New Designs of Wagons
New Designs of Wagons
New Designs of Wagons
AK Khosla
Jindal Rail Infrastructure Ltd.
Presentation Outline
Wagon Holding on IR
Type of Wagons on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
Presentation Outline
Wagon Holding on IR
Type of Wagons on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
Wagon Holding on Indian
Railways
TYPE OF WAGON WAGONS TOTAL QTY.
OPEN WAGON BOXN,BOXNHS,BOXNHL,BOXNLW,BOY,BOST,BO 1,37,360
STHSM2,BOXNLW, BOXNS
COVERED WAGON BCNA, BCNHL, BCNAHS 70,239
FLAT WAGON BFNS,BRNA,BRN22.9,BRHNEHS, 11,694
Wagon Holding on IR
Wagon Types on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
Wagon Types on Indian Railways
OPEN WAGONS
Brake rigging (Under frame mounted/Bogie Bogie mounted Under frame mounted
mounted)
Maximum Speed 100 kmph 100 kmph
FLAT WAGONS
Unloading Bottom & Side Side Air Assisted Bottom Bottom Bottom
discharge discharge discharge discharge discharge
Length over head stock (mm) 10718 10668 9784 9671 9671
Length over couplers (mm) 12000 11597 10713 10600 10600
Length inside (mm) 9000 9296 10085 9327 9327
Width inside/Width Overall (mm) 2863/3189 2743/3020 3129 3340/3500 3340
Height inside/Height(max.)from RL. 1781/3050 3304 4265 2466/3735 2456/3735
Height of C.B.C. from R.L. (mm) 1105 1105 1105 1105 1105
Cubic Capacity (Cu.M) 40.3 34.00 75.8 56.78 56.78
HOPPER WAGON TYPE
BOBRN WAGON BCFC WAGON
SALIENT FEATURES
Types Single pipe & twin pipe graduated release
SALIENT FEATURE
Type of coupler AAR ‘E’ type High tensile Centre Buffer Coupler
(Transition & Non-transition) and Screw coupling
Type Draft Gear High capacity draft gear as per AAR-M901E
Tensile load 1000 kN
Compressive load 2000 kN
Coupler Parts 1. Coupler Body with Shank wear plate - Cast Grade E
2. Knuckle - Cast Grade E
3. Lock - Cast Grade E /Forged
4. Knuckle thrower - Cast Grade B /Forged
5. Knuckle Pin with Anti-theft cotter pin - Forged
6. Rotary bottom operated articulated lock lift assembly - Cast Grade B /Forged
7. Coupler Yoke - Cast Grade E
8. Yoke Pin - Forged
9. Yoke pin support with wear plate - Cast Grade B
10. Striker casting with wear plate - Cast Grade B
Presentation Outline
Wagon Holding on IR
Type of Wagons on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
MAXIMUM MOVING DIMENSIONS
DIAGRAM NO. 1D-2004
Fixed Structure –Non Electrified Route
(Clearance with Max Moving Dimension)
Fixed Structure – Electrified Route
(Clearance with Max Moving Dimension)
Fixed Structure – Bridges & Tunnel
(Clearance with Max Moving Dimension)
MAXIMUM MOVING DIMENSIONS
FOR EASTERN DEDICATED FREIGHT CORRIDOR
MAXIMUM MOVING DIMENSIONS
FOR WESTERN DEDICATED FREIGHT CORRIDOR
MAXIMUM MOVING DIMENSIONS OF IR
Presentation Outline
Wagon Holding on IR
Type of Wagons on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
Design Criteria
• Design Requirements
• Inspection & Testing Procedure
• Acceptance Criteria
Basic Design Requirements
Commodity to be transported
Material of construction
Max. Axle load
Tare weight
Pay Load and volumetric capacity
Center of gravity
Limiting gauge
Special purpose equipment
Type of Brake System, Bogie & Coupler
Design Development Process
• A conceptual sketch within limiting gauge
• Coupling Height
• Bogie Centre
• Track Loading Density
• Selection of material
• After finalization of conceptual sketches, 3D model
preparation
• Finite element analysis of the model and material
optimization
3D Modelling
Finite Element Analysis
• FEA on each sub assembly as well as full wagon
structure under various load conditions
• Pay load on static condition
• 30% extra of pay for dynamic augmentation.
• Buffing load of 250 t
• Draft load of 100 t
• Payload & Buffing load / Draft load
• Simulation analysis
Project Flow of FEA
3D CAD Data Clean Up / Assembly Contacts/ Material
Properties / Boundary Conditions and Loads
Design finalization
Inspection & Testing Procedure
• Quality Assurance Plan
• Welding Procedure Specifications
• Check sheets
• Material, Stage & third party Inspection
• Load test on payload and 25% extra of payload
• Brake force test
• Squeeze load test
• Wagon weighment certificate
• Functional Test
Acceptance Criteria
Wagon Holding on IR
Type of Wagons on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
New Wagon Design Drivers
• Private operators
• CTO
• SFTO
• AFTO
• Wagon Leasing Companies
• Indian Railways for diversified commodities
• Transportation of Bulk commodities
• Higher axle loads for Dedicated Freight Corridors
• Longer/ wider steel products to reduce welding at site
• Export Projects
Commodities for Private Operators &
Leasing Companies
Wagons Holding on IR
Type of Wagons on IR
Max Moving Dimensions & Fixed structures
Design Criteria
Drivers for New Wagon Designs
Brief on Jindal Rail Infrastructure Ltd.
State-of-the-art manufacturing facility
with capacity of 3000 Wagons
Manufacturing Details
BOXNHL Freight Car for Gondola Freight Car for BCNHL Freight Car Brake Vans for DLI
Indian Railways JSPL Mozambique for Indian Railways
Flat Cars for transporting Container Flat Cars Bogie Frames for Indian Floor Frame Assembly for
Rail Panels Railways Coaches Indian Railways Diesel
Locomotives