed on the lower bearing surface of the male casting when the welding cam engages with the control unit. In a tenth embodiment, an assembly is provided for semi-automatically reconditioning a hinged connector. The assembly comprises a welding fixture including an accessory shaft extending upward from the welding fixture and a plurality of clamps for securing welding access to a male casting, a welding device including a torch nozzle assembly for applying welding material, a control unit for indicating the flow of welding material to the torch nozzle, an opening for attachment to the accessory shaft, and a welding cam, wherein an uninterrupted welding pattern is formed on the lower bearing surface of the male casting when the welding cam is engaged with the control unit. In an eleventh embodiment, a method for reconditioning a railcar articulated connector is provided. The method comprises the steps of marking a surface of a portion of an articulated connector to divide the surface into sections, preheating the surface of a portion of an articulated connector, adding solder to a first section of the preheated portion of the articulated connector, and adding solder to a second section of the preheated portion of the articulated connector. nQcnnn / eznz / E / YiAi BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a perspective view of male and female casting portions of an unassembled connector; Figure 2 is a cross-sectional perspective view of an unassembled connector; Figure 3 is a process flow chart for manually reconditioning a connector casting; Figure 4A is a front view of a turning fixture for reconditioning a connector that is mounted to a portion of a male connector; Figure 4B is a top view of the fixture in Figure 4A; Figure 4C is a cross-sectional view of the fixture in Figure 4A showing a clamping mechanism in a loosened position; Figure 4D is a sectional view of the fixture in Figure 4A showing a clamping mechanism in a tightened position; Figure 4E is an enlarged view of a portion of Figure 4D; Figure 4F is a front view of a turning fixture for reconditioning a male connector with an alignment tube installed; Figure 4G is a sectional view of the fixture in Figure 4F taken along line AA; Figure 4H is a sectional view of a turning fixture nocnnn / eznz / E / YiAi for reconditioning a connector; Figure 4I is a front view of a turning fixture for reconditioning a connector; Figure 4J is a right side view of the fixture in Figure 4I; Figure 5 is a flow chart of a semi-automated process for reconditioning a connector casting; Figure 6 is a perspective view of a drill rod assembly with a fixture for turning a connector casting; Figure 7 is a perspective view of a facing head and facing head feed control assembly used for turning; Figure 8 is another perspective view of a facing head and facing head feed control assembly under a male casting to be turned; Figure 9 is a perspective view of a turning fixture for reconditioning a casting showing a facing head assembly and facing head feed control mounted to the fixture including the application of a gauge; Figure 10 is a perspective view of a caliper rod; Figure 11 is another perspective view of a facing head and facing head feed control assembly under a male casting to be turned; Figure 12 is a perspective view of the underside of the male casting including a wear plate; Figure 12A is a sectional view along line AA of Figure 12 showing a male casting including a wear plate; Figure 12B is an alternative sectional view along line AA of Figure 12 showing a male casting including a wear plate; Figure 13A is a side view of a welding fitting attached to a (truncated) male casting; Figure 13B is a top view of the welding fixture of Figure 13A attached to a male (truncated) casting; Figure 14 is a view of a blowtorch assembly; Figure 15 is a view of a welding apparatus attached to a welding fixture; Figure 16 is a view of a welding cam and switch; Figure 17 is a flat view of a welding cam; Figure 18 is a view of a torch assembly and male casting; Figure 19 is a view of a lower bearing surface of a male casting having an interrupted weld pattern; Figure 20 is a view of an insulating box applied over a male casting while applying a torch assembly; Figures 21 and 21A illustrate a concentric wear plate; Figures 22 and 22A illustrate a displacement wear plate. Figures 23 and 23A illustrate a modified wear plate; Figures 24, 24A, 24B and 24C illustrate a caliper for use with the present method; Figure 25 is a bottom view of a connector casting illustrating an octant division and an example of a weld pattern; Figure 26 is a top view of a coiled induction heating cable; and Figure 27 is a perspective view of a male portion of a hinged connector with saddlebags in place holding the induction heating cable of Figure 26. DETAILED DESCRIPTION OF THE INVENTIONReferring to Figures 1-2, the connector castings that are reconditioned are generally attached to the railcar end structure (not shown) and usually include a male casting 10 located on one railcar unit and a female casting 12 located on the adjacent railcar unit so that the male and female castings can interlock, joining the railcar units to form a multi-unit railcar. When the male and female castings are joined, holes 24, 26 in the female casting align with the opening in the male casting 32 so that a pin 16 can be inserted, securing the male and female castings and their internal components together to complete the connector.The connectors are articulated so that they can rotate around the pin and have vertical angularity, allowing the wagon units to rotate relative to each other during movement around curved rails and over undulating terrain. As noted above, there are two dominant types of articulated connectors used when joining railcar units, primarily ASF connectors and National Castings connectors, although other connector types may be similarly incorporated by this invention. The following description refers to ASF connectors. However, this description is illustrative of railcar connectors in general. As such, the following description of the invention is tailored to industry standards, but the invention could be modified to incorporate specific connectors used, including but not limited to National Castings connectors. The illustrative ASF connector, as shown in Figures 1 and 2, comprises a male casting 10 and a female casting 12. The female casting 12 is generally U-shaped in cross-section to receive the male casting 10. The female casting 12 includes an upper portion 18 and a lower portion 20, which are generally flat and are joined by side walls 22 and a generally concave back wall 23. The side walls 22, back wall 23, upper wall 18, and lower portion 20 define the generally U-shaped receiving cavity 34 of the female casting. Both the upper portion 18 and the lower portion 20 of the female casting include cylindrical bores 24 and 26, respectively, which are aligned with each other. In addition, the lower portion 20 includes a spherical ring surface 25. The female casting further includes a wedge system located along the concave back wall 23. The wedge system comprises a wedge 36 and a follower block 38. The follower block 38 is designed to conform to the spherical contour of the portion of the male casting with which it contacts. The wedge is then positioned between the back wall 23 and the follower block 38, holding the follower block 38 in place and providing pressure. The wedge is held in place by gravity and drops as wear occurs within the system to maintain a longitudinal clearance condition, thereby keeping the follower block 38 in constant contact and compression with the male casting 10. The male casting 10 includes a front end 28, nQcnnn / Qznz / e / YiAi, which is a generally LJ-shaped projection of generally constant thickness. The male casting 10 has an opening 32 with generally square features on the side closest to the fastening wagon unit, or rear surface 70 of the opening 32, and with a U-shaped concave surface closest to the opposite front surface 54 of the opening. The male opening 32 is shaped differently from the female bores 24 and 26 because the front surface 54 of the male opening 32 is concave and generally spherical, and the opening 32 has a larger overall volume than required for pin insertion. As such, a pin bearing block 31 is inserted into the opening 32 and mates with the front surface 54 of the opening, as shown in Figure 2.The shape of the pin bearing block 31 is generally spherical along the end that contacts the front surface 54 of the opening 32, to complement the opening, and has a generally vertical concave cylindrical shape along the opposite side to receive the pin 16. When the pin bearing block 31 is positioned in the opening 32, the concave cylindrical side of the pin bearing block 31 and the rear end 70 of the opening 32 define the area for receiving the pin as described below. The front end 28 of the male casting is generally U-shaped to complement the internal shape of the female casting. The front end 28 includes a front surface 30 at the far end of the male casting, which includes the nocnnn / rznz / E / YiAi area, generally U-shaped. The front surface 30 is the portion of the male casting that contacts the follower block 38 when the male casting 10 is inserted into the female casting 12. The front end 28 of the male casting also includes a lower bearing surface 33. The lower bearing surface 33 contacts the spherical ring surface 25 when the male casting 10 is inserted with the female casting 12. With the assembly, as shown in the cross-section in Figure 2, the male casting 10, specifically the front end 28, is inserted into the cavity 34 of the female casting 12. The lower bearing surface 33 of the male casting is positioned over the spherical ring surface 25 so that the opening 32 in the male casting is aligned with the bores 24 and 26 of the female casting. When the two bores 24 and 26 are aligned with the opening 32, a cylindrical pin 16 can be inserted through them. Pin 16 is inserted into the hole 24 in the upper portion 18 of the female casting and then passes through the opening 32 in the male casting 10, which includes the pin bearing block 31, and then passes further to engage the hole 26 in the lower portion 20 of the female casting 12.The top of the pin is preferably secured to the top of the female casting. The wedge system works to eliminate play in the connector system by applying pressure to the male casting and, consequently, to the bores and pin on the cylindrical surface of the pin bearing block. Due to the wedge system and the overall construction of the castings, significant wear occurs in selective areas. On the female casting, wear can occur on the spherical ring surface 25 and the front surfaces 103 of the female bores 24 and 26, as the compressive forces of traction cars push the pin 16 against these surfaces. Conversely, the rear surfaces 102 of the female bores experience negligible wear, as the wedge system prevents pin tension on these surfaces.On the male casting, wear occurs along the lower bearing surface 33 and the front spherical surface 54 of the opening 32, as the pin bearing block 31 is mounted on it. Conversely, the rear surface 70 of the male opening 32 does not experience any wear under normal operating conditions. The male casting also experiences significant wear on the front spherical surface 30 as a result of contact with the follower block 38 and compressive forces from other railcar units. During the use of connected railcar units, wear can occur in at least the areas specified above due to friction caused by the rotation and movement of the railcar units relative to one another. The following are methods for reconditioning and repairing railcars at these common wear sites, either while the nQrnnn / Qznz / e / YiAi connectors are still attached to the railcar or after the connectors have become detached. Reconditioning restores the worn parts of the connectors to their proper dimensions to ensure peak performance upon reconnection of the railcar units. Manual Reconditioning of the Articulated Connector Several methods for reconditioning hinged connectors are described here. Although reference is made below to an ASF male casting, as known to those with a basic understanding of the art, the methods and equipment described can easily be adapted for application to other types of male castings, such as those from National Castings, as well as to female castings. For example, the process described below could be applied to the lower surface 3000 of the female casting 12 shown in Figures 1 and 2. Male castings must be prepared so that accurate measurements can be taken to determine if reconditioning is required, particularly with respect to the areas described above. Such preparation includes cleaning the surfaces of rust, dirt, sand, grease, lubrication residue, or similar contaminants. Substances such as grease, soot, and lubricants can be scraped off the surfaces. Remaining contaminants can be torched off or removed. Damaged metal on surfaces requiring reconditioning must be carefully smoothed to prevent cold wrinkling during subsequent welding. The male castings are then measured to determine if reconditioning is required. Any portion of the casting that exists before the weld is applied can be designated as being “parent casting material.” As noted above, the lower bearing surface 33 and the face surface 30 of the male opening 32 of the male casting are prone to wear because they are in frictional contact with the spherical ring surface 25 and the follower block 38, respectively. Reconditioning the lower bearing surface is discussed below. Regarding the face surface 30, an example of reconditioning techniques can be found in U.S. Patent No. 7,059,062, assigned to TTX Company, which is incorporated herein by reference in its entirety. Figure 3 generally shows the steps of the applicable reconditioning process. Once the area to be measured has been prepared and cleaned 300, the lower bearing surface 33 of the male casting 10 is measured 302, 304 to determine if the lower bearing surface 33 has worn to the point of requiring reconditioning. Any suitable gauge may be used as long as it can be slid along the lower bearing surface to determine if reconditioning is necessary. An illustrative gauge based on the gauge described in U.S. Patent No. 6,944,925 is shown in Figures 24, 24A, and 24B. The preferred nQrnnn / Q7n7 / e / YiAi gauge 2401, as shown in Figures 24, 24A, 24B, and 24C, for use in measuring the ASF male connector, is a pivot gauge, preferably comprising two members: a base 42 and a swing arm assembly 44. The base 42 is generally a block-shaped member having a plurality of sides as shown. The top of the base 42 includes an opening 48 to receive a portion of the swing arm assembly 44. The front side of the base 42 has a relatively spherical surface 52 to engage with the front surface 54 of the bore 32 in the male casting 10, which has a complementary shape. The complementary shapes allow the proper vertical relationship of the gauge to the male casting to ensure accurate measurement of the worn portion.The rear side 56 of the base preferably includes an opening 58 to receive a screw jack assembly 60. The screw jack assembly 60 includes the threaded rod 62 having a support end 64 and a nut 66, forming an expanding clamp support. The support end 64 is configured to support and secure the base 42 against the inside of the male bore 32. Preferably, the support end 64 has three legs 68 that contact the rear surface 70 of the male bore 32. The nut 66, when rotated, extends or retracts the support end 64 from the base 42. As a result, rotating the nut 66 can extend the support until it is flush with the rear surface 70 of the male bore 32, securing the base 42 of the pivot gauge in the male bore 32.The front surface 54 and the back surface 70 are typically unworn or minimally worn portions of the bore 32 that are sufficient for reference measurement for new finishing. The swing arm assembly 44 comprises a swing arm 44a, a cylindrical support 44b, and a plate 44c. The swing arm 44a is generally L-shaped and includes an extension arm portion 74 and a measuring arm portion 76. The length of the extension arm 74 is determined by the dimensions of the male casting, generally including the contact surface 30 and the male bore 32. The swing arm assembly 44 is rotatably connected to the base. The plate 44c is secured to the base 42 by a countersink bolt 48 located on the plate 44c. The countersink bolt 48 is received in the opening 78 in the base 42. The cylindrical support 44b, which preferably has an upper portion 43 and a lower portion 45, is then rotatably attached to the plate 44c. The lower portion 45 of the cylindrical support 41 is preferably inserted into a hole (not shown) in the plate 44c and is secured to the plate, preferably with a c-shaped clip (not shown) inserted into and around a smaller diameter groove in the lower portion 43 of the cylindrical support 41. The upper portion 43 of the cylindrical support 41 includes a notch 47 to receive the extension arm 74 of the swing arm 44a. Additionally, an in-line hole 49 extends horizontally through the cylindrical support 41 that aligns with a similar hole (not shown) in the extension arm. A bolt can then be inserted through hole 49 and the hole in the extension arm 74, securing the extension arm 74 to the cylindrical support 41. The swing arm assembly results in the plate 44c being secured to the base 42 via a countersink bolt 48, the cylindrical support 44b being removably and rotatably secured to the plate 44c, and the swing arm 44a being removably and rotatably secured to the cylindrical support 44b. The swing arm 44a is thus able to rotate generally vertically upward from the base around the line hole 49 and bolt. This allows the swing arm 44a to be rotated upward and away from the male casting 10 when desired. The cylindrical support 44b and therefore the swing arm 44a are additionally able to rotate horizontally about the axis of the cylindrical support 44b, allowing the swing arm 44a and its contour edge 84 to slide along a desired range of the male casting contact surface 30. The swing arm 44a further includes a flat portion 46, which is part of the extension arm 74 that contacts the plate 44c and ensures the proper relationship between the control edge 84 and the spherical surface 52 of the base 42. The measuring arm 76 then extends downward from the extension arm 74. The measuring arm 76 includes a front edge 82 and a contoured edge 84. The curve of the contoured edge 84 is designed to conform to the contact surface 30 of the male casting 10 of the connector. The profiled edge 84 can oscillate throughout the range of nQrnnn / Qznz / e / YiAi the contact surface 30 of the male casting 10. The length of the extension arm 74 is such that the contour edge 84 of the swing arm 44a is less than approximately 0.31 cm (1 / 8”) from the contact surface 30 of a male casting 10 that has no wear. The preferred gauge 2401 of the present invention also includes a rotating component 2400 fixed to a mounting piece 2402 that includes a bolt 2404, a bushing 2403, and a spacer 2405. The gauge 2401 is shown in position in Figure 24C. Once the gauge 2401 is secured in place as described above, the rotating component 2400 is rotated around to measure the amount of weld that needs to be formed, or, if the rotating component is removed and turned over, it is used to measure whether the surface 33 needs additional grinding to regain the proper dimension. Once it is determined that the male connector casting 10 requires reconditioning (i.e., 302, 304 in Figure 3), the lower bearing surface 33 is divided into octants (step 305) and marked using soapstone as shown in Figure 25. The lower bearing surface 33 and surrounding areas are then preheated 307 to between 148.88–260°C (300–500°F) and maintained at this temperature range during the soldering process, for example, by using a torch with a heating tip. It is preferable to use a non-contact thermometer to verify that the preheating temperature is within the desired range. Alternatively, the male casting 10 can be heated nQcnnn / Q7n7 / e / YiAi using an induction heating cable to automatically preheat the casting and maintain it at the desired temperature during soldering.Induction heating can also be used to control slow cooling during the process. Figures 26 and 27 illustrate an example of an induction heating cable 2600 and its application to a male casting 10. The induction heating cable 2600 is typically controlled by a commercially available induction heating system, such as the Miller Proheat [TM] Induction Heating System 35, although other induction heating systems may be used. In operation, the induction heating cable 2600 is wound into circular or oval shapes 2602, having a minimum of two complete windings, as shown in Figure 26. The cable windings 2600 can consist of a single layer or multiple layers, as required to produce the required melt temperature during the reconditioning process. In the process of reconditioning male casting 10, there are preferably at least two of these oval-shaped wire windings 2602, which are symmetrically spaced from the approximate midpoint of the induction heating wire. These oval-shaped windings 2602 are applied symmetrically to each side of the male casting 10 as shown in Figure 27. The windings 2602 are shown in insulating saddlebags 2604 in the illustrations, but any insulating material may be used between the wire windings 2602 and the surface of male casting 10 to separate the windings 2602 from direct contact with the male casting 10 in order to prevent heat damage to the induction heating wire 2600. The affected area is then formed with 206 solder one octant at a time, preferably using a specially modified Stoody hard-coated solder wire (0.011 cm (0.045”) diameter, for example, although other configurations may be used) to permit general soldering and the use of CO2 gas. An equivalent wire having similar chemical and soldering characteristics may also be used. The table below provides illustrative wire compositions and machine properties, but other compositions will be evident to those skilled in the art. Wire Gas Required Welding Position Volts Amps Feed Rate (m / s (ipm)) Stoody (0.011 cm (0.045”) diameter) CO2 0 75% Ar / 25% CO2 Horizontal 27 210 0.13-0.15 (330-370) Stoody (0.011 cm (0.045”) diameter) CO2 0 75% Ar / 25% CO2 Flat (Downward) 28 220 0.16-0.17 (385-425) Stoody (0.011 cm (0.045”) diameter) CO2 0 75% Ar / 25% CO2 Overhead 27 160 0.10-0.12 (245-285) As shown in Figure 25, a weld bead 2500 is preferably applied along each soapstone mark, forming the octants from the center hole 32 toward the outer edge 2502 of the casting. Then, starting at the outer edge 2502, weld 2500 is applied, moving radially inward until the entire octant 2504 is welded. Alternatively, the weld may begin on the inner edge of the casting and be applied, moving radially outward until the entire octant 2404 is welded. The weld is applied to the octants 2504 in the order shown by numbers 1–6 in Figure 25, leaving two diagonally opposite octants 2505 and 2506 unwelded. After the first six octants 2504 are welded, the rotating component 2400 is removed, and the remaining two can be welded. Optionally, and as a precaution, the surfaces of gauge 2401 shown in Figures 24A, 24B, and 24C subjected to weld spatter should be lightly coated with a spatter-resistant product before welding. Preferably, welding to worn surfaces should be performed in a relatively still air environment to prevent shielding gas loss and rapid cooling. The surface temperature of the casting should not be allowed to fall below 148.88°C (300°F) at any time during the forming process. Therefore, it may be necessary to reheat the casting during the process. If the welding process is interrupted for any significant duration, the welded area should be completely covered with an insulating layer to prevent rapid cooling and potential weld cracking. Standard welding practices should be followed regarding the removal of all slag, oxide scale, and spatter between passes. The weld should be finished to avoid a notched effect at the weld-to-parent metal joint, and every precaution should be taken to prevent abrupt changes in section thickness at the fusion line. Following the welding process, the casting is slowly cooled to room temperature using insulating layers or an equivalent, such as an insulating box as shown in Figure 20. Cracks, incomplete fusion, overlaps, notches, unfilled craters, voids, and other defects can be highly problematic and should be avoided. Preheating and slow cooling steps during the process help reduce the potential for cracking. For porosity, non-rounded indications larger than 0.47 cm (3 / 16 in.) in length are preferred, and none of the square regions are acceptable.24 cm (6 inches) containing ten or more rounded indications. Following slow cooling, the insulating layers are removed. The rotating component 2400 is then reapplied in an inverted position. The restored lower bearing surface 33 is then hand-ground 308 to a desired tolerance of the blade surface of the rotating component 2400. The desired standards will depend on turning and / or industry requirements, but in a preferred modality, it is within 0.15 cm (1 / 16 in.) of the new nominal dimension. Grinding generally involves the removal of weld, metal, or other excess material. The weld is further blended into existing adjacent surfaces. Once the 306 welding and 308 grinding are completed, the lower bearing surface 33 is measured, such as by running a caliper over it, to requalify the 310 part and ensure that proper repair has occurred so that no excess wear or formation remains, and that the dimensions are correct. If the desired tolerances are not met, the lower bearing surface must be reconditioned again as described above. Whether both 306 welding and 308 grinding are required will depend on the quality and thickness of the remaining weld. After cooling, the repaired area is tested, such as by magnetic particle dye penetrant inspection, to determine that the surface quality is free of defects. Advantageously, the reconditioning method described above overcomes problems in the previous technique. Notably, when male castings wear out, they are usually removed and replaced, resulting in costly and wasteful materials. The method described above avoids this disadvantage. Furthermore, the octant method, as described, reduces surface cracks such as radial cracks in the weld material. With regard to the application of this process to a lower female 3000 surface, the general principle of forming a surface as a welding material and then grinding it (or turning the surface in a semi-automatic process as described above) also applies. Semi-Automatic Process for Reconditioning Connectors A semi-automatic technique as implemented for reconditioning an ASF male articulated connector casting will now be described. It is envisaged that the currently preferred technique is applicable to other connector castings, such as National Castings articulated connector castings, and their female counterparts. As described above and as shown in Figures 1 and 2 of this description, the male casting of ASF 10 includes a front end 28 having a lower bearing surface 33. The lower bearing surface of the male casting is subjected to wear caused by contact with the spherical ring surface 25 within the female casting 12 during use. As noted in the description of the previous method, the reconditioning of the lower bearing surface 33 on the male casting can be achieved through the manual application of a grinding process once the surface has been rebuilt by welding. The grinding procedure, although more desirable than the known method of removing and replacing the entire casting, can take many hours to complete by hand due to the superior strength of the materials used in the casting and welding. Furthermore, given the length of the task, it is often advantageous to flip or invert the railcars with the male casting so that the lower bearing surface is not being reconditioned from the upside down. This can present challenges due to the large size and weight of the railcar and the casting.Furthermore, the manual reconditioning process usually requires transporting the railcars to a repair shop. Therefore, automating the welding and metal removal process may be desirable. According to the present invention, a welding accessory 800 is provided to assist in the semi-automatic reconditioning of an ASF male casting. Referring to Figures 13A-13B, the welding accessory includes a support plate 802 and a base plate 804 extending substantially perpendicularly from the support plate 802. The base plate 804 includes a cutout 216 that, as explained below, allows the welding device to be connected to the welding accessory 800. It also includes a pickup plate 806 extending downward at an angle relative to the base plate. The pickup plate 806 engages an inner surface of the front surface 54 of the opening in the male casting 10 to secure the welding accessory 800 to the male casting.Although the pickup plate 806 can be angled as desired in order to secure the weld fitting to the male casting, in a preferred embodiment the pickup is angled downwards approximately 54 degrees to the base plate. A pair of side arms 808 extend downward from the base plate 804, such that a side arm 808 is on either side of the male casting 10 when the welding fixture 800 is attached to the casting. As further explained below, each of the support plate 802 and side arms 808 includes a knob 810 which, when adjusted, allows a screw 812 associated with the knob to engage the male casting and secure the welding fixture 800 to the male casting 10. A fixture shaft 814 extends upward from the top plate. The fixture shaft indicates the attachment of a welding assembly to semi-automatically form the weld onto the lower bearing surface of the male casting. A turning fixture assembly 200 is also provided to assist in the semi-automatic reconditioning of an ASF male casting. After the welding step as described above, the male casting 10 is removed from the welding fixture 800 and placed and aligned in the turning fixture 200. Preferably, the fixture includes a rigid, adjustable-frame apparatus as shown in Figures 4A-4H. Referring first to Figures 4A-4B, the fixture 200 includes a horizontally positioned top plate 202 and a corresponding horizontal bottom plate 204. The top plate 202 includes a first opening 206 and a pair of grippers 208. The bottom plate 204 includes a second opening 210, which is substantially aligned with the first opening in the top plate 202.Preferably, and as shown in Figure 4I, the first and second openings 206, 210 are aligned such that measurements L1 and L2 are within approximately 0.07 cm (1 / 32 inch) of each other and measurements D1 and D2 are within approximately 0.15 cm (1 / 16 inch) of each other. However, other tolerances may be used in other configurations. The top and bottom plates 202, 204 are connected via a pair of rigidly fixed, vertical, spaced side plates 212 that extend between the top plate 202 and the bottom plate 204. Shields 214 are mounted at various corners of the fixture 200 frame to reinforce the frame's rigidity. Within the rigid fixture 200 frame, the horizontal plates 202 and 204 and the vertical side plates 212 define an interior space 216. The fixture 200 also includes a centering portion 2000 with a tab 4000 that acts as a guide to help center the fixture 200 laterally over the connector 10. The fitting 200 incorporates a clamp assembly 318 to allow attachment of the fitting 200 to a male ASF casting. Preferably, the clamp assembly 218 includes a hook 220 and a threaded rod 219 which, as further explained below, allows the hook 220 to move in the direction of arrow 222 in Figure 4D. The clamp assembly 218 further includes an alignment plate 224 and at least one spacer 226 attached to the alignment plate 224, such that they are “stacked” in a horizontal direction (i.e., arrows nocnnn / rznz / E / YiAi). 222). A pair of gauge support rods 228 are fixed to the inner surfaces of the side plates 212 and, as shown in Figure 4B, extend outward from the side plates 212. As shown in Figure 4J, the fixture 200 also includes a pair of brackets 230 on one of the side plates 212 to hold a gauge 232. As explained below, the gauge 232 is used in conjunction with the support rods 228 to check the lower bearing surface 33 of the male casting. Referring to Figure 4H, in a preferred embodiment it is desirable to make an upper surface 234 of the support rods 228 approximately perpendicular to a surface 236 of the outer spacer 226 to within 0.1 degrees, and to make the outer surfaces 234 of the support rods 228 approximately parallel to each other to within 0.1 degrees. The first and second bearings 238, 240 are enclosed and centered within the first and second openings 206, 210. The first bearing 238 is positioned on an upper side 242 of the upper plate 202, and the second bearing 240 is positioned on an upper side 244 of the lower plate 204. The first and second bearings 238, 240 must be substantially aligned. One way to align the bearings is by using an alignment tube 246 (Figures 4F-4G). In a desired configuration, the bearings can be aligned such that the vertical axis defined by Yi is parallel to the axis defined by Y2 to within 0.1 degrees, and the vertical axis defined by Y3 is perpendicular to the horizontal axis defined by X1 to within 0.1 degrees. nQrnnn / Q7n7 / e / YiAi Figures 4A-4E show an ASF 10 male casting attached to the fitting. In particular, Figure 4C shows that the threaded rod 219 is loosened so that the hook 220 is pulled closer to the alignment plate 224. This allows the clamp assembly 218 to be lowered into the opening 32 of the male casting 10. The threaded rod 219 is then tightened. Specifically, and as shown in Figures 4D-4E, the threaded rod 219 must be tightened so that the hook 220 and the front opening surface 54 are in contact with each other, and so that the outer spacer 226 and the rear drilling surface 70 are in contact with each other. An illustrative embodiment of the semi-automatic reconditioning technique for the ASF male articulated connector casting will now be described. Figure 5 illustrates a flow diagram of one embodiment of the preferred method. As shown in 552, the ASF 10 male articulated connector casting is prepared for reconditioning. This preparation is similar to that of the embodiments previously described above. In general, however, dirt, grease, lubrication residue, and other contamination must be removed from the underside of the male bearing surface of the casting before the reconditioning procedure. Preferably, this is accomplished by burning and / or turning (i.e., grinding). Burrs are then removed from the inside and outside diameters of the underside bearing surface.Fitting 800 is mounted 553 to casting 10 and casting 10 is nocnnn / rznz / E / YiAi preheated 555 to 148.88°-260°C (300°-500°F). The welding operation can then proceed as in 552 to add weld metal to portions of the lower bearing surface 33 of the male casting. Referring to Figures 14-16, in a preferred embodiment, an automatic welding device 818 is applied to the accessory shaft 814 of the accessory 800 to rebuild the lower bearing surface with weld. An illustrative welding device includes an AutoBoreWelder supplied by Climax Portable Machining & Welding Systems, Inc. of Newberg, Obregón. Of course, a number of other welding devices may be used without departing from the scope of the present invention. The welding device 818 includes a torch assembly 820 and a piercing weld assembly 822. The torch assembly 820 includes a torch nozzle 824 and a spindle 826 for attachment to the piercing weld assembly 822. The spindle 826 is a component of a radial-face torch. Although any suitable radial face may be used, in a preferred embodiment the radial-face torch is a Bortech Model A1035 Radial-Face Torch Assembly supplied by Boretech Corporation of Keene, NI. The piercing welding assembly 822 includes a control unit 828 and a welding cladding head 830. The control unit 828 starts and stops the welding process. It includes a control unit shaft 832 extending upward from the control unit, a welding cam 834 located on the control unit shaft, and a roller switch 836 which, as further explained below, is engaged by the welding cam 834 as it rotates on the control unit shaft 832 when the welding device 818 is in operation. Referring to Figures 16 and 17, the welding cam 834 includes a series of small brakes 838 so that when an 838 passes the roller switch 836, the roller switch 836 will no longer be engaged so that the torch nozzle 824 will stop its welding operation.However, the welding device 818 will continue to rotate due to the continued operation of the welding coating head 830. When a portion of the welding cam 834 that does not have a brake 838 engages the roller switch 836, welding will restart. This allows for intermittent, automatic welding of the lower bearing surface of the male casting. Although in a preferred embodiment there are six equally spaced brakes along the circumference of the welding cam, each allowing 15 degrees of welding interruption, in other embodiments a different number of brakes, or none at all, may be used. The welding coating head 830 controls the rotation and movement of the welding device 818. It is coupled with the control unit shaft 832 and, when the welding device is ready for use, the welding coating head is able to rotate 360 ​​degrees during the welding operation. nQrnnn / Qznz / e / YiAi The piercing welding assembly 822 also includes a connecting beam assembly 840 which at one end 822 is attached to the casing head and at the other end 844 is connected to the control unit 828, which forms a connection between the welding fixture's accessory shaft 814 and the connecting beam assembly 840. To perform welding operation 554, the welding fixture 800 is attached to the male casting 10 so that the front end 28 of the male casting 10 faces the support plate 802. The knobs 810 located on the side arms 808 and the support plate 802 can then be rotated so that their respective screws 812 engage with the male casting to secure the welding fixture 800 to the casting 10. Notably, as the screws 812 are tightened, the pickup plate 806 will also engage with the inner surface of the front surface 54 of the male casting opening. The control unit 828 is fixed to the accessory shaft 814 of the welding fixture, and the torch assembly 820 passes through the cutout 816 in the base plate 804 from the underside of the casting 10. The spindle 826 of the torch assembly 820 is then connected to the piercing welding assembly 822. Referring to Figure 18, the torch assembly 820 is adjusted so that the torch nozzle 824 is positioned along an outer portion 824 of the lower bearing surface 33 of the male casting 10. Alternatively, the torch nozzle 824 can be positioned on an inner portion of the lower bearing surface 33 of the male casting 10. The welding cam 834 must be rotated so that one of the brakes 838 is positioned toward the rear surface 70 of the opening. The male casting must be preheated as described above and maintained at 148.88–260°C (300–500°F) throughout the welding process. This is achieved through the use of an insulating layer or equivalent means. The male casting 10 is reheated as required to maintain the appropriate temperature. By actuating the control unit 828, for example, with a push button, the welding process can then begin. The welding device will start applying the weld to an outer portion of the lower bearing surface, and as rotation continues, the torch nozzle will rotate inward along the lower bearing surface in a counterclockwise direction as viewed from the top of the casting.Typically, the torch nozzle will make 10 to 12 passes or revolutions around the lower bearing surface to apply a weld layer. Typically, 4-8 weld layers can be expected to "rebuild" the lower bearing surface, although the actual number may vary depending on the amount of wear and the desired weld thickness. Furthermore, the gas used with the welding device should preferably be either 100% CO2 or a 75% AR / 25% CO2 composition, although other compositions known to those skilled in the art may be used. As noted earlier, the presence of the welding cam 834 will cause an interrupted weld pattern to form on the lower bearing surface. The roller switch 838 of the control unit will disengage when a brake 838 on the welding cam passes over it. This will cause the torch nozzle 824 to stop “welding” until the welding cam again actuates the roller switch. In a preferred embodiment, and as shown in Figure 19, the weld pattern will be approximately 45 degrees from the weld material 848 followed by approximately 15 degrees of no weld 850. When the automatic welding operation is completed, the amount of weld can be measured with a caliper to determine if the weld formation is satisfactory. If the amount is considered insufficient, the above process can be repeated, with the number of layers applied adjusted accordingly. The welding device can then be removed from the welding fixture. The areas on the lower bearing surface that have no weld can then be manually filled with weld. Using the same type of gas, the manually applied weld can be added to the areas that remain weld-free after the automatic welding process. These areas are blended with the automatically applied weld so that the entire lower bearing surface has been formed for the turning operation as described below. Notably, the automatic application of the weld material reduces the time required for an operator to weld the lower bearing surface.Furthermore, because this operation allows the welding to be applied from below the casting, it also limits any prolonged, difficult handling required by the operator, and does not require inversion of the wagon or casting to perform the welding operation. After the lower bearing surface has been welded, it should be allowed to cool slowly 557 before proceeding with the turning operation. Desirably, even though the welding fixture is still mounted to the casting, the casting should have an insulating box 852, insulating layers, and / or equivalent means applied to it (Figure 20) to control the cooling rate of the casting. The insulating box is a two-piece box with an outer layer made of sheet metal. The insulating box facilitates the cooling of the casting in a controlled manner. Otherwise, if the casting cools too rapidly, the welding material may crack or develop other surface defects. The insulating box includes a pair of doors 854 positioned opposite each other.The doors 854 can be fully open or fully closed to control the casting's exposure to ambient air during cooling. Additionally, any portions of the casting that remain exposed, such as those resulting from cutouts in the insulating box 852, can be wrapped in an insulating layer 858. nQrnnn / Q7n7 / e / YiAi Once the casting has cooled and the insulating box, layers, and fixture have been removed, the casting is mounted 556 and aligned 558 in the turning fixture 200 so that the turning operation 560 can be performed. As described above, this may include facing, grinding, or milling, among other suitable operations, to remove excess weld to a specified dimension. Referring to Figures 6-10, in this semi-automatic method of the present invention, a drill rod assembly 400, a facing head assembly 500, and a facing head feed control 600 are used.The drill rod assembly 400 drives the drill head assembly 500, which includes a turning tool 502 (Figure 11), while the feed control 600 indicates the axial feed of the turning tool as weld material is removed from the lower bearing surface 33 of the male portion 10 of the casting, and indicates the feed rate adjustment of the turning tool 502 during the turning process. In a preferred embodiment, the casing head assembly 500, drill rod assembly 400, and casing head feed control 600 are manufactured by Climax Portable Machining & Welding Systems, Inc. of Newberg, Oregon. Of course, other drill rod and casing head assemblies and / or casing head feed controls may be used without departing from the scope of the present invention. nocnnn / rznz / E / YiAi Referring to Figure 6, the drill rod assembly 400 includes an axial feed assembly 402, a rotary drive assembly 404, a spindle 406, a drill rod 408, a plurality of clamp collars 410a-c, and a clamp ring 412. As further explained below, the drill rod assembly 400 is secured to the fixture by inserting the drill rod 408 into the bearing in the first opening 206 of the top plate 202. Notably, the axial feed assembly 402 enables the adjustment and movement of the drill rod 408 in a vertical direction through its engagement with the spindle 406. The rotary drive assembly 404 includes a motor 405 and a rotary drive unit 407, which together drive and indicate the rotation of the drill rod 408.In addition to the turning tool 502, the casing head assembly 500 includes a casing head 504 and a casing head vehicle 506. As described below, the casing head assembly 500 is connected to the drill rod 408 and thus rotates when the drill rod 408 is driven by the rotating drive assembly 404. The casing head assembly 500 retains the turning tool 502 that turns the lower bearing surface 33 of the casting 10. The casing head feed control 600 is in mechanical contact with the casing head assembly 500 and controls the feed rate, i.e., the rate at which the cutting tool moves or is “fed” in an inward direction along the lower bearing surface as material is removed. welding.It includes a feed adjustment 602 and clutch wheel 604. The clutch wheel 604 secures the feed adjustment 602 in place. When the clutch wheel 604 is loosened, the feed adjustment 602 can be adjusted to change the feed rate of the turning tool 502. To perform the turning operation, the drill rod assembly 400 is placed on the fixture 200 applied to the casting 10. As part of the drill rod assembly 400, clamps 410a and 410b are secured to the drill rod 408 to prevent the drill rod 408 from coming out of the axial feed assembly 402 and the rotating drive unit 407 when the drill rod assembly 400 is reinstalled. The drill rod 408 is inserted into the first bearing 238 in the upper plate 202, completely through the first opening 206 and completely through the male casting opening 32. However, sufficient clearance must be left above the second bearing 240 in the lower plate 204 to allow the casing head assembly 500 to be positioned upwards on the drill rod 408.Following the casing head assembly is a clamp collar 508a, the casing head feed control 600, and another clamp collar 508b. After that, the end 414 of the drill rod 408 is placed through the second bearing 240 until the drill rod assembly clamp ring 412 covers the first bearing 238. The clamp ring 412 is then secured over the first bearing 238, such as through the use of a spring-loaded push-button lock. The turning tool 502 is also positioned after first determining the lowest point of the material on the lower bearing surface 33 to be turned. As shown in Figure 9, the gauge rod 232 is positioned so that a primary flat side 232a (Figure 10) is horizontal across the support rods 228. Then, such as by using a scale or tape measure, the location of the lowest point from the flat side 232 of the gauge rod is assessed and marked for the material to be turned on the lower bearing surface 33. Other methods may also be used. The turning tool 502 is placed in the tool holder vehicle 506 and secured. As noted previously, the tool may be a similar facing or cutting tool to facilitate the removal of weld material. The facing head assembly 500 is slid up on the drill rod 408 until the tip 502a of the cutting tool 502 is positioned near the lowest location of weld material on the lower bearing surface 33, preferably within 0.63 cm (1 / 4 in.). The facing head assembly 500 is securely clamped to the drill rod 408. The clamping collar 508a is slid into direct contact with the lower side 501 of the facing head assembly 500 and clamped to the drill rod 408.The casing head feed control 600 is loosely positioned against the clamping collar 508. Another clamping collar 508b slides upward into direct contact with the lower side 606 of the casing head feed control 600 and is securely clamped to the drill rod 408. The remainder of the configuration indicates “fine tuning.” The tolerances provided below are illustrative, and other tolerances may be used depending on turning requirements. The axial feed 402 includes a handwheel 416 that can be manually engaged to move the drill rod 408 upward so that the tip 502a of the tool 502 is within approximately 0.07 cm (0.030 in.) of a point below the material in the area to be turned. The handwheel 416 is then engaged downward by approximately half a turn, or 0.127 cm (0.050 in.). The liner head also includes a pair of vehicle control knobs 508, one of which can be engaged to position the outer end 506a of the tool support vehicle 506 at a desired distance from the end 503 of the liner head. The tool support vehicle 506 is secured in place to prevent movement.In a preferred embodiment, a pin and brake configuration can be used so that the vehicle control knob “locks” the 506 tool holder vehicle in place. The casing head assembly 500 and turning tool 502 are rotated toward the rear of the casting by engaging the rotary drive system 404, such as by means of a push button (not shown). Once the casing head assembly 500 is in position, the rotary drive system 404 is disengaged. The axial feed crank 416 402 is then engaged by approximately one full turn so that the drill rod 408 is moved upward approximately 0.254 cm (0.100 in.) into the area to be turned. Clamp 410c is then secured and crank 416 is uncoupled from axial feed 402. In a preferred embodiment, the crank has pins that engage with brakes associated with axial feed, so that when the pins are uncoupled the axial feed is secured in place.Once ready for actual turning, the drill rod 408 is engaged by pressing the push button, resulting in the rotary motion of the liner head assembly 500. Using the above properties, approximately 0.050 cm (0.020 in) of material will be removed from the lower bearing surface. However, as noted earlier, this is an illustrative example, and other properties may be used to remove a greater or lesser amount of material. Advantageously, an operator can monitor the turning process without having to perform it, which, as described above, may require the operator to grind the lower bearing surface from below the casting, or it may also require inverting the casting (and potentially the railcar). Each of these techniques requires significant amounts of time and is undesirable because the former requires prolonged and difficult handling by the operator, while the latter requires handling large equipment (casting and / or railcar). Furthermore, hinged connectors are not suitable for such railcar removal since they are integrated into the railcar, and such repair would be inefficient, time-consuming, and costly. In a preferred embodiment, during turning it is desirable to feed the tool holder and vehicle 506 inward along the lower bearing surface approximately 0.025 cm (0.010 in.) per revolution of the turning tool 502. The feed adjustment can be made by loosening the clutch wheel 604 and rotating the feed adjustment 602 in the appropriate direction. In this embodiment, counterclockwise rotation of the feed adjustment 602 decreases the feed, while clockwise rotation of the feed adjustment increases the feed. If the feed is unknown, a slower initial setting may be used until the desired feed is achieved, at which point the clutch wheel 604 may be re-engaged. In addition, metal fragments (Figure 9) created by the turning process may need to be removed during the turning process. One way to achieve fragment removal is by using a low-pressure hose to blow the fragments away. Once the turning is complete, the equipment can be disengaged to determine if the desired casting dimension has been achieved; that is, the casting undergoes qualification 562. In a preferred embodiment, this will occur after one pass along a lower bearing surface by the cutting tool 502. However, in most cases, more than one pass will be required. The upper clamp collar 410c on top of the drill rod 408 is loosened, and the handwheel 416 moves the drill rod 408 downward so that the cutting tool moves in a downward direction away from the lower bearing surface. As such, the liner head assembly 500 is moved out of the way during qualification. The gauge rod 232 is positioned on the support rods 228 so that the primary flat side 232a is vertical.In a preferred embodiment, if the gauge rod 232 can slide under the turned casting surface and the clearance between the gauge rod and the turned surface is within 0.15 cm (1 / 16 in.), then the desired dimension has been achieved. Additionally, it may be desirable to make the cumulative total of the unturned areas of the lower bearing surface no greater than approximately 2.54 cm (1 in.) in diameter. If these tolerances are not satisfied, the process described above may be repeated, except that the drill rod handle 416 may be additionally rotated to raise the liner head assembly 500 toward the lower bearing surface so as to remove additional material. Upon completion of turning, sharp edges of the lower bearing surface are ground to a radius of approximately 0.15 cm.31 cm (1 / 16”-1 / 8”) and the remaining weld formation is blended with the existing adjacent casting surfaces. The restored surface is then inspected for defects. Reconditioning through the Use of Wear Plates This alternative method does not require the application of a forming weld followed by grinding, as described above. Referring to Figure 12, instead, a wear plate 900 can be welded or mechanically fastened to a wear surface 901 of the male casting that has been turned or ground flat using processes such as those described above. The wear surface will be prepared as described above (e.g., turned, ground, deburred, etc.) to accept a wear plate welded to it. For example, with regard to the lower bearing surface 33, the lower bearing surface itself will act as the surface to which the wear plate is welded. The wear plate may include a substrate layer 904 and a welded layer 902 (shown in exaggerated form in Figures 12, 12A, and 12B). The substrate layer 904 is typically made of a weldable material and is the layer that is welded for attachment to the lower bearing surface 33. A suitable material is a weldable steel substrate, nQrnnn / Q7n7 / e / YiAi, while in other embodiments, a low-carbon or high-strength low-alloy steel may be used. The welded layer 902 acts in place of the forming weld material described previously. The surface 906 of the welded layer will contact the spherical ring surface 25 when the male casting 10 is inserted into the female casting 12.Before fitting a wear plate, the lower bearing surface can be turned using the techniques described above until the desired casting dimension is achieved, which can be determined by measuring the casting with calipers. Preferably, the 902 weld layer of the 900 weld plate is made of chromium carbide, although other suitable materials such as hard-faced weld material may be used. Other options for the wear plate include, but are not limited to, box or flame-hardened wear plates that have other resistant surface treatments. Wear plates made entirely of materials like those noted for the substrate layer are also an option. The wear plate could also be made of stainless steel. Consequently, the casting can be reconditioned at a faster rate since the weld does not need to be formed. Rather, the wear plate only needs to be attached to the prepared wear surface. Notably, this procedure can also be used to recondition the lower bearing surface 3000 of the female casting. Many alternative embodiments of the wear plate described herein are provided for. For example, the opening 950 in the wear plate 900 can be concentric to the outer edge 952 of the wear plate 900, as shown in Figure 21. Alternatively, as shown in Figure 22, the opening 950 in the wear plate 900 can have an offset, or non-concentric relationship with the outer edge 952 of the wear plate 900. In another alternative embodiment, the outer edge 952 of the wear plate 900 is not circular but rather has cut-out portions.Other forms are also planned. Of course, a person skilled in the art will realize that the machines, fixtures, tools, and gauges used in the previous version of the reconditioning method are merely illustrative, and many alternatives exist. The examples illustrated here are therefore not intended to be restrictive. Furthermore, although male castings from ASF, as known to those with a basic understanding of the art, are described, the methods and equipment here can easily be adapted for application to other types of male castings, such as those from National Castings, as well as to female castings. If the methods are applied here to female castings, the lower bearing surface (or spherical ring) can be reconditioned in this way.

Claims

1A method for semi-automatically reconditioning a railcar articulated connector, comprising a male portion including parent casting material, the male portion comprising an opening configured to receive a bolt, the method comprising: applying welding material to a lower bearing surface of the male portion of the articulated connector, wherein the lower bearing surface is perpendicular to the bolt opening; mounting a housing defining an interior space for positioning the male portion of the articulated connector within the interior space; centering and stabilizing a fixture laterally on the male portion of the articulated connector; inserting a clamping mechanism attached to the housing within the opening of the male portion of the articulated connector to fix the housing to the male portion of the articulated connector; securing the clamping mechanism to the opening of the male portion;and automatically turn at least a portion of the weld and / or parent casting material; determine if a desired turning dimension has been reached; position an indicator bar within a predetermined distance of the weld material such that the indication reaches the interior space; and run the indicator bar through the portion of weld material and determine if the weld material or parent casting material is within a predetermined distance of the indication where the indicator bar is supported at each end by bars mounted within the interior space of the housing during the stroke. 2.- The method according to claim 1, further comprising: automatically turning a portion of the welding material for a second time.

3. The method according to claim 1, wherein the step of centering the fitting is carried out using flanges and a guide inside the fitting. 4.- The method according to claim 1, further comprising the step of automatically turning at least a portion of the parent casting material of the male portion.

5. The method according to claim 1, wherein the steps of the method are carried out while the male portion of the articulated connector is connected to a wagon.

6. The method according to claim 5, wherein the wagon is in a vertical position. nQrnnn / Qznz / e / YiAi 7.- The method according to claim 5, wherein the wagon is not inverted during the steps of the method.

8. The method according to claim 1, further comprising the step of heating the male portion before and during the soldering step and controlling slow cooling after the soldering step by applying an induction heating wire to the male portion.

9. The method according to claim 8, further comprising the step of providing insulating material between the surface of the male portion and the induction heating cable.

10. The method according to claim 8, wherein the induction heating cable is wound in oval shapes having a minimum of two complete turns in one or more layers, with at least two oval-shaped cable coils applied symmetrically on each side of the male casting.

11. A method for semi-automatically reconditioning a railcar articulated connector comprising a male portion including parent casting material, the male portion comprising an opening configured to receive a bolt, the method comprising: applying welding material to a lower bearing surface of the male portion of the articulated connector, wherein the bearing surface is perpendicular to the bolt opening; mounting a housing defining an interior space for positioning the male portion of the articulated connector within the interior space; centering and stabilizing a laterally stabilized fitting on the male portion of the articulated connector; inserting a clamping mechanism attached to the housing within the opening of the male portion of the articulated connector to fix the housing to the male portion of the articulated connector;securing the clamping mechanism to the opening of the male portion; automatically turning at least a portion of the parent welding and / or casting material; attaching a welding fitting having a catch plate that engages an inner surface of the opening of the male portion of the hinged connector to secure the welding fitting to the male portion; and automatically applying welding material to at least a portion of the lower bearing surface of the male portion. 12.- The method according to claim 11, wherein applying the welding material to at least a portion of the lower bearing surface of the male portion further comprises forming an uninterrupted welding pattern on the lower bearing surface.

13. The method according to claim 11, wherein the step of applying welding material to at least a portion of the lower bearing surface of the male portion is carried out by an automatic welding device.

14. The method according to claim 11, wherein applying the welding material to at least a portion of the lower bearing surface of the male portion further comprises forming an uninterrupted welding pattern on the lower bearing surface.

15. The method according to claim 14, wherein the uninterrupted welding pattern on the lower bearing surface comprises 45 degrees or more of welding alternating with 15 degrees or less of no welding.

16. A turning accessory for semi-automatically reconditioning an articulated connector comprising: a housing having at least two side walls, a top plate having a first opening connecting the side walls, and a bottom plate connecting the side walls, top plate, and bottom plate defining an interior space; a clamping mechanism fixed to at least one of the side walls, the clamping mechanism comprising a curved hook portion, the curved hook portion being laterally adjustable.

17. The accessory according to claim 1, further comprising a removably positionable calibrator within the interior space. nocnnn / rznz / E / YiAi 18. The accessory according to claim 16, further comprising a drive rod positioned within the interior space and through the first opening of the top plate; a rotary drive system electrically connected to the drive rod for automatically driving the drive rod; and a turning mechanism connected to and rotaryly driven by the drive rod, the turning mechanism including a turning tool.

19. The accessory according to claim 17, wherein the rotary drive assembly further comprises a crank mechanism connected to the drive rod for manually adjusting the drive rod.

20. The accessory according to claim 16, further characterized in that it additionally comprises: a housing having a bearing in relative alignment above and below the opening of a male portion of an articulated connector; and a feed control electrically connected to the turning mechanism for controlling the feed rate of the turning mechanism. 21.- The accessory according to claim 16, further characterized in that the lower plate additionally comprises a second opening for activation with the driving rod. 22.- The accessory according to claim 16, further characterized in that the hook includes a portion for activating a front surface of an opening surface of a male portion of an articulated connector; means incorporated in a housing allowing a drill rod to be aligned perpendicularly with a lower drill surface; and at least one plate, wherein an outer portion of at least one plate is for activating a rear surface of an opening of a male portion of an articulated connector.

23. The accessory according to claim 16, wherein the turning tool is a coating tool.

24. An assembly for semi-automatically reconditioning a hinged connector, the assembly comprising a welding fixture including an accessory shaft extending upwards from the welding fixture and a plurality of clamps for securing the welding fixture to a male casting; a welding device including: a torch nozzle assembly for applying a welding material, a control unit for indicating the flow of welding material to the torch nozzle, an opening for attachment to the accessory shaft, and a welding cam having at least one brake, wherein an uninterrupted welding pattern is formed on the lower bearing surface of the male casting when the welding cam is engaged with the control unit.

25. The accessory according to claim 24, wherein the welding cam includes at least six brakes.

26. The accessory according to claim 24, wherein the welding accessory further comprises a base plate, the base plate including a pickup plate being angled at an angle relative to the base plate to engage with a hole in the male casting.

27. The accessory according to claim 26, further characterized in that the collection plate is angled downwards approximately 54 degrees with respect to a plane substantially perpendicular to the base plate.

28. An assembly for semi-automatically reconditioning a hinged connector comprising a welding fitting including an accessory shaft extending upwards from the welding fitting and a plurality of clamps for securing the welding fitting to a male casting; a welding device including: a torch nozzle assembly for applying welding material to a control unit for indicating the flow of welding material to the torch nozzle; an opening for attachment to the accessory shaft; and a welding cam; wherein an uninterrupted welding pattern is formed on the lower bearing surface of the male casting when the welding cam is engaged with the control unit.

29. An apparatus for measuring a portion on an articulated connector with respect to a reference portion of said connector, said apparatus comprising: a base that can be mounted to said connector against said reference portion of said connector; and an arm rotatably mounted to said base and extendable into said portion of said connector; said arm having a measuring portion, said measuring portion being movable through at least one station of said portion of said connector, and a rotating component connected to a mounting piece.

30. The apparatus according to claim 29, further characterized in that the rotating component has a first side and a second side and can be mounted to the mounting piece either with the first side facing upwards or the second side facing upwards.

31. The apparatus according to claim 30, further characterized in that the first side measures whether more solder material should be added to the surface of the connector. 32.- The apparatus according to claim 31, further characterized in that the second side measures whether solder material should be removed from the surface of the connector.

33. The apparatus according to claim 29, further characterized in that said fixable base further comprises a screw mechanism connected to a support end, said screw mechanism adapted to drive said support end against said reference portion. 34.- The apparatus according to claim 29, further characterized in that said base which can be fixed further comprises a clamping mechanism for coupling to an inner portion of said connector.

35. The apparatus according to claim 33, nocnnn / rznz / E / YiAi, further characterized in that said screw mechanism and support end can be mounted within a perforation of said connector.

36. The apparatus according to claim 35, further characterized in that said base which can be fixed complements the shape of said perforation of said connector.

37. A method for reconditioning a wagon connector, comprising: turning a portion of a casting to create a wear plate application surface; placing a wear plate onto the wear plate application surface; and welding the wear plate to the wear plate application surface.

38. The method according to claim 37, further characterized in that turning a portion of a casting to create a wear plate application surface further comprises turning a portion of a lower bearing surface of a male portion of an articulated connector.

39. The method according to claim 37, further characterized in that welding the wear plate to the application surface further comprises: determining whether the male portion has achieved a desired turning dimension after the application of the wear plate.

40. The method according to claim 37, further characterized in that welding the wear plate to the application surface further comprises welding a substrate layer of the wear plate to the application surface.

41. The method according to claim 37, further characterized in that the wear plate includes a layer made of chromium carbide.

42. The method according to claim 37, further characterized in that the wear plate includes a layer made of a weldable steel substrate.

43. The method according to claim 37, further characterized in that the wear plate includes a layer made of stainless steel. 44.- The method according to claim 37, further characterized in that the wear plate is generally circular and includes an opening that is generally concentric with an outer edge of the wear plate.

45. The method according to claim 37, further characterized in that the wear plate is generally circular and includes an opening that is generally not concentric with an outer edge of the wear plate.

46. ​​The method according to claim 37, further characterized in that the wear plate is a non-circular shape.

47. The method according to claim 46, further characterized in that the wear plate includes a generally circular opening defined therein. nocnnn / rznz / E / YiAi 48. The method according to claim 37, further characterized in that the wear plate substantially matches the shape of a lower bearing surface of a male portion of an articulated connector.

49. The method according to claim 37, further characterized in that the application surface of the wear plate is on a female portion of an articulated connector.

50. The method according to claim 37, further characterized in that the turning step is automatic. 51.- A wear plate for reconditioning a surface of an articulated connector, the wear plate having at least one opening defined therein and comprising at least one substrate layer connected to a welded layer. 52.- The wear plate according to claim 51, further characterized in that the wear plate is generally circular.

53. The wear plate according to claim 52, further characterized in that the opening is generally concentric with an outer edge of the wear plate. 54 - The wear plate according to claim 52, further characterized in that the opening is generally not concentric with an outer edge of the wear plate. 55.- The wear plate according to claim nocnnn / rznz / E / YiAi 51, further characterized in that the wear plate is of a non-circular shape. 56.- The wear plate according to claim 55, further characterized in that the opening is generally circular. 57.- The wear plate according to claim 51, further characterized in that the welded layer is composed of chromium carbide.

58. A method for reconditioning a wagon connector, comprising: turning a portion of a casting to create a wear plate application surface; placing a wear plate onto the wear plate application surface; and mechanically fastening the wear plate to the wear plate application surface.

59. A method for reconditioning a railcar articulated connector, the method comprising the steps of: marking a surface of a portion of an articulated connector to divide the surface into sections; preheating the surface of a portion of an articulated connector; adding solder to a first section of the preheated portion of the articulated connector; and adding solder to a second section of the preheated portion of the articulated connector.

60. The method according to claim 59, further characterized in that the articulated connector portion is a lower bearing surface of a male portion of the articulated connector.

61. The method according to claim 60, further characterized in that the sections are wedge-shaped sections. nocnnn / rznz / E / YiAi 62. The method according to claim 61, further characterized in that the surface is divided into eight sections.

63. The method according to claim 62, further characterized in that the welding is added to six of the eight sections leaving two opposite sections without welding.

64. The method according to claim 63, further characterized in that it additionally comprises the step of turning the welded sections.

65. The method according to claim 64, further characterized in that it additionally comprises the step of welding the two remaining unwelded sections.

66. The method according to claim 65, further characterized in that it additionally comprises the step of turning the two remaining sections. 67.- The method according to claim 66, further characterized in that it additionally comprises the step of allowing the articulated connector portion to cool to room temperature.

68. The method according to claim 67, further characterized in that said step of allowing the portion of the articulated connector to cool is performed with the portion of the articulated connector covered in insulating material.

69. The method according to claim 68, further characterized in that the insulating material is an insulating box. nocnnn / eznz / E / YiAi 70. The method according to claim 61, further characterized in that welding is added starting at an outer edge of the lower bearing surface and applied radially moving inwards to an opening in the lower bearing surface.

71. The method according to claim 67, further characterized in that it additionally comprises the step of measuring the lower bearing surface to requalify the portion of the articulated connector.

72. The method according to claim 59, further characterized in that the pre-heating step is performed by applying an induction heating cable to the male portion.

73. The method according to claim 72, further characterized in that it additionally comprises the step of providing insulating material between the surface of the male portion and the induction heating cable.

74. The method according to claim 72, further characterized in that the induction heating cable is wound in oval shapes.

75. The method according to claim 59, further characterized in that the articulated connector portion is a male portion.

76. A method for reconditioning a lower bearing surface of a male portion of a hinged connector, the method comprising the steps of: adding weld to the lower bearing surface one octant at a time; turning the welded sections; and allowing the welded sections to cool.

77. The method according to claim 76, 5 further characterized in that it additionally comprises the step of measuring the lower bearing surface to requalify the male portion of the articulated connector.

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