WELCOME
TO
LOCOMOTIVE DESIGN CENTRE
RDSO
SOFTWARE USED
UNIGRAPHICS(NX) CAD
TEAM CENTER PDM
ANSYS FEM
MSC Nastran Fatigue Analysis
CAD- COPMUTER AIDED DESIGN
PDM- PRODUCT DATA MANAGEMENT
HIGH ADHESION BOGIE
LOCOMOTIVE UNDERFRAME
DETAIL OF UNDERFRAME
WMD3D PLATFORM
LOCO UNDERFRAME WITH SUB ASSEMBLIES
PIPING & ROUTING
HOOD OVER ENGINE ASSEMBLY
LOCOMOTIVE CAB
CONTROL CABINET
ELECTRICAL CABINET
LOCOMOTIVE SHORT HOOD
CONTROL STAND
DIGITAL LOCO DIESEL
PROJECT/LOCO DESIGN COMPLETED
WDM3D END CAB
PROJECT/LOCO DESIGN Completed
BG Sri Lanka 2300 hp BG Bangladesh 2600hp
MG Vietnam 1300hp MG Malaysia 2300hp
SUDAN/MAYANMAR LOCO
ANGOLA LOCO
HOTEL LOAD LOCO
SUDAN/MAYANMAR LOCO
COACH BOGIE DESIGN
AND
AIR SUSPENSION
- TOPICS ON BOGIE DESIGN
- MODES OF COACH BODY OSCILLATION.
- DESIGN OF BOGIE COMPONENTS.
- DESIGN OF SUSPENSION ELEMENTS.
- VEHICLE DYNAMICS SIMULATIONS.
- FIELD TRIALS.
- TOPICS ON AIR SUSPENSION
- NEED FOR AIR SUSPENSION.
- DETAILS OF AIR SUSPENSION.
- CONTROL EQUIPMENTS.
- DESIGN.
- ADVANTAGE.
DESIGN REQUIREMENT
GAUGE
SPEED
AXLE LOAD
MAX MOVING DIMENSION
MIN CURVE NEGOTIATION
ANY OTHER SPECIFIC REQUIREMENT…..
BOGIE DESIGN
VEHICLE MOTION QUANTITIES.
DEGREES OF FREEDOM.
VIBRATION EXCITATION.
SUSPENSION DESIGN.
SAFETY AGAINST DERAILMENT.
RIDING QUALITY.
RESONANCE AND HUNTING
VEHICLE DYNAMICS SIMULATIONS.
OSCILLATION TRIALS.
VEHICLE DYNAMIC SIMULATIONS
(MATHEMATICAL MODELING)
SOFTWARE PACKAGES
NUCARS ADAMS RAIL
FORCES
VEHICLE RELATED
VEHICLE OUTPUT DISPLACEMENT
INPUT
TRACK RELATED DYNAMICS
SOFTWARE VELOCITY
RAIL/WHEEL CONTACT PACKAGE ACCELERATION
VEHICLE OUT PUT
VEHICLE MODEL
•NUCARS - NEW UNTRIED CAR ANALYSIS REGIEM SIMULATIONS
•ADAMS RAIL – AUTOMATIC DYNAMIC ANALYSIS OF MECHANICAL SYSTEMS
ADVANTAGES • MODEL OF ANY RAILWAY VEHICLE CAN BE DEVELOPED.
•ASSESMENT OF VEHICLE RIDING AND STABILITY.
•PARAMETRIC OPTIMISATION OF SUSPENSION
•HAZARD FREE
•COST EFFECTIVE
AIR SUSPENSION
FOR
COMFORT
SAFETY
AND
RELIABILITY WITH
ECONOMY
ADVANTAGES OF AIR
SUSPENSION
- MAINTAINS SAME HEIGHT BY LOAD SENSING.
- ADEQUATE BOGIE CLEARENCES.
- LOW VIBRATIONS AND NOISE.
- LOW SPACE REQUIREMENTS.
- ALMOST SAME NATURAL FREQUENCY UNDER EMPTY
AND LOADED CONDITIONS.
- BETTER RIDING QUALITY.
- REDUCED LATERAL FORCES.
- INCRESE IN SPEED POTENTIAL.
- LOW MAINTENANCE.
BOGIE SYSTEM ON WDG2,
WDP1 & WDP2 LOCOMOTIVES
BOGIE DESIGN CRITERIA
Axle load
Speed Potential
Adhesion requirement
Curve negotiability
Bogie dynamics based on the given
track parameters and wheel profile
L/V ratio
Lateral force
Lateral and Vertical Acceleration
Ride Index
Bogie Swing
BOGIE DESIGN CRITERIA
(Contd.)
Kinematics of bogie linkage
Bogie Clearances
Weight Transfer
Axle load equalization
Braking
Rail bending Stiffness
BOGIE CLASSIFICATION
Based on Suspension
single stage)
Flexi-Coil (Two stage)
High adhesion (Two stage)
Based on Wheel/Axle mechanism
Rigid
Radical – Power Steering
Self Steering
Dynamics of Vehicle
Wheel set Dynamics
Bogie Dynamics
Carbody Dynamics
BOGIE COMPONENT DESCRIPTION
BOGIE FRAME
Integral cast Bogie frame
Fabricated
Cast
SUSPENSION
Single Stage
Steel helical coil spring
Rubber
BOGIE COMPONENT DESCRIPTION
Two Stage
With bolster
Without bolster
Hydraulic dampers
Primary (Vertical ,Lateral, yaw damper)
Secondary (Vertical & Lateral,Yaw Damper
Traction motor damper – used in case of
fully suspended traction motor
BOGIE COMPONENT DESCRIPTION
Traction Arrangement
Primary
Pedestal (Horn)
Guidelink or Primary traction rod
Secondary traction
Chaffing plate
Traction bar
Secondary traction rod
Pivot Pin Assembly
Rigid Pivot
Takes vertical carbody load
Floating Pivot
Used in Two-stage suspension
BOGIE COMPONENT DESCRIPTION
MOTOR SUSPENSION
Nose suspended
Nose Sandwich
Nose link type
Fully suspended
Flexible coupling required to take care of
misalignment of gear and pinion
Suspension bearing
Plain type
Roller type
BOGIE COMPONENT DESCRIPTION
WHEEL, AXLE & BEARING JOURNAL
Wheel
Curved web
Straight web (for disc brake fitment)
Axle
Solid axle
Hollow Axle
Bearing
Cylindrical Roller
Taper Roller
BOGIE COMPONENT DESCRIPTION
BRAKE RIGGING
Conventional
Single or double clasped
Cast iron brake block
Composite brake block
TBU
Disc type (for high speed operation)
Parking brake
In-built in TBU
Separately designed by SAB WABCO
BOGIE COMPONENT DESCRIPTION
Sanding Arrangement
Bogie mounted
Carbody mounted
Safety Component
Horn stay plate
Lifting connection
Lateral & vertical stop component
Liners ; Horn, pivot and wearing surface
Safety strap
HIGH ADHESION BOGIE
Basic design features
Bogie weight 25t
Axle load 20.5t
Wheel base 3800 mm
Journal centers 2300mm
Designed speed 110km/h
Un-sprung mass 13.05t
Basic design features
Bogie Frame Box Section H type
Horn guide axle guidance
16 nos. primary springs 40.8 kg/mm
08 nos. secondary springs 644 kg/mm
Deflection primary 102mm & Sec. 17 mm
Damper primary Vertical 750 kg/10cm/sec
Damper secondary Lat 1150 kg/10cm/sec
Bo-Bo BOGIE
Two Axle (Bo-Bo) Bogie
Axle Load 20 T
Bogie weight 15.5 T
Unsprung weight 4.3T
Wheel base 2800 mm
Journal centre 2300 mm
Speed Potential 120 kmph on Rajdhani Standards
track
Two Axle bolsterless bogie with two stage
suspension
‘H’ shaped bogie frame of fabricated box type
construction
High strength corten steel (IRS M41) used to
reduce weight of bogie frame
Two Axle (Bo-Bo) Bogie (contd.)
Helical coil springs used both in Primary &
Secondary stages
Floating type centre pivot arrangements for
transfer of traction and braking forces between
bogie and carbody
Lateral guidance provided between bogie and
carbody by flexi-coil action of secondary springs
Two Axle (Bo-Bo) Bogie (contd.)
Conventional horn guide arrangement for
transfer of traction & braking forces between
axle and bogie frame
Four vertical hydraulic dampers at primary
stage, one at each axle box
Two vertical hydraulic dampers & two lateral
hydraulic dampers at secondary stage
Axle hung nose suspended BHEL 4906 AZ
Traction Motors
Tread brake unit is provided for brake rigging
FLEXI-COIL BOGIE
WDP2 Locomotive
FLEXI-COIL Mk-5 BOGIE FOR WDP2
LOCO
Axle Load 19.5 T.
Speed Potential 160 Km/h on Rajdhani
Standard Track.
Three Axle Bogie with Bolster.
Fabricated Box Type Bogie Frame.
Two Stage Suspension with Helical Coil
Springs in both the stages.
Lateral guidance between car body &
bogie provided by flexi-coil action of
secondary springs.
FLEXI-COIL Mk-5 BOGIE FOR
WDP2 LOCO (contd.)
Four primary hydraulic vertical
dampers, one each at end axle box.
Four vertical hydraulic dampers & two
lateral dampers at secondary stage of
suspension.
On end axles, axle guidance provided
by guide links. On middle axle by
conventional horn arrangement.
Functions of guide links:
Provides flexible control of lateral & yaw
motion of axle, reduces hunting tendency
of bogie.
Transfer of traction & braking force
between axle & bogie.
FLEXI-COIL Mk-5 BOGIE FOR
WDP2 LOCO (contd.)
Two traction bars ( Nylatron liners on
fitted with pre- centre pivot provides
compressed rubber yaw damping between
pads ) transfer bolster and car body.
traction and braking Axle hung nose
forces between bogie suspended light
& bolster. weight BHEL 5002 AZ
Traction bars located TM with roller
at axle box level to suspension bearings.
minimise weight Conventional type
transfer. brake rigging
arrangement.
COMPARISON OF DESIGN FEATURES OF
BOGIES OF WDP1, WDP2 AND WDG2
LOCOMOTIVE
[Link] WDP1 WDP2 WDG2
1 Axle Load, t 20 19.5 20.5
2 Wt. Of bogie frame, t 2.2 3.4 4.5
3 Wt. Of Assembled bogie, t 15 25 25
4 Wt. Of Traction motor, t 3.6 3.69/3.19 3.75
5 Wheel Base 2800 3920 (2120+1800) 3800(1900+1900)
6 Axle Arrangement Bo-Bo Co-Co Co-Co
7 Design Speed Km/h 135 160 100
8 Starting TE, t/loco 20 29.25 38
9 Bogie Frame Fabricated Fabricated Fabricated
10 Unsprung mass/axle, t 4.2 4.1 4.35
11 Traction motor suspension Axle hung nose Axle hung nose Axle hung nose
arrangement suspended suspended suspended
12 Suspension
(a) Primary Helical coil Spring Helical Coil Spring Helical Coil Spring
(b) Secondary - do - - do - Rubber Sandwich
13 Damping – Primary-Vert Hydraulic 4/Bogie Hydraulic 4/Bogie Hydraulic 4/Bogie
- Secondary – Vert Hydraulic 2/Bogie Hydraulic 4/Bogie Not provided
- Lateral Hydraulic 2/Bogie Hydraulic 2/Bogie Hydraulic 2/Bogie
Hydraulic pivot liner
COMPARISON OF DESIGN FEATURES OF
BOGIES OF WDP1, WDP2 AND WDG2
LOCOMOTIVE(contd.)
WDP1 WDP2 WDG2
14. Longitudinal guidance of Horn guides Guidelink Horn guides
wheel set
15. Lateral wheel set Lateral thrust Guide Link Lateral thrust pad
guidance pad thrust pads on on end axle
end axle boxes boxes
16. Longitudinal guidance of Center pivot Traction bar Center Pivot with
loco body with rubber fitted with rubber bush.
bush rubber pads at
both ends
17. Lateral guidance of loco Secondary flexi- Secondary flexi- Secondary rubber
body coil springs coil springs sand wich spring.
18. Axle Bearings Cylindrical Cylindrical Cylindrical Roller
Roller Roller
19. Gear Ratio 18:65 22:61 24:58
20. Main Braking Clasp Type Clasp Type Clasp Type
Tread Brake Convl. Brake Convl. Brake
Units (TBUs) Rigging Rigging
BOGIES FOR EXPORT
TANZANIA
ANGOLA
MOZAMBIQUE
SUDAN ARE……..
TANZANIA
MOZAMBIQUE
ANGOLA
SUDAN