PRESENT STATUS

AT PRESENT, INDIAN RAILWAYS IS USING COACHES OF TECHNOLOGY ACQUIRED IN 1955 THE TECHNOLOGY WAS FURTHER DEVELOPED INDIGENOUSLY AND MANY VARIANTS WERE DESIGNED: AC 3 TIER BEING THE LATEST AND MOST POPULAR ADDITION HOWEVER, THE TECHNOLOGY HAS REACHED THE PLATEAU AND BASIC DESIGN REMAINED THE SAME

OBJECTIVES OF THE NEW TECHNOLOGY

HIGHER SPEEDS  160 KM/H WITH POSSIBILITY OF UPGRADATION TO 200 KM/H COMFORTABLE RIDE  RIDE INDEX OF 2.5 LIGHT WEIGHT  39 TONNE FOR AC CHAIR CAR SHELL  CORROSION FREE HIGHER AVAILABILITY  REDUCED MAINTENANCE IN DEPOT  INCREASED PERIODICITY OF POH

INDUCTION OF NEW COACH TECHNOLOGY

IN NOV, 1995 IR SIGNED THE SUPPLY AND TECHNOLOGY TRANSFER CONTRACT WITH M/S ALSTOM LHB THE CONTRACT INCLUDED SUPPLY OF 24 COACHES CONSISTING OF 19 AC CHAIR CARS, 2 EXECUTIVE CHAIR CARS AND 3 POWER CARS TRANSFER MANUFACTURING KNOW-HOW FOR THESE HELP IN DESIGNING AND MANUFACTURING FIRST AC, AC SLEEPER AND HOT BUFFET COACH HELP INDIAN RAILWAYS IN DEVELOPING SG VERSION OF THESE COACHES

 

SOME RELATED ISSUES

24 COACHES INCLUDING 2 EXECUTIVE CHAIR CARS AND 3 POWER CARS RECEIVED IN 2000 ALL STATUTORY TESTS COMPLETED AND CRS SANCTION RECEIVED IN MARCH, 2001 INTRODUCED AS SHATABDI EXPRESS BETWEEN NEW DELHI AND LUCKNOW ON 29-5-2001 CERTAIN PROBLEM NOTICED WITH CBC AND RAKE WAS WITHDRAWN FROM SERVICE ON 25-6-2001. REINTRODUCED ON 9-1-2002 MANUFACTURING KNOW-HOW RECEIVED, MANUFACTURING STARTED ALL THE THREE VARIANTS DESIGNED AND MANUFACTURING DOCUMENTS FINALISED

A FEW COMPARISIONS BETWEEN ICF VS LHB COACH

Limitations of ICF bogie Design

Required longitudinal and transverse flexibilities at frame-axle joint can not be obtained. Vertical space constraints to accommodate longer secondary suspension springs. Non availability of friction damping in the transverse suspension. Headstocks increase the yaw inertia of the bogie. Large wheelbase affects curvability / Wheel flange wear.

Ride Index
ICF 2.6 at 160 kmph in vertical modes and 3.4 / 3.5 at 160 kmph in lateral mode FIAT Ride index shall be 2.5 but not exceeding 2.75 both in vertical and lateral modes

Speed potential LHB Test speed 180 kmph Service speed Oil leakage problem 160 kmph No

ICF 160 kmph 140 kmph Very high

Shop Attention Schedule 1st attn 2nd attn ICF 9 months/2 lakh kms (ioh) 18 months/4 lakh kms (poh) LHB 18 months / lakh kms 36 months/ lakh kms 5 10

NO PAINTING REQUIRED FOR 6 YEARS

Bogie Frame
ICF Box type with headstock FIAT H type boxes construction without headstock

Two side frame of Y Shaped longitudinal beam connected by two tubular steel members

Bogie Frame

Wheel Diameter

ICF New: 915 mm Condemned: 813 mm

FIAT New: 915 mm Condemned: 845 mm

Wheel Base

ICF 2896 mm

FIAT 2560 mm

Less Wheel-base improves its ability to negotiate curves

Maximum distance between Inner Wheel

ICF 11887 mm

FIAT 12345 mm

Bearing Arrangement
ICF Spherical roller Bearing FIAT Cartridge tapered roller bearing

Lesser maintenance attention

Bearing Arrangement
ICF FIAT

Bogie Frame Axle Joint

Longitudinal and transverse flexibilities of the axle can be optimised independently.

Bogie Frame Axle Joint

Primary Suspension Unit

More reliable and maintenance free as compared to dash pot.

Secondary Suspension Unit

Bolster
ICF FIAT

Bogie - Body Joint

Bogie Body Joint of ICF

Bogie - Body Joint of FIAT

Bogie - Body Joint of FIAT

Bogie - Body Joint of FIAT

Brake System
ICF Clasp type brake FIAT Axle mounted disc brake

Reduces wheel tread wear Suitable for offer higher braking force Require lesser maintenance

Brake System
ICF FIAT

Clasp type brake

Disc Brake

SALIENT FEATURES OF LHB DESIGN COACHES

SALIENT FEATURES OF LHB DESIGN COACHES

  

STAINLESS STEEL USED FOR SIDEWALL, ENDWALL AND ROOF TO REDUCE CORROSION LIGHT WEIGHT SHELL WITH INTERLOCKED SIDEWALL FRAME AND CORRUGATED ROOF IMPROVED RIDE INDEX FITTED WITH CBC HAVING ANTICLIMBING FEATURE LONGER COACH WITH HIGHER CAPACITY

SALIENT FEATURES OF LHB DESIGN COACHES

    

ERGONOMICALLY DESIGNED SEATS AS PER INDIAN ANTHROPOMETRIC DATA LARGE WINDOWS WITH GOOD VISIBILITY AUTOMATIC CLOSING TRANSITION DOORS BI-FOLDING LAVATORY DOORS CONTROLLED DISCHARGE TOILETS MICROPROCESSOR CONTROLLED AIRCONDITIONING WITH HUMIDITY CONTROL

SALIENT FEATURES OF LHB DESIGN COACHES

 

 

SIDE WALLS AND CEILINGS MADE OF GLASS-FIBRE REINFORCED POLYESTER NO VISIBLE SCREWS IN THE INTERIOR READING LIGHTS FITTED LUGGAGE RACK MADE FROM ALUMINIUM EXTRUSIONS ENTRANCE AREA PANELING OF HPL TOILET COMPARTMENT MADE OF GLASS FIBRE REINFORCED POLYESTER WITH CORUNDUM SURFACE

SALIENT FEATURES OF LHB DESIGN COACHES

 

 

SALIENT FEATURES OF LHB DESIGN COACHES

BOGIES WITH FLEXICOIL SPRINGS,YAW DAMPER, LATERAL DAMPER AND ANTIROLL BAR SILENT BLOCKS USED IN PRIMARY AND SECONDARY SUSPENSIONS AND STOPS TO CUT OUT NOISE AND JERKS INCREASED COACH AVAILABILITY DUE TO REDUCED MAINTENANCE

A FEW PHOTOGRAPHS

TIG WELDING ON EXISTING BUTT SEAM WELDING MACHINE

SPOT WELDING OF FRAME ON SIDE WALL SHEET

ROOF BEARER WITH SIDE WALL SHEET

HEAD STOCK

UNDER FRAME

ROOF

ROOF FROM UNDERNEATH

END WALL

SHELL

SAND BLASTING

COACH UNDER FURNISHING

INTERIOR UNDER FURNISHING

CORRUGATED ROOF

COUPLER

TRANSITION DOORS

CONTROL DISCHARGE TOILET

LUGGAGE RACK

MODULAR TOILET

FLOORING PANELS
MACORE WOOD

CORK

MACORE WOOD

BOGIE

RUBBER BONDED METAL COMPONENTS

LONGITUDINAL BUMP STOP (0.67 kg) CENTRE PIVOT SILENT BLOCK (3.3 kg)

ELASTIC CONNECTION (20 kg) SILENT BLOCK FOR ANCHOR LINK (3.5 kg)

Sl

Dimension/ feature

LHB/FIAT coach

ICF AC Chair car

1.

Gauge

1676 mm

1676 mm

2.

Length over body

23540 mm

21340m

3.

Buffer-centres (if buffers provided)

1956 mm

1956 mm

4.

Maximum width over body

3250 mm

3245 mm

5.

Height of centre-line of coupler from raillevel under tare condition

1105 mm

1105 mm

6.

Height of compartment floor from rail-level under tare condition

1303 mm

1313 mm

Sl

Dimension/ feature

LHB/FIAT coach

ICF AC Chair car

1.

Maximum distance between inner wheels

12345 mm

1189 mm

2.

Maximum buffer-drop under gross load and worn condition

75 mm

75 mm

3.

Maximum height of centre-line of sidebuffers above rail-level for empty vehicles

1105 mm

1105 mm

4.

Minimum height of centre-line of side-buffers above rail-level for loaded vehicles

1030 mm

1030 mm

5.

Maximum height of centre of screw-coupling above rail-level for empty vehicles

1055 mm

1054 mm

6.

Maximum tare weight for AC chair car with all supplies in working order, including water

39 t

43.1 t

7.

Maximum axle-load permissible

16 t

16 t

Sl

Items

ICF all coiled

Fiat Bogie
6.536 t.

1.

Weight of the Bogie.

6.2 t.

2.

Speed cleared for.

140kmph

160kmph.

3.

Wheel Base.

2896 mm.

2560 mm.

4.

Bogie frame.

Box type with headstocks.

H-type boxes construction.

5.

Wheel diameter.

915 mm (New) 813 mm (Condemned)

915 mm (New) 845 mm. (Condemned)

6.

Brake.

Clasp type brake.

Axle mounted disc brake.

Sl

Items

ICF all coiled

Fiat Bogie
Air.

7.

Braking system.

Vacuum & Air.

8.

Type of bearing at journal

Spherical roller bearing.

Cartridge tapered roller bearing.

9.

Suspension vertical (Axle level).

Coil spring with dashpot arrangement.

Coil springs are nested.

10.

Axle guidance.

Rigid.

Articulated by control arm.

11.

Noise feature.

Limited noise control feature.

Isolation of noise from bogie to coach body connection.

12.

Position of secondary spring.

Secondary spring on lower spring beam through hangers.

Secondary spring directly mounted on side frames.

Sl

Items

ICF all coiled

Fiat Bogie
No leakage

13.

Oil leakage problem.

Very high.

14.

Coach load transfer.

100% through side bearers.

100% transfer through body bogie connection.

15.

Traction & shock load transfer.

Through centre pivot.

Through pivot assembly on transverse beam and bracket on doom.

16.

Anti roll bar arrangement.

Not provided.

Provided.

17.

Ride index.

2.6 at 160kmph in vertical modes and 3.4 / 3.5 at 160kmph in lateral modes.

Ride index shall be 2.5 but not exceeding 2.75 both in vertical and lateral modes.

Sl

Items

ICF all coiled

Fiat Bogie
Very little due toDisc brake. Cartridge tapered roller bearing. Bogie frame, springs and rubber components. Wheel with improved curving characteristic.

18.

Maintenance requirement in POH.

More due toAxle box guide arrangement. Spherical roller bearing. Clasp brake. More pin joints.

19.

Maximum distance between inner wheels.

11887 mm.

12345 mm. 12340 mm (Proposed)

17.

Ride index.

2.6 at 160kmph in vertical modes and 3.4 / 3.5 at 160kmph in lateral modes.

Ride index shall be 2.5 but not exceeding 2.75 both in vertical and lateral modes.

19.

Maximum distance between inner wheels.

11887 mm.

12345 mm. 12340 mm (Proposed)

Thank you