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, 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, 2 EXECUTIVE CHAIR CARS AND 3 POWER CARS

TRANSFER MANUFACTURING KNOW-HOW FOR THESE HELP IN DESIGNING AND MANUFACTURING FIRST AC, AC

SLEEPER AND HOT BUFFET COACH

HELP INDIAN RAILWAYS IN DEVELOPING SG VERSION OF THESE COACHES

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, 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CERTAIN PROBLEM NOTICED WITH CBC AND RAKE WAS WITHDRAWN FROM SERVICE ON 25-6-2001. REINTRODUCED ON 9-1-2002

MANUFACTURING KNOW-HOW RECEIVED, MANUFACTURING STARTED

ALL THE THREE VARIANTS DESIGNED AND MANUFACTURING DOCUMENTS FINALISED

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.

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.

Large wheelbase affects curvability / Wheel flange wear.

Ride Index

ICF• 2.6 at 160 kmph in

vertical modes and 3.4 / 3.5 at 160 kmph in lateral mode

FIAT• Ride index shall be

2.5 but not exceeding 2.75 both in vertical and lateral modes

Speed potential LHB ICF

Test speed 180 kmph 160 kmph

Service speed 160 kmph 140 kmph

Oil leakage problem

No Very high

Shop Attention

Schedule ICF LHB

1st attn 9 months/2 lakh kms (ioh)

18 months / 5 lakh kms

2nd attn 18 months/4 lakh kms (poh)

36 months/ 10 lakh kms

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

ICF 2896 mm

FIAT 2560 mm

Less Wheel-base improves its ability to negotiate curves

Wheel Base

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.

ICF• Secondary spring on

lower spring beam through hangers

FIAT• Secondary spring

directly mounted on the side frames

Vertical space constraints to accommodate desirably softer secondary suspension springs.

Secondary Suspension Unit

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

Bogie - Body Joint of FIAT

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

SALIENT FEATURES OF LHB DESIGN COACHES

STAINLESS STEEL USED FOR SIDEWALL, 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

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 AIR-

CONDITIONING 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

SALIENT FEATURES OF LHB DESIGN COACHES

BOGIES WITH FLEXICOIL SPRINGS,YAW DAMPER, 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

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 PANELSMACORE WOOD

CORK

MACORE WOOD

BOGIE

LONGITUDINAL BUMP STOP (0.67 kg)

SILENT BLOCK FOR ANCHOR LINK (3.5 kg)

RUBBER BONDED METAL COMPONENTS

CENTRE PIVOT SILENT BLOCK (3.3 kg)

ELASTIC CONNECTION (20 kg)

Sl Dimension/ feature LHB/FIAT coach

ICF AC Chair car

1.     

 Gauge 1676 mm 1676

mm

2.     

 Length over body 23540 mm 21340m

3.     

 Buffer-centres (if buffers provided) 1956 mm 1956

mm

4.     

 Maximum width over body 3250 mm 3245

mm

5.     

 Height of centre-line of coupler from rail-level under tare condition

1105 mm 1105 mm

6.     

 Height of compartment floor from rail-level under tare condition

1303 mm 1313 mm

Sl Dimension/ feature LHB/FIAT coach

ICF AC Chair car

1.     

 Maximum distance between inner wheels 12345 mm 1189

mm

2.     

 Maximum buffer-drop under gross load and worn condition

75 mm 75 mm

3.     

 Maximum height of centre-line of side-buffers above rail-level for empty vehicles

1105 mm 1105 mm

4.     

 Minimum height of centre-line of side-buffers above rail-level for loaded vehicles

1030 mm 1030 mm

5.     

 Maximum height of centre of screw-coupling above rail-level for empty vehicles

1055 mm 1054 mm

6.     

 Maximum tare weight for AC chair car with all supplies in working order, including water

39 t 43.1 t

7.     

 Maximum axle-load permissible 16 t 16 t

Sl Items ICF all coiledFiat Bogie

1. Weight of the Bogie.

6.2 t. 6.536 t.

2. Speed cleared for. 140kmph 160kmph.

3. Wheel Base. 2896 mm. 2560 mm.

4. Bogie frame. Box type with headstocks.

H-type boxes construction.

5. Wheel diameter. 915 mm (New)813 mm (Condemned)

915 mm(New)845 mm.(Condemned)

6. Brake. Clasp type brake. Axle mounted disc brake.

Sl Items ICF all coiledFiat Bogie

7. Braking system. Vacuum & Air. Air.

8. Type of bearing at journal

Spherical roller bearing. Cartridge tapered roller bearing.

9. Suspension vertical (Axle level).

Coil spring with dashpot arrangement.

Coil springs are nested.

10. Axle guidance. Rigid. Articulated by control arm.

11. Noise feature. Limited noise control feature.

Isolation of noise from bogie to coach body connection.

12. Position of secondary spring.

Secondary spring on lower spring beam through hangers.

Secondary spring directly mounted on side frames.

Sl Items ICF all coiledFiat Bogie

13. Oil leakage problem.

Very high. 

No leakage 

14. Coach load transfer.

100% through side bearers.

100% transfer through body bogie connection.

15. Traction & shock load transfer.

Through centre pivot. Through pivot assembly on transverse beam and bracket on doom.

16. Anti roll bar arrangement.

Not provided. Provided. 

17. Ride index. 2.6 at 160kmph in vertical modes and 3.4 / 3.5 at 160kmph in lateral modes.

Ride index shall be 2.5 but not exceeding 2.75 both in vertical and lateral modes.

Sl Items ICF all coiledFiat Bogie

18. Maintenance requirement in POH.

More due to-Axle box guide arrangement.Spherical roller bearing.Clasp brake.More pin joints.

Very little due to-Disc brake.Cartridge tapered roller bearing.Bogie frame, springs and rubber components.Wheel with improved curving characteristic.

19. Maximum distance between inner wheels.

11887 mm. 12345 mm.12340 mm (Proposed)

17. Ride index. 2.6 at 160kmph in vertical modes and 3.4 / 3.5 at 160kmph in lateral modes.

Ride index shall be 2.5 but not exceeding 2.75 both in vertical and lateral modes.

19. Maximum distance between inner wheels.

11887 mm. 12345 mm.12340 mm (Proposed)

Thank you