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LHB air brake system
Transcript of LHB air brake system
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AIR BRAKE SYSTEMOf
LHB COACHES
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COMPONENTS OF BRAKE SYSTEM
� Mainly Brake Equipment's are placed at four locations:
� Pressure tanks (Air reservoirs):
� Main reservoir -One 125L for brake application
(Protected by check valve)
� Auxiliary reservoir - One75L for toilets & brake
(Capacity of Both125L and 75L available for brake application)
� Controlled reservoir -One 6L
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CONSTITUENTS OF BRAKE SYSTEM
Brake control panel
Test fittings
Feed Pipe
Brake Pipe
Control Reservoir
Brake Cylinder
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Pressure switch to operate WSP (connected to FP):At 1.3 Bar-Off
At 1.8 Bar-On
Filters for BP and FP
Isolating cocks for:
1. Feed pipe
2. Toilet
3. Bogie-1 and Bogie-2
4. Isolating cock for emergency brake (ACP system).
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Choke -2mm in Brake indicator line:
(Fitted in connection to the brake indicators to minimize
the loss of brake cylinder pressure in the event of
indicator failure)
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� Distributor Valve with intermediate flange:
� Relay valve is directly mounted.
� It has a quick release device mounted to the valve body.
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� Equipment's on Bogies:
� Hose connections:
� 4 Nos (To Connect BC line to each axle)
� 8 Nos (Bifurcates BC to each brake cylinder)
� Brake caliper unit:
� Qty required: 8 Nos (4 nos per bogie-2 LH and 2 RH)
� Suitable for fitting UIC type 200x2 pads of thickness 35 mm
� Calipers shall give effective brake radius of 247mm
� Lever Ratio: 2.17 for all except 2.48 for ACCN/SG and
Power car
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� Brake cylinder :
� Compact construction
� Auto slack adjuster - Brake shoe clearance due to wear
corrected automatically by single acting slack adjuster.
� No manual adjustment to make after brake pad
replacement.
� Piston travel: 21 mm (max)
� Slack capacity: 160mm (max)
� Cylinder size: 10 inches
� Max BC pressure: 3.0 kg/cm2
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� Brake pads -35mm thick and 200 Cm2
(Composite type): � Quantity per coach: 32 Nos. (16 LH - 16 RH)
(16 on each bogie-2 on each caliper)
� Wear limit -28mm max.
� Brake Disc: � Quantity per coach -8 Nos (two per axle)
� Disc dimensions -640X110
� Material: Grey cast iron
� Speed censor cable with pole wheel (80 teeth):� 4 Nos. -One per axle)
� Gap between speed
Sensor and pole wheel - 0.9 to 1.4 mm
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Emergency Brake system
� In each compartment emergency pull boxes are installed, which operates through emergency brake valve.
� If handle of pull box moved then the brake valve exhaust the BP via a large orifice up to 2 bar after this it stop to vent.
� Emergency brake light outside the coach will be activated by using the pull box, which is equipped with an electrical switch.
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� Equipment on car body:
� Angle cocks 8 Nos. (Old), 4 (New)
(At coach ends on BP and FP Pipes-FP and BP bifurcated into two branches to make coupling between two adjacent coaches)
� Brake and feed pipe coupling 8 Nos. (4BP and 4 FP) Old
4 Nos. (2BP and 2 FP) New
� Brake application and release indicators 4 Nos (2per Bogie-2 on each side of the coach)
� Antiskid valve /Dump valve 4 Nos� 2 per Bogie or One per Axle
� Terminal Box for speed sensor cable - 4 Nos
� Terminal Box for Antiskid valve - 4 Nos
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� Emergency Brake accelerator -1 Nos.
� Mounted on brake pipe. If the BP drop rate is 1.5 kgf/sq.
cm or more within 3 seconds, brake accelerator
activates.
� Brake accelerator designed to operate during
emergency brake application and ACP only.
� Two 28mm pipes running through the coach for BP and FP
� DV is activated by BP pressure increase or reduction for brake application and release
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PIPES AND PIPE FITTINGS
� Pipes used:
� 28mm for BP and FP Thickness =1.5mm
� 10mm for emergency
and pressure gauges Thickness = 1mm
� 18mm for brake
cylinder pipes (BC line) Thickness =1.5mm
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PIPE FITTINGS-BITE TYPE
� Cutting ring ensures sealed joint.
� Designed for metric tubes i.e. OD of pipe is important
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� Precautions:
� Fittings are to be handled with care. Bite edge to be
protected
� Do not use hand cutters. Edge of should be straight
� Fix pipes line with clamps.
� Non standard materials or tolerances lead to incorrect
fittings.
� The tools & lubricants recommended by EO ensure safe
assembly.
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� Advantages:
� Sealing capability
� High pressure resistance
� Durability
� Bite control
� Assembly cost
� Integrated preassembly tool
� Reliability
� Make-up
� No phantom leaks
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ADDITIONAL EQUIPMENT FOR HAND BRAKE
� Hand brake indicators 2 Nos (One on side of
Power car/Guard van)
� Cheek valve 1 Nos. (In feed pipe)
� 6 Ltrs. Air cylinder- 1 Nos. (Mounted on ABP)
� Flexi ball cable- 1 Nos.
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ADDITIONAL EQUIPMENT FOR HAND BRAKE
� Pressure gauges- 3 Nos.
� FP
� BP
� BC
� Brake caliper units- 2 Nos.
(of different type suitable for hand brake flexible
connections)
� Connecting part for flexible ball- 2 Nos.
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� Less thick stainless steel pipes (Metric pipes).
� No threads/Flange joints -Bite Type fittings used.
� No brake rigging
� Wheel slide protection unit -Take cares wheel flattening
� Centralized control -Complete coach.
� Braking on Axle mounted disc -No wheel wear due to braking.
� Brake accelerator -for sharp reduction of BP pressure in complete train set.
� DV with relay - Ensures brake application time and release.
� All Pipes below under frame -Ease for maintenance.
� Release rod -Improved design (Properly supported
� Brake Indicators -RED means brake applied
-Green means brake released
Feature of axle mounted disc brake system with WSP (compared with conventional brake system)
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BRAKE CONTROL PANEL AND INDICATOR UNIT
Brake indicatorBrake control panel
DV
Release Rod
Reservoir
Test fittingsIsolating cocks
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SAB WABCO CONTROL
PANEL
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Axle mounted brake disc
Brake calipers
Brake Cylinder
Brake Pads
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SPEED SENSOR CABLE WITH TERMINAL BOX
Cable sensor
Terminal Box
Pole Wheel inside the cover
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EMERGENCY PULL BOX
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BRAKE ACCELERATOR
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WSP ELECTRONIC UNIT
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Principle of Antiskid System
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PRINCIPLE OF BITYE TYPE FITTING
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Tightening of the bite fitting
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Anti skid/ Dump valve assembly design.
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Knorr Air Brake Panel
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Faiveley Air Brake Panel
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Air strainer/Filter
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Division of FP and BP pipe joints in two parts (Old), replaced in new design
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Wheel shelling marks
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Brake cylinder
Pressure pipe connection
Brake caliper unit
Brake disc