AIR SUSPENSION SYSTEM IN EMU

PRESENTED BY

E.M.U.CARSHED / HOWRAH
EASTERN RAILWAY

INTRODUCTION
EMU COACHES ARE PROVIDED WITH DOUBLE STAGE SUSPENSION SYSTEM PRIMARY SUSPENSION SECONDARY SUSPENSION
PREVIOUSLY END GROUNDED CLOSED COIL HELICAL SPRINGS WITH OIL DUMPER / SHOCK ABSORBER ARE USED BOTH FOR PRIMARY AND SECONDARY SUSPENSION. BUT NOW AIR COLUMN IS USED IN PLACE OF COIL SPRING IN SECONDARY SUSPENSION DUE TO ITS CLASSIC CHARACTERISTICS OF VARYING STIFFNESS.

ADVANTAGES OF AIR SUSPENSION SYTEM

1. CONSTANT HEIGHT OF COACH IRRESPECTIVE OF LOAD. 2. NO CHANCE OF PLATFORM RUBBING. 3. VERY SMOOTH RIDING. 4. LESS MECHANICAL FAILURE. 5. LESS MAINTENANCE.

AIR SUSPENSION BOGIE FOR EMU

BOLSTER SHOCK ABSORBER

LEVELING VALVE

DUPLEX CHECK VALVE AIR SPRING BELLOW INSTALLATION LEVER

HISTORY
In the year 2001a trial had been done by RDSO on 3-point and 4-point air suspension coaches. After the trial RDSO declared that the 3-point suspension system is not suitable for EMU service. Only 4-point suspension system remain is in system and one trailer coach with 3-point suspension is converted to 4-point suspension as per ICF drawing by CS/HWH & in one Motor with 3-point suspension is in service with conventional coil springs in secondary.

AIR SUSPENSION BOGIE FOR EMU

BOLSTER SHOCK ABSORBER

LEVELING VALVE

DUPLEX CHECK VALVE AIR SPRING BELLOW INSTALLATION LEVER

WORKING PRINCIPLE
Air from MR flows to air spring bellow through leveling valve when this valve is in charging position. As the pressure inside the bellow increases bellow height increases as well as bolster also lifts up and the link of leveling Valve approaching to horizontal position. When the Leveling valve enters within dead band zone no further air will flow to bellow. Now if the load on air spring increases, bolster goes down and leveling valve will be in charging condition admitting more air into the bellow. This causes bolster again lifts up to the preset level.

WORKING PRINCIPLE
Now when the load on air spring decreases, the bolster goes up and leveling valve will be in discharging mode. Then air from bellow flows out to atmosphere through leveling valve. Thus bolster as well as leveling valve goes down up to the same preset level.

SCHEMATIC DIAGRAM FOR 4-POINT AIR-SUSPENSION

INSTALLATION LEVER LEVELING VALVE LEVELING VALVE

20 LTRS. RESERVOIR

AS

DUPLEX CHECK VALVE

DUPLEX CHECK VALVE CHECK VALVE

TWO WAY DIRT COLLECTOR

AS

ISOLATING COCK FOR AIR-SUSPENSION

INSTALLATION LEVER

MAIN RESERVOIR PIPE LINE

20 LTRS. RESERVOIR

150 LTRS. RESERVOIR

POPULATION
PNEUMATIC
Division Bellow (Contitech) Bellow (Firestone) Leveling valve Leveling valve Duplex check Duplex check valve valve (Knorr(FTIL) bremse) (Knorr-bremse (FTIL)

HWH SDAH TOTAL

173 292 465

39 80 119

116 172 288

96 200 296

58 92 150

48 94 142

MECHANICAL
Division Vertical Shock absorber (300 kg.) (ESCORTS) Vertical Shock absorber (300 kg.) (Gabrial) Vertical Shock absorber (300 kg.) (IAI) Lateral Shock absorber (200 kg.) (ESCORTS) Lateral Shock absorber (200 kg.) (Gabrial) Lateral Shock absorber (200 kg.) (IAI)

HWH SDAH TOTAL

194 260 454

NIL 86 86

18 26 44

194 260 454

NIL 86 86

18 26 44

TOTAL FAILURE (IN HWH DIV.)

1. 2. 3. 4. 5. 6. 7. 8. Hose Lateral shock absorber Installation lever Duplex check valve Miscellaneous Bellow Leveling valve Vertical shock absorber 30 NOS 12 NOS. 16 NOS. 03 NOS. 02 NOS NIL NIL. NIL

FAILURE OF VERTICAL SHOCK ABSORBER (IN HWH DIV.)

MOTOR COACH NO. 60040 DATE OF COMMISSIONING 31.03.2005. DATE OF LAST POH 01.03.07. DATE OF FAILURE 15.11.07. TOP HOLDING BRACKET FOR VERTICAL SHOCK ABSORBER

VERTICAL SHOCK ABSORBER

FAILURE OF HOSE (IN HWH DIV.)

Rubber braided flexible hose. About 30 nos of flexible rubber braided hose out of 108 nos. had been failed within 09 months of commissioning. These were replaced by CS/HWH/E.Rly. Population of hose per coach - 08 Nos.

FAILURE OF RUBBER HOSE (IN HWH DIV.)

POPULATI ON LIFE TOTAL FAILURE FRPCPY

312

12 NOS. 07 YRS. 54 NOS. - 03.33 YRS. 54 NOS. - 03 YRS. 54 NOS. 01.17 YRS. 30 NOS. 0.42 YRS. 54 NOS. - 0.25 YRS. 54 NOS. 01 MONTHS.

30 NOS.

5.8

FAILURE OF LATERAL SHOCK ABSORBER (IN HWH DIV.)

THERE ARE A GOOD NUMBR OF FAILURE OF LATERAL SHOCK ABSORBER DUE TO BREAKAGE OF ITS FIXING BOLTS. THESE FAILURES WERE TAKEN PLACE WITHIN 05 MONTHS OF COMMISSIONING IN M/S JESSOP & CO. MAKE COACHESONLY.

AVAILABLE GUIDELINES FROM RDSO/LKO CMI 9802 (REV. 1) MAY 2001 & (REV. 2) FEBRUARY 2008.

PROCEDURE FOR LEAKAGE TESTING AND PERMISSIBLE PROCDURE OF CHECKING BOGIE CLEARANCES AND CE . PROCEDURE FOR PROCEDURE FOR INSTALLATION LEV GENERAL TECHNICAL DATA FOR SPRINGS. MAINTENANCE SCHEDULE. SUSPENSION DATA.

GUIDELINE REQUIRED
MR PRESSURE SETTING. CLEANING OF FILTER FOR LEVELING VALVE. EXCESS RUNNING TIME OF MCP. PROBLEM WITH MAINTENANCE OF M/S FTIL MAKE LEVELING VALVE REGARDING LEAKAGE. NON INTERCHANGEABILITY OF BASE PLATE FOR AIR SPRING BELOW.