1. BRAKE SYSTEM COMPONENTS
1.1 Brake system components Drawing System Diagram (Please see Figure 1) brake system adopts a brake device with a air pressure of 500 Kpa in train pipe. The system contains distribution valves assembly, brake cylinder assembly with a diameter of 305 mm and piston stroke of 254 mm, dust collector assembly, automatic slack adjuster, empty and loaded adjuster and high-phosphorus cast iron brake shoe etc. Hand brake NSW is used to brake a wagon manually.
This brake system separately controls the basic brake equipment of wagon with 2 sets brake cylinder assembly, and with 2 sets automatic slack adjuster.
Figure 1: Air Brake System Diagram
1.2 The names and their documents’ numbers for all parts of the system
○1distribution valves assembly
○2brake cylinder assembly
○3reservoir assembly
○4automatic slack adjuster
○5reservoir assembly
○6 reservoir assembly
○7 pressure limiting valve
○8 empty and loaded adjuster
○9 dust collector assembly
Name and specification of pipes used to connect kinds of parts for the brake system.
○1 Train pipe DN32
○2 Distribution valves assembly to dust collector to train pipe DN25
○3 Distribution valves assembly to reservoir assembly DN20
○4 Distribution valves assembly to reservoir assembly DN20
○5 Distribution valves assembly to Pressure limiting valve DN20
○6 brake cylinder assembly to brake cylinder assembly DN20
○7 brake cylinder assembly to tee joint (DN20x20) to Pressure limiting valve DN10
○8 brake cylinder assembly to tee joint (DN20x10) to empty and loaded adjuster DN20
○9 pressure limiting valve to Empty and loaded adjuster DN10
○10 reservoir assembly to Pressure limiting valve to tee joint (DN10x20) DN20
2. DISTRIBUTION VALVES ASSEMBLY
2.1 Distribution valves assembly
1. Main valve 2. Semi-automatic release valve 3.base 4.Emergency valve
Figure 2: Distribution valves assembly
2.2 The routine inspection and maintenance of air control valve should be inspected the appearance carefully, breakage and loss of parts, cracks on valve body and various pipe seats, cracks of weld, aging and deformation.
of rubber sealing on various pipe seats and leakage at various pipe seats are forbidden. Performance testing are according to the single wagon testing. Specific process and methods meet the section 11 – Single testing of brake system “Operation and Maintenance Manual of Railway fittings (Bogie and Brake System) “
4.3 Regular repair of Distribution valves assembly must obey the following requests:
4.3.1 Disassembly inspection of main valve, emergency valve, base.
4.3.2 Rusting on outside wall of the base must be cleared, blowing the inside lumen and gas path with the pressure air. Testing with a wind pressure more than 600kPa: Various cavities and gas paths should not connect or leak, it will be changed when the inside wall leaks. If the outside wall leaks and has cracks and defects, it needs to be welding repair or replaced; Testing the welding repaired products with a wind pressure more than 600kPa, and putting into using after pass the compressed air test. Replace when the plug is leaking, and painting the sealing compound or lead oil on the thread. Cleaning the air strainer and replaced it when it has deformation or is damaged. Replace the valve seat of the main valve and emergency valve with new ones, replace bolts and nuts when they have deformation or are damaged. Testing the installed base, main valve and emergency valve according to the requirements of single wagon test.
4.3.3 Replace the moderating valve when the thickness is less than 5mm.
4.3.4 Replace the side valve when the ease slot deepness under the side valve is less than 2.2mm.
4.3.5 Replace the side valve when the remainder thickness is less than 16mm.
4.3.6 Wearing on the side valve seat: Replace the side valve seat when the vertical height above and below the side valve seat exceed 46.8mm.
4.3.7 Replace all rubber sandwich valves with new ones.
4.3.8 The seal ring on the guide lever of the main valve, the quick service limiting valve piston, the accelerated release piston, the emergency piston combination and any other parts should not be disassembled when they are benign. Disassembled when entering into the professional repair and factory repair, and all rubber parts need to be replaced to new ones.
4.3.9 Only after maintained Distribution valves assembly has passed testing by computer control test bench, it shall put into use.
4.4 The service period of Distribution valves assembly reached 12(twelve) years counted from the manufacturing time shall not be installed and repaired.
5 BRAKE CYLINDER ASSEMBLY
5.1 brake cylinder assembly drawing
Figure 3: Cutaway View of the Brake Cylinder
5.2 Requirements for routine inspection and maintenance
The routine inspection and maintenance of brake cylinder should be done by special crew for the train examination. Mainly inspect the valve appearance, cracks on valve body and various pipe seats, replace when breakage of spring and deformation of piston rod. Cracks of weld, aging and deformation of rubber sealing on various pipe seats and leakage at various pipe seats are forbidden.
5.3 Regular repair requirements of brake cylinder are as following:
5.3.1 Cleaning the outside rust of the brake cylinder before disassembling.
5.3.2 Protecting the non-pressure head of the brake cylinder from popping out when dismounting. Protect the inside wall of brake cylinder from damaging when taking the piston out. Cleaning all the inside wall, piston and the spare parts.
5.3.3 Replace when the length of wear and scratch of inside wall is more then 2mm. replace when the cylinder body is deformation or having cracks. Replacing when the corrosion deepness of cylinder body is more then 1mm. If the corrosion depth is less then 1mm, it needs to be grinded.
5.3.4 Test on the spring dynamometer must accord with the following provisions.
5.3.4.1 Steel wire diameter 11mm;
5.3.4.2 Free height 571-531mm;
5.3.4.3 Assembled height 430mm;
5.3.4.4 Assembled load 990-765N;
5.3.4.5 Working height 270mm;
5.3.4.6 Working load 2114-1634N;
5.3.5 Piston combination
5.3.5.1 Replace the piston rod when it is seriously bend, fracture and corrosion. Replace the rivet when it is loose and fracture.
5.3.5.2 Replace the piston when it is crack, damaged and leaking.
5.3.5.3 Replace the pressing plate when it is crack and deformation.
5.3.5.4 Replace Solid stamp piston when it is deformation, Replace or welding repair when the corrosion depth is over 2mm.
5.3.5.5 Replace spear parts of centering device of push rod when it is corrosion; Replace centering spring or steel wire when the diameter wear is over 0.5mm.
5.3.6 Front/rear cover
5.3.6.1 Replace the front sealing cover and piston rod when the deformation and wear are over 3mm.
5.3.6.2 Replace or maintain the cylinder seat of spinning sealed brake cylinder when it is deformation, replace or repair cylinder seat when the welding seam is gapping, clearing the cracks before welding. The damages on the flange plate before the cylinder seat is less then 2, and the length is less then 50mm, so that the brake cylinder can continue to be used.
5.3.7 Assembly
Paint the brake cylinder grease 89D on the inside cylinder wall, piston and packing cup before assemble the piston. Painting the brake cylinder grease 89D on inside wall of cylinder body after placed the piston, and the total weight is 0.13kg. Saturating the blanket of brake cylinder lubricant and front cover with 89M grease, and heating the 89M grease up to 50℃,saturating the blanket over 3 hours.
5.4 Performance test
5.4.1 Feeding 80kPa compressed air into the brake cylinder and then exhausting with no piston sliding resistance.
5.4.2 Feeding 600kPa compressed air into the brake cylinder and keeping the pressure for 1 min after the piston reaches the total-stroke, and the pressure shall not drop down.
5.4.3 Feeding 400kPa compressed air into the brake cylinder, and keeping the pressure for 1 min when the piston stroke reach 80mm, 120mm, 200mm, and the pressure shall not drop down.
5.5 Brake cylinder accessory
5.5.1 Replace the push rod of brake cylinder when it has crake, maintaining when it is bended, and the end face should be SR50mm sphere. Replacing and maintaining the push rod when the length less then the design size. Choosing overlaying or splicing for maintaining the push rod. Re-process the end after overlaying the push rod. Welding the connector X-welding when splicing the push rod and polishing the surface.
5.6 The service period of brake cylinder reached 12(twelve) years counted from the installing time shall not be installed and repaired.
6 AUTOMATIC SLACK ADJUSTER
6.1 Automatic slack adjuster drawing
6.2 Technical provisions of inspection and maintenance
Inspecting the surface with the routine inspection, maintenance and periodic repair, and insuring no bend, deformation and damage on the back lever, screw, sleeve body and control level. Welding the back lever, screw and control level when the wear is over 3mm. Replace it when there is crack. Replaced sleeve body when the wear is over 3mm or broken.
6.3 The service life of brake shoe slack adjuster counted from the installing time reaches 6(six) years shall not be installed and maintained.
7 AIR RESERVOIRS
7.1 The air reservoir for brake system contains following types:
○1 Accelerated release cylinder:
○2 Auxiliary cylinder:
○3 Se-compression reservoir:
Structure of the reservoir
The reservoir consists of cylinder body, lug, front cover, flange, end cover and adapter etc. See figure 5.
Bolt;2- Gasket;3- Flange;4- Front cover;5- Cylinder body;
6- Adapter;7- Plug;8- End cover;9- Lug;10- Nut;11- Gasket
Figure 5: Air Reservoir
7.2 Provisions of routine inspection, maintenance and period repair:
7.2.1 Inspecting the surface of the air reservoir with routine inspection, maintenance and period repair, cleaning the seeper and dirt inside the reservoir.
7.2.2 Welding repair the crack of air reservoir when the length is less then 50mm, and replace when the length is more than 50mm or corrosion depth of wall thickness of cylinder is more than 2mm. Drilling a hole of Φ6mm on the ends of crack for protecting the crack from expanding. Plugging up the holes after welding repair and polish the surface. Welding repair should accord with the technological requirements of welding.
7.3 Test
Water pressure test must be proceeded with 900kPa and keeping the pressure with 3 min without leaking and permanent deformation. Replace or welding repair the reservoir when it leaks, re-testing the reservoir after welding repaired, cleaning the water in the reservoir after testing.
7.4 The service life of air reservoir reaches 12(twelve) years counted from the installing time shall not be installed and maintained.
8 EMPTY AND LOADED ADJUSTER AND PRESSURE LIMITING VALVE
8.1 Automatic empty and load brake equipment is connecting by weight feedback device, see figure 6, the limiting valve, see Figure 7: the se-compression reservoir 17L and relevant pipes.
8.2
1. Check plate 2.Bracket 3.Contact 4.Sensor valve
Figure 6:
1. Check plate 2.Bracket 3.Contact 4.Sensor valve
Figure 6: The empty and loaded adjuster
1. Pressure limiting valve 2.Empty and load wagon indicating plate
Figure 7: Pressure Limiting Valve
8.2 Technical requirements of routine inspection, maintenance and periodic repair:
8.2.1 Inspecting the surface of automatic empty and load brake equipment with routine inspection and maintenance. Bolts of each place shall not release; all the air pipes shall not leak; feeler level of sensor valve shall expand and contract neatly; display panel should flexible, the check plate shall not clamping stagnation; Replace or filling the accessories when it is disappear or performance bad.
8.2.2 When periodic repair, the weight feedback device and pressure limiting valve shall disassembly inspect and maintain, and shall put into using after passing the test via the micro control equipment.
8.3 Test methods of automatic empty and load brake equipment see the “Operation and Maintenance Manual of Railway fittings (Bogie and Brake System)”.
8.4 The service life of automatic empty and load brake equipment reaches 12(twelve) years counted from the installing time shall not be installed and maintained.
9 DUST COLLECTOR ASSEMBLY
Figure 8: The dust collector assembly
9.2 Technical requirements of routine inspection, maintenance and periodic repair
9.2.1 Mainly inspecting the surface of built-up dust collector. Replace the collector when the body has cracks. All the spare parts shall not disappear or damage. Aging and deformation of the rubber sealing on various pipe seats and leakage at various pipe seats are forbidden.
9.2.2 Disassembly inspect the repaired built-up dust collector. Install the built-up dust collector on the test table, plugging the other side of pipe, feeding compressed air of 600kPa. Inspecting the body of dust collector and the connector with rust proof compound, and ensure that it shall not leak.
9.3 The service life reaches 6(six) years counted from the installing time shall not be installed or maintained.
10 HAND BRAKE NSW
Figure 9: Hand Brake NSW
10.2 Technical requirements of routine inspection, maintenance and periodic repair
10.2.1 Inspect the performance of the brake, release, regulating brake and lock and make sure they are in good condition.
10.2.2 Inspect the hand wheel assembly of the hand brake and the housing assembly, and make sure no loss and breakage happens. When the brake and release do not work or work poorly, dismantle the hand brake and repair. After repairing the hand brake, open the plug of the oil hole and smear some grease 89D for the brake cylinder on the friction parts inside the hand brake.
10.2.3 Inspect the hand wheel assembly of the hand brake and the housing assembly. Cracks on the bodies or on the welds should be repaired by welding and be grinded. When the winding shaft works poorly and the diameter of the link is under Φ9mm, replace them. Cracks on the link should be repaired by fusion welding and a tension test with a tensile force of 14.7 kN should be done for the repaired link.
10.3 The service life of hand brake reaches 8(eight) years counted from the installing time shall not beinstalled or maintained.
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