HSR Rolling stock IRIEEN (1).pptx for Railways
- 1. HIGH SPEED RAIL ROLLING STOCK TECHNOLOGY Silabhadra Das Professor(IRIMEE)
- 3. OBJECTIVE By the end of this lecture, participants will be able to- The design requirements of a High speed rail rolling stock Understand the difference between Concentrated Power train and Distributed Power train Explain briefly the history of HSR Describe Aspects of high speed rolling stock being incorporated in MAHSR Explain
- 4. BULLET TRAIN
- 5. High Speed Rail (WHAT) • Operational speed greater than 200 Kilometer per hour on existing track • Operational speed greater than 250 Kilometer per hour on new track • Significantly faster than traditional railway trains • E.g.- Bullet Train (Japan) - ICE (Germany) - TGV (France) - CRH (China)
- 7. SEMI HIGH-SPEED RAIL Operational speed between 160 Kilometer per hour to 200 kilometer per hour e.g. Vande Bharat Express, Gatiman Express
- 8. Concentr ated P o w e r train Distributed P o w e r train Locomotive Coach Coach Coach Coach Coach Motor coach Coach Coach Coach Coach Coach Coach Motor coach Coach Coach Motor coach Coach Coach HOW
- 9. HIstory of H S R ( W H E N & W H E R E )
- 10. (210 KMPH) Distributed Power EMU trainset with 6 motor coaches 1964 - JAPAN – SHINKANSEN
- 11. 1983-FRANCE TGV -300 Kmph Developed by ALSTOM Concentrated Power
- 13. W H I C H C O U N T R Y H A S T H E L A R G E S T H I G H - S P E E DR A I L N E T W O R K T O D A Y ?
- 15. 2008
- 16. 2017
- 17. HSR in CHINA • 1997 – China launched large scale speed up campaign • 1999 – China star EMU was developed indigineously (Vmax = 250 Kmph). Was a commercial failure • January, 2004 – Chinese government identified 4 North-South and 4 East-West corridors for High speed rail • October, 2004 – Chinese Railway ordered 60 sets of CRH 2A rolling stock from Kawasaki, 40 sets of CRH5A from Alstom, 60 sets of CRH1A from Bombardier. All had to adapt their HSR train-sets to China's own common standard and assemble units through local joint ventures (JV) or cooperate with Chinese manufacturers. • 2008 – First commercial High speed rail trains were operated. • 2013 – Independent innovation started. China standard EMUs with individual Intellectual Property Rights
- 18. WHY HSR? • 1,600 million passengers per year carried by high speed trains in the world • 80% modal split obtained by high speed trains in relation to air transport when travel time by train is less than 2.5 hours. • HSR stations are important nodal points in city centres and they serve wider social functions, by offering accessibility to a comprehensive and wide range of services, such as shopping facilities
- 19. WHY HSR? HSR provides city centre to centre connectivity. Lesser Door to Door travel time.
- 20. WHY HSR ? • Energy efficient • Lesser carbon footprint
- 22. Rolling stock requirement • Self propelled, fixed composition and bi-directional • High level of technology • Limited axle load (11 to 17 tons for 300 km/h) • High traction power (approx. 11 to 24kW per ton) • Power electronic equipment: GTO, IGBT based Control circuits • Computer network. Automatic diagnostic system • Optimised aerodynamic shape • In-cab signalling system/s • Several complementary braking systems • High level of RAMS (Reliability, Availability, Maintainability and Safety) • Airtight structure
- 23. Wheel • Flatter tread, Wheel conicity should be 1:40, 1:60 or 1:80
- 24. SUSPENSION
- 27. Carbody Tilting
- 28. MAHSR ROLLING STOCK E5 series Shinkansen, Top speed – 320 kmph
- 29. General Overview TRAIN OPERATION PLAN Year Start of Operation (SOO) After 10 Years After 20 Years After 30 Years Train Configuration 10 10/16 16 16 Number of Rakes 24 24 +11 44 71 Number of Train Trip (per day/one-direction) 35 51 64 105 Train Capacity 750 750/1250 1250 1250 Traffic Volume (day/one direction) 17,900 31,700 56,800 92,900 Peak Hour: 3 4 6 8 Off peak: 2 3 3 6 0 to 320 Km/h in 310 s (distance - 18 Km) 320 to 0 Km/h in 167s (distance - 8.5 Km) 320 to 0 Km/h in 78s (distance - 3.87 Km) 3 types (Standard, Business, Grand Class) Standard class 1.5 times of AC-I (about INR 3000) Operational Control Centre: Sabarmati & Maintenance Depot/Workshop (Rolling Stock): Thane, Sabarmati & Surat Train Acceleration: Braking: Service brake: Power failure detection brake: Classes of coach: Tentative Fare: Annual Energy requirements (Trains, Stations etc): 1100 million unit
- 30. MAHSR Rolling Stock • 10 car train (8-Motorized & 2-Trailer) 729 Seats - Start of Operation • 16 car train (14-Motorised & 2-Trailer) 1250 Seats – After 10 years Car No.1 Trailer Car (30) Car No.2 Motor Car (100) Car No.5 Motor Car (59) Car No.6 Motor Car (100) Car No.3 Motor Car with Pantograph (85) Car No.7 Motor Car with Pantograph (85) Car No.4 Motor Car (100) Car No.8 Motor Car (100) Car No.9 Motor Car (55) Business class Car No.10 Trailer Car (15) Grand /First class
- 31. Achieving High Speed Aerodynamic Design For high speeds, air drag is to be minimized. Aerodynamically designed Car body with long nose to reduce drag When high speed train exits a tunnel, a blasting sound is generated due to micro pressure waves. To reduce this micro pressure, the front car is designed with a nose section.
- 32. Achieving High Speed Reducing Air Drag Side and Bottom covers for Bogies and other underframe mounted equipment Fairings fitted all around the gaps between cars
- 33. Avoiding Ear Pressure in tunnels The car body is pressurized to avoid discomfort to passengers due to drop in pressure inside the passenger cabin in tunnel. T o achieve this complete car body is made air tight and a pressure inside the car is kept above the atmospheric pressure. Double skin hollow Aluminum extrusions with truss section Cross section area = 10.8m2 End body structure Roof structure Side structure underframe Central part of carbody End part of carbody End part of carbody Passenger Comfort
- 34. Passenger Comfort Noise Mitigation Bogie covers Sound-absorbing construction Pantograph noise insulation panel covers) Fairing (Smooth between cars
- 35. Bogie portion Bogie portion Main transformer Air tight floor(double skin) Air tight floor(double skin) AluFmlooinriubmoahrdonanedycfolomorbcpo avneerilnflgomorabteoraiardl Sound insulation floor board, Al honecomb+Carbon Steel, steel+glass wool, A lFsloouonr dboinasrdulaantidonfloboarocrdo+veforianm g emdat reersi ainl Floor board arrangement Air tight floor(standard) of Al Air duct for air conditioner Sound insulation floor board, Al honecomb+Carbon Steel, steel+glass wool, FloAolrsboouanrdd iannsduflalotoiorncobvaeorridn+gfomaamteeri dalresin Noise Mitigation Side view of the Car Sound proofing in the floor -- Inside noise < 70 dB (A) Passenger Comfort
- 36. Special Lurch Control System Intelligent control system that detects car body swaying and then reduces lateral vibrations. Passenger Comfort
- 37. Passenger Comfort Ergonomically designed interiors All seats have adjustable headrests When a seat is reclined, a seat sliding mechanism operates in tandem. Flip-up type Armrests (middle ones) Soft indirect lighting Seat leg rests operate in conjunction with seat tilting. Seatback has an improved shape Reading lamp is installed in a seatback upper corner. Grand/First class Seat pitch : 1300mm, width : 520mm
- 38. Passenger Comfort Men &Women’s toilet Women’s toilet Men and Women’s washroom Wheelchair accessible toilet Modernised toilets Men’s urinal Women’s washroom Wheelchair accessible washroom
- 39. Passenger Comfort Passenger Interface Voice communication system - Public address (PA) system; Automatic announcement system; Emergency call equipment; Wired / Wireless interphone (for crew). Staff rooms Refrigerator-freezer, hot-case, boiling water facility and tea and coffee maker, hand towel warmer (Business class) Space for On-board sellers LCD type Passenger information display English, Hindi, Gujarati and Marathi Train name and number Current station, next stopping station and destination Schedule and expected time to reach next stop and destination stations Information in emergency situations Text news Door-opening side Speed
- 40. Passenger Comfort Facilities for the differently abled
- 41. Multi-purpose room - Folding bed, baggage rack, mirror, etc. especially for sick persons or child feeding women. Passenger Comfort
- 42. Passenger Comfort Emergency Intercom System
- 43. Security
- 44. Automatic Seat Rotation & Cabin Cleaning
- 45. Various Maintenance Schedules Schedule Periodicity of schedules Downtime for Schedule Main Items Attended Daily Inspection 48 hours 2 hrs. Functional check of brake system, propulsion system, air-conditioners, pneumatic devices through S-TIMS; Check of bogies, wheels, pantographs, doors, interior equipment, toilets / washrooms, public address devices, headlights, taillights, wipers; Consumables, light repairs Regular Inspection 30,000 km or 30 days 8 hrs. All items of DI; Check of underfloor equipment; UST of axles Bogie Inspection 600,000 km or 18 months 5 day Bogie components (Bogie frame, Wheelset, Damper, WN Coupling, Axle Spring, Axle box, Axle bearing, Traction motor) are disassembled, inspected and re-assembled; Final inspection after bogie assembling; Test run in depot and on main line General Inspection 1,200,000 km or 36 months 20 days Uncoupling of cars of trainset; Disassembling of bogies; Disassembling of roof, underfloor, and interior equipment, Inspection, repair and overhaul of equipment (almost all major equipment are inspected, repaired and overhauled – Pantograph, Tight lock coupler, Seats, Doors, Toilet WC, Master controller, Brake controller, Traction converter, Blower, APU, Battery, S-TIMS unit, Air-conditioner, Ventilation equipment, Waste & Water tanks, Compressor); Painting; Air tightness of car body and wiring continuity test; Exchange of bogies; Coupling of cars into train set; Final inspection, Test run in depot and on the main line Wheel re-profiling Based on noise/ vibration, wheel profile data 2 days As per requirement, Without de-coupling the trainset ATC Characteristics Inspection 90 days 8 hrs. Train Radio Inspection a. 6 months b. 1 year 8 hrs. a. Train radio function check b. Measurement of radio output power and radio frequency Un-scheduled repair Whenever necessary As per nature of repairs As per requirement, Without de-coupling the trainset
- 46. General Inspection Train To ensure safety for the high speedrailway operation Periodic inspection of the track, S&T and electrical facilities Accurate measurement during running Manufactured year; 2001, Design basis; E3 Shinkansen (1997) Maximum speed: 275 km/h Train formation; 5M1T; 5 motor cars and 1 trailer car
- 47. Basic Concept Measuring/inspection equipment; based on the East-i. proven technology. Carbody and sub systems; based on the commercial Train Set for MAHSR Design basis; E5 Maximum speed: 320 km/h Train formation: 4M2T; 4 motor cars and 2 trailer car General Inspection Train for MAHSR
- 48. Daily Inspection Within 48 hours Check Bogies and Wheels / check Brake linings Check Doors Check Pantographs / check contact strips Check function in cabin (Brake, Propulsion system, Air- conditioning, etc.) Check Rest rooms
- 49. Regular Inspection Inspection of Bogies and Wheels / Replacement of Brake linings Check Doors Inspection of Pantographs / Replacement of contact strips Check function in cabin, (operation function, etc. ) Check Rest rooms Ultrasonic flaw inspection for hollow axle Clean or exchange air filter Check equipment Check cabin and interior Within 30,000 km or 30 days
- 50. Bogie Inspection Bogies are exchanged with spare bogies Bogie components are disassembled, inspected and assembled Within 600,000 km or 18 months
- 51. Disassemble Assemble General Inspection Almost all equipment are inspected and repaired Disassemble & Inspected Body Paint Within 1,200,000 km or 36 months
- 52. Depot Machinery – A Summary Type of Machine D-2 D-1 Some Examples Tester 63 02 Bogie Running Test Machine, ATC Tester, Oil Damper Tester Data reader 15 07 Data Management terminal, DS-ATC data reader, Other Data Readers Measurement 17 04 Wheel-axle Ultrasonic Flaw Detector, Thrust Clearance Measurement Machine Oil/Grease filling 05 00 Bearing Oil Filling Machine, TM Grease Filling Machine Painting 27 00 Automatic Car body Painting Machine, Automatic Polishing Machine Special Purpose 63 13 Wheel Lathe, Wheel-axle Ultrasonic Flaw Detector, Bogie Exchange Lifting Machine Assembly / Disassembly 25 00 Wheel Fitting Press, Bogie Assembly Machine Cleaning/Drying 59 04 Bogie Washing Machine, Gear Box / Axle Box Flushing Machine, Automatic Car body Washing Machine Surat Depot Roof Safety Step; Door Locking Device for Roof Deck; Underfloor Wheel Lathe Battery Pusher Portable compressor Forklift. Cranes 12 02 Overhead Traveling Crane, Balancing Crane, Jib Crane Compressor 10 02 Air Compressor (High), Air Compressor (Low) Heaters 06 00 Bearing Induction Heater, WN Gear Coupling Induction Heater Material handing 13 01 Traverser, Underfloor Equipment Lifter, Forklift, Battery Car Storage 08 01 Wheel Set / Wheel Disc Storage Machine, TM Storage Machine Working Platform 07 01 Underfloor Inspection Vehicle, Lifting Deck Car, Working Deck General Purpose 21 04 Charging Machine, Punching Press, Arc Welding Device Total 351 41 Summary Machines Sabarmati - 273 Different Types, 351 Specifications, 1023 Nos.
- 53. Some Key Machines for Safe Running at 320 km/h Automatic Carbody Washing Machine Bogie Running Test Machine Wheel-Axle Ultrasonic Flaw Detector Car Body Airtight Tester, etc. Automatic paint machine
- 54. Automatic Carbody Washing Machine Automatic Trainset washing Car body is sprayed with detergent and washed by RO water (inbuilt RO system) . Distributed Washing Stations – Chemical & Water Speed 5 km/h or less Water Consumed : 340 L per car (ETP recycled Water) Machine Parameters / Configuration Chemical washing units (03 Nos.): • Detergent spraying & brushing, 40 litres/minute • Water spraying & brushing, 100 litres/minute Water washing units (01 Nos.): • Washing Water spraying rate 440 litres/minute • RO water spraying rate 280 litres/minute Control Room at 2 Locations
- 55. Bogie Running Test Machine Need - Malfunction of bogie leads to serious accident Test of the overhauled Bogie at 320 km/h under load Main Parameters Driving wheels (4 nos.) drive the Machine in both directions Testing room Measuring and operation room (Sound proof) Air is supplied to air suspension to simulate the car body load. Measurements Vibration and Temperature of axle bearing, traction gear bearing, traction gear, and traction motor Air leakage from air suspension and piping Voltage and rotation speed of tachometer generator Oil leakages Temperature Vibration
- 56. Wheel-Axle Ultrasonic Flaw Detector Higher loads and vibrations on the axle in high speed running Detector detects flaws on hollow axle Main Parameters Automatic Flaw detection and whether axle is passed or failed Memory - Approx. 80 Axles. Only 01 operator is required Automatic calibration with test axle
- 57. Car Body Airtight Tester Need - Car body is pressurized for passenger comfort Tester measures the airtightness of car body Main Parameters Tester supplies air into the car body through car end cover until the test pressure (400 mm Aq (millimetre aqua or water column) or 0.04 Kgf/cm2) is reached Measures the time taken for the pressure to reduce from 400 mm Aq to 100 mm Aq or 0.01 Kgf/cm2 (should be 40 sec or more). Automatically judges whether the car body has passed / failed the test Machine equipped with car end cover set
- 58. A Modern Paint Workshop Automatic Car Body Painting Machine Moving device - moves vertically and longitudinally Robotic device – movement in all required directions Painting is automatically stopped if ventilation stops Booth with Ventilation Collects and exhausts paint mist and organic solvents through filter and duct to the outdoors Ventilation and Exhaust System (3850 m3/min) Explosion proof lighting
- 59. SUMMARY HSR operational speed greater than 200 Kmph Distributed power trains desirable for HSR Japan was the pioneer in the field of HSR China is the current world leader in HSR India will adopt HSR from Japan HSR will boost the economy and will create employement
- 60. THANK YOU