Modified Fiat Bogie

1,540 views
1,312 views

Published on

Presentation on 'Modified Fiat Bogie' extensively used in worldwide Locomotive....:):)

Published in: Automotive, Business
0 Comments
1 Like
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
1,540
On SlideShare
0
From Embeds
0
Number of Embeds
4
Actions
Shares
0
Downloads
81
Comments
0
Likes
1
Embeds 0
No embeds

No notes for slide

Modified Fiat Bogie

  1. 1. DESIGN FEATURES
  2. 2. BOGIE FRAME Y-FRAME -STEEL SHEETS (St-52) 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.
  3. 3. MATERIALS USED: STEEL CASTINGS (GS20Mn5V; DIN 17182): BRAKE SUPPORT PIN BRACKET SPRING CENTERING IN SECONDARY (1268840) BUMP STOP BRACKET LH/RH SGCI CASTINGS (IS:1865) AXLE BOX FRONT COVER CONTROL ARM TOP CONTROL ARM LOWER LEFT/RIGHT PRIMARY SPRING CENTERING LOWER AND UPPER
  4. 4. MATERIALS USED: FORGINGS : TRACTION CENTER CENTER PIVOT PIN CONTROL ARM SUPPORT BKT LH/RH ANTI ROLL BAR FORK ANTI ROLL BAR BRACKET PLATE/TUBES (S355J2G3;EN10025) BOGIE FRAME BOGIE BOLSTER CROSS SECTION
  5. 5. IMPORTED BOGIE ITEMS: FORGED WHEEL DISCS BRAKE SYSTEM PRIMARY SPRINGS SECONDARY SPRINGS DAMPERS RUBBER-METAL COMPONENTS (06 TYPES) MINER PAD ON PAC
  6. 6. Primary suspension Four nos. each per bogie Nested coil springs, primary vertical dampers, control arm, elastic joints-connecting the bearing on wheel-set to bogie frame. Flexible guidance.
  7. 7. Primary suspension Rubber Pad Outer Spring Spring Guide Inner Spring Lower Spring Guide Bump Stop
  8. 8. WHEEL SET: Two brake disks (4), diameter 640 mm and width 110 mm. Two wheel discs of dia 915 (New), 845 (worn).
  9. 9. Wheel Re-profiling and balancing: DYNAMIC BALANCING 320 RPM LESS THAN/EQUAL TO 50 gm GLUE THE NEEDED WEIGHTS Balancing machine Weights
  10. 10. Axle bearings CARTRIDGE TAPER ROLLER BEARING PRE-ASSEMBLED UNIT
  11. 11. 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 877/BECORIT984
  12. 12. BRAKE CALIPER UNIT
  13. 13. 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
  14. 14. (With Bolster Lifted) Sec. Vertical Damper Bogie Bolster Cross Section Nested Secondary Spring Assembly Yaw Damper
  15. 15. (With Secondary Spring System Exploded) Bogie Bolster Miner Pad Spring Guide Outer Spring Inner Spring Rubber Spring
  16. 16. (Bolster removed) Lateral Damper Lateral Bump stop Longitudinal Bump stop
  17. 17. (X-section lifted) Traction Lever Traction Center Anti Roll Assly Curve Roll
  18. 18. ANTI-ROLL BAR: A TORSION BAR WITH TWO FORKSBETWEEN BOGIE FRAME & BOLSTER, CONNECTED BY ROLL LINKS. RESISTS ROLLING MOTION OF COACH. AS PER UIC 515-1 TILTING CO-EFFICIENT <0.4.
  19. 19. ANTI-ROLL BAR:
  20. 20. A Anti-roll Assly
  21. 21. BODY BOGIE CONNECTION
  22. 22. BOGIE BODY CONNECTION:
  23. 23. 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.
  24. 24. Principles of force transmission Vertical forces: BODY-BOLSTER-MINER PAD-SEC. SUSPENSION-BOGIE FRAME-PRIMARY SPRINGS/BALL JOINT CONTROL ARMAXLES.
  25. 25. Lateral forces: BODY-BOLSTER-MINER PAD/SEC. SPRINGS/LATERAL BUMP STOP-BOGIE FRAME-BALL JOINT CONTROL ARMAXLES.
  26. 26. Traction and braking forces: BODY-TRACTION CENTRETRACTION LEVER/LONGITUDI NAL BUMP STOPBOGIE FRAMECONTROL ARMAXLES.
  27. 27. A Traction Center
  28. 28. CURVE NEGOTIATION: CONTROL ARM (SGCI TO IS:1865) CONNECTING AXLE BEARING AND SIDE FRAME THROUGH ELASTIC CONNECTION. FLEXIBLE GUIDANCE TO WHEEL-SET.
  29. 29. 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 UNDER- SLUNG.
  30. 30. Main Data:
  31. 31. CARDAN SHAFT ARRGT. FOR 25KW ALTERNATOR
  32. 32. CARDAN SHAFT ARRGT. FOR 25KW
  33. 33. CARDAN SHAFT ARRGT. FOR 25KW
  34. 34. SELF-GENERATING BOGIE WITH 4.5kW ALTERNATOR & V-BELT
  35. 35. SELF-GENERATING BOGIE WITH 4.5kW ALTERNATOR & V-BELT:
  36. 36. THANKY OU
  37. 37. PROBLEMS REPORTED IN FIAT BOGIE BY ZONAL RAILWAYS:
  38. 38. 1. CONTROL ARM BKT WEAR CONTROL ARM BRACKET (BOGIE) HALF ROUND MAX. RADIUS DEPTH (1267401 & ASSLY DRG NO. 1272174, 1267532) CONDEMNING SIZE TO BE SPECIFIED FOR DIA 85 AS PER DESIGN, NO MOVEMENT IS PERMITTED IN CONTROL ARM BRACKET FIXING WITH BOGIE FRAME IF PROPER TIGHTENING OF FASTENER IS ENSURED. HENCE NO WEAR LIMIT IS REQUIRED.
  39. 39. 2 WEAR ON BOLL JOINT CONTROL ARM ø85 –0.036/-0.090 CONDEMNING SIZE TO BE SPECIFIED AS PER DESIGN, NO MOVEMENT IS PERMITTED IN CONTROL ARM BRACKET FIXING WITH BOGIE FRAME IF PROPER TIGHTENING OF FASTENER IS ENSURED. HENCE NO WEAR LIMIT IS REQUIRED.
  40. 40. 3. BOLSTER SPRING HEIGHT 517 mm SHOWN IN DRG NO. 1268801 & OTHER SEC SUSPENSION DRAWINGS. ACCEPTABLE RANGE TO BE GIVEN. FOR DIFFERENT TYPE OF COACHES DIM. TO BE MENTIONED ALONG WITH THEIR ACCEPTABLE RANGE. THIS IS FOR INFORMATION DURING MANUFACTURE AND APPLICABLE FOR ALL TYPES OF RAJDHANI COACHES. HENCE NEED NOT TO BE CHECKED DURING POH
  41. 41. 4. HEIGHT OF BOGIE FRAME TOP FROM RAIL LEVEL: DIMENSION 925+0/-5 SHOWN IN 1268801 WILL DECREASE WITH REDUCTION IN WHEEL DIA HEIGHT UNDER MIN. DIA OF WHEEL TO BE MENTIONED. DIMENSION IS SPECIFIED WITH NEW WHEEL DIA (MENTIONED IN CONCERNED DRAWING). DIMENSION CAN BE CALCULATED WITH ACTUAL SIZE OF WHEELS ON COACHES. CONDEMNING SIZE OF WHEEL IS Φ845 mm AND NEW WHEEL DIA IS Φ915 mm
  42. 42. 5. HEIGHT OF PIN BRACKET MACHINED SURFACE FROM RAIL LEVEL: FROM RAIL LEVEL 930+6/-2 (1272056). HEIGHT UNDER MIN. DIA OF WHEEL TO BE MENTIONED. HEIGHT UNDER WORN WHEEL MAY BE CALCULATED AS PER ACTUAL WHEEL WEAR MEASURED.
  43. 43. 6. CLEARANCE BETWEEN PRIMARY VERTICAL BUMP STOP GAP 13 mm FOR C. CAR & 8mm FOR GEN. CAR. DIM. NOT SPECIFIED FOR CN,CB,CW & FAC ADVISE SUITABLE MEASURING DEVICE AND PROCEDURE THIS DIMENSION IS FOR INFORMATION AND SHOWN IN CONCERNED PRIMARY SUSPENSION. DIMENSION 13MM IS APPLICABLE FOR CN, CB, CW & FAC COACHES AS SHOWN IN THEIR APPLICABLE PRIMARY SUSPENSIONS
  44. 44. 7. CLEARANCE BETWEEN VERTICAL STOP & LUG OF CONTROL ARM UPPER CLEARANCE = 45mm & LOWER CLEARANCE = 37.5mm. MAXIMUM AND MINIMUM LIMIT ARE NOT GIVEN THESE DIMENSIONS ARE FOR INFORMATION ONLY. HOWEVER, DURING SERVICE THESE DIMENSIONS MAY BE: 45mm MAY BE REDUCED MAXIMUM AS UNDER: FOR GEN. CAR BY 15mm & FOR OTHER COACHES BY 20mm DIMENSION 37.5mm WILL INCREASE BY SAME AMOUNT.
  45. 45. 8. MAX. NO. OF SHIMS AT BODY BOGIE CONNECTION 55mm AS PER ALSTOM L. NO. CL 704 Dt.01.09.2001 (ANNEXURE II-b). HOW MANY SHIMS CAN BE ADDED AT ITS LAST SHOP ISSUE WE CAN ADD 5mm THICK SHIMS UPTO WHEEL WEAR OF 30mm ON RADIUS - BECAUSE WHEN WHEEL WEAR REACHES 35mm ON RADIUS, THE WHEEL WILL HAVE TO BE CONDEMNED (845mm DIA)
  46. 46. 9. AXLE BOX TO BOGIE FRAME (PRIMARY SPRING HEIGHT) DIMENSIONS GIVEN IN DRG NO. 1267411 & 1277142 (264+0/-4, 252+0/-4) DIM. NOT SPECIFIED FOR CN,CB,CW & FAC THESE DIMENSIONS ARE UNDER TEST LOADS OF INDIVIDUAL PRIMARY SPRINGS. NEED NOT TO BE SPECIFIED FOR DIFFERENT COACHES.
  47. 47. 10. RAIL LEVEL TO CONTROL ARM BRACKET (VARIES DEPENDING ON WHEEL DIA.) DIM 462.5+/-4 FOR 1272056 DIM 459+/-4 FOR 1277672 G. SIDE-1 DIM 464+/-4 FOR 1277673 G. SIDE 2 WITH REDUCTION IN WHEEL DIA, HEIGHT FROM RAIL LEVEL TO CONTROL ARM BKT. DECREASES. HEIGHT WITH MIN. WHEEL DIA TO BE MENTIONED THESE DIMENSION SHALL BE CALCULATED FOR OTHER COACHES AND SHALL BE ADVISED
  48. 48. 11. CONDEMNING LIMIT TO BE SPECIFIED FOR CENTER PIVOT Ø100 : TOLERANCE GRADE IS g8 ON Ø100 CENTER PIVOT PIN (-0.012/-0.066) AS PER EXISTING PRACTICE ON BG ICF BOGIES, TOLERANCE TO BE MAINTAINED ON EVERY IOH/POH. IF THE COMPONENT IS OUT OF TOLERANCE RANGE SAME TO BE REPLACED.
  49. 49. 12. QUERY RELATED TO CHAPTER-6 PAGE 6/13 OF MAINTENANCE MANUAL: QUERY: CONDEMNING LIMIT OF CENTRE PIVOT HOLE DIA OF 0.7 TO 1.2mm. SOLUTION: AIR GAP OF 0.7 TO 1.2mm IS SPECIFIED FOR SPEED SENSOR AND DOES NOT RELATE TO CENTER PIVOT PIN.
  50. 50. 13. RUBBER SPRING FREE HEIGHT CONDEMNATION LIMIT TO BE SPECIFIED 235mm FREE HEIGHT IS NOT REQUIRED TO BE CHECKED. HOWEVER, RUBBER SPRINGS SHOULD BE CHECKED FOR LOAD DEFLECTION CURVE GIVEN IN DRAWING.
  51. 51. 14. ANTI ROLL BAR GAP BETWEEN ROLL LINK & FIXING BLOCK ANTI ROLL BAR – GAP BETWEEN ROLL LINK BKT. AND FIXING BLOCK1267422 NOT SPECIFIED. TO BE SPECIFIED. QUERY NOT CLEAR
  52. 52. CONTROL ARM CORROSION AND WEAR: WEAR AND CORROSION ON MATING SURFACE WITH BEARING. TOLERANCE MAY BE ENSURED ON EVERY IOH/POH Ø230+ /- Ø210 . IF WEAR OCCURS, MAY BE REMACHINED BY GIVING A CUT OF 0.3 TO 0.5mm ON BOTTOM FACE. IF IT CAN NOT BE RECTIFIED BY ABOVE MACHINING SAME MAY BE REPLACED. M/S FIAT HAS RECOMMENDED TO USE LUBRICATING OIL BLASOL-135 DURING FITMENT TO MINIMISE WEAR ON CONTROL ARM AND AVOID CORROSION.
  53. 53. FAILURE OF DAMPER: END FITTING DAMAGE, STONE HITTING, LEAKAGE RDSO HAS BEEN ASKED TO REVIEW THE SPECIFICATION OF END MOUNTING RUBBER VIDE MD23161 DTD. 08.08.07 WR HAS BEEN REQUESTED TO PROVIDE FURTHER DETAILS PERTAINING TO TYPE OF DAMAGE/FAILURE IN DAMPERS VIDE MD23161 DTD. 08.08.07

×