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Coaching stock

Detailed process of designing, manufacturing, and testing railway coach stock, including electrical systems and layout plans. Explains self-generation and head-on generation systems for coaches. Maintenance schedules and philosophy discussed.

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Coaching stock

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  1. Coaching stock

  2. Manufacturing of coaching stock • Sanction (Pink book, RSP) (Nodal directorate-PU) • Issue of Particular specification including Electrical part and layout plan by RDSO • General layout • Type of shell and Bogie • Type of key materials and systems (brakes, electrics etc) • Preparation of detailed drawings by Mechanical design of PU

  3. Manufacturing of coaching stock • Preparation of detailed drawings by Electrical design of PU • Issue of material schedule for procurement of materials • Setting up jigs and fixtures • Manufacturing of prototype • Tests and trials in coordination with RDSO • Issue of speed certificate by RDSO • CRS sanction

  4. Head On Generation (HOG) Coaches

  5. SELF GENERATION (SG) SYSTEM • Generation is AC which after AC-DC rectification becomes 110 Volt DC (with battery back up) for lights & fans. For AC (RMPU) ,it gets converted into 415 V, 3 ph through Inverters. • END-ON-GENERATION (EOG) SYSTEM • 750 Volt Generation from DG sets placed in power cars at the ends. HEAD-ON-GENERATION (HOG) SYSTEM • Power Supply from OHE through LOCO Transformer

  6. SELF GENERATION SYSTEMS • Axle driven under slung alternator with V - belts • 110V DC regulated at different speeds through RRU • Battery back up during standing/slow movement of train •   2X25KVA, 110 V DC/415 V inverters for AC load. • 110 V DC supply for lights and fans

  7. MOUNTING ARRANGEMENT OF AXLE DRIVEN ALTERNATOR

  8. SGAC LAYOUT BeltPulley 25 kVA ACCoach Inverter ACControlPanel ACPackageUnit Pulley mounted on Wheel 3 PhaseACAlternator Rectifier cum Regulator Unit 25 kVA ACCoachInverter ACControlPanel ACPackageUnit Self Generation System Battery Light & fans

  9. Batteries for TL & AC • Non-AC Coaches • 120 Ah- 110 V DC (nominal) , 18 Mono blocks of 6 volt each • Air Conditioned coaches • 1100/800 Ah (VRLA/low maintenance)- 110 V DC: 56 cells of 2 Volt each. • Alternator for TL & AC • Non AC- 4.5 kW • AC (RMPU)- 25 kW, AC (US)- 18 kW

  10. ADVANTAGES OF SG SYSTEM • Flexibility in rake formation • Independent of mode of traction • No separate power car required  •   Failure in one coach do not affect other coach •  Feed extension is possible in emergency from adjacent coach

  11. DISADVANTAGES OF SG SYSTEM • Load restricted to 2X25kw per coach • Bulky 1100 Ah(AC)/ 120Ah (Non-AC) coach battery required during standby / slow movement •   No standby alternator/battery •  Extensive maintenance due to under-slung alternator, battery, axle-pulley •  Poor system efficiency 54%  

  12. END-ON-GENERATION SYSTEM • Rajdhani, Shatabdi type fully AC trains with large power requirements. • Two power cars each with 2X250 kW (new high Capacity ) Diesel alternator sets. • Power fed by two feeders 750V 3- ph by I V couplers step down to 415V 3 ph for AC by 50/60 kVA transformers • 110V AC lighting and fans by 415/110 AC transformer

  13. Advantages of EOG system • No restriction of Load due to high capacity power cars • Does not require bulky batteries, alternators •  Standby DA sets •   Independent of mode of traction •   Less maintenance required due to elimination of under slung alternator, battery, axle pulley etc. • Higher system efficiency

  14. Disadvantages of EOG system • Flexibility in rake formation not possible •   High cost of energy due to high fuel cost •   Noise and smoke pollution from power car •   Passenger capacity reduced due to provision of power car

  15. HEAD-ON GENERATION SYSTEM (HOG) • Power supply received from loco or tapped from OHE in power car • Cost effective, reliable and energy efficient • Elimination of heavy under slung alternator in SG coaches and DA sets in EOG power car avoiding noise and smoke pollution

  16. HOG SYSTEM • Single phase power from OHE through Loco/ separate Pantograph in power car. •  Inverter (single phase to 3 phase) can be bulk mounted on/under power car or individual coach.

  17. TL & AC Maintenance

  18. Maintenance schedules • Trip maintenance, under gear and safety checking • Monthly maintenance : Schedule ‘A’ • Quarterly maintenance : Schedule ‘B’ • IOH after 9(conventional)/18 Months (LHB) : Schedule ‘C’ • Periodical Overhauling (POH) : once in 18 (conventional)/36 Months (LHB)

  19. Maintenance philosophy • At present all TL items like alternators, regulators, fans, lights, battery are maintained departmentally. • Under- slung type AC Coaches all equipment like compressors, condenser, evaporator, panel are maintained departmentally. • Contract with OEM for 4-monthly schedule of inverters. • Comprehensive service contract for RMPU for Trip, monthly, 3-monthly & Periodic overhaul with RDSO approved sources. • Selective outsourcing of ACCA.

  20. THANKS

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