Presentation on fabrication of Bogie under frame used in worldwide Locomotive...:)

2. DESIGN FEATURES:

3. FIAT BOGIE
SUB-SYSTEMS

4. BOGIE FRAME
 Y-FRAME
-STEEL SHEETS(St-52)
 TWO SIDE FRAMES CONNECTED BY TWO CROSS BEAMS
-SUPPORT BRAKE UNITS.
 BOGIE FRAME ON THE PRIMARY SPRINGS AND SUPPORTS
VEHICLE BODY THROUGH BOLSTER.
 BOLSTER-BOGIE
FRAME
THROUGH
SECONDARY
SUSPENSION.

5. BOGIE FRAME

6. BOGIE FRAME

7. (Bogie frame lifted)
Primary Spring assly
Primary Damper

8. MATERIAL PROPERTIES:
UTS IN Mpa
YIELD
STRENGTH
Mpa
ELONGATI
ON %AGE
IMPACT
CHEMICAL
%AGE:
S355J2G3;
EN10025
490-630
355
GS20Mn5V;
DINl:17182
500 – 650
360
SG400/18;
IS:1865
400
250
SG400/15;
IS:1865
400
250
22
24
18
15
27J AT -20
0
C
C 0.23, Mn
1.7, Si 0.6, S
&P 0.045
70 J
--
--
C 0.17 to
---0.23, Si 0.60,
Mn 1.00 to
1.50, S≤
0.020,
P≤
0.015, Cr ≤
0.30, Mo ≤
0.15, Ni
0.40
≤
---

9. Primary suspension
 Four nos each per bogie -nested coil springs, primary
vertical dampers, control arm, elastic joints-connecting the
bearing on wheelset to bogie frame.
 Flexible guidance.


10. (Primary exploded)
Rubber Pad
Outer Spring
Spring Guide
Inner Spring
Lower Spring Guide
Bump Stop

11. (Wheel set with Primary suspension)
Control Arm
Bearing Assly
with earthing
eq./speed sensor

12. (Wheel set with Primary springs removed)
Primary Damper
C
Control Arm

13. WHEELSET
Two brake disks (4), diameter
640 mm and width 110 mm.
 Two wheel discs of dia 915
(New), 845 (worn).


14. Wheel & Axle Assly
Brake Disc

15. DIMENSIONS OF WHEEL SET:

16. Wheel Disc:

17. WHEEL RE-PROFILING AND
BALANCING:
DYNAMIC BALANCING 320RPM
 LESS THAT/EQUAL TO 50GM.M
 GLUE THE NEEDED WEIGHTS.


18. DETAIL OF ADDED WEIGHTS:

19. AXLE BEARINGS
 CARTRIDGE
TAPER
ROLLER BEARING
 PRE-ASSEMBLED UNIT.
 MAINTENANCE FREEOVERHAUL 1.2 MILLION
KM.

20. CTRB

21. BRAKE CALLIPER UNITS
AXLE MOUNTED DISC BRAKE
 INBUILT SLACK ADJUSTER IN BRAKE
CYLINDERS
 CALLIPER RATIO 1:2.17 FOR ALL
COACHES EXCEPT ACCN/SG & POWER
CAR WHICH IS 1:2.48
 35mm BRAKE PADS

 JURID
877/BECORIT984 KB & SABWABCO.

23. BRAKE CALLIPER UNIT

24. SECONDARY SUSPENSION
NEST OF FLEXI-COIL SPRINGS INNER AND OUTER,
RUBBER SPRING AND SECONDARY PAD
 VERTICAL DAMPERS
 LATERAL DAMPERS
 YAW DAMPERS
 ANTI-ROLL BAR
 ANCHOR LINKS


25. SECONDARY SUSPENSION

26. (With Bolster Lifted)
Sec. Vertical
Damper
Bogie Bolster
Cross Section
Nested
Secondary
Spring
Assembly
Yaw Damper

27. (With Secondary Spring System Exploded)
Bogie
Bolster
Miner Pad
Spring Guide
Outer Spring
Inner Spring
Rubber Spring

28. SECONDARY SUSPENSION

30. (Bolster removed)
Lateral Damper
Lateral Bumpstop
Longitudinal Bumpstop

31. (X-section lifted)
Traction Lever
Traction Center
Anti Roll Assly
Curve Roll

32. ANTI-ROLL BAR:
A TORSION BAR WITH TWO FORKS- BETWEEN
BOGIE FRAME & BOLSTER,CONNECTED BY
ROLL LINKS.
 RESISTS ROLLING MOTION OF COACH.
 AS PER UIC515-1 TILTING CO-EFFICIENT <0.4.


33. ANTI-ROLL BAR:

34. A
Anti-roll assly

35. ANTI ROLL BAR

36. BUFFER HEIGHT ADJUSTMENT
Shims at body/bogie connection.
 Shims NOT added/removed in Primary and
Secondary Suspension for wheel wear compensation
or buffer height adjustment.


37. BOGIE BODY CONNECTION:

38. BODY BOGIE CONNECTION

39. PRINCIPLES OF FORCE TRANSMISSION
Vertical forces:
 BODY-BOLSTER-MINER PAD-SEC.SUSPENSIONBOGIE FRAME-PRIMARY SPRINGS/BALL JOINT
CONTROL ARM-AXLES.


40. LATERAL FORCES:

BODY-BOLSTER-MINER
PAD/SEC.SPRINGS/LATERAL BUMP STOP-BOGIE
FRAME-BALL JOINT CONTROL ARM-AXLES.

41. TRACTION AND BRAKING FORCES:

BODY-TRACTION
CENTRE-TRACTION
LEVER/LONGITUDINAL
BUMP STOP-BOGIE
FRAME-CONTROL ARMAXLES.

42. A
Traction Center

43. CURVE NEGOTIATION:
CONTROL ARM (SGCI TO IS:1865) CONNECTING
AXLE BEARING AND SIDE FRAME THROUGH
ELASTIC CONNECTION.
 FLEXIBILE GUIDANCE TO WHEELSET.


44. SUSPENSIONS OF VARIANTS

THE COMMON SUSPENSION GROUPS ARE:
 GS,SCN,SLR
 CC,EC,CB,FAC/EOG,ACCW/EOG.
 ACCN/EOG,FAC/SG,ACCW/SG
 ACCN/SG,WLRRM
 WLRRM
SIDE 2.
SIDE 1.
 SLR UNDERSLUNG.

45. MAIN DATA:

46. SPEED LIMIT
Cleared upto 160KMPH.
 upto 200KMPH with magnetic brakes/sintered brake
pads.


47. RIDE INDEX

CHAIR CAR:
 VERTICAL
2.75
 LATERAL 2.5

48. SELF-GENERATING BOGIE WITH VBELT:

50. CARDAN SHAFT ARRGT. FOR
25KW ALTERNATOR

53. THANK
YOU