Technology & Quality Specification for 3 Pieces Cast Steel railway Bogie

Technology & Quality Specification for 3 Pieces Cast Steel Bogie

TABLE OF CONTENTS

1.0 SCOPE ............................................................................................3

2.0 MAIN STRUCTURE ......................................................................... 3

3.0 MAIN STANDARD ............................................................................3

4.0 MAIN PERFORMANCE AND DIMENSIONS .......................................3

5.0 WHEEL, AXLE AND WHEELSET .....................................................4

6.0 ROLLING BEARING DEVICE .............................................................5

7.0 SIDE FRAME AND BOLSTER .........................................................   5

8.0 DAMPING DEVICE............................................................................6

9.0 CONSTANT CONTACT ELASTIC SIDE BEARING ................................6

10.0 PAINT AND MARK .........................................................................7

11.0 GUARANTEE ................................................................................7

1.0 SCOPE

The bogie is available to be used on the railway gauge of 1000mm. This bogie

is applied for new-making and servicing wagons. The axle load is 20t and the

maximum operating speed is 80km/h. The arrangement shall permit for ready

accessibility for maintenance.

2.0 MAIN STRUCTURE

This bogie falls into categories of cast steel three-piece bogie. It is mainly comprised

of wheel set, side frame, bolster, brake rigging, center spring suspension system,

variable friction damper device, bearing, and constant-contact elastic side bearing

assembly etc.

3.0 MAIN STANDARD

AAR M-101 Axles, Carbon Steel, Heat-Treated

AAR M107/M-208 Wheels, Carbon Steel

AAR M-201 Casting, Steel

AAR M-202 Truck Bolsters, Cast or Structural- Design and Testing

AAR M-203 Truck Side Frames, Cast Steel-Design and Testing

AAR S-393 Side Frames and Bolsters-Produced Prior to 1978

BS EN 13260:2009 Railway applications-Wheel sets and bogies-Wheel sets-Product

Requirement

4.0 MAIN PERFORMANCE AND DIMENSIONS

Railway gauge: 1000mm

Wheel base: 1750mm

Distance between Journal centers: 1575mm

Distance of side bearing: 950mm

Wheel diameter: 851mm

Brake lever ratio of the brake rigging: 6.23

Axle load: 20t

Roller bearing: FAG Class “D” 5 1/2”×10”

Max. Operating speed: 80km/h

Tare weight: 3800kg

5.0 WHEEL, AXLE AND WHEELSET

Wheel shall be in accordance with AAR M107/M-208 Wheels of 851mm diameter on

tread with standard profiles, Carbon Steel. The Wheel centres shall be manufactured

to comply with EN 13262.The material is Class B. See Figure 1.

Axle shall be in accordance with AAR M-101 Axles, Carbon Steel, Heat-Treated. The

material is Grade F. The axle shall be manufactured from steel and shall comply to

BS 24 part 1, section 2. To eliminate the necessity of wearing of cast steel side

frames, the axle pedestal guides will be machined to close limits to ensure

interchangeability and will be in accordance with existing pedestal opening i.e.242

mm. See Figure 2.

Fig1 3D Exploded view of wheel Fig2 3D Exploded view of wheel

Fig3 3D Exploded view of wheel sets

The press-mounted of wheels and axle is according to BS EN 13260:2009 Technical

requirement of railway vehicle’s wheel sets installation. See Figure 3.

Fig1 3D Exploded view of wheel Fig2 3D Exploded view of wheel

Fig3 3D Exploded view of wheel sets

6.0 ROLLING BEARING DEVICE

Use Class “D” 5 1/2”×10” tapered roller bearing device in accordance with AAR

Standard.

7.0 SIDE FRAME AND BOLSTER

The design of side frame and bolster conforms to AAR M-202 Truck Bolsters, Cast

or Structural-Design and Testing, AAR M-203 Truck Side Frames, Cast Steel-Design

and Testing and AAR S-393 Side Frames and Bolsters-Produced Prior to 1978. The

material of side frame and bolster is according to AAR M-201 Grade B＋. See

Figure4 and Figure5.

Fig4 3D Exploded view of side frame

Fig5 3D Exploded view of bolster

8.0 DAMPING DEVICE

Variable friction wedge type damping device is adopted as damping structure, which

consists of side frame column wear plate, combined friction wedge, wedge pocket

wear plate and cylindrical helical spring groups. The combined friction wedge

consists of friction wedge, washer, wedge slope wear plate and pin. The friction

wedges are made of ductile iron, and the main friction face is fixed with main wear

plate made of polymer composite material. See Figure 6.

Fig6 3D Exploded view of damping device

9.0 CONSTANT CONTACT ELASTIC SIDE BEARING

The constant contact side bearing consists of side bearing body assembly,

longitudinal locking, and adjusting pad. The side bearing body assembly consists of

bearing seat, roller, roller shaft, side bearing wear plate and rubber layer. The two

elastic side bearings on the same bogie shall be installed in opposition direction

against each other. See Figure 7

Fig7 3D Exploded view of side bearing

10.0 PAINT AND MARK

The wheels tread adapter surface, bearing, side frame column wear plate, side frame

slide wear plate, bolster wear plate, centre plate surface, wedge friction surface and

bogie side bearing wear plate, and any grease is prohibited.

The other surface of bogie frame paint thickness is not less 120um. The surface

paint shall be varnish or black paint.

Mark shall be painted according to the samples provided by the buyer. The numbers

shall be given in Arabic system, and the letters and numbers shall be painted in

white.

All painted surfaces shall be given a coat of deep lacquer as a protective coating for

Ocean shipment. The precise colours of all paints shall conform unless otherwise

specified to B.S. 2660.

11.0 GUARANTEE

The guarantee period for the scope of delivery shall be 24 months from the date of

bill of lading of the railway bogie.

It shall be the responsibility of Supplier to rectify as quickly as possible and at own

expense, by means of repairs or replacement, all defects or damages that may

become apparent during the guarantee period in any component of the scope of

delivery. The supplier will be free of the responsibility if user don’t operate or

maintain the equipment with the right way.