Presentation

On
Indian Railways
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 CONCEPT OF LOCOMOTIVE BOGIE

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EMD LOCO BOGIE
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 Bogie in service in IR Locomotive
•Three types of bogies are
running in Indian railways
1.Single stage suspension CO-CO tri
mount
2.Two stage CO-CO tetra mount, high
Adhesion Bogie
•With equalizer
Next •Without equalizer
Previous 3. Flexi-float two stage suspension
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•With Bolster-WDP3A,WAP- 1/4/6
•Without Bolster-WDP-1,WAP5/WAP7/WAG9
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 Locomotives fitted with single stage
suspension
Locomotives fitted with single stage suspension
CO- CO tri mount (120 Km/h) max.
WDM2, WDM3A WAM4, WAG5,
WAG5HB,WCAM1
• Single piece casted/fabricated bogie frame
• Axle load 18.5 t
• Car body is directly supported on three points of
bogie frame.
• Three points constitutes one centre pivot and
Next two side bearer points
• 60 % load on centre pivot
Previous • 40% load on two side bearer
Home • Axle load equalization is provided by
Exit equalizer beam arrangement mounted on axle
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box crown
 Single stage suspension Bogie

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Previous
Home CO-CO tri mount bogie
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 Locomotives fitted with single stage
suspension

 Four group of Primary

suspension coil springs are
kept on equalizer beams.
 Bogie rotates about centre pivot
 Cylindrical roller bearings
Next
provided in axle box
 Conventional clasp type brake
Previous
Home rigging
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 Locomotives fitted with two stage
suspension tetra mount

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Previous
Tetra mount high adhesion bogie
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 Locomotives fitted with two stage
suspension tetra mount

• WDG3A ,WAG7, WCAM3, WDG4 WDP4

• Axle load varies from 20 -22 T
• Car body supported on bogie frame at 4 points via secondary
rubber side bearer on each bogie
• Centre pivot transmits traction and braking forces
• No vertical load comes on pivot
• Uni-directional traction motors, reduction in mechanical weight
transfer
Next • With Equaliser
Previous • Axle load equalization by providing compensating beam mechanism
• 4 group of primary coil spring are kept on equalizer beams
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• Cylindrical roller bearings provided in axle box
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 Locomotives fitted with two stage
suspension tetra mount EMD loco
•High adhesion
•Without Equaliser
•WDG4 WDP4 are provided with flexi float pivot fitted with
car body traction bar
•Car body and pivot link constitute a four bar mechanism.
•WDG4 WDP4 are imported EMD designed bogie
•WDG4 WDP4 bogies are designed for 21 and 19.5 t axle
load
•EMD bogies are equalizer less bogie
•EMD bogies are provided with primary coil springs mounted
Next on bearing adaptor work as axle box
•EMD bogies are provided with primary traction link between
Previous bearing adaptor and bogie frame
• bearing adaptors are provided with CTRB bearing.
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 Locomotives fitted with two stage
suspension tetra mount EMD loco

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Previous GM loco Bogie
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 Locomotives fitted with Flexi coil two stage
suspension
WDP3A,WAP4, WAP5 (Bo-Bo),WAP7, WAG9
•Two stage helical coil spring suspension
•Primary springs are kept on axle box
•Hydraulic dampers are provided at primary and secondary
stage
•In WAP-7,WAG-9 and WAP-5 traction bars are fitted to
transmit traction between car body and bogie frame
•Lateral and vertical Stops are provided for restriction of
motion at primary and secondary stage of suspension
•Axle boxes are provided with primary guide link between
axle box and bogie frame.
Next •WAP3A and WAP4 loco bogies are fitted with bolster having
Previous center pivot which takes 100 % load of car body
•WAP7 and WAP5 have two point secondary coil springs
Home which bear the load of car body and no bolster is provided
Exit there with.
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 •Design parameters for new bogie

• Service required- Freight or Passenger service

Freight- High tractive effort, Stiff secondary, High adhesion
Passenger- Soft suspension
•Loco wheel base –Dictated by loco design, curve, throw over
•Axle load- Hard suspension (Energy absorption more with
certain deflection)
•Speed potential
•Negotiability-Curving ability
High longitudinal clearance lead to hunting
•Maximum Moving dimensions
•Performance criteria
Next •Adhesion level
•Track data
Previous •Climatic condition
Home •Manufacturing practices

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 Bogie assembly component

•Bogie frame
Integrated piece fabricated or casted
with hollow sections
• Support weight of super structure
• Subjected to dynamic loading
i. longitudinal
ii.Vertical
Next iii. Lateral
Previous iV. Diagonal
Home •Retain brake rigging and traction motors
Exit
and other devices.
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 EMD Bogie frame

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Previous GM bogie casting frame

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 Bogie assembly component

Wheel axle set

Function as
•Support weight of vehicle
•Bear torsional force due to torque applied by
traction motor
•Support traction motors
•Retain axle box roller bearing
Next •Move forward while rotating
•Wheel Interact with track and follow track geometry
Previous Sustain track forces
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 Wheel axle set

Next
Wheel axle set with
Previous motor suspension and
Home CTRB bearing mounting

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 Bogie assembly component

 Brake rigging
Constitute brake gear arrangement
Function as to stop the vehicle with
in certain distance.
Existing brake arrangements are of
Clasp type conventional
Next T.B.U
Previous
Disc mounted
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 EMD bogie with single shoe brake rigging

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Previous
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 Bogie assembly component

•Primary suspension
Function as to absorb the shock load
arises due to irregularities arises from
Wheel rail contact. Reduce vibration.
Guide Wheel axle set.
Suspension component comprise
Coil spring
Next Hydraulic dampers
Previous Rubber springs
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 Bogie assembly component

Secondary suspension
Suspension may be hard or soft as per
requirement
Meant for good riding behavior
This consist of
•Helical coil in conjunction with shock
absorber
Next •Damper may be fitted in lateral vertical
and yaw mode
Previous
• rubber springs with shock absorber
Home •Air spring
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 EMD bogie two stage suspension

Next Primary helical coil

spring and secondary
Previous with rubber side bearer
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 Bogie assembly component

•Traction motors
Function as torque input to wheel set
provided with gear assembly. Traction motors
are
•Axle hanged nose suspended.
•Fully suspended motors
•BHEL make 4906
Next •AC light traction motors Simen
Previous •Provision of nose link suspension
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 EMD Bogie simen traction

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Previous
AC-AC transmission
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 Bogie assembly component

•Centre pivot
Function as transfer of tractive effort between
car body and bogie. Pivot may be of integral
part of b/frame or attached by traction
bars.Pivots are as
•Fixed integral loading pivot(WDM2)
•Floating pivot(WDG3A)
•Flexi float pivot(WDG4,WDP4)
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Previous
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 GM EMD Bogie Centre pivot
arrangement (Four bar mechanism)

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Previous
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 Bogie assembly component

•Car body traction rod

Function to transmit traction and braking
force. Attached to pivot by elastomeric
constraints.
These may be
Next Single car body bar
Previous Four bar arrangement
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 Bogie assembly component
•Axle box
Function to accommodate the roller
bearing inside it. Bear the suspension load
coming via primary suspension. Axle
boxes may be of
•Conventional type
•Wing type
Next •Conventional with
Equalizer beam w
Previous
•Adaptor type Wing type axle box
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 Bogie assembly component

•Primary traction link

Function to transmit traction from axle to
bogie like conventional horn guide and
simultaneously provides cushioning to
longitudinal forces. Reduce longitudinal
shock of traction and braking forces.
Guidance to axle box
Next Axle guide links
Previous
•Alastom type
•ABB type
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 Primary traction link

ALSTOM TYPE
AXLE GUIDE
LINK

ABB TYPE
AXLE GUIDE
Next LINK
Previous
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 Bogie assembly component

Bearing adaptor (EMD

Provides housing for journal bearing
Connected with guide links
Support primary coil springs
Support lower damper brackets
Provided with locking arrangement

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Previous
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 System followed in introducing a new
bogie

•Concept Lay out and FEASIBILITY STUDY

•Component selection as per design space
•Fixing of dimensions
•Making a concept Design
•FEA and NUCARS
•Finalisation of Design
•Final assembly drawing
•Prototype production
Next •Prototype Inspection and testing
•Fatigue testing & Oscillation trial
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•Field Evaluation
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 Oscillation trial
New designed vehicle after
prototype production is handed
over to zonal railways. The
speed certificate is issued after
conducting the oscillation trial.
The oscillation trial is
Next conducted at 10 % higher speed
Previous than the maximum designed
Home speed for the said track
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 •Field evaluation

After conducting oscillation trial, successfully

passed vehicle as per performance criteria are
handed over to zonal railway for service.
Feedback of Newly launched vehicle is observed
for running performance against hunting lurching
or any abnormal motion. The defects are noticed
and rectification is carried out for the cause of
Next defects. Feedback of components for their
functioning and life is recorded. These way
Previous components are developed and standardized.
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 •Conduction of oscillation trials

As per policy circular no. 6 a vehicle

should be subjected to oscillation trials,
if
•Different principal dimensions
•Different bogie design
•New braking system
•Change in axle load and track loading
Next density
Previous •Change in unsprung mass
Home •Change in suspension system
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 •Conduction of oscillation trials

Trials are conducted as per following

•Identification of test section
•Zonal railway obtain the permission from
CRS
•Submit a joint safety certificate duly signed
by chief engineer, chief mechanical
engineer, chief operating manager, chief
signal and telecommunication engineer and
Next chief electrical engineer on electrified
Previous routes.
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 •Conduction of oscillation trials

•Test section 1 km straight (2 nos.)

•700 – 800 meter 2 degree curve
•Station yard
•Test vehicle should be last vehicle and
data acquisition system car in adjacent to
it
•Accelerometer on floor level , LVDT for
Next spring deflection and load cell for lateral
Previous force
Home •Vehicle start with low speed 60 to 80 km/h
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 •Conduction of oscillation trials

•Increase speed in step of 5 to 10 Km/h

•Stop run if record show any parameter
exceeds criteria
•Run up to test speed
•Trial follow by long confirmatory run on 50
km long section
Next •Long confirmatory run check resonance at L-
xing, culvert, bridge and others
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 Conduction of oscillation trials

•Oscillation trial parameters

•Acceleration vertical
•Acceleration lateral
•Ride index vertical
•Ride index lateral
•L/V ratio
•Hy-2m force (t)
Next •Bogie rotation
•Bogie swing
Previous
Spring deflection
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