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Wagon Airbrake System, Indian Railways.
Wagon Airbrake System, Indian Railways.
INDIAN RAILWAYS
Created by A.srinivas,
junior engineer,
Wagon workshop,
rayanapadu,vijayawada.
SAFE WORKER IS THE
BESTWORKER
TOPICS
Introduction & Types Of Air Brake System
1. Distributor valve.
2. Common pipe bracket with control reservoir.
3. Auxiliary reservoir-100 Litres & 75 Litres.
4. Brake cylinder 355mm dia. , 300 mm dia.,BMBS & BMBC.
5. Isolating cock.
6. Three way centrifugal dirt collector.
7. Cut off angle cock (32mm size on either ends of brake pipe &
feed pipe).
8. Air brake hose coupling (32mm for brake pipe / 32 mm from
feed pipe).
9. Brake pipe/feed pipe (32mm dia).
10. Branch pipes from BP/FP to brake equipment (20mm bore).
11. Guard emergency brake valve.
12. Pressure gauges for BP/FP.
13. Quick Coupling.
AIR BRAKE SYSTEM
The processes involved in working of
graduated release air brake system are:-
1. CHARGING STAGE.
2. APPLICATION STAGE.
3. RELEASE STAGE.
CHARGING STAGE
5 charging time BC
kg/cm2 3 - 4 min.
5kg/cm2 DC
Created BP
by A.srinivas
JE/AB/WWS/GTPL/SCR
DV CPB
Driver AR C
brake
valve 5kg/cm2 R Created by
5kg/cm 2
srinivas
Created BP
by A.srinivas
JE/AB/WWS/GTPL/SCR
DV CPB
Driver AR C
brake
valve 45kg/cm
kg/cm22
R Created by
5kg/cm2 srinivas
For application of brakes, the pressure in brake pipe has to be dropped. This
is done by venting air from driver's brake valve. Reduction in brake pipe
pressure positions the distributor valve in such a way that the control reservoir
gets disconnected from brake pipe and auxiliary reservoir gets connected to
brake cylinder. This results in increase in air pressure in brake cylinder resulting
in application of brakes. The magnitude of braking force is proportional to
reduction in brake pipe pressure.
NOTE:- 1. Brake Application takes places when Brake pipe pressure is
RELEASE STAGE
3.8kg/cm2
1.5
5 release time BC
DROP2
kg/cm 45 - 60 sec.
5kg/cm2 2
3.5kg/cm DC
Created BP
by A.srinivas
JE/AB/WWS/GTPL/SCR
DV CPB
Driver AR C
brake
valve 4
5 kg/cm
kg/cm22 EXHAUST R Created by
5kg/cm 2
srinivas
APPLICATION
FP
5kg/cm2 DC
CreatedBPby A.srinivas
JE/AB/WWS/GTPL/SCR
NRV
DV CPB
AR C
6kg/cm2 R Created by
5kg/cm 2
srinivas
CreatedBPby A.srinivas
JE/AB/WWS/GTPL/SCR
NRV
DV CPB
AR C
6kg/cm2 R Created by
5kg/cm 2
srinivas
ISOLATING
JE/AB/WWS/GTPL/SCR
COAC
DV CPB
AR CR
Created by
srinivas
JE/AB/WWS/GTPL/SCR
EXH
R-CHARGER
5
kg/cm2
CR
QRV
BP PRESSURE
CR PRESSURE 5 kg/cm2
AR PRESSURE
OFF
BC PRESSURE CHARGING ON
NO PRESSURE Created by srinivas
3-PR.VALVE
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 5 kg/cm2
JE/AB/WWS/GTPL/SCR
EXH
R-CHARGER
5
kg/cm2
CR
QRV
BP PRESSURE
CR PRESSURE 5 kg/cm2
AR PRESSURE
BC PRESSURE CHARGING Created by
ON
NO PRESSURE
3-PR.VALVE
0.6
3.7 3.6
3.9
0 kg/cm
kg/cm22
U-CTLR A-CTLR MAX.LR MIN.LR
B
0.4 0.2 3.8 0.8 C
EXH
AR
Created by A.srinivas 54.7-4.2
kg/cm
4.1- 4 2
kg/cm2
JE/AB/WWS/GTPL/SCR
EXH
R-CHARGER
5
5 kg/cm2
CR
QRV
4.8-3.7
3.6-3.4
BP PRESSURE
CR PRESSURE 51.4
0.2 - 1.6
1.3
kg/cm2
AR PRESSURE DROP
BC PRESSURE
NO PRESSURE APPLICATION Created by
3-PR.VALVE TAKE LAP POSITION
3.7
1.25 -3.9
3 kg/cm2
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
GRADUATED GRADUATED
EXH APPLICATION
Decrease BP pressure
RELEASE
AR
Increase BP pressure
Created by A.srinivas
BP {kg/cm2} BC {kg/cm2} BP {kg/cm2} BC {kg/cm2}
54.7-4.2
kg/cm2
4.1- 4
4.8 0.6 3.6 kg/cm2
kg/cm
3.8 2
JE/AB/WWS/GTPL/SCR
EXH
5
kg/cm2
4.2 2.4 4.2 2.4
JE/AB/WWS/GTPL/SCR
0
EXH
R-CHARGER
5
5 kg/cm2
CR
QRV
0
BP PRESSURE
CR PRESSURE
AR PRESSURE
5
5 kg/cm
DROP
2
BC PRESSURE
NO PRESSURE EMERGENCY Created by
3-PR.VALVE
3.7 3.9
0 kg/cm
kg/cm22
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 54kg/cm
- 4.1 2
kg/cm2
JE/AB/WWS/GTPL/SCR
0
5
EXH
R-CHARGER
5
5 kg/cm2
CR
QRV
5
0
BP PRESSURE
CR PRESSURE
AR PRESSURE
5
5 kg/cm
DROP 2
BC PRESSURE
NO PRESSURE RELEASE Created by
3-PR.VALVE
0 kg/cm2
U-CTLR A-CTLR MAX.LR MIN.LR
B
C
EXH
AR
Created by A.srinivas 5 kg/cm
4.9 2
4.8
4.7
JE/AB/WWS/GTPL/SCR
EXH kg/cm2
4.9
4.8
4.7 R-CHARGER
5
4.9
4.8
4.7
5 kg/cm2
CR
QRV
JE/AB/WWS/GTPL/SCR
EXH
R-CHARGER
5
5 kg/cm2
CR
QRV
4.4
BP PRESSURE
0.6 kg/cm2 2
CR PRESSURE 5 kg/cm
in 6 sec.
AR PRESSURE
BC PRESSURE
NO PRESSURE SENSITIVITY Created by
3-PR.VALVE
EMPTY
LOAD
U-CTLR A-CTLR MAX.LR MIN.LR
P
EXH T
Created by A.srinivas
A
JE/AB/WWS/GTPL/SCR
EXH
R R-CHARGER
B
5 C
5 kg/cm2
CR
0.4-2.2
0.6-3.8
0
QRV
AR LSD
4.8-0
BP PRESSURE
CR PRESSURE 0.2-55kg
kg/cm2
DROP
AR PRESSURE SPRING
BC PRESSURE EK PT Created by PLANK
NO PRESSURE
LOAD
SENSING
DEVICE
BOBR/BTAP/BCCW &
LOAD SENSING DEVICE
BLC wagons are provided
with' automatic two stage
empty load device to cater for
higher brake power in loaded
condition instead of the
conventional manual empty
load' device. With the
provision of this, brake
cylinder pressure of 2.2 kglcm2
is obtained in empty condition
So as to obtain this3.8
and a change
kglcm2over mechanism
is obtained in
called "Load Sensing Device"
loaded (LSD) is interposed
condition.
between the bogie bolster and spring plank. The
mechanism gets actuated at a pre determined
change over weight and the distributor valve
LOAD SENSING DEVICE
LSD AR
Created by A.srinivas 5 kg/cm2
PT
JE/AB/WWS/GTPL/SCR DV CPB
C
R
5 kg/cm2
BP
5
SPRING kg/cm2
PLANK
3.8
2.2
Created by
BC srinivas
In loaded
Load
Another condition
Sensing
flexible the
Device
hose operating valve lets
(LSD) consisting
is connected between the
ofELoperating
port of
compressed
distributor air signal
valve and spring
valve buffer
pipe tomounted
EL port
bracket andof
ondistributor
the bogie
operating valve pipe
and pipe
valve. The bracket
with
operating
and
valvethe
flexible transformer
hoses
remains gets
Compressed
closed theairpneumatic
in empty command
from auxiliary
condition. andenters
Thusreservoir the brake
no pneumatic into
signal
BLC-DOUBLE CHECK
VALVE
Created byCONTAINER
A.srinivas
JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2
N1
LSD
LSD
AR AR
R BC Created by
srinivas
BLC-DOUBLE CHECK
VALVE
Created by CONTAINER
CONTAINER A.srinivas
JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2 4 kg/cm2 5 kg/cm2
N1
LSD
LSD
AR AR
R BC Created by
srinivas
BLC-DOUBLE CHECK
VALVE
Created by A.srinivas
CONTAINER
JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2 4 kg/cm2
N1
LSD
LSD
AR AR
R BC Created by
srinivas
AUTOMATIC
PRESSURE
MODIFICATION
{EL-60 VALVE}
EMPTY APM
RESERVIOR
BC BC
1 2
DV CPB
3.8
APM
2.2
Created
104mm by A.srinivas SENSOR ARM
JE/AB/WWS/GTPL/SCR Created by
srinivas
BC BC
1 2
DV CPB
3.8
APM
3.8
Created by A.srinivas
JE/AB/WWS/GTPL/SCR Created by
srinivas
Created by A.srinivas
FP FP
FP
HOSE ISOLATING HOSE
COCK DC
5kg/cm2
3.5kg/cm
COAC COAC
JE/AB/WWS/GTPL/SCR
BP
BP
BP CPB BP
HOSE 6 HOSE
kg/cm2 APM
NRV
3.8 T
DV FLANGE
AR APM RESERVIOR
100 LTRs (WITH OUT PT)
ISO.COCK
WITH VENT
FLEXIBLE
HOSE
PIPE
Created by 10 BC FOR
EMPTY LOAD 10 BC FOR
BOGIE 1 (WITH
srinivas BOGIE 2 2.2 3.8 HANDBRAKE
CABLES)
BMBS-BRAKE CYLINDER
GASKET
Created by A.srinivas
PISTON
INDICATOR
ASSLY. BC PIN
COMPR.SPRING 3
JE/AB/WWS/GTPL/SCR
CLUTCH LOCKING STUD
COMPENSATOR
SAB SPRING RAM ASSEMBLY
COMPR.SPRING 1
COMPR.SPRING 2
Created by srinivas
The brake cylinder receives pneumatic pressure from auxiliary reservoir after
being regulated through the distributor valve and APM device. Brake cylinder
develops mechanical brake power by outward movement of its piston with ram
assembly.
BMBS-BRAKE CYLINDER
BC PRESSURE
Created byPISTON
A.srinivas
STROKE
54+/-10mm
JE/AB/WWS/GTPL/SCR
Created by srinivas
The piston rod assembly is connected to the brake shoes through a system of rigging
arrangement to amplify and transmit the brake power. The compression spring provided
in the brake cylinder brings back the ram thus the rigging is also brought to its original
position when brake is released.
BMBS-BRAKE CYLINDER
BC PRESSURE
Created by A.srinivas
JE/AB/WWS/GTPL/SCR
Created by srinivas
The
This
The built-in
brake
ensures slack
cylinder
that adjuster
every
has time compensates
got aevery
double
time
acting for the
the brake
slack wear ofasbrake
application
adjuster takes blocks
a result the during
place,sufficient
the brake
actuator
brake ofapplication
force is
brake
delivered through
cylinder
on the equivalent
willwheels.
continue pay-out.
Thetobrake For
tillpaying-in,
movecylinder
out compensates a pry
all the slack inforbar
theanyis
applied
system in
change between
is gap the
takebetween
care offbrake
and
brake shoe and
reaction
block andwheel
force ofand
wheel the the
throughrigging
wheels is pushed
theisinbuilt
encountered. in.
slack adjuster.
BOGIE MOUNTED BRAKE SYSTEM
BK.BLOCK
BELL CRANK
LEVER
SECONDARY BEAM
Created by A.srinivas
PRIMARY BEAM
P
BMBS W U
DOUBLE
JE/AB/WWS/GTPL/SCR
BOGIE
TOP
H
EE
L
ACTING
S
H
R
SE O
VIEW T D
s
BC PIN
EYE PIN
CLEVIS PIN
Created by srinivas
BOGIE MOUNTED BRAKE SYSTEM
BMBS
Created by A.srinivas
JE/AB/WWS/GTPL/SCR
BOGIE
TOP
VIEW
Created by srinivas
BOGIE MOUNTED BRAKE SYSTEM
NEED FOR ADOPTION OF BMBS
IN FREIGHT STOCK: