www.rdso.indianrailways.gov.inwww.rdso.indianrailways.gov.in

Annual Report 2011-2012

MOTIVE POWER

RESEARCH, DESIGN & DEVELOPMENT

Design and Development of 5500 HP WDG5 Diesel Locomotive

Improved Crashworthy Design of WDP4B Locomotive

Narrow Gauge Diesel Hydraulic Railbus (610 mm Gauge) for Neral-Matheran Section

n

n

n

n

n

n

n

n

n

n

n

n

n

Development of Inter-Operable Distributed Power Control System (DPCS) of Diesel Electric Locomotives

locomotives, was fitted with the DPCS of the same make. Based on the current requirements, an exercise for revision of specification was under taken so as to provide interoperability of systems of different makes. The revised specification has been prepared in Nov '11 Indian Railway under took a project jointly with M/s EMD with the following additional important features i.e. for developing a 5500 hp high horse power WDG5 interoperability across different makes of the DPCS locomotive. Different loco assemblies were designed by made possible with requirement of common protocol for RDSO in consultation with EMD-USA. The developed radio frequency communications, improved integration loco design would not only augment traction-power with locomotive systems, improved logic for loss of availability, but would also serve, as a platform for future communications, improved software interlocks for design of high hp diesel traction. First prototype increased safety and reduction of operator errors and locomotive has been manufactured by DLW in Feb analysis of failure modes effects and criticality analysis 2012.has been made mandatory at the design stage. The revised specification allows for different makes of the DPCS to work together for greater operational flexibility. Additional software interlocks have been provided for improved safety.

To improve the crashworthiness of WDP4B locomotive structure, two more anti-collision posts in driver's cabin have been introduced. This has resulted in relocation of CCB from driver's cabin to cooling hood. Some changes have been made in the under frame structure to accommodate CCB into the cooling hood. Finite element analysis has been done in Oct '11 to check the effect of this modification on the strength of the under frame structure and the results have been found RDSO has prepared a specification incorporating the satisfactory. Indian Railways shall be benefited by following important modern features.improved crashworthy structure of the locomotive.Bi-directional unit with driving cab at both ends

Two-axle bogie capable of negotiating 127.3°curve

Self-propelled by 150hp diesel engine

Hydrodynamic transmission

Max. Operating speed of 20 km/h

Ergonomically designed driver's cab & seat

Twin pipe graduated release air brake

Panel mounted brake system

Standalone VCD

Air dryer

Pneumatic horn

Twin beam headlight, Flasher light, marker light

Speed indicator cum recorder

Previously RDSO had developed a specification for distributed power operation, which was applicable to

Solid Model of Modified Under Frame Structure

Stress Plot (Drag Load Case) Where Structure Modified

47

www.rdso.indianrailways.gov.inwww.rdso.indianrailways.gov.in

Annual Report 2011-2012 MOTIVE POWER

Development of Light Weight Maintenance Friendly (LWMF) Bogie for High Horse

Development of WDG5 Locomotive Bogie Power LocosFrames

Modification of Exhaust Manifold From Existing Three Entry to Modified Single New Rough Tread Profile of Locomotive Entry Design for ALCO Locos Fitted with WheelABB TPR-61Turbocharger

Introduction of Single Pin Design Clevis in H-Type Transition Tight Lock Coupler

Development of Solid Wheel for NG Railcar for Kalka- Simla Section of Northern Railway

solid wheel followed by FEM analysis in July '11 and sent to concerned railway.

A new design of lightweight maintenance friendly bogie applicable to Dual Cab WDP4D high horse high speed A new design of bogie has been developed for 5500 hp locomotive is being developed by RDSO. This design is WDG5 locomotives, which largely is of fabricated expected to have much less weight compared to the design but has several critical cast components. The existing Fab-II or HTSC bogie, besides being more bogie has several advantageous features, the most maintenance friendly. General arrangement of bogie notable one being very light weight of 3.6T as against assembly and suspension design of LWMF bogie after 5.5T of the existing HTSC cast bogie for WDG4 preliminary simulation results of bogie on Rail ADAMS locomotive, while supporting higher axle load of 22.3 T. has been finalized in Oct '11. Main advantages of this development are ease of manufacture & maintenance, efficient brake gear arrangement, reduction in axle load and useful for high-speed locomotives

A new rough tread profile has been prepared to In three-entry exhaust manifold, there have been some minimize the wheel diameter reduction during finish failures of turbochargers due to breakage of turbine machining of tread profile of locomotive wheel in Dec blades. To overcome the problem, Single Entry exhaust '11. As a result, life of the wheel is expected to increase manifold with improved features was developed and the by 5% without any additional cost. Besides this, it will same has been tested for its performance on the engine also reduce machining time and cost.test bed as well as in the field and the results obtained Durgapur Steel Plant has been advised to manufacture were satisfactory. For the implementation of the single 100 nos. wheels on trial basis. Indian railways shall be entry exhaust manifold a modification sheet has been benefited by increased wheel life, less cut required to issued. Implementation of modified design will reduce obtain finish wheel tread profile from rough profile.pulsation on turbine blades, consequently reduction in turbine blade failures in ABB TPR-61 turbochargers.

Railways have reported problems with double pin design of clevis initially applied on H-type transition tight

To resolve the problem in procurement of tyred wheel being used in the existing NG Railcar for Kalka-Simla section of NR, RDSO has prepared a design drawing of

1

24

3

8

6

9

To Be Alloted

BOGIE GENERAL ARRANGEMENT

5

7

10

(HTSC-LWFM)

General Arrangement of Lightweight Maintenance Friendly Bogie

48

www.rdso.indianrailways.gov.inwww.rdso.indianrailways.gov.in

Annual Report 2011-2012 MOTIVE POWER

lock couplers. In view of the above, a new design of the permissible limit. Vehicle dynamic simulation was single pin clevis has been conceptualized. This single done at 135 - 160 Kmph on NUCARS software. The pin design will improve the reliability and reduce the result was found satisfactory. The weight of the LWMF operational problems. bare bogie frame is only 4T in comparison to 5T of Fab-II

or HTSC bogie. Important features of this bogie are: -

Light weight bogie frame useful for increasing speed

Ease of maintenance.Presently WDG4/WDP4 locomotives are fitted with

Simplified bogie frame.HTSC bogie and Fab-II bogies. A lightweight Simple guide link arrangement.maintenance friendly (LWMF) bogie has been Efficient brake gear arrangement.designed, which besides being significantly lighter than

the existing bogies will be more maintenance friendly too. Solid modeling was done in UG NX-5. FEA was done in IDEAS NX using NASTRAN solver. The design strength of bogie frame with the combination of different load cases as per RDSO procedure was found within

The basic requirements of high-speed vehicle are low axle load and low un-sprung mass. Existing bogies running under EMD class WDP series locomotives are equipped with nose suspended motor, in which 50% weight of this assembly contributes as unsprung mass. To reduce unsprung mass, it is required to have fully suspended motor and drive gear system such that the weight is fully supported by bogie/underframe. Besides the traction motor too is required to support high speed. Specification has been prepared in August 2011 to invite expression of interest from global experts to assist Indian Railway in this venture.

Design Development of Light Weight nMaintenance Friendly HTSC (LWMF) Bogie

Frame for WDP4B Seriesn

n

n

n

Development of a Locomotive Drive Gear System with Fully Suspended Traction Motor for High Speed (220 kmph) Locomotive Bogie

49