www.rdso.indianrailways.gov.in

Annual Report 2010-2011

MOTIVE POWER

RESEARCH, DESIGN & DEVELOPMENT

Design and development of 5000 HP WDG5

Diesel Locomotive

ModalAnalysis of 5500 hp WDG5 locomotive

Weight Reduction of 5500 hp WDG5 Locomotive

Modeling and FEA Analysis of Control Console forWDG5 Locomotive

FEA Analysis of Dynamic Braking Grid (DB) Hood

Compartment

FEA Analysis of Equipment Rack

For faster, longer and heavier trains, there is an

imperative requirement of high horse power

locomotives. Indian Railway has under taken a project

jointly with M/s EMD to fulfill the requirement of IR with

developing 5500 hp WDG5 locomotive. The project is a

design development effort by RDSO, without the back

up of a formal ToT contract. Different loco assemblies

are being designed in consultation with DLW & EMD-

USA. The developed loco design would not only

augment traction-power availability, but would also

serve, as a platform for future design of high hp diesel

traction.

Regarding the design, different meetings such as designreview (DDR) meeting and teleconferencingdiscussions held during April'2010 to May 2010. RDSOhas prepared General arrangement drawings of WDG5locomotive and also completed FEA of WDG5locomotive underframe, Cab and Fuel Tank. Generalarrangement drawing has been sent to DLW.

Again detailed design review (DDR) meeting conductedduring September 2010 at RDSO with the Designers ofM/s EMD. Important design aspects of the project andoutstanding issues were discussed and finalized withEMD and DLW.

Following design work has been done to finalize thedesign of 5500 hp WDG5 diesel locomotive.

After assembling global model of WDG5 loco on Hypermesh, modal analysis has been done to find out thenatural frequency - IR shall be benefited by pre-determination of violent shock and vibrations to beexperienced by locomotive due to natural frequencyduring service.

Due to axle load limitation (22.3T) and considering FEAreports, weights of different structures of locomotivewere reviewed and weight reduction was done in thevarious sub-assemblies - IR shall overcome the axleload constraint of 22.3 t on these locomotives.

3D-Model of control console prepared on UG andmeshed along with driver's cab and solved for differentload cases - IR shall be benefited in improvement indesign accuracy and improved reliability.

3D-Model of Dynamic Braking Grid (DB) Hoodcompartment prepared on Hyper mesh and solved forsix different load cases - IR shall be benefited inimprovement in design accuracy and improvedreliability.

3D-Model of Equipment Rack prepared on Hyper mesh

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Annual Report 2010-2011

and solved for three different load cases - IR shall bebenefited in improvement in design accuracy andimproved reliability.

3D-Model of Cattle Guard prepared on UG after making

the required modification in mounting arrangement - IRshall be benefited in improvement in design accuracyand improved reliability.

The other deliverables like Air Brake Schematic forWDG5 locomotive, technical specifications and STR of3-Ø induction motor & radiator cooling fan assembly

have been prepared and given to DLW for preparation ofmanufacturing drawings and procurement of material.

A new design of 4500 hp WDG4 locomotives developedwith incorporating automatic control engine stop(ACES) and auxiliary power unit (APU) for significantfuel saving.

Crashworthy structure has been provided for safety tocrew. Compact computer controlled brake system (CCBIR) and radial grids have been used in the locomotivesto improve dynamic braking. Compact after-coolerpiping has been used to improve compressor cooling.

3-D model and particular specification of the locomotivecompleted and delivered to DLW.

The multi-genset loco was initially planned on aWDM2/WDS6 underframe, However in detailed design,it has been shown that a WDM3D loco underframewould be more suitable for this application as it is longerin length. Accordingly, the specification has beenrevised including the use of underframe of WDM3D locobesides incorporating other technological upgradations.

The main features of multi-genset loco are:

It shall consist of diesel engines that are at leastU.S. EPA certified at Tier-II Off-Road emissionslevels.

Microprocessor based control system.

Equipped with remote diagnostics system.

Extended range dynamic braking system.

It shall have 20- 25% more fuel efficiency andreduced NOx emissions.

General layout of loco on WDM3D under frame shallensure better integration of equipments on theunderframe.

The design of loco wheels currently used on IR locos isunsuitable for WDG5 applications. A new versions 'S'shaped wheel has been designed and the mechanical &thermal analyses have shown satisfactory results.Interference analysis was done by M/s EMD and it wasfound suitable. Drawing has been issued to EMD fordesigning of the axle and wheel-axle assembly. This hasavoided the import of wheels and indigenousmanufacturing as been enabled.

4500hp WDP4B AC/AC locomotive (loco no. 40001)built with electrics from M/s Medha Servo drives Pvt.,Ltd, Hyderabad has been fitted with hotel load capabilityof 500 kVAas per RDSO specification. Loco shall deliverfull hotel load power at idle speed itself. Satisfactory full

Design Finalization of Cattle Guard

Crashworthy Design of 4500 hp WDG4 Locomotive

Development of Energy Efficient Multi-Genset 2400BHP BG DE Locomotive

Design Development of S-Shaped Wheel for 5500HP WDG5 Locomotive

Development of 4500hp Hotel Load Locomotive

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General arrangement of ACES+APU & CCB-IR on Crashworthy WDG4

Motive Power

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Annual Report 2010-2011

“GOLD”, Guidance for Optimized Loco

load trial of hotel load system powering 10 AC coachesin stationary condition has been conducted in completerake formation of 12535/12536 Garib Rath Exp at NERcoaching depot, LKO. It would eventually be possible topower all EOG (10 nos.) coaches of Garib Rath train andeliminate one generator car.

Zonal Railways have been reporting problems ofpremature failures/less life of side bearers due topermanent set, cracking of rubber, de-bonding of rubberfrom the metal plates etc. in WDG3A/WDM3Dlocomotives. To improve the life and reliability oflocomotives side bearers, certain changes with respectto rubber chemistry have been made and variouslaboratory tests have been conducted on prototypesamples including endurance testing for 1.0 millionscycles. In addition, based on study of failure pattern ofside bearers, their geometry has also been revised toreduce de-bonding and cracking from edges. RDSOhas been prepared a design showing improvedgeometry/contour without affecting interchangeability.

One prototype developed by M/s Avadh Rubber,Lucknow has been tested for 1.2 million cycles to ensurefatigue life and other stipulations given in RDSOSpecification. Problem of premature failure/less life ofside bearers due to permanent set, cracking of rubber,

de-bonding of rubber from the metal plates shall beeliminated. This increases the life and lessmaintenance.

GOLD system is an in-cab advice system that helps locopilots to save fuel while maintaining time by using theoptimal control theory to determine desirable speedprofiles. Field trials with the imported as well asindigenous versions of this system have shownsignificant savings in fuel.

Based on the satisfactory trials, a specification has beenframed and issued to Railway Board. Railway Boardmay like to accord sanction in next years RSP forprocurement based on this specification. The systemshall result in significant savings in IR fuel bill.

Locomotives like WDG4, WDP4 etc, are provided withbogie without pedestal and in such cases lifting of wheelis not possible. To address this problem, Wheel settrolley has been designed for movement of locomotivesas light engine in self-power, during axle lock conditionof the locomotive. The performance of the Wheel SetTrolley (Towing Trolley) was validated when one EMDWDP4 locomotive no. 20016, which failed due to axle

Development of Improved Rubber Side Bearer forlocomotive bogies to improve fatigue life andreliability

Technical Specification of Guidance for OptimisedLoco Driving (GOLD)

Design & development of compact design Wheel settrolley (Towing Trolley) in EMD loco

Old Design

Motive Power

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Annual Report 2010-2011

bearing seizure at location no. 3, was brought on selfpower from Fursat Ganj (near Raibreilly) to Alambaghdiesel shed, Lucknow (About 90 km distance) in Feb.2011 at 15 kmph speed using Wheel Set Trolley. Thistrolley helps in clearing the Block Section very easilywhen axle gets locked. Uniform load distribution on

track also avoids the damage of track. It is easy to movethe loco to the nearest shed on self-power without thenecessity of wheel change at site.

WDP1 bogies are having a number of problems relatedto design. In one WDP1 Loco 15051, modifications wereone in the bogies and under frame under the supervisionof RDSO and the same has been put on trial. Based onthe basic concept of the modifications done in thebogies of one WDP1 loco and further many significantchanges in the bogies. RDSO has designed a new bogieby bringing about several further changes like change ofmaterial of bogie frame to steel IS 2062, increasedthickness of plates of bogie frame, modification ofwinged type axle box, change in the design of brake pullrod, change in the position of lateral stopper,modification in vertical stopper, change in the pedestaletc. This will improve the reliability of WDP1 bogies.RDSO will advise for fitment of this design bogies inWDP1 locomotives during rebuilding, after the trial oftwo modified bogies is found successful.

A simulation study of rake containing two double deckercoaches at speed of 160 Kmph was conducted toassess whether any turbulence or difference in pressureis formed after change of the coach width from 3250mmto 3050 mm. After analysis no significant difference inpressure was observed. IR shall be benefited by thissimulation study and apply the same for design and

calculation activities as and when required.

RDSO has mooted that a high performance fuel-

efficient 2300 hp locomotive has been developed inthree versions, viz., WDS7A for light freight/shuntingduties on IR, WDS7B for pilot duties of NRCs andWDM9 for light passenger services on IR.

3D-Model of locomotive WDS7A under frame & generalarrangement have been completed and delivered toDLW. RDSO has prepared a report no. MP.Proj.18covers complete technical feasibility of the project andsent to Railway Board.

Indian Railway will be benefited with this type oflocomotive by low fuel consumption and lowermaintenance cost due to higher fuel efficiency in freightoperation & lower maintenance cost in sheds.

Design of New, Reliable and Maintenance FriendlyBogie for WDP1 Locomotive

Computational Flow Dynamics (CFD) Analysis ofrunning of two Double Decker coaches at 160 kmph

Design & development of 2300 hp freight/industrial/shunting locomotive (WDS7A)

New Compact Design

Double Decker Streamline Velocity

Double Decker Vector Velocity

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