Podcast
Questions and Answers
What type of springs are used in the primary suspension system of the bogie?
What type of springs are used in the primary suspension system of the bogie?
- Rubber bellow springs
- Air springs
- Coil springs (correct)
- Leaf springs
How many metal bonded conical rubber springs are provided on each bogie?
How many metal bonded conical rubber springs are provided on each bogie?
- 4
- 12
- 16
- 8 (correct)
What is the main purpose of the secondary suspension system?
What is the main purpose of the secondary suspension system?
- To increase ride comfort (correct)
- To support the weight of the bogie
- To prevent mechanical damage
- To stabilize the bogie during turns
Which component can disable the secondary air spring suspension in case of a defect?
Which component can disable the secondary air spring suspension in case of a defect?
What ensures that the same body height is maintained in the air suspension system?
What ensures that the same body height is maintained in the air suspension system?
What characteristic of air suspension allows it to respond to changing loads?
What characteristic of air suspension allows it to respond to changing loads?
What is the main function of hydraulic shock absorbers in the secondary suspension system?
What is the main function of hydraulic shock absorbers in the secondary suspension system?
What component is included in the design of air suspension to provide damping?
What component is included in the design of air suspension to provide damping?
What document can be referred for details on the maintenance of air suspension in coaches?
What document can be referred for details on the maintenance of air suspension in coaches?
What type of load do the metal bonded conical rubber springs in the primary suspension system primarily experience?
What type of load do the metal bonded conical rubber springs in the primary suspension system primarily experience?
What should the motorman maintain in the air spring compressor?
What should the motorman maintain in the air spring compressor?
What speed restriction must be observed if there is heavy air leakage from the air spring system?
What speed restriction must be observed if there is heavy air leakage from the air spring system?
During inspection of the air spring, what should be checked for collection?
During inspection of the air spring, what should be checked for collection?
What should be done to the lower spring beam if corrosion is noticed?
What should be done to the lower spring beam if corrosion is noticed?
Which method is used to check for leakage in the air spring piping?
Which method is used to check for leakage in the air spring piping?
What diameter should the air spring fixing holes of the lower spring beam be built to if elongated?
What diameter should the air spring fixing holes of the lower spring beam be built to if elongated?
What size is the reservoir mentioned for testing leakage?
What size is the reservoir mentioned for testing leakage?
What pressure should the compressed air source provide when connecting to the reservoir?
What pressure should the compressed air source provide when connecting to the reservoir?
What is recommended if corrosion is seen on the top surface of the lower spring beam?
What is recommended if corrosion is seen on the top surface of the lower spring beam?
What does the motorman need to do before inspecting the air springs?
What does the motorman need to do before inspecting the air springs?
What purpose does the height monitoring valve serve in pneumatic suspension?
What purpose does the height monitoring valve serve in pneumatic suspension?
Which advantage of air suspension significantly reduces passenger fatigue?
Which advantage of air suspension significantly reduces passenger fatigue?
What characteristic of air suspension improves lateral stability?
What characteristic of air suspension improves lateral stability?
How does the design of the leveling valve help with air consumption?
How does the design of the leveling valve help with air consumption?
Which of the following is NOT an advantage of air suspension?
Which of the following is NOT an advantage of air suspension?
What is a primary function of air springs in pneumatic suspension systems?
What is a primary function of air springs in pneumatic suspension systems?
Which characteristic of air suspension is primarily determined during the design stage?
Which characteristic of air suspension is primarily determined during the design stage?
How does air suspension address issues related to low buffer and coupler heights?
How does air suspension address issues related to low buffer and coupler heights?
What does constant floor height in air-sprung coaches ensure?
What does constant floor height in air-sprung coaches ensure?
What has a significant effect on the natural frequency of air suspension systems?
What has a significant effect on the natural frequency of air suspension systems?
What role do metal bonded conical rubber springs play in the suspension system?
What role do metal bonded conical rubber springs play in the suspension system?
What is the primary function of the hydraulic shock absorber in the secondary suspension system?
What is the primary function of the hydraulic shock absorber in the secondary suspension system?
How does air suspension respond to variations in load?
How does air suspension respond to variations in load?
In what situation can the secondary air spring suspension be disabled?
In what situation can the secondary air spring suspension be disabled?
What is the maximum allowable pressure that should be maintained in the compressor according to the operating instructions?
What is the maximum allowable pressure that should be maintained in the compressor according to the operating instructions?
In the event of significant air leakage from the air spring system, what is the stipulated speed limit for the affected bogie?
In the event of significant air leakage from the air spring system, what is the stipulated speed limit for the affected bogie?
Which aspect of air springs contributes significantly to the comfort of passengers?
Which aspect of air springs contributes significantly to the comfort of passengers?
What characteristic allows air suspension to effectively cushion impacts?
What characteristic allows air suspension to effectively cushion impacts?
What should be inspected for any damage or leakage during the maintenance of the air spring?
What should be inspected for any damage or leakage during the maintenance of the air spring?
What maintenance document is specifically referenced for AC, DC & AC-DC EMU/HHP DMU Coaches?
What maintenance document is specifically referenced for AC, DC & AC-DC EMU/HHP DMU Coaches?
If corrosion is discovered on the lower spring beam, which process should be undertaken?
If corrosion is discovered on the lower spring beam, which process should be undertaken?
What specific diameter should the air spring fixing holes be built to if elongated?
What specific diameter should the air spring fixing holes be built to if elongated?
Which of the following is NOT a characteristic of the air spring system?
Which of the following is NOT a characteristic of the air spring system?
When inspecting the air spring piping for leakage, what method is recommended?
When inspecting the air spring piping for leakage, what method is recommended?
What does the height monitoring valve do in pneumatic suspension systems?
What does the height monitoring valve do in pneumatic suspension systems?
What effect does the natural frequency have on air suspension systems?
What effect does the natural frequency have on air suspension systems?
What component must be connected to the drain plug locations of the reservoir during a leakage test?
What component must be connected to the drain plug locations of the reservoir during a leakage test?
What pressure is the compressed air source required to provide when connecting to the 150-litre reservoir?
What pressure is the compressed air source required to provide when connecting to the 150-litre reservoir?
Why is it necessary to provide packing in the gap between the bolster and the bogie frame during testing?
Why is it necessary to provide packing in the gap between the bolster and the bogie frame during testing?
Which aspect should the motorman monitor prior to performing inspections on the air springs?
Which aspect should the motorman monitor prior to performing inspections on the air springs?
What function does the leveling valve serve in pneumatic suspension systems?
What function does the leveling valve serve in pneumatic suspension systems?
Which feature of air suspension contributes to improved ride comfort?
Which feature of air suspension contributes to improved ride comfort?
In terms of air suspension design, what characteristic is primarily defined at the design stage?
In terms of air suspension design, what characteristic is primarily defined at the design stage?
How does air suspension manage the consumption of air during vehicle oscillation?
How does air suspension manage the consumption of air during vehicle oscillation?
Which advantage of air suspension allows it to handle high passenger volumes typical of suburban traffic?
Which advantage of air suspension allows it to handle high passenger volumes typical of suburban traffic?
What is a consequence of maintaining a constant floor height in air-sprung coaches?
What is a consequence of maintaining a constant floor height in air-sprung coaches?
What characteristic of air suspension is specifically achieved through compression of air?
What characteristic of air suspension is specifically achieved through compression of air?
What impact does the isolation of structure borne noise have on passenger experience?
What impact does the isolation of structure borne noise have on passenger experience?
What design aspect helps air suspension maintain reliability and reduce maintenance effort?
What design aspect helps air suspension maintain reliability and reduce maintenance effort?
Which statement best describes the lateral spring characteristics of air suspension?
Which statement best describes the lateral spring characteristics of air suspension?
What material is primarily used for creating the air spring in the pneumatic suspension system?
What material is primarily used for creating the air spring in the pneumatic suspension system?
Which characteristic of air suspension allows it to adjust to varying loads?
Which characteristic of air suspension allows it to adjust to varying loads?
What is the primary role of the hydraulic shock absorber in the secondary suspension system?
What is the primary role of the hydraulic shock absorber in the secondary suspension system?
What happens to the air spring when a mechanical defect occurs?
What happens to the air spring when a mechanical defect occurs?
Which feature of air suspension directly contributes to passenger comfort?
Which feature of air suspension directly contributes to passenger comfort?
What aspect of the air suspension system is specifically designed to manage different load conditions?
What aspect of the air suspension system is specifically designed to manage different load conditions?
What is the function of the emergency rubber spring in the air suspension system?
What is the function of the emergency rubber spring in the air suspension system?
What is a common maintenance instruction referenced for air suspension systems in coaches?
What is a common maintenance instruction referenced for air suspension systems in coaches?
Which system component is responsible for height adjustment in air suspension?
Which system component is responsible for height adjustment in air suspension?
Which type of spring is primarily used for the primary suspension in the bogie system?
Which type of spring is primarily used for the primary suspension in the bogie system?
What is the maximum pressure the motorman should maintain in the compressor?
What is the maximum pressure the motorman should maintain in the compressor?
What should be done if heavy leakage of air is observed from the air spring system?
What should be done if heavy leakage of air is observed from the air spring system?
Which component needs to be inspected for corrosion on the lower spring beam?
Which component needs to be inspected for corrosion on the lower spring beam?
What method is suggested for checking leakage in the air spring piping?
What method is suggested for checking leakage in the air spring piping?
What should be done if corrosion is found on the lower spring beam?
What should be done if corrosion is found on the lower spring beam?
What is the purpose of connecting pressure gauges to the drain plug locations of the reservoir during a leakage test?
What is the purpose of connecting pressure gauges to the drain plug locations of the reservoir during a leakage test?
What pressure should the compressed air source provide when connecting to the 150-litre reservoir?
What pressure should the compressed air source provide when connecting to the 150-litre reservoir?
What should be inspected for water collection during the maintenance of the air spring?
What should be inspected for water collection during the maintenance of the air spring?
Which aspect should be inspected for damage or leakage during air spring maintenance?
Which aspect should be inspected for damage or leakage during air spring maintenance?
What is the primary function of the height monitoring valve in pneumatic suspension systems?
What is the primary function of the height monitoring valve in pneumatic suspension systems?
How does air suspension enhance passenger comfort?
How does air suspension enhance passenger comfort?
What is one advantage of air suspension related to super dense crush loads?
What is one advantage of air suspension related to super dense crush loads?
What characteristic of air suspension is achieved by varying the effective area in the lateral direction?
What characteristic of air suspension is achieved by varying the effective area in the lateral direction?
What design feature helps to avoid excess air consumption due to dynamic oscillations?
What design feature helps to avoid excess air consumption due to dynamic oscillations?
Which feature of air suspension contributes to its ability to maintain a constant natural frequency?
Which feature of air suspension contributes to its ability to maintain a constant natural frequency?
What quality does air spring compression provide in the vertical direction?
What quality does air spring compression provide in the vertical direction?
In air suspension systems, improved reliability often comes with:
In air suspension systems, improved reliability often comes with:
What aspect of air suspension helps reduce passenger fatigue during travel?
What aspect of air suspension helps reduce passenger fatigue during travel?
What is a major benefit of having soft flexible characteristics in the air suspension?
What is a major benefit of having soft flexible characteristics in the air suspension?
Flashcards
Primary Suspension
Primary Suspension
A system that uses coiled springs to provide initial cushioning between the bogie frame and axle box. This system is designed to absorb vertical, lateral, and longitudinal forces during train operation.
Secondary Suspension
Secondary Suspension
A system using air springs that provides additional cushioning between the bogie frame and the coach body. It helps further reduce shock and vibration for a smoother ride.
Air Spring
Air Spring
A type of spring made of pressurized air confined within a rubber bellows. It adapts to changing loads by varying its height and stiffness.
Shut-Off Valve
Shut-Off Valve
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Air Spring Valve
Air Spring Valve
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Hydraulic Shock Absorber
Hydraulic Shock Absorber
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CMI-9802 (Rev.2)
CMI-9802 (Rev.2)
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Pneumatic (Air) Suspension
Pneumatic (Air) Suspension
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Load Leveling
Load Leveling
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Ride Comfort
Ride Comfort
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Air Suspension
Air Suspension
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Leveling Valve
Leveling Valve
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Height Adjustment
Height Adjustment
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Super Dense Crush Loads
Super Dense Crush Loads
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Constant Floor Height
Constant Floor Height
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Virtually Constant Natural Frequency
Virtually Constant Natural Frequency
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Isolation of Structure Borne Noise
Isolation of Structure Borne Noise
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Delayed Reaction Leveling Valve
Delayed Reaction Leveling Valve
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Flexibility to Choose Characteristics
Flexibility to Choose Characteristics
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Pneumatic Suspension
Pneumatic Suspension
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Schematic Layout
Schematic Layout
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Air Spring Leakage
Air Spring Leakage
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Leakage Test
Leakage Test
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Water Collection Inspection
Water Collection Inspection
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Lower Spring Beam Inspection
Lower Spring Beam Inspection
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Pipe Line Inspection
Pipe Line Inspection
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What is pneumatic (air) suspension?
What is pneumatic (air) suspension?
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What is a leveling valve?
What is a leveling valve?
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What is height adjustment in air suspension?
What is height adjustment in air suspension?
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What are 'super dense crush loads' in air suspension?
What are 'super dense crush loads' in air suspension?
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What is constant floor height in air suspension?
What is constant floor height in air suspension?
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How does air suspension isolate structure-borne noise?
How does air suspension isolate structure-borne noise?
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What is a delayed reaction leveling valve?
What is a delayed reaction leveling valve?
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How does air suspension allow flexibility in choosing characteristics?
How does air suspension allow flexibility in choosing characteristics?
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How does air suspension contribute to ride comfort?
How does air suspension contribute to ride comfort?
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Why is air suspension used in trains?
Why is air suspension used in trains?
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Compressor Pressure
Compressor Pressure
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Air Spring Leakage Procedure
Air Spring Leakage Procedure
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Lower Spring Beam Welding Inspection
Lower Spring Beam Welding Inspection
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Air Spring Piping Inspection
Air Spring Piping Inspection
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Air Spring Seat & Plate Inspection
Air Spring Seat & Plate Inspection
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Leakage Test Procedure
Leakage Test Procedure
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Study Notes
Suspension Systems
- Bogies have two types of suspension: primary and secondary.
- Primary suspension uses coil springs in parallel.
- Each coach has two bogies with 16 metal-bonded conical rubber springs (8 per bogie).
- These springs are between the bogie frame and axle box.
- They handle dynamic loading in vertical, lateral, and longitudinal directions during running.
- Secondary suspension uses air springs for improved ride comfort.
- Air spring suspension can be disabled via a shut-off valve located below the body.
- Air springs maintain body height regardless of load.
- Secondary suspension includes hydraulic shock absorbers to reduce rocking.
Air Suspension Working Principle
- Air suspension uses air pressure for cushioning.
- An enclosed pressurized air chamber (air spring) made of rubber bellows and emergency rubber springs is used as the spring.
- Load changes cause the air spring support and vehicle body distance to adjust.
- This is monitored by a height monitoring valve (leveling valve).
- The valve controls air pressure in the air spring, maintaining the original vehicle height.
- There is a control loop for pressure regulation.
Air Suspension Advantages
- Can handle high loads (super dense crush loads) typical of suburban traffic.
- Maintains a consistent vehicle floor height.
- Offers superior ride comfort for passengers.
- Provides relatively constant natural frequency, reducing passenger fatigue (from low to full loads).
- Good isolation of structure-borne noise.
- Designed for greater reliability, minimizing maintenance.
- Offers flexibility for adjusting characteristics during design.
Air Suspension Characteristics
- Soft and flexible in vertical direction (achieved by air compression).
- Desired lateral spring characteristics are achieved by varied effective area in lateral direction.
- Avoids excess air consumption due to sudden oscillations or pressure changes through a delayed reaction valve.
Construction Details
- Air spring construction details are shown (diagrams).
- Some air springs have outside emergency springs, others have inside emergency springs.
Pneumatic Suspension Control Equipment
- Schematic layout of equipment has been provided. (Diagram)
Operating and Maintenance Instructions
- Motorman should maintain 7 bar pressure in the compressor.
- For air spring leaks, isolate affected bogie and limit speed to 50kph until fixed.
- Inspect air springs for water collection, damage, or leaks.
- Inspect air spring seats and top plates for corrosion and repaint if necessary.
- Inspect pipe lines for leaks and repair as needed.
- Inspect and repair lower spring beam weldings and holes.
- Inspect and adjust lower spring beam elongation if needed.
- Inspect and repair corrosion on lower spring beam and repaint if needed.
Testing for Leaks
- Connect hosepipes to leveling valves.
- Connect pressure gauges to the drain plugs.
- Ensure packing in bolster-bogie frame gap.
- Connect 150-litre reservoir, pressurize it to 9.0 kg/cm², and regulate the air spring pressure using a leveling valve.
- Monitor pressure gauge (keep it at 9.0 kg/cm²).
- Close the isolating cock on the 150-litre reservoir.
- Check for leaks at joints.
- After one hour, pressure drop should be less than 1% of 9.0 kg/cm2 pressure.
- Release pressure by adjusting lever and remove packing.
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Description
This quiz covers the fundamental concepts of suspension systems, focusing on both primary and secondary suspensions used in bogies. It explains the function of coil and air springs, as well as the dynamics of shock absorbers. Test your understanding of how these systems impact vehicle performance and ride comfort.
