Bogie and Suspension System (Updated) PDF

Bogie & Suspension System Presented By- Md. Uzzal Hossain, Training Coordinator (RS)  Bogie Overview In simple terms, a bogie is a structure underneath a railway body tha...

Bogie & Suspension System Presented By- Md. Uzzal Hossain, Training Coordinator (RS)  Bogie Overview In simple terms, a bogie is a structure underneath a railway body that carries and ties all the components of the locomotive together and axles & wheels are attached through bearings.  Bogie Overview MRT Line-6’s Bogie is a fabricated “H-shape” frame type without end beams, being composed of radius arm primary suspension, bolster-less secondary suspension with air springs and single traction link configuration. Bolster bogie without End Beam Bolster-less Bogie without End Beam (taken from google) (Used in MRT Line-6) Bolster bogie with End Beam (taken from google)  Types of Bogie Used in MRT Line-6 There are three types of bogies for MRT Line-6 Motor bogie- will be available only in motor car i.e M1/M2/M3/M4 car Type-1 trailer bogie (for cab end of trailer car)- in every Tc car’s front side i.e cab end Type-2 trailer bogie (for gangway end of trailer car)- in every Tc car’s rear bogie i.e near gangway  Type-1 Trailer Bogie The type 1 trailer bogie is equipped with the following equipment: 1. Four-disc brake units with parking brake on transoms; 2. Obstruction deflector and detector on bogie frame of the car end side; 3. Air injection type flange lubricator (oil mixed) on bogie frame for each wheel of the car end axle; 4. Speed sensors for brake system installed on one axle box of each axle; and 5. Speed sensors for signalling system (tachogenerator) installed on one axle box of each car end side axle.  Type-2 Trailer Bogie The type 1 trailer bogie is equipped with the following equipment: 1. Four-disc brake units with parking brake on transoms; 2. Speed sensors for brake system installed on one axle box of each axle; and 3. Speed sensors for signalling system (tachogenerator) installed on one axle box of each car end side axle.  Motor Bogie The motor bogie is equipped with the following equipment: 1. Four tread brake units without parking brake on transoms; 2. Two traction motors on transoms; 3. Two gear boxes on transoms and axles; 4. Earthing device installed on each gear unit; and 5. Speed sensor for brake system installed on an axle box of each axle. Bogie Arrangement  Main Component Description Bogie Frame Motor Bogie Frame Trailer Bogie Frame Bogie frames are of a welded fabricated “H-shape” frame type consisting of two side frames and one transom. The side frame has auxiliary air reservoir for the air spring. Gear unit supports, motor supports, tread brake supports are mounted on the motor bogie frame. Disc brake supports (caliper brake supports), deflector support seats, and traction link support are mounted on the trailer bogie frames.  Main Component Description Bogie Frame Motor Bogie Frame Trailer Bogie Frame Spring seats, radius arm rubber holders, damper brackets, and air spring seats are mounted on both bogie frames. Each bogie frame has four frame hangers to enable hang the complete bogie assembly to be removed from or installed on the rails.  Main Component Description Primary Suspension primary damper Spring Speed Sensor for Brake system Axle Box The primary suspension of the bogie provides excellent ride quality and running stability. The primary suspension is of the radius arm type consisting of the radius arm type axle box, primary spring with rubber seat, radius arm rubber bush, primary damper (vertical damper) and wheelset hanger (axle box hanger).  Main Component Description Primary Suspension (Damper) The damper's job is to control the motion of the spring and manage the weight transfer and shock loads of the car. Without a damper, the coil spring would oscillate to the end of time, once disturbed.  Component Description of Secondary Suspension The secondary suspensions of the bogie also provides excellent ride quality and running stability. The secondary suspension is of bolster- less suspension consisting of centre pin installed on the carbody, two air springs, two levelling valves, one lateral damper, two lateral stop rubbers, and one single traction link with two single link rubber bushes. Levelling valves- used for height adjustment between train’s floor and platform. Levelling valves  Component Description of Secondary Suspension Secondary Suspension The air spring has a vertical rubber stopper to sustain the carbody safely when the two air springs in a bogie are simultaneously deflated by the differential pressure valve due to, e.g. air leakage.  Component Description of Secondary Suspension ✓ Shim Plate is added under the air spring in the secondary suspension to enable adjustment of carbody height after wheel turning. Air Spring & Leveling valve  Component Description of Secondary Suspension Shim Plate ✓ Shim Plate is added under the air spring in the secondary suspension to enable adjustment of carbody height after wheel turning.  Component Description of Secondary Suspension Two lateral stop rubbers (elastic rubber blocks ) to absorb impact forces due to lateral movement. The centre pin with the vertical stopper installed to the carbody and the vertical stop seats installed to the bogie permit lifting of the carbody and the bogies as a complete unit. The traction link connects the centre pin installed on the carbody and the transom of the bogie frame. It transmits the traction force from the bogie to the carbody. Lateral Stop Rubber and Vertical Rubber Component Description of Secondary Suspension  Component Description Wheel Set The motor wheelset consists of two wheels, one axle, one gear unit, and two journal bearings. The trailer wheelset consists of two wheels, one axle, two brake discs, and two journal bearings. The wheels, journal bearings, brake discs, and gear are mounted on the axles by press fitting.  Component Description Wheel Assembly M car Bogie Tc car Bogie  Component Description Journal Box Assembly (Axle Box Assembly) Type 1: without speed sensor on the journal boxes for the motor and trailer bogie; Type 2: with speed sensor for the brake system on one journal box of each axle used for the motor and trailer bogie; and Type 3: with speed sensor for the signalling system (Techogenerator) on one journal box of the trailer bogie. Type-1 Type-2 Type-3  Component Description Journal Box Assembly (Axle Box Assembly) Type-1 Type-2 Type-3  Component Description Journal Box Assembly (Type 1, Typical)  Component Description Obstruction Deflector and Detector Type-1 (Tc car) is equipped with an obstruction deflector to prevent obstructions on the track. The obstruction deflector is equipped with the obstruction detectors to send an alarm to the OCC through TIS whenever an obstruction is detected by the obstruction detector. When an obstruction hits the deflector, deflector swings around the special pin, and deflector shears the special bolt and wire. Then, signal breaks off and an obstruction is detected. The clearance between the deflector and rail can be manually adjustable after the wheel turning to secure a constant clearance.  Component Description Wheel Flange Lubricator The wheel flange lubrication system is of service proven oil-mixed air injection type flange lubricator. Wheel flange lubricators are provided at the both leading wheels of the train. In straight section, activates after each 2 min and sprays lubricant for 6 sec. In curve section, activates after each 3 Spray nozzle sec and sprays lubricant for 6 sec. The train moving directional signal is used to control the operation of the lubricators so that the signal operates only when the said lubricators are located in the leading position and stops the injection when located at the trailing position.  Bogie Maintenance ▪ Major Damages of Wheel  Bogie Maintenance Wheel Tread Profile Wear Limit Dimensions These dimension are checked by mechanical gauge or automatic wheel profile meter.  Bogie Maintenance Wheel Wear Limit and Diameter Gauge Diameter is only measured by Groove diameter gauge  Bogie Maintenance Addition of Shim Plate (after wheel turning operation)  Bogie Maintenance Addition of Shim Plate B Dimension  Bogie Maintenance Addition of Shim Plate The Set Height for “B dimension” is provided by following formula. H = 260 + t1 +t2 H: Set Height for “B dimension” (mm), This is the height from the punch mark on the side frame to bottom of under frame. t1: Thickness of shim inserted between the bogie frame and air spring (mm). Thickness of shim is 6 mm per one shim. t2: Thickness of permanent shim under carbody (mm) There are three thickness of shims, i.e. 1 mm, 2 mm, and 3 mm.  Bogie Maintenance Addition of Shim Plate  Bogie Maintenance Addition of Shim Plate Criteria For ‘B’ Dimension Criteria For ‘A’ Dimension There are three thickness of shims, i.e. 0.5mm, 1.2mm, and 2.3mm.  Load transfer Mechanism The car +passenger load is transferred to track in following manner Car load+ Passenger load Secondary suspension Bogie Frame Primary Suspension Axle Box Wheels Track 34  Tractive Force transfer Mechanism The Tractive force is transferred to car body in following manner Traction motor Drive Gear Axle Axle Box Primary Suspension Bogie Frame Traction Link Centre Pivot Car Body 35  Braking Force transfer Mechanism The Braking force is transferred to car body in following manner Wheel Axle Axle Box Primary Suspension Bogie Frame Traction Link Centre Pivot Car Body 36 Thank You All Q&A Suggestions  Bogie Overview B’ B’ – two bogies or wheel assemblies under the unit. Each bogie has two powered axles, operated by a single motor by a driving. Bo´Bo´- two bogies under the unit and each bogie have 2 individually-driven powered axles or wheelsets (power via traction motors). 75% of all modern locomotives are configured as Bo´Bo´. Co´Co´- two bogies under the unit and each bogie have 3 individually-driven, powered axles (power via traction motors). Bo´Bo´ + 2´2´ + 2´2´- multiple units, first unit: two bogies, each bogie has two individually-driven powered axles; second and third unit: two bogies, each bogie with two non-powered axles. Bo´ 2´ Bo´- articulated vehicle: first and last bogie has two individually-driven powered axles/middle bogie (Jacobs design) with two non-powered axles. https://theengineeringblog.com/railway-locomotive-bogie/