LHB-FIAT-Bogie made by indian railway .ppt

LHB bogie

2. DESIGN FEATURES:

3. MATERIALS
 STEEL CASTINGS (GS20Mn5V; DIN 17182):
 BRAKE SUPPORT
 PIN BRACKET
 SPRING CENTERING IN SECONDARY
(1268840)
 BUMP STOP BRACKET LH/RH
 SGCI CASTINGS (IS:1865 SG400)
 AXLE BOX FRONT COVER
 CONTROL ARM TOP
 CONTROL ARM LOWER LEFT/RIGHT
 PRIMARY SPRING CENTERING LOWER AND
UPPER

4. MATERIALS
FORGINGS :
 TRACTION CENTER
 CENTER PIVOT PIN
CONTROL ARM SUPPORT BKT LH/RH
ANTI ROLL BAR FORK
ANTI ROLL BAR BRACKET

PLATES (S355J2W+N;EN10025 Part-2)
 BOGIE FRAME
 BOGIE BOLSTER
 CROSS SECTION

5. Materials used
Name Spec. Composition Mechanical Properties
S355J2W+N
St 52
Plates &
forgings
EN10025, Part-2 & 5 C- 0.23, Si-0.60, Mn-1.70,
Cu-0.60, P-0.035, S-0.035
Yield Strength= 355Mpa
UTS = 470-630Mpa
%age elongation = 20%
Impact = 27J at -20°
Steel CastingGS 20Mn5V, DIN 17182C-0.17-0.23, Si- 0.60, Mn-
1.00-1.50, P<0.020,
S<0.015, Cr<0.30,
Mo<0.15, Ni <0.40
Yield Strength= 360Mpa
UTS = 500-650Mpa
%age elongation = 24%
Impact = 70J
Nodular Cast
Iron
IS:1865, SG400/18L Left to discretion of
manufacturer complying
mechanical properties
Yield Strength =
250Mpa
UTS = 400Mpa
%age elongation =18%
Impact =9 J at -20°±2
IS:1865, SG400/15L Left to discretion of
manufacturer complying
mechanical properties
Yield Strength =
250Mpa
UTS = 400Mpa
%age elongation = 15%
Impact =

6. Materials used
Name Spec. Composition Mechanical Properties
Seamless
tubes
(St 52.4)
DIN 1630, DIN 2448C-0.22 max, Si-0.55 max,
Mn < 1.60, P-0.04max, S-
0.035max
Yield Strength = 355Mpa
UTS = 500-650Mpa
%age elongation
21% - longitudinal
19% - Transverse
Minimum Impact at +20°:
43 J - Longitudinal
27 J - transverse

7. Coach weights as per Suspn. diagram
Coach type Tare
weight (t)
No. of passengers Pay load in
(t)
Gross
weight in (t)
2
nd
AC-Chair Car EOG 41.4 78 6.24 47.64
AC Chair car exe. EOG41 56 4.48 45.48
Hot Buffet Car 40.9 18 , pantry equip 3t3.24 44.14
1
st
AC-Sleeper EOG 43.3 24 1.92 45.22
AC-2T EOG 44.5 54 4.32 48.82
AC-3T EOG 45.6 72 5.76 51.36
Power car 53.6 --- 3.045 53.645
GS/SG 37.6 99 15.84 53.44
SCN/SG 39.6 78 6.24 45.84
SLR/SG 37.9 37 , lugguage-6t 8.96 46.86
SCN/EOG 41.24 78 6.24 47.48
SLR Under slung 44.0 03, 14t luggage 14.24 58.24
Bogie Weight = 6.6t

8. FIAT BOGIE
SUB-SYSTEMS

9. BOGIE FRAME
Y-FRAME -STEEL SHEETS(St-52, now weathering
steel)
TWO SIDE FRAMES CONNECTED BY TWO CROSS
BEAMS -SUPPORT BRAKE UNITS.
BOGIE FRAME ON THE PRIMARY SPRINGS AND
SUPPORTS VEHICLE BODY THROUGH BOLSTER.
BOLSTER-BOGIE FRAME THROUGH SECONDARY
SUSPENSION.

10. BOGIE FRAME

11. Primary Damper
Primary Spring assly
(Bogie frame lifted)

12. Primary suspension
Four nos each per bogie -nested coil springs,
primary vertical dampers, control arm, elastic
joints-connecting the bearing on wheelset to
bogie frame.
 Flexible guidance.

13. Rubber Pad
Spring Guide
Outer Spring
Inner Spring
Bump Stop
Lower Spring Guide
(Primary exploded)

14. (Wheel set with Primary suspension)
Control Arm
Bearing Assly
with earthing
eq./speed sensor

15. C
Primary Damper
(Wheel set with Primary springs removed)
Control Arm

16. Two brake disks (4),
diameter 640 mm and
width 110 mm.
Two wheel discs of dia
915 (New), 845 (worn).
Wheelset

17. Wheel & Axle Assly
Brake Disc

18. DIMENSIONS OF WHEEL SET:

19. Wheel Disc:

20. DYNAMIC BALANCING 320RPM
Unbalanced moment on each wheel plan
must be less than or equal to 50GM
GLUE THE NEEDED WEIGHTS.
Wheel Re-profiling and
balancing:

21. DETAIL OF ADDED WEIGHTS:

22. BOGIE FRAME
Top/Bottom
Plate 12mm
Vertical
web Plate
12mm
Tube thickness
14mm,
OD-168mm
Brake Support
(Steel casting)
Control Arm Support
(Forging)

23. Axle bearings
CARTRIDGE TAPER
ROLLER BEARING
PRE-ASSEMBLED UNIT

24. BRAKE UNITS
AXLE MOUNTED DISC BRAKE
INBUILT SLACK ADJUSTER IN BRAKE
CYLINDERS
CALIPER RATIO 1:2.17 FOR ALL
COACHES EXCEPT POWER CAR,
WHICH IS 1:2.48
35 mm BRAKE PADS
JURID /BECORIT

26. SECONDARY SUSPENSION
NEST OF FLEXI-COIL SPRINGS INNER AND
OUTER, RUBBER SPRING AND SECONDARY
PAD
VERTICAL DAMPERS
LATERAL DAMPERS
YAW DAMPERS
ANTI-ROLL BAR
ANCHOR LINKS

27. SECONDARY SUSPENSION

28. (With Bolster Lifted)
Bogie Bolster
Nested
Secondary
Spring
Assembly
Yaw Damper
Sec. Vertical
Damper
Cross Section

29. (With Secondary Spring System Exploded)
Bogie
Bolster
Miner Pad
Spring Guide
Outer Spring
Inner Spring
Rubber Spring

30. SECONDARY SUSPENSION

32. Lateral Damper
Lateral Bumpstop
Longitudinal Bumpstop
(Bolster removed)

33. Anti Roll Assly
Traction Lever Traction Center
Curve Roll
(X-section lifted)

34. ANTI-ROLL BAR:
A TORSION BAR WITH TWO FORKS-
BETWEEN BOGIE FRAME &
BOLSTER,CONNECTED BY ROLL LINKS.
 RESISTS ROLLING MOTION OF COACH.


35. ANTI-ROLL BAR:

36. A
Anti-roll assly

37. BUFFER HEIGHT ADJUSTMENT
Shims at body/bogie connection.
Shims NOT added/removed in Primary and
Secondary Suspension for wheel wear
compensation or buffer height adjustment.

38. BOGIE BODY CONNECTION:

39. BODY BOGIE CONNECTION

40. Principles of force transmission
Vertical forces:
BODY-BOLSTER-MINER PAD-
SEC.SUSPENSION-BOGIE FRAME-PRIMARY
SPRINGS/BALL JOINT CONTROL ARM-
AXLES.

41. Lateral forces:
BODY-BOLSTER-MINER
PAD/SEC.SPRINGS/LATERAL BUMP STOP-
BOGIE FRAME-BALL JOINT CONTROL
ARM-AXLES.

42. Traction and braking forces:
BODY-TRACTION
CENTRE-TRACTION
LEVER/LONGITUDI
NAL BUMP STOP-
BOGIE FRAME-
CONTROL ARM-
AXLES.

43. A
Traction Center

44. CURVE NEGOTIATION:
CONTROL ARM (SGCI TO IS:1865)
CONNECTING AXLE BEARING AND SIDE
FRAME THROUGH ELASTIC CONNECTION.
FLEXIBILE GUIDANCE TO WHEELSET.

45. SUSPENSIONS OF VARIANTS
THE COMMON SUSPENSION GROUPS ARE:
GS,SCN,SLR
CC,EC,CB,FAC/EOG,ACCW/EOG.
ACCN/EOG,FAC/SG,ACCW/SG
ACCN/SG,WLRRM SIDE 2.
WLRRM SIDE 1.
SLR UNDERSLUNG.

46. Main Data:

47. Speed limit
Cleared upto 160KMPH.
upto 200KMPH with magnetic
brakes/sintered brake pads.

48. RIDE INDEX
CHAIR CAR:
VERTICAL 2.75
LATERAL 2.5

49. Description Photo Average
rate in
ruppes
QPC
Axle Box Pivot Bush
Drg.No.1247488001
13,007 08 nos
Ball joint roll link (Drg no. C53 973
REB BRED 8416 )
4,399 08 nos
Traction center Elastic joint Drg.
No. C53 973 REF BRED 8397 rev 02
2,385 02 nos
Ball joint traction lever Drg.No. C53
973 REF BRED 8403 rev 02
2,775 08 nos
IMPORTED BOGIE ITEMS:

50. Description Photo Average rate
in rupees
QPC
Lateral Bump Stop (Drg no. C53 973
REB BRED 8374 rev 02 )
2,775 04 nos
Rubber Spring
( Drg no. 1268685 Ver ‘01’ )
3,386 04 nos
Pad for Secondary Suspension
(Drg No. 1903149 alt ‘a’)
14,627 08 nos
Primary Vertical Bump Stop
(Drg No. 1227081)
New to
imported
08 nos
IMPORTED BOGIE ITEMS:

51. IMPORTED BOGIE ITEMS:
Drawing Nos.1267411 1267412 1277142 1277143
Average rate12,013 7,023 13,877 8,188
QPC
08 08 08 08
Spec. No. T.S. 17.248 100 05
Drawing Nos.126951312695141277145127714612688361268837
QPC.
04 04 02 02 02 02
Average rate
9,66315,13116,25542,86033,23519,707
Spec. No. T.S. 17.248 100 05
Secondary Springs
Primary Springs
Sources: i) M/s Grueber, Germany
ii) M/s LANGEN and SONDERMANN GMBH, Germany

52. IMPORTED BOGIE ITEMS:
Drawing Nos. LW05100
Sec. lateral
LW05101
Sec. Vertical
LW05102
Primary
Vertical
LW05103 Yaw LW 05122
Lateral
damper for Air
spring bogie
QPC 02 nos 04 nos 08 nos 04 nos 02 nos
Average rate 8,711 8,275 7,353 29,167
Spec. No. T.S. 17.560 100 03
Description Average rate in
ruppes
QPC
Wheel Disc 45,000 08
Brake Disc KB’s drg no.
1B83756/1
53,000 08
Dampers:

53. Spring combinations – Helical
Primary Inner spring:
Primary Outer spring:
Secondary Inner Spring
PL No./Drawing No. Applicable for EOG Coaches
1.33503035/1267411 AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper, AC-2T, AC-3T
2.33500368/1277142 Power Car
PL No./Drawing No. Applicable for EOG Coaches
1.33503047/1267412 AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper, AC-2T
2.33500356/1277143 AC-3T, Power car
PL No./Drawing No. Applicable for EOG Coaches
1.33503060/1269514AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper, AC-2T
2.33500381/1277146Power car side-1
3.33500400/1268836AC-3T, Power car-side2
PL No./Drawing No. Applicable for EOG Coaches
1.33503059/1269513 AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper, AC-2T, AC-3T
2.33500370/1277145 Power car side-1
3.33500393/1268837 Power car side-2
Secondary Outer Spring

54. Spring combinations Air spring type:
PL No./Drawing No. Applicable for Coaches
1.33503035/1267411 AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper, AC-2T, AC-3T
2.33500368/1277142 Power Car, AC-DD chair car
PL No./Drawing No. Applicable for Coaches
1.33503047/1267412 AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper,
2.33500356/1277143 AC-2T, AC-3T, Power car, AC-DD chair car
RDSO Spec. No. Applicable for Coaches
1.C-K508 AC-Chair Car/Exe, 2
nd
AC-Chair car, Hot-buffer car, FAC sleeper, AC-2T, AC-3T, Power car, AC-DD chair car
Primary Inner spring:
Primary Outer spring:
Secondary Suspension

55. Coupling of Springs
Each flexicoil spring is provided with
the following markings:
The positive directions of the alignment
deviations is indicated with an
Aluminium band (secured tightly and
wound twice arround the spring)
The length of the spring under test load
and the value of the alignment
deviation (in mm) are printed on a
nonferrous metal band.

56. ALIGNMENT DEVIATION (COUPLING
INSTRUCTIONS)
The difference between the alignment
deviations of the two outer springs not to
exceed 4mm and that of the inner springs 8mm.
In addition, the outer and inner springs with the
greater alignment deviations must be situated
in the same spring assembly, that is:
If A greater than B, C should be greater than D
A - B = 4 mm max, C - D = 8 mm max
C
A B
D

57. THANKY
OU