Design And Specification For Freight Car/Wagon (Part2)

II. TECHNOLOGY SELECTION
II.1 Under Frame
There are 3 Types Of Under frame :
 Under frame with Strengthen Construction (Type A)
 Under frame with Strengthen (Type B)
 Under frame For Special Load (Type C)

Design Parameter : Smallest Deflection, Absorbable of Impact Load and Easy Maintenance
II.2 Car Body
 To built for opened car and covered/box car
 Non monologue Type (The under frame support Uniformly or Centrally Distribution Load)
 More than simple compare with the the passenger car body
 Car body Design to fit in with Commodities shall be Moved
Design Parameter :
 To Fit in With Commodities Moved
 Rigid
 Easy Maintenance
II.3 Bogie
a. Parameter Design :
 Type of Bogie
 Riding Quality
 To fit in with track condition
 Max axle load
 Max operating speed
 Wheel sets Type (Wheel, Axle and Bearing)
 Wheel Tread and Flange Profile
 Smallest the wear of both Wheel and Rail
 Domestic Product for Frame Bogie

a. There are many types of Bogies :
 2 Axle with leaf spring (Old Type)
 Rigid bogie with leaf spring (Old Type – Romania)
 Three Pieces Bogie :
 Barber (Japan – Korea – Canada)
 Ride Control (Japan – Romania)
 Barber Baraga for 5X9 and 5 ½ X 10 S2HD INDON
 Steering Bogie (Sample Test)
 Gloucester and Chevron (Sample Test)
C. Wheel sets and Bearing
 Type of solid wheel : Cast Steel & Forged Steel
 Wheel Diameter : 774 mm & 850 mm
 The axle shall be as steel forged axle (SFA)
 Bearing :
 Cartridge type with Class C (5x9) and Class D (5 ½ x 10) NFL Type
 Ball and Cylindrical Roller Bearing
 Plain Bearing (Old Type)

II.4 Coupler
a. Parameter Design :
 Train gross loads
 Max operating speed
 Track geometry and Condition
 Compatible and Interchangeable
 Max Buff and Draught force (Compression and Tension Force)
 Domestic Product
 Knuckle contour – AAR 10A Standard

b. There are various type of coupler are as follow :
 Endicott type
 Sumitomo type
 Claw type (Old model)
 Tight Lock type
 Fixed and Rotary type (For 18 tons axle load)

c. The coupling device shall have coupler, coupler yokes and draft gear.
II.5 Door (Loading and Unloading facility)
a. Design Parameter :
 Easy to operate both loading and Unloading activities
 Minimum water leakages
 Safe For Operator


b. Type of Door :
 Sliding Door
• Inside sliding door
• Outside sliding door
• Single or twin doors
 Swing door with Hinge
 Bottom Discharge
 Telescopic car body
 Sliding Roof
 Removable Roof
II.5 Air Brake
a. Design Parameter :
 Brake type
 Stopping distance
 Hand brake requirement
 Specification of individual component
 Compatible and Interchangeable
 Maximum gradient
 Domestic product with license of manufacture

b. Main component :
 Distributor valve (Control valve)
 Brake cylinder
 Slack Adjuster
 Air Reservoir
 Empty Load Device

c. Manufacture :
 Knur
 Westinghouse (WABCO)

Design And Specification For Freight Car/Wagon (Part1)

I. Rolling Stock Requirement
to quarantine the safety, The rolling stock operating in Indonesian Railway shall comply with the following requirements
A. Track Gauge : 1067 mm
B. Minimum Curve :
- On Main Lines : 150 meters
- On Branch lines and Depot/Workshop : 80 meters
C. Maximum Axle Load :
1. Special Lines (South Sumatra) : 18 ton
2. Standard Lines : 14 ton
D. Maximum Gradient : 30 0/00
E. Rolling Stock and Structure Clearance Shall Comply with IRC
CLEARANCE DIAGRAM No. D-2042 (Vehicle Gauge)
 The drawing to explain about “permissible rolling stock out line” and “permissible structure out line “ and their relationship to one another.
 Calculation of limitations include operation
 Presentation of vehicle cross section
 Arrangement of spring and dampers with vertical and lateral clearance
F. Atmosphere Condition
1. Relative humidity max : 90%
2. Ambient temperature : 35 0 C
G. Operation Performance
1. Max load capacity :
• South Sumatra Line : 50 ton + 1,5%
• Standard Line : 30 ton + 1,5%
2. Comparability when coupled with other rolling stock, as follow :
a. Coupler :
1) The knuckle contour shall be in accordance with AAR 10A profile
2) The center line knuckle height shall be 775 +10/-0 mm from top of rail
b. Braking :
The air brake system shall be in accordance with UIC code 540
3. Calculation against derailment
4. Calculation of car stability
5. Location of center of gravity by calculation
H. MAINTENANE
The wagon construction and main component shall be built with easy maintenance.

I. SAFETY ELEMENTS
In order to cover safety operation, furthermore design of wagon shall be accordance with the rule of safety by Indonesian Railway Corporation and the other regulation

Improvement of Safety on Indonesian Railway System

OBJECTIVES :

Following safety measures should be immediately implemented in order to delete the factors which may trigger railway accidents;

1. Installment of safety sidings in major stations where shunting work is frequently carried out, by which accidents such as head-on collision could be avoided.

2. Implementation of countermeasures against landslides along railway lines. For example, the dangerous areas with possible landslides are found along Jakarta - Bandung corridor. Some urgent countermeasures should be taken before a landslide brings about a serious railway accident.

3. Review of present technical regulations and installing safety regulations in all technical categories

4. Implementation of educational training for train operation staff, by which increasing their incentive to keep safety operation and reducing human errors in train operation

5. Preparation of inspection and maintenance manuals, by which reducing accidents due to insufficient maintenance of facilities. Technical transfer of inspection and maintenance method from advance countries in the form of OJT is effective

6. Procurement of equipment and tools for inspection and maintenance is essential for OJT

ACTIVITIES :

§ Construction of safety sidings in 16 major stations in Java.

§ Protective work for possible landslides on Jakarta - Bandung corridor.

§ Procurement of equipment and tools for inspection and maintenance

§ Preparation and recommendation of new regulations for controlling safety operation.

§ Review and preparation of regulations for facilities and safety train operation.

§ Review and preparation of inspection and maintenance manuals.

§ Improvement of training program and training centers

§ Establishment of a accident study team and training for them

§ Training (OJT) for operation, inspection and maintenance staff, especially in DAOP (I and III)