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. AC SLEEPER AND HOT BUFFET COACH HELP INDIAN RAILWAYS IN DEVELOPING SG VERSION OF THESE COACHES . 2 EXECUTIVE CHAIR CARS AND 3 POWER CARS TRANSFER MANUFACTURING KNOW-HOW FOR THESE HELP IN DESIGNING AND MANUFACTURING FIRST AC. 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. 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INTRODUCED AS SHATABDI EXPRESS BETWEEN NEW DELHI AND LUCKNOW ON 29-5-2001 CERTAIN PROBLEM NOTICED WITH CBC AND RAKE WAS WITHDRAWN FROM SERVICE ON 25-6-2001. MANUFACTURING STARTED ALL THE THREE VARIANTS DESIGNED AND MANUFACTURING DOCUMENTS FINALISED . REINTRODUCED ON 9-1-2002 MANUFACTURING KNOW-HOW RECEIVED.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. . . 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. . Large wheelbase affects curvability / Wheel flange wear. 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. 75 both in vertical and lateral modes .6 at 160 kmph in vertical modes and 3.Ride Index ICF 2.4 / 3.5 at 160 kmph in lateral mode FIAT Ride index shall be 2.5 but not exceeding 2. 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 ICF Rigid FIAT Articulated by control arm Longitudinal and transverse flexibilities of the axle can be optimised independently. . Bogie Frame ± Axle Joint ICF FIAT . Primary Suspension Unit ICF Coil spring with dashpot level FIAT Coil springs are nested with hydraulic damper and control arm More reliable and maintenance free as compared to dash pot. . .Secondary Suspension Unit ICF FIAT Secondary spring on Secondary spring lower spring beam directly mounted on through hangers the side frames Vertical space constraints to accommodate desirably softer secondary suspension springs. Bolster ICF FIAT . Bogie .Body Joint ICF Through Centre pivot FIAT Through pivot assembly on transverse beam and bracket on doom . Bogie ± Body Joint of ICF . Bogie .Body Joint of FIAT . Bogie .Body Joint of FIAT . Body Joint of FIAT .Bogie . 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 . 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 STAINLESS STEEL USED FOR SIDEWALL. 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 BETTER INSULATION AGAINST NOISE AND HEAT FLOOR MADE OF SOUND ABSORBING PANELS WITH CORK CORE FLOATING ON NOISE DAMPING RUBBER PROFILES USE OF FIRE RETARDANT MATERIALS AXLE MOUNTED DISK BRAKE WITH WHEEL SLIP PROTECTION DEVICE CARTRIDGE TAPER ROLLER BEARINGS . 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 .YAW DAMPER.SALIENT FEATURES OF LHB DESIGN COACHES BOGIES WITH FLEXICOIL SPRINGS. 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 . . . 5 kg) .3 kg) ELASTIC CONNECTION (20 kg) SILENT BLOCK FOR ANCHOR LINK (3.RUBBER BONDED METAL COMPONENTS LONGITUDINAL BUMP STOP (0.67 kg) CENTRE PIVOT SILENT BLOCK (3. Length over body 23540 mm 21340m 3. Height of centre-line of coupler from raillevel under tare condition 1105 mm 1105 mm 6. Maximum width over body 3250 mm 3245 mm 5.Sl Dimension/ feature LHB/FIAT coach ICF AC Chair car 1. Buffer-centres (if buffers provided) 1956 mm 1956 mm 4. Height of compartment floor from rail-level under tare condition 1303 mm 1313 mm . Gauge 1676 mm 1676 mm 2. Maximum buffer-drop under gross load and worn condition 75 mm 75 mm 3. Maximum tare weight for AC chair car with all supplies in working order. Minimum height of centre-line of side-buffers above rail-level for loaded vehicles 1030 mm 1030 mm 5.1 t 7. Maximum height of centre-line of sidebuffers above rail-level for empty vehicles 1105 mm 1105 mm 4.Sl Dimension/ feature LHB/FIAT coach ICF AC Chair car 1. including water 39 t 43. Maximum axle-load permissible 16 t 16 t . Maximum height of centre of screw-coupling above rail-level for empty vehicles 1055 mm 1054 mm 6. Maximum distance between inner wheels 12345 mm 1189 mm 2. 2 t.536 t. (Condemned) 6. . 2560 mm. 5. 3. 4. Bogie frame.Sl Items ICF all coiled Fiat Bogie 6. Speed cleared for. Brake. 140kmph 160kmph. 6. 2896 mm. Clasp type brake. Axle mounted disc brake. Wheel diameter. Box type with headstocks. Weight of the Bogie. 915 mm (New) 813 mm (Condemned) 915 mm (New) 845 mm. H-type boxes construction. Wheel Base. 1. 2. Sl Items ICF all coiled Fiat Bogie Air. 7. 9. Axle guidance. Articulated by control arm. Isolation of noise from bogie to coach body connection. Noise feature. Secondary spring on lower spring beam through hangers. Braking system. 10. Coil spring with dashpot arrangement. Position of secondary spring. Suspension vertical (Axle level). Limited noise control feature. 11. 12. Secondary spring directly mounted on side frames. . Rigid. Vacuum & Air. 8. Cartridge tapered roller bearing. Type of bearing at journal Spherical roller bearing. Coil springs are nested. 5 at 160kmph in lateral modes. 17. Not provided. 100% transfer through body bogie connection. Very high.6 at 160kmph in vertical modes and 3.4 / 3. 2. Ride index. Oil leakage problem. 15. . Provided. Through centre pivot. 14.5 but not exceeding 2.Sl Items ICF all coiled Fiat Bogie No leakage 13. Anti roll bar arrangement. Through pivot assembly on transverse beam and bracket on doom. 100% through side bearers.75 both in vertical and lateral modes. Coach load transfer. Traction & shock load transfer. 16. Ride index shall be 2. 75 both in vertical and lateral modes. More pin joints. Wheel with improved curving characteristic. 12345 mm. 12340 mm (Proposed) 17. 18. springs and rubber components. Maximum distance between inner wheels.5 but not exceeding 2. Bogie frame. Cartridge tapered roller bearing. Maintenance requirement in POH. 19. More due toAxle box guide arrangement. 19. Clasp brake. 12340 mm (Proposed) . Ride index shall be 2.5 at 160kmph in lateral modes. 11887 mm. Spherical roller bearing.6 at 160kmph in vertical modes and 3. Ride index. Maximum distance between inner wheels. 2. 12345 mm.Sl Items ICF all coiled Fiat Bogie Very little due toDisc brake.4 / 3. 11887 mm. Thank you .