ICF Coach ComponentsICF Coach Components

Jogendra Yadvendu Dy.CMM-MTN, CR yadvendu@gmail. com

Virtual WareHouse !The dilemma Materials Management or a stores Cader ?Materials Management sounds impressive !Do we know the product we buy day in and day out ?Have we seen the product ?Well, this is not really a part of my jobMy job is to tender & place purchase order.

How many times we call for the drawing, study it and only then float a tender ?

How many times the T.C. has the knowledge of the product it is deliberating about ?

A stores guy has an idea about the product. A materials manager knows the product.

The Dust Bin !The Dust Bin ! We all have an idea about the dustbin used in

coaches Do we know the dust Bin ? Purchased as per ICF Drg No WGSCWAC-6-

4-005 ALT. l/4 There are total 49 sub components in it. Yes 49

! Majority of the components are of IS: 2062

steel

Some components such as Pedal Lever & pedal end piece is of IRS M41

Which fabricator will obtain IRS M41 steel for the few components ?

Result: Either a vigilance case or harassment to the vendor

Why not change the material spec for the Dust Bin.

Well, that’s not my Job !

The DustBin

Virtual WarehouseVirtual Warehouse The writing is on the wall ! No awards for guessing ! There is limited or no attempt to know the

product before tendering or at the time of placement of order !

Common refrain: Time nahi hai ! Locomotive sheds/ Workshops are not far away. Will is lacking to know the product. It is not considered important

Virtual WarehouseVirtual Warehouse Busy officers not able to go to the

shed /Workshop to see the product. An attempt has been made to bring the

product to the confines of Air Conditioned environs .

Why know the components ?Why know the components ?Most purchase officers are trained engineers.However, most officers cannot identify the item

they are buying.Totally dependent on decision of user

department for very basic issues.No role in vendor development.No role in inspection of stores at depot levelHence , the non technical Tag.No professional satisfaction.

Materials Management or Stores ?Materials Management or Stores ? Stores ? Warehouse Manager ? Clerical ? Materials Manager: Knows about Material Types of steels , Rubber & Why to use a particular one. What is the component ? Where is it used ? Why does it need replacement ? How Can the frequency of replacement be reduced ?

Is there a better material available ? Best time to learn is when there is a crisis.

How does one start ?How does one start ?Go to the basics.Macro to micro. Assemblies to Sub Assemblies.Sub Assemblies to components.25 KV to movement of a wheelLoad transfer in rolling stockTransfer of Buffing Gear forces in a rolling stockNo one is too old to learn.

What is the minimum web thickness of the ICF Wheel ?

A. 50 mm B. 150 mm C. 250 mm D. 350mm E. > 350 mm

What about LHB Wheel ?

Wheel ProfileWheel Profile

Minimum Web Thickness of Minimum Web Thickness of WheelWheel

ICF : 19 mm

LHB: 13 mm

What is the difference ?What is the difference ?

Lower Spring SeatTop Spring Seat

ICF BogieICF Bogie

Main Assemblies in ICF BogieMain Assemblies in ICF Bogie Bogie Frame Bogie Bolster Primary Suspension Secondary Suspension Axle Box Housing Lower Spring Beam Center Pivot Arrangement Anchor Link Assembly Wheel Set arrangement Brake Beam Assembly Axle Pulley & Alternator arrangement

Bogie FrameBogie Frame

Bogie FrameBogie Frame

Fabricated structure made up Mild steel channels and angles welded to form the main frame of the bogie.

Divided into seven sections. The central section has Bogie Bolster at the bottom & connects the Body Bolster of the coach through the center Pivot

Various types of brackets are welded to the frame for supporting bogie components.

Mechanical code silent about bogie condemnation.Bogie POH periodicity reduced to 9 months.

Bogie Bolster

Bogie BolsterBogie Bolster

Bogie BolsterSide Bearer HousingBronze wearing PieceWearing PlateBrackets for Anchor Link-Design Issue.Silent Block for center Pivot-HistoryCenter Pivot Sleeve-

Primary Suspension

Primary SuspensionPrimary Suspension Axle Box Housing-Design Changes Washers- Hytrel or Rubber-Case Study-Delrin ? Lower Spring Seat- Honning Axle Box Spring- Three categories Dashpot Cover- Shop Practice Axle Box Guide- Two Holes,cap Guide Bush- Development Guide Ring Circlip- Rubber Packing Ring Air Vent Screw

Axle Box Guide ArrangementAxle Box Guide Arrangement

Secondary SuspensionSecondary Suspension

Secondary SuspensionSecondary Suspension Bogie Bolster Lower Spring Beam-Plank-AC & NAC Rubber Washers- Upper & Lower-

Hytrel Secondary spring Shock Absorber: 600 & 900 Kg. ? Flange for Shock Absorber Equalizing Stay Rod- 13 T & 16 T Anchor Link- Shop Practice Silent Block for Anchor Link- History

Axle Box Arrangement

Axle Box HousingAxle Box Housing Collar for DM Roller Bearing Rear cover for Axle Box- V Groove Labyrinth Ring Nitrile O Ring Woolen felt- Density Issue Bearing End cap Locking Plate Locking Bolt Front Cover- History & Practise Front cover Bolts

Front & Rear Cover Assembly

Lower Spring Beam

Lower Spring Beam AssemblyLower Spring Beam Assembly

Trapezoidal SectionFabricated MemberConnected to Bogie Frame with BSS HangerConnected to Bogie Bolster with Anchor LinkReceives vertical load of coach through bogie

Bolster & secondary springsTransfers load to Bogie Frame through BSS

Hanger.

Center Pivot AssemblyCenter Pivot Assembly

Center Pivot AssemblyCenter Pivot AssemblyNo vertical load transfer.Acts as a center of rotationTransmits tractive/Braking

forces onlyCenter PivotSilent Block for center PivotCenter Pivot Sleeve

Anchor Link Arrangement

Anchor Link arrangementAnchor Link arrangement

Consists of Anchor Link & Silent BlockSeamless tube welded with Cylindrical

housing Anchor link Bracket for Bogie Bolster &

Bogie Frame.Holds the Bogie Bolster to the Bogie

FrameTwo anchor link per BogiePermits Bogie Bolster to rise , fall & sway.

Wheel Set assemblyWheel Set assemblyWheel AxlePulley Rubber Pad- Historical DataV Grove Pulley: 4 & 6 GroovePulley Bolts- Karnavati Accident V Belt

Brake Beam AssemblyBrake Beam Assembly

Brake Beam AssemblyBrake Beam AssemblyBrake Beam: 13 T & 16 T-- MythBrake Head- Types Brake Block- TypesBushes: Nylon & Phenolic ( Issues )BracketsSafety wire rope (Rajdhani ?)Block Hanger

Draw Gear ArrangementDraw Gear Arrangement

Draw Gear ArrangementDraw Gear ArrangementDraw Hook Draw Bar with castle NutDraft KeyScrew CouplingDraw Bar SpringsYokeYoke Housing

Draw GearDraw GearScrew Coupling- SparesDraw Hook – 60 to 75 TonDraft YokeDraft KeyDraw Bar & Castle NutRubber Buffer SpringManufactured from IS:5517-93 Grade 35

Mn6Mo3. Proof Load 75 TonBreaking Load 130 Ton

Contd.Contd.Specially heat treated to obtain the desired

strength. Not to be heated above 550 deg. No tempering allowed.

Only yoke can be reclaimed. No reclamation of any draw gear

components permitted.Load application gradual, hold for 2

minutes. No permanent set .No creep motion permitted. In pins and

oblongity in holes.

Buffer HeightBuffer HeightMaximum height from rail level(Loaded)MAX- 1105 mmMIN - 1090 mmReason for different Buffer Heights ?A. Wheel tread wear .B. Different Types of Springs (Green, Blue,

Red)Adjustment- How ?Use compensating Ring & Packing Ring.

Buffer Height AdjustmentBuffer Height Adjustment Use Packing Ring under the flange of Lower Spring

Seat. Lowest wheel diameter permissible is 836 mm. Compensating ring to be used based on the tare weight. Check for height of bolster top level from the rail level. Provide packing ring below the axle spring if Buffer

height requires further adjustment. Total height of Axle spring and compensating ring <

295 mm. Minimum clearance of 40 mm between the Axle box

wing lug & Safety strap

Rolling GearRolling Gear

Wheel. Drawing No. W/WL/1660. Spec. IRS R-19/93 Part II

Axle Roller Bearing 22326 / C3 130 mm bore

Rolling Gear ComponentsRolling Gear ComponentsEnd Locking PlateEnd Locking BoltFelt Ring- Why Important ?Retaining RingCollarRear & Front Cover- Historical DataAxle Box Housing- Case of Hytrel Washer

Roller BearingRoller BearingOuter Race, Barrel Rollers, Inner RaceSelf Aligning properties.Can take care of radial, axle, complex

loads. Suitable for Vibrations & Shocks.130 mm bore dia.Dismount every POH or 2 Lakh Km.

Air Brake SystemAir Brake System

6

6

5

5

Air Brake Components Air Brake Components Feed Pipe Brake Pipe Common Pipe Bracket Intermediate Piece Cut off Angle Cock Three way dirt Collector Brake Cylinder- BMBC & N-BMBC Auxiliary Reservoir Distributor Valve Isolating Cock PEASD PEAV Check Valve

Principle of Air BrakePrinciple of Air BrakeFP Pressure 6 Kg./Cm Sq.Auxiliary Reservoir 6 Kg./Cm Sq.BP Pressure 5 Kg./Cm Sq.Control Reservoir 5 Kg./Cm Sq.Braking by dropping air Pressure in B.P.

Brake ApplicationBrake ApplicationHow.Control Reservoir Disconnected from B.P.D.V. connects the Auxiliary Reservoir to Brake

Cylinder & Brake cylinder piston moves out.Auxiliary Reservoir is continuously charged with

6 Kg pressure from F.P.

Brake ReleaseBrake ReleaseRecharge B.P with 5 Kg pressure through

drivers brake ValveD.V. isolates brake cylinder from Auxiliary

reservoirBrake cylinder Piston moves inwards.

Common Pipe Bracket & Intermediate PieceCommon Pipe Bracket & Intermediate Piece

Common Pipe Bracket: Mounted on under frame & suitable for all types of D.V.

Intermediate Piece: Mounted on CPB to fit D.V on CPB.. Blanks all holes on CPB other than required for a particular D.V. IP is specific for each D.V.

Air Brake HosesAir Brake HosesF.P Hose: Maintains connectivity along the

train.F.P. : WhiteB.P. Green.Testing at 10 Kg./ Cm2

BMBCBMBC8 “ instead of 14” Brake CylinderFour BC per coach instead of 2 earlier.External Slack adjuster removedK type Brake Blocks used.Cylinder has built in slack adjuster.M.A. of 7.644 & 8.40 for NAC & AC

Coach.15 mm pneumatic pipe.

Brake BlocksBrake BlocksLow friction composite Brake Blocks.Uniform coefficient of friction. 0.25 for k Type &

0.15 for L type.Reduced wear. Max 12 mmLess noise.Less weight

Brake Head with Brake Block & Brake Shoe KeyBrake Head with Brake Block & Brake Shoe Key

Brake HeadBrake Head•Brake Head holds the Brake Block•Brake Shoe Key is used for mechanical interlocking•Two types of Break Head based on the Brake Block.•L type Brake Blocks use ICF Brake Head•K Type Brake Blocks use IGP Brake Head

Brake Block ComparisonBrake Block ComparisonParameters Type of Brake Blocks

L K CIApplicability Under frame

B.C.BMBC V.B. & Under

Frame B.C. Speed 110 KMPH 110 KMPH 140 KMPHCoefficient of friction

0.13 0.25 0.13

Weight 3 Kg. 3 Kg. 9 Kg.Braking Distance(110 KMPH, 18 C)

905 800 905

Weight reduction 492 Kg.No of Pins 102 843 Kg. 102

Inner & Outer Head Stock

Draw Gear ArrangementDraw Gear Arrangement

Head stockHead stockHead stock : Two Types. Inner & Outer

connected by Center Buffer Stiffener- Hole ?Under frame supports various equipmentsEnd section has four vertical pillars of box

sectionThey are connected transversely by Z section

members

Draw Bar with Draft Key Draw Bar with Draft Key

Floor DetailsFloor Details

Shell Components-Under Shell Components-Under FrameFrame

Sole Bar- Negative Camber Outer & Inner Head StockTurn Under (Why Oblong Holes)Body Pillar – RH & LHTubular FrameTrough Floor – MS to SS

Body Pillar, Sole Bar & Turn UnderBody Pillar, Sole Bar & Turn Under

Buffing GearBuffing Gear

Buffing GearBuffing Gear•Buffers of 1030 Kg-m Capacity used to IRS-M 10 Spec.

•Buffer Assembly•Buffer Casing- Cracks on line•Buffer Plunger: Repair Practice•Rubber Buffer Pads- Single pad to G4•Buffer Spindle•Destruction Tube•Recoil Spring •Recoil Spring Parting Plate•Recoil Spring Washer•Buffing Spring Parting Plate•Face Plate- Hardfacing & Hytrel•M24 Hex Head Bolt.

ShellShell

Made of a framework of hoops, x beams, BSP, roof Car lines, .

Longitudinally by sole Bar, Waist Rail, CAR Rail. 2mm CR sheet makes the skin. 1.6 mm CR sheets makes the roof. 2mm CR corrugated trough floor is used. Tubular structure provided in place of trough floor

at the lavatory area.

Shell Components- Super Shell Components- Super StructureStructure

TRA Ventilator ?Door HandlesDoor Pivot- 100 day sick markingBody Bolster- Repair Center PivotWater Tank- 2 piece Floor Channel- MS to SS

PaintingPainting Paint Schedule “A” Paint remover-Strip to bare metal every 5th POH Use petroleum solvent to remove paint remover IS: 1745 Sand paper Red oxide zinc chromate IS: 2074-92 DFT 25 micron. 1st coat of brushing filler IS:110-83 , DFT 30 micron Apply knifing stopper putty IS 5083: 88, sport application & wet

rubbing Second filler coat IS:110-83 DFT 30 micron Wet rub with Bone Cuttle & emery paper SiC 120 & 220 No. Under coat IS: 8662-93 DFT 25 micron Rub with 320 paper & enamel IS: 8662-93 Rub 400 No paper , Second coat IS:8662:93 DFT 20 micron

Train LighteningTrain Lightening

BG Coach

EOG SG MOG

SUUnder slung

RMPU AC NAC

SUUnder slung

RMPU with 25 KV Alternator

Battery Box

Fabricated from MS Sheets & Angles with FRP Trays

BCT Battery Charging Terminal provided on Both end of the Coach for external Charging

RJB Rotary Junction Box in the coach for control & power supply to various equipments

EFT Emergency Feed Terminal at both end of the coach to feed additional supply to adjacent coach in case of emergency

TL Lamp 25 W& 40 W lamps.20 W , 110 V DC Tubelight

Axle & Alternator Pulley with V Belt & Alternator

Air-conditioning EquipmentAir-conditioning Equipment Axle Pulley- Two Halfs V Belt Alternators 4.5 & 25 kw Battery & Battery Box 120, 800, 1100 AH, Compressor & Condenser Motor Evaporator Motor Compressor – Maneurope & Scroll Condenser Dehydrator & Liquid Receiver Filters- Thermostats- RMPU Panel Board Pre Cooling Unit

AlternatorsAlternators

Type of Coach Alternator Type

Non AC Coach 4.5 KW, 37.5 A, 120 V DC

SG AC Coach 18 KW, 138.5 A, 130 V DC X

SG AC Coach 22.75/ 25 KW, 175/195 A, 130 V DC

TL ComponentsRRU Rectify 3 P AC output of Alternator through

DC Full Wave Bride Rectifier & regulate output current

Battery 6V, 120AH-Non AC BG SG Coach2V, 120 AH, VRLA on NAC BG SG 2V, 1100 AH, 56 Cell, VRLA , 110 V on coaches with RMPU2V, 800 AH, Flooded Type on Under Slung Split AC 120 AH, 24 V on EOG AC

Shop Manufactured ItemsShop Manufactured Items•32 mm Plate•Anchor Link Bracket for Bogie Frame•Anchor Link Bracket for Bogie Bolster•Pull Rod•Thickener for Alternator Bracket

25 mm PlateBottom Pivot for BEML CoachYoke Bracket for trimmer Bar

•20 mm Plate•Lever Hanger Short •Lever Hanger Long•Vertical Lever•Hinge for Flap Door•Milk Tanker Center Pivot Base Plate•Face Plate for Buffer Plunger•Center Pivot Cotter

16 mm Plate16 mm PlateBogie Alternator Bracket Support Plate

Holding Device for Vestibule Foot PlatePacking Plate for Draft LinkHorizontal Levr for Power Car

12 mm Plate Plate for Destruction Piece Hinge for NMG Closing Palte for AB Guide Lever for Hand Brake Pull Rod Support plate for Vestibule Foot Plate

Compensating RingBrake Cylinder Bracket Buffer Head Stock patchIGP Brake Head Stopper PiecePacking Plate for AB HousingInner Head StockBase PlateTrimmer BarModified Brake Head PieceFulcrum Bracket

10 mm Plate

Equaling Stay Rod Bracket Side Plate Head Stock Buffer Head Stock Patch Eye Piece for UIC Vestibule Compensating Ring Buffer Bolt Stiffner Battery Box Knee Side Berth Pivot Plian washer for rubber Bump Stopper Bend Plate for side bearer Packing Plate for AB Housing

8 mm Plate

Water Tank Support Bracket Lug for Brake Beam Safety Strap Comensating Ring Wire Rope Bracket Common Pipe Bracket Stiffner Angle for Sole Bar Formed Channel C Channel

6 mm Plate

5 mm PlateSole BarEqualizing Stay Rod BracketHead Stock Inner C & U ChannelRib of Brake Cylinder BracketCommon Pipe Bracket PlateHinges for Seat BerthAngle for Vestibule Foot PlateBrake Beam PlateCollar of Protective TubeClip for Anchor Link Bracket

Water Tank for BEMLVacuum Reservoir for Double DeckerCenter Pivot Top PlateFoot Step for ICF C & U TubeCenter Pivot Cap

3.15 mm Sheet

2 mm Sheet Trough Floor Body Side Lower Panel U Tube Z Type Car Line Moulding UIC Vestibule Bracket Z Pillar Body Pillar , Right & Left Turn Under

1.6 mm Sheet Z Molding Half Round Roof Carline Patch Waist Rail Side & Stiffener Angle for Battery Box Battery Box Moldings of various sizes. Wall Protector Wheel Tag Locking Plate for Anchor Link

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