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Carriage - Research Design and Standards Organisation

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Carriage - Research Design and Standards Organisation Powered By Docstoc
					2.                 CARRIAGE DIRECTORATE

                   ‘Recently Completed’ Projects :
2.1                Development of crashworthy design of ICF coach
Project ID:        1.3.03.27.03.017.0.0.04.05
Start Date:        01/04/03
Completion Date:   31/12/06
Deliverables/      Benefits :
Benefits:          In the case of accident
                   1. No or minimum deformation in passenger occupied areas
                   2. No climbing of coaches one over the other.
                   3. Energy absorption in non-passenger areas through controlled collapse
                   4. Low accelerations (decelerations)- To avoid injuries to occupants
                   Deliverable :
                   1. FE Models of existing GS and SLR coaches.
                   2. Component and assembly drawings of the modified design of coaches.
                   3. Instrumentation and test scheme for cras tests.
                   4. Development of Crashworthiness Design Centre at RDSO, with
                       necessary software and hardware
                   5. Training of IR personnel in crash simulation & testing technique.
Current Status:    1. On the basis of test results, design of GS coach has been finalized. A
                       list of drawing has been advised to production units for mass
                       manufacturing of crashworthy GS coach in June 2006.
                   2. Design and drawings of remaining type of ICF coaches except SLR has
                       been issued to Production Units in July 2006.
                   3. Crashworthy SLR design & drawings have been sent to Pus for series
                       manufacturing in November 2006.
                   An approval for closure of the project has been received from Railway
                   Board vide letter No. 96/MI/7/1 dt. 25.6.2007.

2.2                Fitment of Capsule type Shock Absorber in primary suspension in lieu
                   of conventional dashpot
Project ID:        2.5.02.27.03.014.0.0.03.04
Start Date:        01/01/02
Completion Date:   31/03/07
Deliverables/      Benefits :
Benefits:          i. Saving of expenditure due to replenishment of oil
                   ii. Better riding characteristics
                   iii. Maintenance friendly
                   Deliverable :
                    Spec. of suitable shock absorber.
                    Fitment design in the existing bogie
Current Status:    96 GS & SLR type of coaches had been put in service trial by ICF during
                   2005-06.      The feedback and observations reveal the following three
                   problems:-
                   1. Dropping of the bottom pin due to loosening of the securing circlip and
                        consequent damage to shock absorbers.
                   2. Excessive wear on acetal guide bush and consequent rubbing of
                        protection tube with lower spring seat.
                   3. Hit marks on Lower Spring Seat due to over travel of shock absorber
                        caused by excessive loading.
                   The following action have been taken:
                   1. Circlip arrangement has been replaced by locknut and split pin to
                        prevent the drooping of the bottom pin because of loosening of the
                        circlip.
                   2. Self-lubricating guide bushes have been developed to deal with the
                        excessive wear on acetal guide bushes caused by lack of lubrication.
                   3. The problem of overloading has been noticed mainly on services in
                        Northern India and in GS & SLR type coaches. The problem of over
                      travel will be overcome by adopting air springs on GS & SLR coaches
                      and after the trials are successful capsule shock absorber will be
                      provided.
                   Railways have been advised to modify the coaches undergoing service trial
                   to
                    Conventional dashpot oil arrangement where problem of over loading
                      has been experienced.
                    New arrangement of capsule shock absorbers with lock nut and split-
                      pin alongwith self-lubricating guide bushes where the problem of over
                      loading is not there.
                    Pus have been advised to provide the improved arrangement of capsule
                      shock absorbers with lock nut and split-pin alongwith self lubricating
                      guide bushes on 100 coaches each (only on SCN & AC coaches) for
                      extended service trials. In view of issue of final design to Zonal
                      Railways and Pus the project is closed.

                   ‘In-Progress’ Projects :
2.3                High capacity 180 KN air spring for EMU/DMU bogie
Project ID:        2.5.04.23.03.035.0.0.12.07
Start Date:        31/03/04
Completion Date:   30/06/08
Deliverables/      Deliverables :
Benefits:           Development of specifications for higher capacity air springs by RDSO.
                    Procurement of air springs of higher capacity for trial purpose.
                    Manufacture of prototype coaches of EMU and DMU for oscillation
                       trials.
                    Oscillation trials of prototype coaches.
                    Service trials of EMU and DMU coaches provided with these air springs
                       for a minimum of six months followed by joint inspection by RDSO, ICF
                       and Zonal Railway to assess performance.
                   Benefits: Operation of EMUs and DMUs at the standard working pressure
                   of 6Kg/cm2 thereby increasing the service life of air springs and pneumatic
                   equipment as the present practice of raising the feed pipe pressure setting
                   can be discontinued. Further, this provides scope for increase in payload
                   capacity if the need is felt in the future.
Current Status:    1. RDSO STR C-K 406 issued in June 2004 for procurement of air
                       springs. Sources advised for procurement to ICF.
                   2. Prototype HHP DMUs have been manufactured and have completed
                       oscillation trials successfully.
                   3. Prototype EMUs have been manufactured and dispatched to Central
                       Railway. Oscillation trials are in progress.

2.4                Development of air springs for LHB stock
Project ID:        3.5.05.28.03.034.0.0.04.08
Start Date:        31/03/05
Completion Date:   31/03/09
Deliverables/      Deliverable :
Benefits:          1. Specification of air springs for fitment at the secondary suspension of
                      LHB coaches.
                   2. Sources of supply for specified air springs.
                   3. Manufacture of prototypes for oscillation trials.
                   4. Oscillation trials over Mainline and Rajdhani standard track to establish
                      ride behavior.
                   5. Service trial for one year to ascertain performance
                   Benefits :
                   1. Reduction in the great diversity in the number of steel coiled springs
                      presently being used for the LHB coaches particularly due to the
                      manufacture of the indigenous variants.
                   2. Removing bottlenecks in production of LHB coaches, as an air spring to
                      a single specification shall be provided at the secondary suspension
                      over the entire range of LHB coaches.
                   3. The problem of low buffer height and vertical uncoupling has been
                      reported on some of the LHB coaches. With the variable stiffness of the
                      Air spring and it’s ability to maintain a constant height irrespective of
                      the load, the severity of these problems shall be reduced to a great
                      extent.

Current Status:    Extensive simulation studies have been carried out with the entire range of
                   LHB stock, based on which a design of air spring at secondary suspension
                   stage has been evolved. RDSO has developed a specification No. C-K 508
                   for these air springs, which has already been advised to RCF.
                   RCF has been advised to manufacture three prototype coaches for the
                   purpose of detailed oscillation trials along with three sources for
                   procurement of air springs for LHB coaches by this office letter no.
                   SV.AS.ML dt. 30.11.2005. Orders for procurement of air springs have
                   been placed by RCF and prototype coaches are under manufacture.

2.5                Standardization and upgradation of narrow gauge bogie for 610mm
                   gauge
Project ID:        3.3.04.30.03.033.0.0.05.07
Start Date:        01/12/04
Completion Date:   31/03/08
Deliverables/      Deliverable:
Benefits:          1. Study of existing design on NG bogies of 610 mm gauge to finalise the
                      modifications required for improvements in passenger comfort
                   2. Placement of orders based on specifications prepared by RDSO for
                      improved bogies on new coaches.
                   3. Manufacture of prototype coaches.
                   4. Oscillation trials of new coaches to assess ride behaviour.
                   5. Finalisation of improved design by service trials
                   6. Preparation of specifications for procurement of superior bogie designs
                      through tender process.
                   Benefits: Better ride quality and higher speed potential in Darjeeling
                   Himalayan section trains.
Current Status:    RDSO specification No K6-N-01 of February 2006 has been prepared for
                   the purpose of procurement of new bogies and advised to NF Railway and
                   Railway Board.
                   In view of the above, Board has been requested to close the project.

2.6                Standardization and upgradation of narrow gauge bogie for 762 mm
                   gauge
Project ID:        3.3.04.30.03.032.0.0.05.07
Start Date:        01/10/04
Completion Date:   31/03/08
Deliverables/      Deliverable:-
Benefits:           Study of existing design on NG bogies to finalise the modifications
                       required for improvements in passenger comfort
                       Placement of orders on identified sources for supply of improved
                       suspension elements
                    Manufacture of prototype coaches by Northern Railway for oscillation
                       trials.
                    Oscillation trials to assess ride behaviour with new/improved
                       suspension elements.
                    Finalization of improved design by service trials.
                    Preparation of specification for procurement of superior bogie designs
                       trough tender process.
                   Benefits:-
                    Improved ride quality and higher speed potential with existing bogies
                       by upgradation of suspension design.
                      Superior design bogies to be procured through tendering for new
                       coaches.
Current Status:    1. RDSO has suggested measures to improve riding performance in
                      existing design of bogie. Three suspension elements were identified for
                      this purpose are hourglass type rubber spring for primary suspension,
                      friction damper for the secondary suspension and a roll damper
                      (hydraulic) provided between the carbody and bogie to reduce carbody
                      roll motion.
                   2. Sources for procurement of improved suspension elements has been
                      advised to Northern Railway. Supply orders have been placed by
                      Northern Railway and material has been received by Kalka workshop.
                      Prototype is under manufacture.
                   3. As a parallel action, RDSO has made specification for new bogie design
                      (STR K5-B-02 of October 2005). It has been sent to Railway Board for
                      procurement of new bogies for KLK-SML section.

2.7                Development of classical design NG coach with roller bearings and air
                   brakes
Project ID:        3.1.05.30.03.030.0.0.09.07
Start Date:        06/09/05
Completion Date:   31/12/07
Deliverables/      Deliverable: Specification
Benefits:          Benefits: Improved safety
                   Lightweight structure
                   Improved ambience and aesthetic interiors
                   Modern amenities
Current Status:    Specifications have been sent to Board on 30-11-05 for KSR and on 07-04-
                   06 for DHR for procurement action. The specifications for DHR have been
                   revised and sent to Board on December 2006. Coaches for DHR are under
                   manufacture at Kurduwadi workshop.
                   In view of the above, Board has been requested to close the project.

2.8                Development of new NG coach with panoramic windows
Project ID:        3.1.05.30.03.029.0.0.09.07
Start Date:        06/09/05
Completion Date:   31/12/08
Deliverables/      Deliverables : Specification
Benefits:          Benefits : Improved safety
                   Lightweight structure
                   Improved ambience and aesthetic interiors
                   Modern amenities
Current Status:    Revised specification for tourist coaches for DHR alongwith layouts has
                   been finalised on the basis of heritage dtes. comments for operating speed
                   of 50kmph and issued to Board on 4.12.07

2.9                Setting up of fire test lab
Project ID:        1.1.06.27.03.028.0.0.12.08
Start Date:        01/01/06
Completion Date:   31/12/09
Deliverables/      Deliverables : Feasibility study, Technical specification for the fire testing
Benefits:          equipments, Process for fire testing, Specification for fire retardant coach
                   furnishing     material,      Development     of   fire retardant    material,
                   Improvement in fire safety of coaches.
                   Benefits : Fire test facilities will help in development in fire worthiness of
                   coaches. Fire accidents and consequent fatalities will be reduced by 80%
                   by adoption of fireproof coaches and fire retardant material in the existing
                   coaches. The value of human lives saved and the improvement in the
                   corporate image of Indian Railways in public cannot be assessed in terms
                   of money. The fire testing lab developed can also provide its services to the
                   industry manufacturing the coach furnishing materials, textile industry
                   and building material industry for testing their materials, thereby, earning
                   revenue.
Current Status:    A proposal for setting up of fire testing laboratory was presented to GCM,
                   which has directed to review it in the same meeting. Project has been
                   reviewed and only consultancy part of it being taken up first. The project
                   has been sanctioned under DG’s power after finance vetting. After detailed
                   estimate vetting, global tender has been invited. Tender has been opened
                   on 15.1.2008. Briefing note is under preparation.

2.10               Development of Soft side buffers for CBC equipped coaching stock
Project ID:        3.1.06.27.03.027.0.0.12.06
Start Date:        19/01/06
Completion Date:   31/03/08
Deliverables/      Deliverables :
Benefits:           Design and spec of soft side buffers compatible with IR coaching CBCs
                       and operating pattern.
                    Development of prototypes and field trials on one rake.
                   Benefits : Will pave way for complete switch to CBCs with its associated
                   benefits.
Current Status:    Use of soft side buffers with CBC to reduce the effect of longitudinal jerks
                   taken up as a fresh project. the indigenous developed soft side buffers has
                   been put on one rake of Tamil Nadu Express. Soft buffers for LHB coach
                   had been developed. The supply to RCF is expected by Feb 2008. The
                   buffers will be put on trials on newly manufactured coaches.

2.11               Development of crashworthy design of LHB type coaches
Project ID:        1.5.06.28.03.024.0.0.06.07
Start Date:        16/03/06
Completion Date:   15/10/08
Deliverables/      Deliverable : Crashworthy design of LHB Type GS coach.
Benefits:          Benefits : In the case of accident
                    No or minimum deformation in passenger occupied areas
                    No climbing of coaches one over the other.
                    Energy absorption in non-passenger areas through controlled collapse
                    Low decelerations to avoid injuries to occupants
Current Status:    Development of FEM model, crashworthy behavior of existing design
                   through computer simulation completed, design optimization is under
                   progress. A crashworthy design of LHB coach has been developed.

2.12               Development of Fire Retardant Coaches
Project ID:        1.3.04.27.03.022.0.0.03.06
Start Date:        01/03/04
Completion Date:   30/12/08
Deliverables/      Deliverables : Development of fire retardant materials for coach
Benefits:          construction and furnishing.
                   Benefits :
                    Prevent loss of human lives due to fire accidents.
                    Saving Railway assets from accidental fires
Current Status:    All specifications of coach furnishing materials including UIC vestibule
                   have been issued.

2.13               Development of environment friendly          Toilet Discharge System in
                   coaches
Project ID:        7.3.05.27.03.023.0.0.12.08
Start Date:        01/08/05
Completion Date:   31/12/08
Deliverables/      Deliverables :
Benefits:               Development & design of the proposed toilet system for adoption on
                         new & existing coaches.
                     Manufacture and testing of prototype.
                    Benefits : Discharge on track and in station will be eliminated. Water will
                    be recycled to be used for toilet flushing. Possibility of corrosion due to
                    effluents is eliminated.
Current Status:     A project to develop an environment friendly toilet system is going on along
                    with IIT/K. The model being developed by IIT/K is based on separation of
                    solid and liquid matter, suitable treatment of liquid using membrane
                    technology, recycling the liquid for flushing and retention of solid residue
                    till the end of journey where it will be evacuated and converted to manure.
                    The first prototype is under fabrication and is likely to be put on a coach
                    for service trial by March 2008 end. The coach will be put on 2623/24
                    Chennai Thiruvananthapuram Mail for field trials. During the trial the
                    evacuation will be arranged by the industry partner using a mobile
                    evacuation system.
                    As a parallel action the specifications for biological toilets were also made
                    by RDSO and sent to Board in May 2005. Order for 80 Biological Toilets
                    have been placed on M/s. Aikon Technologies, Faridabad who have tied up
                    with Microphor, USA. The first prototype has been provided on a WGACCN
                    coach no. NR 6149C in Prayagraj express since 17.05.2007 and has now
                    been placed in AP Express 2723/2724 by N. Rly. All the 80 toilets have
                    now been provided on a new rake from RCF and put in service on NDLS-
                    Rewa express 2427/2428. Vacuum toilet specifications were finalized in
                    November 2006. Board floated a global tender for design, development,
                    manufacture, supply, installation, commissioning, maintenance and
                    operation of the Vacuum Toilet System in Coaching Stock on IR. Technical
                    scrutiny of the offers received has been done and sent to Board on 20.2.07.

2.14                Air Springs for main line ICF bogies
Project ID:         3.5.04.27.03.007.0.0.11.07
Start Date:         24/05/04
Completion Date:    30/04/08
Deliverables/       Benefits :
Benefits:           1. Much superior ride comfort as predicted by simulations. Particularly
                       notable improvement in lateral ride quality.
                    2. Overcoming problems of low buffer height due to constant height of air
                       spring.
                    3. Overcoming problems associated with overloading on GS coaches.
                    Deliverable :
                    Design of suspension proven by oscillation and service trials with a single
                    variant of air spring for the entire range of ICF type stock.
Current Status:    1. RDSO has successfully conducted oscillation trials of mainline ICF coach
                       of EOG type. Two such coaches – one power car and one AC chair car
                       are presently undergoing service trial over Southern Railway:
                   2. For the SG variants of mainline ICF coaches, One GS coach has been
                       successfully subjected to oscillation trial over mainline standard track.
                       Trials on Rajdhani standard track shall be carried out shortly. RCF has
                       been instructed to manufacture one 3-tier AC SG prototype coach for
                       oscillation trial, which is in progress.
                   3. Extensive simulation studies have been carried out with the entire
                       range of LHB stock, based on which a single air spring at secondary
                       suspension stage has been designed and RDSO’s Specification CK – 508
                       developed. RCF had been advised to manufacture three prototype
                       coaches for detailed oscillation trail along with source of procurement of
                       air springs. Orders for procurement of air spring has been placed and
                       one coach set had already been received at RCF. Prototype coaches are
                       under manufacture at RCF.
                   4. On the instructions from Railway board, RCF has manufactured on AC
                      3 tier SG coach with LHB shell and ICF bogie provided with air springs.
                      This coach has successfully completed oscillation trials. Preparations
                      for oscillation trials of future variants are being made at RDSO. Board
                      has instructed RCF to manufacture one GS coach with this
                      configuration for oscillation trials.

2.15               Fitment of Centre Buffer Coupler on ICF coaches
Project ID:        1.3.00.27.03.003.0.0.12.02
Start Date:        20/01/00
Completion Date:   31/03/09
Deliverables/      Benefits :
Benefits:          1.    Enhanced safety of passengers.
                   2.    Reduction in maintenance costs.
                   3.    Increased passenger earnings due to haulage of longer trains.
                   Deliverable :
                   Design and specifications of CBC for coaching stock
Current Status:    1. Key, drawings, Squeeze Test Scheme, etc. sent to ICF.
                   2. Specification for procurement of CBCs prepared.
                   3. CBC Tender finalized and supply received.
                   4. The CBC specification has been revised in view of service experience
                      gained so far.
                   5. On advise from Railway Board, the project was continued to dealwith
                      problem of longitudinal jerk.
                   6. Use of soft side buffers with CBC to reduce the effect of longitudinal
                      jerks taken up as a fresh project. the indigenous developed soft side
                      buffers has been put on one rake of Tamil Nadu Express. Soft buffers
                      for LHB coach had been developed. The supply to RCF is expected by
                      Feb. 2008. The buffers will be put on trials on newly manufactured
                      coaches.
                   7. A new design of draft gear offered by M/s Dellner, Sweeden is also being
                      evaluated. RCF has placed an order for 60 nos on m/s Dellner. DP
                      31.12.2007, extended by 6 months.

				
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