GLOBAL VIEW

An overview of RDSO & its activities

4th December ,2006

Research Designs & Standards Organisation

The sole R&D organisation of Indian Railways. Established in 1957 An ISO-9001 organization. 3085 staff. 22 Directorates. Spread over 159 hectares

Indian Railways

A state-owned railway company of India. One of the largest and busiest rail networks in the world, Transporting over 5 billion passengers and over 650 million tons of freight annually. Gross Traffic Receipts estimated at Rs. 54,600 cr. (approx US$ 12 billion) Operating Ratio - 83.7 %.

Functions of RDSO
Development of new & improved designs. Development, adoption and absorption of new technologies for use on Indian Railways. Development of standards for materials and products specially needed by Indian Railways. Technical investigations, statutory clearance, testing and providing consultancy services. Vendor approval and Inspection of critical & safety items of Rolling stock, Locomotives, Signaling and Telecommunications equipment and Track components.

Laboratories and other Testing Facilities of RDSO

Diesel Engine Development Laboratory

Four test beds capable of testing diesel engines from 100 HP to 6000 HP Fully computerized system for recording over 128 test parameters at a time.

Brake Dynamometer Laboratory

Testing of Brake blocks for different types of rolling stock.

Air Brake Laboratory

Facilities provided
1. Simulating operation of air-brakes on freight trains up to 192 wagons and 3 locomotives. 2. Simulation of operation of air brakes on passenger trains up to 30 coaches.

Fatigue Testing Laboratory

Facilities provided Application of cyclic loads on bogies
and other components. Stress and fatigue analysis using computerized data acquisition systems. Closed loop electro-hydraulic fatigue testing equipment Hydraulic actuators from 9t to 25t capacity working at 2 to 40 Hz.

Track Laboratory
Measurement of stresses at various locations of track components under simulated load conditions. Testing of full scale track panel under dynamic load patterns. Rail tensioning system for application of longitudinal forces on rail samples to simulate the thermal forces. Facility of fatigue testing of welded rail joints.

Signal Testing Laboratory

Testing of all types of Signaling equipments such as signaling relays, block instruments, power supply equipments, point machines, signaling cables, electromechanical signaling equipments and components. Facilities provided Environmental testing section equipped with testing facilities including programmable heat, humidity and cold chambers, mould growth, dust, rain chambers. Working systems like; SSI, Universal Axle Counter, Audio Frequency Track Circuiting, Block instruments etc.

Psycho technical Laboratory Assessing critical psycho technical attributes of operating staff like; drivers, station masters. Assessment of psycho technical capabilities of operating staff like; drivers, switchmen and stations masters. Evolving criteria for on the job assessment of operating staff involved in safety of train operations. Facilities provided Laboratory is equipped with Bio-feedback system for assessment of GSR (Galvanic Skin Resistance), temperature pulse and respiration rate, used for stress management exercise. Speed anticipation tester, Multiple Discrimination Reaction Tester for Vigilant behaviour of Drivers

Metallurgical & Chemical Laboratory

Destructive and non-destructive testing of metals, polymers, composites, paints and petroleum products. Testing of entire range of components used in rolling stock and infrastructure. Testing of rails. Facilities provided Scanning electron microscope, direct reading spectrometer, ultrasonic flaw detector & other NDT equipment, polymer and composite evaluation facilities, thermal analyzer. Corrosion engineering evaluation facilities, including weather meter. Static 760hr test rig for grease testing. Dynamic test rig for grease testing.

Bridge And Structures Laboratory

Testing of full scale models of beams, slabs, columns, towers, shells & other concrete and steel component under static and dynamic loads. Facilities provided 6mx14m heavy-duty testing floor. High frequency (250-700 cycles/minute) pulsator for applying pulsating loads from 2 to 20 tonnes. Static load of 40 tonnes on heavy duty testing floor. Switching and balancing units, acoustic emission equipment and data acquisition system. Multi channel dynamic strain recording system and analogue strain indicator.

Geo t - echnical Engineering Laboratory

Determining strength parameter of soil in laboratory and field condition . Testing of sub-structure, embankment and formations in lab and field conditions. Facilities provided Sub-surface interface radar system Laser based soil particle analyzer Computerized consolidation test apparatus Computerized static tri-axial shear apparatus to determine strength of soil and for design of embankment. Dynamic Tri-axial Shear Apparatus for soil testing under simulated field conditions. Portable Nuclear Compaction Gauge

Mobile Testing Facilities

Oscillograph cars Track recording cars Ultrasonic rail testing car OHE inspection-cum-test car
Inside view of TRC Lab

OHE inspection-cum-test car

Track recording cars

Computer Aided Design Facilities

Unigraphics including wave control, scenario for structure & motion, Ansys Multi-physics, NX Nastran. NUCARS ( AAR) ADAMSRAIL AutoCAD on PCs

ADAMSRAIL Facilities

Crashworthiness Design Centre

High computing power Computer Cluster and two Work Stations. Expertise in FEM Modeling and Crash Simulation has been developed.

Telecommunication Laboratory
Equipment with testing facility for: Optical line terminal equipment Digital multi-plexer equipment Optical fibre accessories Digital Microwave Equipment and Universal Communication System equipment Control telephone, wayside equipment etc.

Electrical and Traction Installation Lab

Testing equipment and capability to perform HV test on electrical equipment up-to 50 kv Vibration testing of electrical equipment

R&D activities undertaken in RDSO

R&D activities in Rolling Stock modernization

Bogie
Track friendly bogie for wagons Higher axle load bogies: micro- alloying of wheels & axles Brake system Intelligent brake system Disc brakes with microprocessor controlled anti-slip mechanism Bogie Mounted Brake system Composite brake blocks

Improved Suspension

Sandwich Pad

R&D activities in Rolling Stock modernization

Wheel: Solid wheels for EMU Wheels & axles of improved metallurgy S Shaped wheel for locomotives for higher axle loads-24 T

R&D activities in Rolling Stock modernization

Suspension: Air spring in secondary suspension

Capsule type shock absorber for Coach Dash pot Metacone primary suspension of EMUs

R&D activities in Rolling Stock modernization

Couplers
High capacity buffer pack for coaches CBC with anti-climbing features in Coaches Crashworthy Buffers Soft buffers to minimize jerks

R&D activities in Rolling Stock modernization

Superstructure
Stainless steel shell for EMU stock Aerodynamic profile of DEMU Crashworthy design of coaches-honeycomb absorbers

Honey comb-before and after crash test

R&D activities in Rolling Stock modernization

Superstructure
Environment friendly toilet discharge system Fire retardant material for coach Fire simulation on coaches FRP modular toilet Aluminium wagons

Area of 80 C isotherm

Special types of Wagons

Aluminum Body Wagons BOBRAL & BOXNAL
Payload to tare ratio increased to 2.63 from 2.17 for BOBRN and to 3.45 from 2.61 for BOXN

Container Flat Wagon for 100 km/h Steel Coil Wagon BFNS

R&D activities in Rolling Stock modernization

Locomotives
to meet hotel loads Driver friendly cabs Aerodynamic profile On Board Diagnostics

Development of design for export of Diesel Locomotives to Sudan & Angola

1400 HP, 12t axle load, cape gauge locomotives to Sudan 2300 hp, 17 t axle load cape gauge locomotive to Angola.

R&D activities for development of an environment friendly system

Bio Diesel blends CNG based DEMU Composite brake blocks to avoid noise pollution Eco-friendly refrigerant on underslung AC coaches- Replace CFC (R12)type refrigerant with HCFC/HFC (R22) refrigerant Measurement & Reduction of Emissions from engines of Diesel Locomotives Environment friendly toilet discharge system

R&D activities in Rail & Track Fittings

Corrosion Prevention of Rails Anti Sabotage PSC Sleepers. Elastic rail clip with improved toe load & anti vandal features Composite & FRP Sleepers for Girder Bridges as a substitute for wooden sleepers.

R&D activities in Propulsion Systems

IGBT based propulsion system for 3 phase Electric Locomotive Development of high Horse Power traction motor for AC EMUs Design & development of 3300HP diesel-electric locomotive with hotel load facility Development of 8000 HP Electric Freight Locomotive Development of 6000HP Diesel Locomotive Self propelled Accident Relief Train
TRA NSM ISSIO N

1282

1104

1282

952 D IA: 3357

2896 14783 BOG IE C EN TERS 21417 OVE R BO DY

1282

2896 3277

915 3277

2896 14783 C RS OF BO GIES 21337 OVER BOD Y

2896 3277 3277

2896

FUEL TANK

ENG INE AXLE DRIVE

2896 3357

952 D IA:

14783 C RS . OF B OG IE S 21417 OVE R BO DY

SUPERVISO R VAN(DPC-I)

M EDICAL VAN (TC)

TO O L VAN (DPC-II)

1104

3886

R&D activities in Electrics

Development of microprocessor control for RMPUs (Roof mounted package unit) Development of solid state temperature control for AC coaches Development of composite insulators for electric traction installations

Electronic thermostat

R&D activities in Signaling

Train Actuated Warning Device Anti-Collision Device (ACD) Digital Axle Counter Block Proving By Axle Counter LED Signals

View of Automatic Braking Unit (ABU) of ACD undergoing trials on NF Rly.

R&D activities in fault monitoring and detection systems

Wheel Impact Load Detection System Oscillation Monitoring System Bridge foundation scour monitoring Vibration Signature Analysis for Bridge Health Monitoring

 Trackside Bogie Monitoring System including dragging equipment detector Derailment Detection Devices
Electronic Detector for Passenger Coaches Pneumatic Detector for Freight Stock

R&D activities in fault monitoring and detection systems

Sensors for detecting Hot boxes, Hot Wheels

Temperature of Axle box Temperature of Wheels Display of wheel & axle box temperatures

R&D activities in fault monitoring and detection systems

Representative front panel template for aiding trouble shooting at shed level

On-Board Diagnostics Design & development of Measuring Wheel Rail Flaw Detection Instrumentation - Use of Electromagnetic Acoustic Transducer technology with Phased array transducers

 Satellite Imaging for Rail Navigationusing GPS and GSM

R&D activities in Operations

Continuously track every train for its location, speed and direction of movement. Dynamically disseminate information so gathered to passengers and to the general public Transfer data from running train to central server regarding the health of the locomotive and other vehicles in the train. Fog Vision Instrumentation Increasing productivity through Heavy Haul operation

Equipment installed in Locomotive

Introduction of double stack container service on identified routes Development of roll-on-roll-off door to door service.

Delhi-Howrah Delhi-Mumbai

Double Stack Container Service

Future developments in Rail Transport in India

Dedicated Freight Corridor Track Structure, Freight Stock Higher Axle load Higher Payload to Tare ratio MoU with TTCI for heavy haul operation Metro Trains in Cities High Speed Operation- 200kmph/250kmph Mobile Communication System Train Protection and Warning System

MoU with TTCI for Heavy Haul Operation

Design and Development of 25 t & 32.5 t Axle Load Wagons Development of Testing Facilities for Higher Axle Load Wagons Design, Development and up-gradation of Track for Heavier Axle Loads Consultancy for Test Track Capability Assessment and Condition Monitoring of Bridges Wayside Bogie Performance Detection System Trackside Acoustic Bearing Detection System to monitor and detect bearing defects in IRs Train

Expectations from Global View

Similar Projects taken up on IR

Projects similar to applications of Galileo- inteGRail Satellite Imaging for Rail Navigation Anti-Collision Device Display and public announcement in running train Integrated Passenger Information System GPS based Synchronized digital clock for uniform time over IR Video surveillance system Projects similar to ERTMS,GSM-R Train Protection & Warning System
Pilot Project - New Delhi- Agra Cantt section ERTMS level-1 Equipment procured from M/s Ansaldo Signal

Mobile communication System

Sections identified: HWH-GHY,HWH-Jammu, NDLS-JHS (approx 3000km) Equipment procured from: Siemens, Germany & Nortel, Finland

Similar Projects taken up on IR

Projects similar to Green & Rail Energy Reduction of emissions from Diesel Locomotives Use of Biodiesel and CNG as fuel for Diesel Locomotives Use of eco-friendly (HFC) refrigerant in AC coaches. Removal of harmful gases from exhaust of power car. CO/CO2 controlled Ventilation system for EMU Coaches Projects similar to Silence Noise reduction in power car Noise reduction from Diesel Locomotives Use of Composite brake blocks Projects for Low cost passenger service Head-on-Generation Development of fuel cell/solar Panel for wayside station lighting. Simplified version of 3-phase IGBT based AC Electrics for EMU

Usefulness of various projects

ERTMS
GSM-R: standardization of hardware & software of GSM-R network for easy maintainability. ERTMS level-1: may be useful when high speed trains are introduced.

EUROPAC
Monitor the condition of overhead lines through on-board & trackside monitoring system

INNOTRACK
Issues related with reduction in Life cycle cost of a conventional line with mixed traffic duty. Leading edge track system technologies esp for fastening systems.

RAILCOM
Reduce the time & resources required to demonstrate EMC compliance of rolling stock Increase communication system capacity and availability through the elimination of repeated messages due to corruption by electromagnetic interference Increase in track capacity/ occupancy and traction power through refinement of worst case scenarios and assumptions currently employed in EMC assessment of rolling stock and train detection system. Standardization of EMC/EMI for various signaling equipments. Measurement techniques of EMC/EMI

MODTRAIN
MODBRAKE: Computer controlled brake system Different locomotive control processor; essential to interface brake system microprocessor with locomotive control microprocessor. Develop Interchangeable modules for brake system MODBOGIE: Development of new specification for EMU/DMU motorized bogie, Tilting Bogies for Trains of Speed 200-250 kmph.

 GREEN: Reduce emissions from diesel locos Combustion technology-training in the areas of combustion modeling and CFD (Computational Fluid Dynamics) Design of experiments on combustion system Advanced fuel injection technology-development of common rail systems for diesel locomotives EGR (Exhaust Gas Recirculation) for diesel locomotives After treatment devices for diesel locomotives like SCR (Selective Catalytic Reduction), etc. RAIL ENERGY: Use alternate fuels eg biodiesel & CNG - technological requirements inteGRail Passenger information system Development of TCN (Train Control Network) compatible vehicle control for 3-phase drive locomotive Predictive Maintenance and lean maintenance concept for track. Rail Break prediction and broken rail detection Detection of track locations needing immediate attention based on ride quality monitoring.

Areas for Future Cooperation under FP 7

Research Needs of Indian Railways
Tilting Trains Oil free compressor for Electric Locomotives Locotrol for hauling heavier loads IGBT based 3-phase traction propulsion system for Electric Locomotives Accelerated pre-cast/modular pre-cast construction techniques for construction of new bridges. Condition monitoring of Insulators for Traction Installations Unified Power quality monitoring requirement on 25kV traction power supply system Maintenance free & corrosion resistant fittings for Traction installations

Areas for Future Cooperation under FP 7

Collaborative Projects

Thermit Welding Flaw Detection Techniques for rails. Air raised high reach pantograph for high horsepower locomotives (>7.4m) Rail Fracture detection Fog Vision

Thank You