AR

AR

Schematic diagram of air brake system for ICF Vs LHB

BC

DV

DV

ASV

BC

CR

CR Main brake pipe

From microprocessor

ICF brake

LHB brake

FEATURES OF BRAKE SYSTEM

Less braking distance Stainless steel pipes used Wheel turning frequency reduced Fitted with brake ON/OFF indicator Microprocessor based wheel slide protection fitted

Brake Equipments

Placed at four locations:

On Under frame On Bogie On car body Inside the coach On pipe line

Brake Equipments On Under frame

Underframe mounted Container Frame

Brake control panel or module plate fitted on container frame

Brake Equipments On Under frame

Container Frame
1. Air reservoirs
1.1 Main reservoir  One 125L for brake application only (Protected by check valve)

1.2 Auxiliary reservoir  One75L for toilets & brake 1.3 Controlled reservoir  One 6L for DV

Brake Equipments On Under frame contd.. contd..

2. Brake control panel or module plate
2.1 Test fittings (To Check Pressure) :  Feed Pipe pressure  Brake Pipe pressure  Control Reservoir pressure  Brake Cylinder pressure

Operating Position

Pressure measurement

Test fittings

Brake Equipments On Under frame contd.. contd.. 2.3 Isolating cocks for :
  

Feed pipe Toilet BogieBogie-1 and Bogie-2 Bogie2.4 Filters for BP and FP 2.5 Distributor valve 2.6 Pressure switch (to operate WSP connected to BP): At 1.3 Bar-Off At 1.8 Bar-On 2.7 Screw in Choke 2mm in indicator line

Brake Equipments on Bogies

Brake Disc

Brake Equipments on Bogies

1. Hose connections (6 Nos. per bogie):
2 Nos per bogie (To connect BC line to each axle) 4 Nos per bogie (To bifurcate BC line to each brake cylinder)

2. Brake Disc:
4 Nos per bogie (two per axle) Disc dimensions : 640X110 Material : Grey cast iron

Brake Disc

Brake Equipments on Bogies contd..

Brake calipers:
4 nos per bogie- (2 LH and 2 RH) Suitable for fitting UIC type two pads of 200 cm2 & thickness 35 mm Lever Ratio : 2.41

Brake Equipments on Bogies contd..

Brake pads
35mm thick and area 200 Cm2 Composite type Quantity per coach:32 Nos. (16 LH - 16 RH) 16 on each bogie- 4 on each caliper Wear limit 28 mm max.

Speed censor (pulse generator) :

4 Nos. -One per axle Gap between speed Sensor and pole wheel - 0.7 to 1.1 mm

Speed censor (pulse generator)

Speed censor (pulse generator)

Generates pulse frequency proportional to the number of revolutions and teeth of the phonic wheel. It comprises a magnetic sensor by which the value of the resistance across the sensor terminals is modulated by variation of the air gap in the magnetic circuit made up of the phonic wheel and the sensor itself. These pluses are proportional to the number of axles revolutions and are amplified and converted into digital data as a function of the peripheral wheel speed and the effective wheel diameter. Each bogie microprocessor device controls and manages the signals originating from the two axles of the relevant bogie

Brake Equipments on Bogies contd.. contd..

Brake cylinder:
Auto slack adjuster No manual adjustment required to make after brake pad replacement. Piston stroke Slack capacity Cylinder size Max BC pressure Application time Release time : : : : : : 21 mm (max) 160mm (min) 10 inches 3.8 kg/cm2 3 - 5 sec 15 - 20 sec

1- Yoke, 2- Clamping nut, 3- thrust nut, 4- Positioning ring, 5- Adjusting ring, 6- Nut, 7- Coupling sleeve, 8- spindle, 9- compression spring, 10-Piston tube, 11-Piston, 13- Packing, 14- Cylinder, 15- Compression spring, 16- Breather plug, 17- Cover, 18- Needle bearing, 19- Ball bearing, 20-Compression spring, 21-bellows, C- Air supply, DCone coupling, N-Cone coupling, Z-Geared coupling

Brake cylinder

Brake Equipments
(Equipment on car body):

Brake Equipments on car body :

Angle cocks : 8 Nos. 4 Nos (2 per Bogie/ 2 on each side of the coach) 4 Nos (2 per Bogie or one per Axle : 4 Nos : 4 Nos Brake application & release indicators : Antiskid valve :

Terminal Box for speed sensor cable Terminal Box for Antiskid valve

Brake application and release indicators

1-Outer valve seat, 2- Inner valve seat, 3-Twin valve seat, 4-side plate, 5-Armature spring, 6-Housing, 7-Diaphragm d, 8-conical spiral spring, 9-control chamber SD, 10 & 14 valve seat 11 & 13- nozzle, 12 valve bracket 15-diaphragm C, 16-control chamber Sc C- to brake cylinder, D-to DV,

Antiskid valve

G-to anti-skid control unit

Antiskid valve
It actuates by getting signal from microprocessor. It functions following as accordinglyIt raises BC pressure. It reduces BC pressure It maintains BC pressure

Brake Equipments Inside the coach

Brake Equipments Inside the coach

 WSP micro processor (Electronic unit)  Emergency Brake Pull Boxes One in each toilet and one in each cabin except Chair Car (5) operates through emergency brake valve.  Emergency brake valve Directly connected to BP and vent it when being actuated (vent the pipe quickly) via a large orifice up to 2 bar after this it stop to vent. Emergency brake light outside the coach will be activated, which is equipped with an electrical switch.

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Brake Equipments on pipe line

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