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Smoothness running of train on uneven tracks with the help of air springs
1.
INTERNATIONAL JOURNAL OF
MECHANICAL ENGINEERING International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME AND TECHNOLOGY (IJMET) ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online) Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME: www.iaeme.com/IJMET.asp Journal Impact Factor (2014): 7.5377 (Calculated by GISI) www.jifactor.com 427 IJMET © I A E M E SMOOTHNESS RUNNING OF TRAIN ON UNEVEN TRACKS WITH THE HELP OF AIR SPRINGS Dr. Jinesh Kumar Jain1, Dr. M. P. Singh2, Dr. G.S. Dangayach3, Dhananjay Chauhan4 1Associate Prof., Department of Mechanical Engineering, Govt. Engg. College, Ajmer(India) 2Associate Prof. Department of Mechanical Engineering, Jagannath University, Jaipur(India) 3Prof., Department of Mechanical Engineering, MNIT, Jaipur(India) 4PG Scholar Department of Mechanical Engineering, Govt. Engg. College, Ajmer(India) ABSTRACT The main purpose of the air spring is to restrict the vibration at a desirable level as per requirements. Higher rail vehicle speeds generally results in increased vibrations in the car body, which has a negative impact on ride comfort. The suspension of the vehicle has to be modified in order to reduce the vibration and journey should be comfortable i.e. Jerk free journey. It is always desirable to keep the vibration level as low as possible by introducing damping. One of the most important techniques used in the present problem for improving damping is utilizing the air spring in place of helical spring, because due to damping the helical spring gets break up and which causes the serious accident. One of the techniques used in the present problem for improving damping is utilizing the air spring in place of helical spring. This paper consists of two different parts: a theoretical analysis of the problem and an experimental work. In railway vehicles, air springs are used for improving comfort for the passengers and for the prediction of the vibrations in the car body. The design concept evolved from this research work in trusses and frames, transporting system and rail coaches where higher damping is required, which can be made safely by utilizing the air spring system. This system is also help full to reduce the maintenance cost in transportation system. Keywords: Spring, Vibration, Ride Comfort, Air Spring, Cost, Life Time. I. INTRODUCTION The study on “Smoothness running of trains on uneven tracks with the help of air spring” and its importance in structures has become increasingly significant for controlling the undesirable effects of vibration. The manufacture of such structures also requires high damping
2.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME capacity and stiffness with light weight for its effective use. Such requirements demanded and popularized the use of air spring as structural members with high damping capacity. In rail operation today, there is a general trend towards increased vehicle speeds, directly which is correlated with vibration. As we know rise the higher speeds usually generate increased forces and accelerations on the vehicle, which has a negative impact, on ride comfort. Furthermore, the demands for higher speeds in turn increase the requirements for lighter air spring which reduce the impact between wheels and rails i.e. reduce the vibration. Active technology in rail vehicles can be utilized in order to achieve one or more of the following goals; a) Improve passenger ride comfort, b) Maintain good ride comfort although vehicle speed is increased, c) Maintain good ride comfort although track conditions are worse, d) Reduce wheel and rail wear by means of improved curve negotiation, e) Secure running stability at higher vehicle speed. 1.1 Objectives of Air spring a) Improve passenger ride comfort, b) Maintain good ride comfort although vehicle speed is increased, c) Maintain good ride comfort although track conditions are worse, d) Reduce wheel and rail wear by means of improved curve negotiation, e) Secure running stability at higher vehicle speed. 428 1.2 Curve negotiation When negotiate a curve at an excessive speed, vehicles will roll over and automobiles will lose traction and slake out of a curve instead of rolling over. The more top-heavy a vehicle is, the more likely it will roll over than slake out of a curve. If the ride comfort is already good, further improvement at unchanged vehicle speed and track conditions is generally not justified due to the high costs of implementing active suspension. However, goals b) and e) allow large possibilities for cost-efficient improvements, since vehicle speed can be increased. Moreover, goals (c and d) have good potential of being worth the investment of active technology, since bogie maintenance will be saved .In order to achieve this control loop in the suspension of a rail vehicle, actuators, sensors and a controller must be added to the mechanical system. Fig. The concept of an active suspension system 1.3 Working principle of pneumatic suspension Air suspension is a suspension where properties of air are used for cushioning effect (springiness). Enclosed pressurized air in a pre-defined chamber called air spring, made up of Rubber bellow emergency rubber spring, provides various suspension characteristics including
3.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME damping. Air springs are height-controlled load leveling suspension devices. With changing loads, air spring reacts initially by changing the distance between air spring support and vehicle body. The height monitoring valve is in turn actuated, either taking the Compressed air pressure to the air spring or releasing air pressure from it to the atmosphere. This Process continues until the original height is restored). 429 Fig. Working principle of pneumatic suspension Passengers Fig. Air spring at standard height 1.4 Comparison with existing coil suspension Unlike steel spring, air springs retain their height under changing loads. In case of coil spring, deflection is proportionate to the load, therefore, under high payload situation, space constraint become critical, leading to the use of stiffer springs resulting in unsatisfactory ride behavior and reduced speed potential but air springs control mechanism, offer a load proportionate stiffness, constant floor height and prospects of better ride behavior with higher speed potential. Helical is springs are light, but they’re not perfect. Some advantages of air springs are: i) Capable to sustain Super Dense Crush Loads typical of suburban traffic. ii) Maintain constant floor height of coach. iii) Provide superior ride comfort. iv) Virtually Constant natural frequency from tare to full loads, reducing passenger fatigue. v) Isolation of structure borne noise, this improving comfort. vi) Improved reliability, reduced maintenance effort. vii) Flexibility to choose characteristics as per requirement at design stage. 1.5 Characteristics features of air suspension i) Soft flexible characteristics in vertical direction - Achieved by compression of air. ii) Excellent lateral spring characteristics, as desired. - Achieved by variation in effective area in lateral direction. iii) Avoids excess air consumption due to instantaneous modes of vehicle oscillation or change in air pressure- Achieved by designing delayed reaction leveling.
4.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME 430 2. LITERATURE REVIEW In the early 1930's, the Firestone Tire and Rubber Company began experiments to develop the potential of pneumatic springs. Between 1935 and 1939, several makes of U.S. automobiles were equipped with air springs and extensively tested to prove the potential of automotive air suspension systems. . In the early 1950's, after several years of intensive product development, the air sprung bus finally went into production. That was the beginning of the air spring success story. These systems generally employ small, electric or engine-driven air compressors which sometimes fill an on-board air receiver tank which stores compressed air for use in the future without delay. High-pressured industrial gas bottles (such as nitrogen or carbon dioxide tanks used to store shielding gases for welding) are sometimes used in more radical air suspension setups. The installation and configuration of these systems varies for different makes and models but the underlying principle remains the same. The metal spring (coil or leaf) is removed, and an air bag, also referred to as an air spring, is inserted or fabricated to fit in the place of the factory spring. When air pressure is supplied to the air bag, the suspension can be adjusted either up or down (lifted or lowered). General Motors used its experience with commercial bus air suspension to introduce systems for its automobile lines, introducing it as standard equipment on the Cadillac Eldorado Brougham in the 1957 model year. The following year it was offered as optional equipment on all Cadillac’s, and in 1959 it was made standard equipment on all Eldorado’s. Air bellows at each wheel replaced standard coil springs, and had sensors to keep the car level under load and in turns. It was too slow to react in sudden maneuvers. Period reviews rated the air suspension somewhat superior in ride quality, but not dramatically so. But now a day in air spring system is become a reliable system whose design is changed according to ancient air spring which was designs from Land Rover, Ssang Yong, Chrysler, Subaru, Audi, Volkswagen, Tesla, Porsche, and Lexus models etc. Now a day’s its shape has been changed and made it more comfortable for passenger and made it jerk free also designed as to reduce the maintenance cost in transportation system by using air spring. 3. WORKING PRINCIPLE OF PNEUMATIC SUSPENSION It enclosed pressurized air in a pre-defined chamber called air spring, made up of rubber bellow emergency rubber spring, provides various suspension characteristics including damping. air springs are height-controlled load leveling suspension devices. With changing loads, air spring reacts initially by changing the distance between air spring support and vehicle body. The air springs replace only the secondary suspension, whereas primary suspension continues to use steel coil springs. an auxiliary air reservoir of 150 litre capacity is provided below each coach which is fed from feed pipe through a non-return valve. Maintains 7 bar pressure in loco compressor and air springs operate at a limiting pressure of 6 kg/cm2 4. EXPERIMENTAL RESULTS The following environmental conditions are maintained during the experiments: Air suspension fitted in EMU/DMU stock shall be subjected to the following environmental condition: *Max. Temperature under sun: 60°C *Ambient temperature: 0° to 45°C in shade.*Average relative humidity: 70% to 90%, 100% on several days. *Rainfall: Fairly heavy, maximum being 200mm in 24 hrs typical to the coastal areas.*Atmosphere: Duties for several months of the year.
5.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME 431 4.1 Vertical stiffness of air spring assembly Minimum air cushion provided under minimum tare load condition shall be 25mm, with installed height of 255±0.5mm. At dz±20 mm at constant speed of 5mm/sec the vertical stiffness (Cz) shall be: Table A: Vertical stiffness of air spring Load in KN(static) Vertical stiffness Cz in N/mm Additional Volume 20 dm3 Additional volume 40dm3 50 600±100 N/mm 550±100N/mm 165 1200±200/mm 1000±200N/mm 180 1350±200N/mm 1150±200N/mm 4.2 Lateral spring stiffness of air spring assembly At dy ±20mm at constant speed of 5mm/sec the lateral stiffness shall be: Table B: Lateral spring stiffness of air spring Load in KN(static) Lateral stiffness Cy in N/mm 50 250±50N/mm 165 450±100N/mm 180 500±100N/mm 4.3 Horizontal Stiffness At dy ±20mm at constant speed of 5 mm/sec, the horizontal stiffness shall be: Table C: Horizontal Stiffness Load in KN (Static) Lateral stiffness Cy in N/mm 50 150 ±25 N/mm 115 175±25 N/mm 140 140 200±25 N/mm
6.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME i) Installed height without spigot =255±0.5mm. ii) Maximum permissible diameter of air spring =Ø740mm. iii) Maximum permissible external diameter of to plate of air spring =Ø750mm. iv) Min, height of air spring under full load with no air without spigot =215 mm. 432 5. SPACE CONSTRAINS 5.1 Pneumatic supply connection Air inlet connection point to be air spring shall be located at the centre of top plate through a spigot shall be as under: i) Outer diameter=Ø85-0.036 -0.071mm. ii) Height=35±0.5 mm. iii) Diameter of “O” ring =5.7±0.1mm 5.2 Tolerance test Table A: Tolerance in measured valve during characteristics tests S.No. Characteristic Tolerance 1 Pressure force Characteristic ±5% 2 Load deflection Characteristic ±10% 3 Stiffness under sinusoidal ±15% Table B: Vertical acceleration and Lateral acceleration (PSD) in (m/s2) /Hz Vertical acceleration(PSD) in (m/s2)/Hz Lateral acceleration(PSD) in (m/s2)/Hz 0.7Hz 1.0Hz 2Hz 4Hz 10Hz 3Hz 4Hz 7Hz 10Hz 15H z 9.34 1.38 0.41 0.68 1.66 0.0156 11.48 0.0507 0.0968 0.2 5.3 CHARACTERISTICS TESTSAIR BELLOW Characteristics tests S.No Pressure in kg/cm2 Specific load in KN Observed load in KN 1. 1 kg/cm2 30.4 to 33.60 KN 31.25 KN Specified inspections Lot size upto 10 25 50 75 100 No of samples 2 3 4 5 6
7.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME 433 Check list for inspection of air spring S.NO Item Firm’s RDSO approved Drg.No. 1 Top plate 750 mm 2 Spigot Height-35mm, Ø-85mm 3 Base plate with fixing holes 400X 600 mm 4- “O” ring Ø-5.8mm 5.4 LIFE CYCLE Table C: Comparison of life cycle of helical spring and air spring S.NO Month (Year-2013) Helical spring Air spring 1. January No change No change 2. February No change 3. March No change 4. April Change 5. May No change 6. June No change 7. July No change 8. August Change 9. September No change 10. October No change 11. November No change 12. December Change By above data we concluded that the life cycle of air spring is much better than that of helical spring. Cost of helical spring is Rs10000 and life cycle 4 months but cost of air spring is Rs75000 and life cycle 12 years which is shown by below graph. Fig. Cost Vs life cycle
8.
International Journal of
Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online), Volume 5, Issue 9, September (2014), pp. 427-434 © IAEME 434 6. CONCLUSION In the previous days, helical spring is used to design and demonstrate the wheel monitoring system in train. The helical spring less reduce the vibration at most for current researches. The current researches scenario the continuity improved the quality and safety purpose and it announce new theme i.e. air spring suspension system. The air spring suspension reduces the sudden failure rate and it is more comfortable in compare to helical spring. And one of best thing with this spring is, it have emergency spring which keeps it safe after any problem. These are the effective points because, when damping the helical spring the bogie frame structure get damaged/cracked. One air spring capacity up to 180 KN=18Ton, and a coach have 45.5/46 Tare load=Ton. In a coach has 2 bogie and a bogie have two air spring so; it is capable to bare the train load at and situation. At and emergency situation emergency spring is also given. One helical spring have 3-4 months life time but an air spring have 10-12 years life time. So it is more effective. One of the important factor is emergency spring which keeps save as per the own name. So at last we can say that this paper play an effective role in future. REFERENCE [1] 1959 Rambler Wagons brochure. Oldcarbrochures.org. Retrieved 14 August 2013. [2] Suarez B., Mera J.M., Martinez M.L. and Chover J.A. (2012): Assessment of the influence of the elastic properties of rail vehicle suspension on safety, ride quality and track fatigue. Vehicle System Dynamics: International Journal of Vehicle Mechanics and Mobility. [3] Cheng, Y.C., Lee, and S.Y.Chen, H.H. (2009): Modeling and nonlinear hunting stability analysis of high-speed railway vehicle moving on curved tracks. Department of Mechanical Engineering, National Cheng Kung University, Tainan, Taiwan 701, ROC. [4] Orvnäs, A., (2011): On Active Secondary Suspension in Rail Vehicles to Improve Ride Comfort. PhD Thesis. Department of Aeronautical and Vehicle Engineering, KTH Engineering Sciences. [5] Johnsson, A., Berbyuk, V., Enelund, M. (2012). Pareto Optimisation of railway bogie suspension damping to enhance safety and comfort. Vehicle System Dynamics: International Journal of Vehicle Mechanics and Mobility, 50:9, 1379-1407, DOI:10.1080/00423114.2012.659846. [6] Mousavi, M., Berbyuk, V., (2013): Multiobjective optimization of a railway vehicle dampers using genetic algorithm. Proceedings of the ASME2013 International Design Engineering Technical Conferences Computers and Information in Engineering Conference, IDETC/CIE 2013, August 4-7, 2013, Portland, USA (Paper DETC 2013- 12988). [7] Kamoshita, et al.: Electro-hydraulic Actuators for New Type Railway Vehicle with Tilting Control. RRR. 62 (5), 24-27 (2005) 10) Tajima: Driving Bogies for Series E5 Shinkansen Vehicles. Rolling Stock and Technology. (157), 7-9 (2009). [8] Uekura, et al.: Development of Active Suspension Control System by Actuator of Decreased Air Consumption. Proc. 17th Jointed Railway Technology Symposium. Japan Society of Mechanical Engineers, S5-1- 1, 305-308 (2010). [9] Mohd Azman Abdullah, Azhar Ibrahim, Yohei Michitsuji and Masao Nagai, “Active Control of High-Speed Railway Vehicle Pantograph Considering Vertical Body Vibration”, International Journal of Mechanical Engineering Technology (IJMET), Volume 4, Issue 6, 2013, pp. 263 - 274, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.
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