WAGON AIR BRAKE SYSTEM,INDIAN RAILWAYS.

1
AIRBRAKE SYSTEM INDIAN RAILWAYS Created by
A.srinivas, junior engineer, Wagon
workshop, rayanapadu,vijayawada.
2
SAFE WORKER IS THE BESTWORKER
3
TOPICS
4
AIR BRAKE SYSTEM
5
AIR BRAKE SYSTEM

• INTRODUCTION-
• In the air brake system, a lot of developments
  have taken
• place such as bogie mounted Air brake
  system, Twin pipe
• air brake system, Automatic load sensing
  device etc,.
• As a result, the maintenance and
  requirements have changed
• considerably.
• Recently, Bogie mounted Brake System (BMBS)
  has also
• been introduced for freight stock. The
  details of BMBS
• for freight stocks are given in this
  seminar.

6
AIR BRAKE SYSTEM

• CLASSIFICATION OF AIR BRAKE SYSTEM-
• On the basis of type of release,
• air brake system is classified as
• Direct release air brake system.
• Graduated release air brake system.
• Both Direct and Graduated release are
• further available in two forms viz.
• Single pipe and
• Twin pipe
• On the basis of type of fitment,
• air brake system is classified as
• 1.Under frame mounted air brake system.
• 2.Boige mounted air brake system.

7
AIR BRAKE SYSTEM

• The graduated release air brake system
• consists of following components-
• 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.

8
AIR BRAKE SYSTEM

• The processes involved in working of
• graduated release air brake system are-
• CHARGING STAGE.
• 2. APPLICATION STAGE.
• 3. RELEASE STAGE.

9

CHARGING STAGE
BC
5 kg/cm2
charging time 3 - 4 min.
5kg/cm2
DC
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BP
BP
CPB
DV
AR
Driver brake valve
CR
5kg/cm2
Created by srinivas
5kg/cm2
During this stage, brake pipe is charged
to 5kg/cm2 pressure which in turn charges control
reservoir and auxiliary reservoir to 5 kg/cm2
pressure via distributor valve. At this stage,
brake cylinder gets vented to atmosphere through
passage in Distributor valve.
10

APPLICATION STAGE
3.8kg/cm2
BC
BC
1.5 DROP
5 kg/cm2
Application time 18 - 30 sec.
5kg/cm2
DC
3.5kg/cm2
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BP
DV
CPB
AR
AR
Driver brake valve
CR
5kg/cm2
4 kg/cm2
Created by srinivas
5kg/cm2
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 dropped. 2.
The drop of pressure may be a) Intentional and
b) Accidental.
11

RELEASE STAGE
3.8kg/cm2
BC
BC
1.5 DROP
5 kg/cm2
release time 45 - 60 sec.
5kg/cm2
DC
3.5kg/cm2
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BP
DV
CPB
AR
Driver brake valve
CR
4 kg/cm2
5 kg/cm2
EXHAUST
Created by srinivas
5kg/cm2
For releasing brakes, the
brake pipe is again charged to 5kg/cm2 pressure
by compressor through driver?s brake valve. This
action positions distributor valve in such a away
that auxiliary reservoir gets isolated from brake
cylinder and brake cylinder is vented to
atmosphere through distributor valve and thus
brakes are released.
12

CHARGING
BC
NEED FOR APPLICATION
6kg/cm2
FP
DC
5kg/cm2
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BP
DV
CPB
NRV
AR
CR
6kg/cm2
Created by srinivas
5kg/cm2
TWIN PIPE SYSTEM- In
addition to the brake pipe, there is one more
pipe called feed pipe Running from loco to the
brake van to charge the auxiliary reservoir to
6kg/cm2.Up to 5kg/cm2 it is charged by both BP
FP. Beyond 5kg/cm2 up to 6kg/cm2 it is
exclusively charged by FP. The CR is charged
through the DV to 5kg/cm2 from BP.
13

CHARGING
BC
READY TO APPLICATION
6kg/cm2
FP
DC
5kg/cm2
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BP
CPB
DV
NRV
AR
CR
6kg/cm2
Created by srinivas
5kg/cm2
TWIN PIPE SYSTEM- In
addition to the brake pipe, there is one more
pipe called feed pipe Running from loco to the
brake van to charge the auxiliary reservoir to
6kg/cm2.Up to 5kg/cm2 it is charged by both BP
FP. Beyond 5kg/cm2 up to 6kg/cm2 it is
exclusively charged by FP. The CR is charged
through the DV to 5kg/cm2 from BP.
14
ADVANTAGES OF TWIN PIPE

15

ENROUTE BP FAILURE
BC
5kg/cm2
6kg/cm2
FP
Created by A.srinivas JE/AB/WWS/GTPL/SCR
5kg/cm2
0kg/cm2
DC
BP
ISOLATING COAC
CPB
DV
AR
CR
Created by srinivas
BYPASS TWIN PIPE SYSTEM-
In case due to any reason brake pipe of a coach
or any wagon gets damaged or goes defective, it
can be bypassed in twin pipe system and the
detachment of the coach or wagon would not be
essential as in the case of single pipe system,
But in this case the train will be worked as
single pipe system.
16
HEART OF THE AIRBRAKE
DISTRIBUTOR VALVE
17
DISTRIBUTOR VALVE

• Distributor valve is the most important
  functional component of the air brake system and
  is also sometimes referred to as the heart of the
  air brake system.
• The function of the distributor valve is to
  distribute compressed air received from brake
  pipe to auxiliary reservoir and control
  reservoir. In addition to this it also senses
  drop and rise in brake pipe pressure for brake
  application and release respectively.

• It is connected to brake pipe through
  branch pipe. Various other components connected
  to the distributor valve are auxiliary
  reservoir, brake cylinders and control reservoir.
• The distributor valve is removed for
  overhaul, maintenance replace without
  disturbing the pipe connections.
• The complete working of braking system
  depends upon the working of distributor valve.

18
DISTRIBUTOR VALVE

• Two designs of distributor valves are
  in use on wagons. These are
• 1) KE Type distributor valve.
• 2) C3W Type distributor valve.
• The KE type distributor valve consists of
  the following
• main subassemblies-
• Three pressure valve 5.
  Minimum pressure limiter
• U Controller
  6. Maximum pressure limiter
• R charger
  7. A controller
• Choke cover
  8. Quick release valve

19
KE DV / R-CHARGER
FUNCTIONS
ASSEMBLING

• The function of R- charger are
• To charge the auxiliary reservoir from BP to 5
  kg/cm2 in single pipe system during charging.
• It prevents back flow of air from AR to BP during
  brake application.
• To isolate the DV in case of malfunctioning.
• To release the air from AR BC manually.

R-CHARGER

• In dv assembling
• 48 no.s must change items,
• 64 no.s spare parts,
• 20 no.s bolts nuts,
• total near about 140 items
• are used.
• around 60 Tools are used in
• assembling.

20
KE DV / A-CONTROLLER
FUNCTIONS
ASSEMBLING

• The functions of A-controller are
• It charges control reservoir to
• 5 kg/cm2 from BP during charging.
• It isolates the CR from BP, when the brake pipe
  pressure is reduced at the faster rate, during
  sensitivity range.
• It connects CR with BP,when the brake pipe
  pressure is reduced at the slower rate, during
  insensitivity range.
• As soon as BC gets a pressure of
• 0.2 kg/cm2 A-controller closes the passage
  b/w CR BP during brake application.

21
KE DV / U-CONTROLLER
FUNCTIONS
ASSEMBLING

• The function of U-controller is
• to reduce the brake pipe pressure further by
  0.4 kg/cm2, in addition to brake pipe pressure
  reduced by the driver from the loco, to
  accelerate the brake application.
• As soon as BC gets a pressure of 0.4
  kg/cm2,The U-controller closes the passage B/w
  BP exhaust, which in turn prevents any further
  drop in BP pressure.

22
KE DV / 3 PRESSURE VALVE
FUNCTIONS
ASSEMBLING

• It connects AR with BC during brake application.
• It connects BC with Exhaust during brake release.
• It admits BC pressure in steps, when the brake
  pipe pressure is reduced in steps, to facilitate
  graduated application.
• It releases air from BC in steps, when the brake
  pipe is pressure is increased in steps, to
  facilitate graduated release.

23
KE DV / MIN.PR.LIMITER
FUNCTIONS
ASSEMBLING

• The function of MIN.pressure limiter is to admit
  a pressure of 0.8kg/cm2
• immediately into the BC during brake
  application to overcome the resistance offered by
  the brake rigging.
• It is a non restricted passage between AR BC.
• Initially during brake application the air from
  AR is sent into BC through two passeges.one with
  restrictions and another without restrictions. as
  soon as BC gets a pressure of 0.8 kg/cm2 the
  min.limiter closes the non-restricted passage and
  further admission of air from AR is sent into BC
  through restricted passage.

24
KE DV / MAX.PR.LIMITER
FUNCTIONS
ASSEMBLING

• The function of MAX.pressure limiter is to admit
  a max.pressure of 3.8 kg/cm2 even emergency
  application.
• It is a restricted passage between AR BC.
• When the BC gets a pressure of 3.8 kg/cm2 max.
  limiter closes the restricted passage. and this
  passage is closed, the AR completely disconnected
  from BC.and further admission of air from AR in
  to BC is stopped.

25
KE DV / QUICK RELEASE VALVE
FUNCTIONS
ASSEMBLING

• The function of quick release valve is to release
  the air from CR manually to facilitate manual
• release.
• NOTE- In case of C3W DV,
• it is a double release valve and it is to
  release the air from CR as well as from AR
  manually.
• When the release valve is pulled only onceshort
  pull the air from CR is released completely.
• On continuous release, AR can also be released.

26
KE DV / CHOKE COVER
FUNCTIONS
ASSEMBLING

• The choke cover has application release chokes
  inside it. The application and release chokes
  help in regulating the application and release
  times of brake.
• The following are the different hole sizes used
  in our workshop.
• BOXN,BCN,BTPN,BOBYN,BCNHL etc.
• application/release choke hole size - 1.7/1.7
  mm
• Any BMBS wagons
• application/release choke hole size -
  1.42/1.52 mm
• 3. BOBR , BLC, BCCW, BTAP etc.wagons (PT
  DV)
• application/release choke hole size -
  0.44/0.42 mm

27
3-PR.VALVE
0 kg/cm2
BC
U-CTLR
MAX.LR
MIN.LR
A-CTLR
AR
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
5 kg/cm2
EXH
R-CHARGER
5 kg/cm2

CR
CR
QRV
BP PRESSURE
5 kg/cm2
CR PRESSURE
OFF
AR PRESSURE
ON
CHARGING
BC PRESSURE
Created by srinivas
NO PRESSURE
28
3-PR.VALVE
0 kg/cm2
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
5 kg/cm2
EXH
R-CHARGER
5 kg/cm2

CR
QRV
BP PRESSURE
5 kg/cm2
CR PRESSURE
AR PRESSURE
CHARGING
ON
BC PRESSURE
Created by srinivas
NO PRESSURE
29
3-PR.VALVE
0 kg/cm2
0.6 3.6 kg/cm2
3.7 3.9 kg/cm2
BC
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
0.8
3.8
0.2
0.4
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
5 kg/cm2
4.7-4.2 kg/cm2
4.1- 4 kg/cm2
EXH
R-CHARGER
5 kg/cm2
5

CR
QRV
4.8-3.7
3.6-3.4
BP PRESSURE
0.2 - 1.3 DROP
1.4 - 1.6 DROP
5 kg/cm2
CR PRESSURE
AR PRESSURE
APPLICATION
BC PRESSURE
Created by srinivas
NO PRESSURE
30
TAKE LAP POSITION
3.7 3.9 kg/cm2
3-PR.VALVE
0 kg/cm2
1.25 - 3 kg/cm2
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
GRADUATED APPLICATION Decrease BP pressure
GRADUATED RELEASE Increase BP pressure
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
BP kg/cm2
BC kg/cm2
BP kg/cm2
BC kg/cm2
5 kg/cm2
4.7-4.2 kg/cm2
4.1- 4 kg/cm2
4.8
3.6
0.6
3.8
EXH
4.6
3.8
1.2
3.6
R-CHARGER
4.0
3.0
5 kg/cm2
4.4
1.8
5
4.2
2.4
4.2
2.4

CR
4.0
4.4
3.0
1.8
QRV
3.8
4.6
3.6
1.2
3.6-3.4
BP PRESSURE
3.6
4.8
3.8
0.6
0.5 - 1.2 DROP
1.4 - 1.6 DROP
5 kg/cm2
CR PRESSURE
AR PRESSURE
APPLICATION
BC PRESSURE
Created by srinivas
NO PRESSURE
31
3-PR.VALVE
0 kg/cm2
3.7 3.9 kg/cm2
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
5 kg/cm2
4 - 4.1 kg/cm2
0
EXH
R-CHARGER
5 kg/cm2
5

CR
QRV
0
BP PRESSURE
5 DROP
5 kg/cm2
CR PRESSURE
AR PRESSURE
EMERGENCY
BC PRESSURE
Created by srinivas
NO PRESSURE
32
3-PR.VALVE
0 kg/cm2
3.7 3.9 kg/cm2
BC
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
AR
EXH
Created by A.srinivas JE/AB/WWS/GTPL/SCR
5 kg/cm2
4 - 4.1 kg/cm2
0
5
EXH
R-CHARGER
5 kg/cm2
5

CR
QRV
5
0
BP PRESSURE
5 DROP
5 kg/cm2
CR PRESSURE
AR PRESSURE
RELEASE
BC PRESSURE
Created by srinivas
NO PRESSURE
33
3-PR.VALVE
0 kg/cm2
BC
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
5 kg/cm2
4.9 kg/cm2
4.8 kg/cm2
4.7 kg/cm2
EXH
4.9
4.8
4.7
R-CHARGER
5 kg/cm2
4.9
4.8
4.7
5

CR
QRV
BP PRESSURE
0.3 kg/cm2 in 60 sec.
5 kg/cm2
CR PRESSURE
AR PRESSURE
INSENSITIVITY
BC PRESSURE
Created by srinivas
NO PRESSURE
34
3-PR.VALVE
0 kg/cm2
1.5 kg/cm2
BC
BC
U-CTLR
A-CTLR
MAX.LR
MIN.LR
0.8
0.2
0.4
AR
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
5 kg/cm2
4.6 kg/cm2
EXH
R-CHARGER
5 kg/cm2
5

CR
QRV
4.4
BP PRESSURE
0.6 kg/cm2 in 6 sec.
5 kg/cm2
CR PRESSURE
AR PRESSURE
SENSITIVITY
BC PRESSURE
Created by srinivas
NO PRESSURE
35
3-PR.VALVE
EMPTY
LOAD
MAX.LR
MIN.LR
U-CTLR
A-CTLR
PT
Created by A.srinivas JE/AB/WWS/GTPL/SCR
EXH
AR
EXH
R-CHARGER
BC
5 kg/cm2
5

0
0.4-2.2
0.6-3.8
CR
QRV
LSD
AR
4.8-0

BP PRESSURE
5 kg/cm2
0.2-5 kg DROP
CR PRESSURE
AR PRESSURE
SPRING PLANK
EK PT
BC PRESSURE
Created by srinivas
NO PRESSURE
36

LOAD SENSING DEVICE
37
LOAD SENSING DEVICE

• BOBR/BTAP/BCCW 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 and 3.8 kglcm2 is obtained in
  loaded condition.

• So as to obtain this a change over mechanism
  called "Load Sensing Device" (LSD) is interposed
  between the bogie bolster and spring plank. The
  mechanism gets actuated at a pre determined
  change over weight and the distributor valve
  which has the additional feature (i.e.EK PT/C3W2)
  controls the brake cylinder pressure.

38
LOAD SENSING DEVICE
AR 5 kg/cm2
LSD
Created by A.srinivas JE/AB/WWS/GTPL/SCR
PT
CPB
CR
DV
BP
5 kg/cm2
5 kg/cm2
2.2
SPRING PLANK
3.8

Created by srinivas
BC
In loaded condition the operating
valve lets the compressed air signal to EL port
of distributor valve pipe bracket and the
transformer gets the pneumatic command and the
brake system gets adjusted to a max .. brake
cylinder pressure of 3.8 0.1 kg./cm2
Load Sensing Device (LSD)
consisting of operating valve and spring buffer
mounted on the bogie and pipe with flexible hoses
Compressed air from auxiliary reservoir enters
into the operating valve through the pipe
connection and flexible hose.
Another flexible hose is connected
between EL port of distributor valve pipe bracket
and operating valve. The operating valve remains
closed in empty condition. Thus no pneumatic
signal is passed on via EL port to the
transformer which controls the maximum brake
cylinder pressure of 2.2/- kg/cm2.
39
BLC-DOUBLE CHECK VALVE
CONTAINER
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2
N1
LSD
LSD
AR
AR

2.2
3.8
CPB
DV
PT
SPRING PLANK
SPRING PLANK
CR
BC
Created by srinivas
40
BLC-DOUBLE CHECK VALVE

CONTAINER
CONTAINER
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2
5 kg/cm2
4 kg/cm2
N1
LSD
LSD
AR
AR

2.2
3.8
CPB
DV
PT
SPRING PLANK
SPRING PLANK
CR
BC
Created by srinivas
41
BLC-DOUBLE CHECK VALVE
CONTAINER
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BLC WAGON
5 kg/cm2
4 kg/cm2
N1
LSD
LSD
AR
AR

2.2
3.8
CPB
DV
PT
SPRING PLANK
SPRING PLANK
CR
BC
Created by srinivas
42

AUTOMATIC PRESSURE MODIFICATION EL-60 VALVE
43

EMPTY
APM RESERVIOR
BC2
BC1
DV
CPB
APM
2.2
3.8
Created by A.srinivas JE/AB/WWS/GTPL/SCR
SENSOR ARM
104mm
Created by srinivas

• AUTOMATIC PRESSURE MODIFICATION-
• APM device is interposed between bogie side frame
  of Casnub bogie and the under frame of wagons.
• APM should sense the gap only at the time of air
  brake application.
• During remaining time it should not be in contact
  with the bogie side frame.

44

LOAD
APM RESERVIOR
BC2
BC1
DV
CPB
APM
3.8
3.8
Created by A.srinivas JE/AB/WWS/GTPL/SCR
Created by srinivas
Created by srinivas
AUTOMATIC PRESSURE MODIFICATION-
It restricts the brake cylinder pressure
coming from the Distributor valve to 2.2 0.25
Kg/cm2 in empty condition of the wagon and allows
the brake cylinder pressure of 3.8 0.1 Kg/cm2
in loaded condition of the wagon. The
factory setting for the movement of the sensor
point is 104mm which is consisting of loaded
empty zone. First 79mmtop-bottom of the sensor
point is for LOADED ZONE the balance 25mm
bottom-top is for the EMPTY ZONE.
45

BOGIE MOUNTED BRAKE SYSTEM
46
BOGIE MOUNTED BRAKE SYSTEM
BP HOSE
COAC
COAC
DC
6kg/cm2
Created by A.srinivas JE/AB/WWS/GTPL/SCR
FP HOSE
FP HOSE
FP
ISOLATING COCK
DC
5kg/cm2
3.5kg/cm2
COAC
COAC
BP
BP
CPB
BP HOSE
BP HOSE
6 kg/cm2
APM
NRV
3.8
T FLANGE
DV (WITH OUT PT)
APM RESERVIOR
AR 100 LTRs
ISO.COCK WITH VENT
FLEXIBLE HOSE PIPE
10 BC FOR BOGIE 1 (WITH HANDBRAKE CABLES)
EMPTY 2.2
LOAD 3.8
Created by srinivas
10 BC FOR BOGIE 2
47
BMBS-BRAKE CYLINDER

GASKET
Created by A.srinivas JE/AB/WWS/GTPL/SCR
PISTON
INDICATOR ASSLY.
BC PIN
COMPR.SPRING 3
LOCKING STUD
CLUTCH
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.
48
BMBS-BRAKE CYLINDER

BC PRESSURE
Created by A.srinivas JE/AB/WWS/GTPL/SCR
PISTON STROKE 54/-10mm
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.
49
BMBS-BRAKE CYLINDER

BC PRESSURE
Created by A.srinivas JE/AB/WWS/GTPL/SCR
Created by srinivas
The built-in slack adjuster compensates for
the wear of brake blocks during the brake
application through equivalent pay-out. For
paying-in, a pry bar is applied between the brake
shoe and wheel and the rigging is pushed in.
The brake cylinder has got a double acting slack
adjuster as a result the actuator of brake
cylinder will continue to move out till all the
slack in the system is take care off and reaction
force of the wheels is encountered.
This ensures that every time every time the brake
application takes place,sufficient brake force is
delivered on the wheels. The brake cylinder
compensates for any change in gap between brake
block and wheel through the inbuilt slack
adjuster.
50
BOGIE MOUNTED BRAKE SYSTEM
BK.BLOCK
BELL CRANK LEVER
WHEEL SET
PUSH RODs
Created by A.srinivas JE/AB/WWS/GTPL/SCR
DOUBLE ACTING
BMBS BOGIE TOP VIEW
PRIMARY BEAM
SECONDARY BEAM
BC PIN
EYE PIN
CLEVIS PIN
Created by srinivas
51
BOGIE MOUNTED BRAKE SYSTEM
Created by A.srinivas JE/AB/WWS/GTPL/SCR
BMBS BOGIE TOP VIEW
Created by srinivas
52
BOGIE MOUNTED BRAKE SYSTEM

• NEED FOR ADOPTION OF BMBS
• IN FREIGHT STOCK
• In order to overcome the problem faced in
  conventional bogie breakage, missing
  components and malfunctioning of SAB. In BMBS
  fitted wagons, BC is equipped with in built SAB.
• In conventional BOXN/BCN wagons due to frequent
  theft of control rod, main pull
  Rod, End pull rod Brake Rigging parts in
  tripling operation of wagons causing
  poor brake power in Rakes, resulting Detentions
  of wagons. In BMBS, wagons these Items are
  eliminated.
• In order to Improve Mechanical
  efficiency of brake power.
• In a Normal Rake of BOXN wagon Fitted with
  conventional type brake system there was around
  18 Brake fading after a trial run of 1000 Km.
  But In case of BMBS fitted Rakes No brake fading
  is observed
• after around 5000 km Trial Run.
  

53
BOGIE MOUNTED BRAKE SYSTEM

• NEED FOR ADOPTION OF BMBS
• IN FREIGHT STOCK
• Braking distance of conventional Rake of 58 1
  wagons of BOXN is 1350 m.
• However in BMBS wagons it is 880 m
  (approx).
• In conventional wagons setting of A Dimension
  was a major problem. If any change made in sleeve
  nuts of E/L device that may create to heavy loss
  of wagon creating brake binding / wheel skidding.
  In order to overcome this, BMBS fitted wagons
  came into field which contains in built slack
  adjuster.
• In case of BMBS system Automatic Load sensing
  Device is used which Gives 2.2Kg/cm2 Pressure to
  brake cylinder during empty condition 3.8 Kg/cm2
  pressure during loaded for avoiding the above
  Problems.

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BOGIE MOUNTED BRAKE SYSTEM
SILENT FEATURES
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BOGIE MOUNTED BRAKE SYSTEM
SILENT FEATURES
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BOGIE MOUNTED BRAKE SYSTEM
DISADVANTAGES
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SINGLE WAGON TEST RIG
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BMBS-SINGLE WAGON TEST RIG
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BMBS-SINGLE WAGON TEST RIG
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BMBS-SINGLE WAGON TEST RIG
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BMBS-SINGLE WAGON TEST RIG
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RAKE TEST RIG
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RAKE TEST RIG

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RAKE TEST RIG

• The procedure is as follows
• A. Prepare set up (Rig) for Rake Test.
• B. Carry out Visual Examination.
• C. Conduct Leakage, Service Application and
  Release Test.
• Prepare set up (Rig) for Rake Test-
• Place a board DANGER - MEN AT WORK on either
  side
• of the formation for safety.
• Connect RTR to the main source of Air
  Compressor
• with 8 - 10 kg/cm2 capacity.
• Set the Pressure Regulator to 5 kg/cm2 6
  kg/cm2
• For BP FP respectively.
• Couple the BP FP to the first wagon of the
  rake.
• B. Carry out Visual Examination-
• Visually inspect by coupling the
  BPs FPs one by one wagon is a check of air
  brake subassembly, for any damage in all other
  under frame components etc.

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RAKE TEST RIG


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RAKE TEST RIG


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RAKE TEST RIG


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RAKE TEST RIG


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RAKE TEST RIG

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RAKE TEST RIG
Service Application-

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RAKE TEST RIG
Full Service Application 1.5kg/cm2-

(BVZI- 45 mm/- 10)
/BOBYN
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RAKE TEST RIG
Full Service Application 1.5kg/cm2-

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RAKE TEST RIG
Release Test-

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