PNEUMATIC

BRAKING
SYSTEM
What is Pneumatics?
Pneumatics is a branch of engineering that makes use of gas or pressurized air. Pneumatic systems
used extensively in industry are commonly powered by compressed air or compressed inert gases. A
centrally located and electrically powered compressor powers cylinders, air motors, and other
pneumatic devices.

Pneumatics braking system

A brake which uses air as working fluid is a pneumatic brake. The system actuated to apply
this phenomenon is known as Pneumatics brake system

An Pneumatic brake or a compressed air brake system, is a type of friction brake for train in
which compressed air pressing on a piston is used to apply the pressure to the brake pad
needed to stop the train

THE DIFFERENT PART OF PNEUMATIC BRAKING SYSTEM

All pneumatic or compressed air brakes act by pressing the brake blocks or pads against the
wheels or
break discs by means of compressed air.
The braking force can be regulated by altering the air pressure.

1. Compressor

The compressor sucks in air from the atmosphere and compresses it. The compressed air is
stored in the main reservoir from where it is distributed to the main air supply pipe
 2. Main reservoir

The compressor starts up automatically if the pressure falls under 7 bar and shuts down when
the
pressure level reaches 9 bar.
In most cases the compressor is fitted with an air dryer

3. Air dryer
PNEUMATIC BRAKING SYSTEM

1. (U1) Its is said to be BABY COMPRESSORor AUXILARY COMPRESSOR

which is reciprocating type having single mounted on a it
2. (U2) RUBBER GAUGE is fixed at the joint of auxiliary compressor for prevent
the transfer of any type of vibration to the compressor.
3. (U3)EMERGENCY EXPANSION VALVE, when the pressure exeed above the 9
bar , it get opened and release the pressure from it.
4. (U4) NON-RETURNING VALVE , it is like barrigate for pressure which allow to
passed over it or not.
5. (U5) SWITCH , which have the function of cut off the pressure at 6-7 bar.
6. (U6) AIR FILTER, having a function of clean the air entering in a pipe or
removing dust particle from pressurised air.
7. (U7) SURGE TANKorRESERVOIR in which excess amount of pressure is stored
in it.
8. (U7.1) PRESSURE RELEASING VALVE at which when the amount of pressure
is more than its ability of storing then it helps to release the pressure in
atmosphere.
9. (U12) VCB(VACCUME CIRCUIT BREAKER) it has function in a circuit like
MCB in household , they cut off the power when load is heavy then it is used.

1. (A1) MAIN COMPRESSOR having 2 piston in V-shape on single crankshaft for

producing more pressure then auxiliary compressor. It is also a reciprocating type
having 2 piston of V-shape is mounted on a compressor.
2. (A2) RUBBER GAUGE , helps to prevent the transfer of vibration to other
circuit.
3. (A3) PRESSURE RELEASING EXPANSION VALVE , when pressure exceeding
more then 12bar , it get opened and release pressure in atmosphere.

4. (A4) AIR DRIER , it consist 2 chamber and work alternatively one by one.
 Helps to absorb air from atmosphere.
 Fixed near the compressor .
 MT oil is used to clean the air drier.
5. (A6) AIR FILTER , helps to purify the air before storing in a surge tank or
resrvoir.
 6. (A7) SURGE TANK (200L) helps to stored the pressurised air in a tank upto
200L.
7. (A9) SWITCH , which helps to cut-off the pressure at maximum 10bar and if the
pressure is below 7.5bar then it gives command to main compressor to rise the
pressure.
8. (A10) ELECTRO-MAGNETICCONTROLLING SWITCH, which helps to contrl
the all other switch.
9. (A13) OIL FILTER , helps to prevent the entering the oil in the air drier.
10. (A14) AIR FILTER , helps to filtered the air or reefing the air before leaving in
the atmosphere.
11. (A15) SILENCER , it reduces noise from the system and make them noiseless.

REQUIREMENT FOR PNEUMATIC BRAKES

 Pressurized air generator (Compressor).

 Piping module for air flow.
 Air Reservoirs to store high pressure air.
 Valves to control the air flow.
 Governors to monitor/control the system.
 Isolating cocks to open/close the air flow.
 Brake actuator to move the brake shoe.

BRAKING SYSTEM

1. SERVICE BRAKE

2. EMERGENCY BRAKE
3. PARKING BRAKE

PANTOGRAPH
 PANTOGRAPH ASSEMBLY

1. BASE ASEMBLY
2. LOWER ARM ASSEMBLY
3. FORTH BAR ASSEMBLY
4. UPPER ARM ASSEMBLY
5. PAN HEAD ASSEMBLY
6. AIR EQUIPMENTS
 OVER HEIGHT DETECTOR
 AIR CONTROL SCHEMATIC
 CONTROL PANEL

7. RAISING CYLINDER ASSEMBLY

8. . FOOT INSULATOR

SPECIFICATIONS

 Setting of Pressure Switch RS1( rolling stock 1 ) :

3.8 Bar (Upper Range)
1.0 Bar (Lower Range)
 Setting of Pressure Switch RS2( rolling stock 2 ) :
5.0 Bar (Upper Range)
1.5 Bar (Lower Range)
 Min. Pressure to Raise Pantograph : 3.8 Bar
 Min. Pre. to Maintain 90N Contact Force : 5.5 Bar

Location:
The Pantograph is located on top of the Vehicle roof structure to allow unhindered access to the
overhead lines.

Function:
The function is to collect the current from the overhead wire by the carbons, which is
carried by thestructural members of the unit to the power take off points on the base
frame. The insulated bearings,are by passed by the flexible shunts. The pantograph is
attached via 4 foot insulators that support and insulate the pantograph on the vehicle roof.
The Pantograph receives an air supply from the vehicle via the control panel and air feed
insulator allowing the pantograph to be raised and lowered on demand and maintain
contact force with the overhead wire when in the raised operational mode

GENERAL MAINTENANCE OF PANTOGRAPH

  Cleaning, Inspection & Re- greasing of Insulator.
 Inspection of Upper Arm.
 Inspection of Lower Arm.
 Inspection of Pantograph Head.
 Inspection of 4thBar Assembly.
 Inspection of Air Equipment.
 Inspection of Pantograph Head Shunt Assembly.

PRECAUTION WHILE WORKING ON PANTOGRAPH

1. PANTOGRAPH SHOULD BE LOWERED .
2. OVERHEAD LINE SHOULD BE PROPERLY DE-ENERGIED & EARTHED.
3. SAFETY BELT SHOULD BE USED WHILE WORKING ON PANTOGRAPH.
4. AVAILABILITY OF COMPRESSED AIR SUPPLY IS NEEDED IN NEAR BY.
.
 TESTING PANTOGRAPH

While testing pantograph during my training in DELHI METRO RAIL CORPORATION

Ltd. I learned so many things that panto-up and panto-down is all done by pneumatically
not by electrically. The minimum pressure that required to raise the pantograph is only 3.8bar.

The testing of pantograph is done by me under the guidance of MR. ASHISH SIR. The
testing is done of new pantograph is 300 times panto-up and panto-down because we have to
check that is pantograph was working properly or not.

While testing pantographs of RS-1 metro which is also called BOMBARDIER imported all
the way from GERMANY.
We are checking Carbon strip thickness should not be less than 2mm pantograph .
MECHANICAL
SECTION
 WHAT IS BOGIE?

FIG. OF BOGIE

 Takes the load of vehicle.

 Transfer the tractive/braking forces
 Maintain good ride quality
 Pass the curves smoothly

Types of Bogie
• Driving Trailer Front/Rear

• Motor Bogie

DIFFRENCES BETWEEN M-CAR AND T-CAR

M-CAR T-CAR
 DRIVE MOTOR  ATC PICK UP COIL
 TRACTION MOTOR  APC RECEIVER
 ATC BEACOME
RECEIVER
MAIN PARTS OF BOGIE
 1. Center pivot device

a. Upper

b. Lower
c. Lateral damper

d. Mono link

e. Lateral buffer
2. Anti role bar
3. Secondary suspension
4. Primary suspension
5. Wheel sets
6. Axle Box

(1). CENTER PIVOT DEVICE

1. Center pivot upper

3. Mono link

4. Lateral damper

2. Center pivot lower 5. Lateral buffer

FUNCTION:- To transfer the tractive and braking efforts from coach to bogie.
To control relative lateral movement between coach and bogie.
 (2)ANTI ROLL BAR

FUNCTION :- To prevent rolling of coach.

(3)SECANDARY SUSPENSION

Auxiliary
rubber spring

FUNCTION:-To improving riding index by absorbing jerks.

To maintain coach or train to level height.
(4) PRIMARY SECTION

FUNCTION :-To absorb shocks or jerks coming from rail.

To control lateral and longitudinal movement between bogie frame and wheel.

TECHNICAL DATA OF BOGIE

 WHEEL DIA. 860/780mm
 WHEEL GUAGE 1600mm
 WHEEL BASE 2400mm
 BOGIE WIDTH 2877mm
 LENGTH OF BOGIE 3470mm
 AXLE LOAD 17000kg
 MASS OF MOTOR BOGIE 8100kg
 MAX OPERATING SPEED 80kmph
 DESIGN SPEED 90kmph
 AIR
CONDITIONING
SECTION

What is air Condition?

a system for controlling the humidity, ventilation, and temperature in a building or vehicle,
typically to maintain a cool atmosphere in warm conditions .
Why Air Conditioning is used ?

Because human feels comfort only with some specified parameter of temperature, humidity
& purity & distribution of air in the occupied area , but outside condition is variable &
doesn’t fulfill the requirement.

FUNCTIONING OF AIR CONDITIONING

 To control temperature
 To control humidity
 To supply pure air
 To distribute air properly
 Remove heavy gases from occupied area.

COMPONENTS OF AIR CONDITIONING

• Refrigeration system :-
Refrigeration system to control the temperature & humidity of air to be supplied in the
occupied zone.

• Air Transfer Equipment :-

Air Transfer Equipment supply & distribution of air in the occupied area .

• Electrical Equipments &controls :-

Electrical equipment to supply electrical power supply & controlling all the
equipments.

Composition of Air-Conditioning system installed on train

 DT Car:- 02 Saloon AC + 01 Cab AC

  M Car:- 02 Saloon AC

It means there are 08 Saloon AC & 02 Cab AC installed on 04 Car system.

MAIN COMPONENTS OF SALOON AIR COMPRESSOR

 1. COMPRESSOR

The function of the compressor is to pump the refrigerant through the system and
to compress the low pressure, low temperature refrigerant into a high pressure
high temperature super heated vapour, to allow condensing to occur.

Type:- Semi-Hermetic Four Cylinder

Reciprocating Suction Gas Cooled

Speed:- 1450 rpm

Swept volume:- 82.21 m3/h

Displacement:- 945 ccm

1.

2. CONDENSER COIL

The function of the condenser coil is to reject the heat from refrigerant during the
compression process.

Type: Copper finned, copper tube,

brass frame heat exchanger

Quantity: 2 per unit

Air Flow: 2700 l/s (each coil)

 3. T-X valve
The TX valve regulates the refrigerant flow into the evaporator coil, expanding the
liquid from high pressure to low pressure, and causing a large drop in refrigerant
temperature.

Refrigerant R22

Factory Superheat 5K

Max bulb temp. 100 o C

Max working pressure 28 bar

4. EVAPORATOR COIL

The prime function of the evaporator coil is to suck the latent heat from saloon .
Type :- Copper finned, copper tube,
brass frame heat exchanger.

Quantity:- 1 per unit.

Air Flow :- 1350 l/s

Face Velocity :- 2.5 m/s

Cooling Capacity :- 41 kW
 5. CONDENSER FAN

Its function is to draw the atmospheric air through condenser coil, through
which hot refrigerant is flowing for the purpose of heat rejection & condensing
of refrigerant.

Type: Multi wing axial fan, 9 blades

Quantity: two (2) per unit

Direction of flow: Draw through

RPM Range: 0 – 2045 rpm

6. SUPPLY FAN
It supplies the conditioned air inside saloon. It draws 70% return air & 30% fresh
air & supply the mixture inside the saloon.

Type: Two double inlet centrifugal blower

wheels with double shafted

motor

Quantity: Two (2) per unit

Supply Air: 1350 Litres/second at 470 Pa

external static pressure

Motor:- 2.2 kw @1500rpm, 415 v

Operating modes in Metro

1. Normal Operating Mode
In Normal Operating Mode A/C unit provides cooling and ventilation, switching
automatically by various sub modes to fulfil specified condition.

2. Emergency Operating Mode

When 3Ph. Power supply is not available , ac will work in this mode & will supply
fresh air only.

3. Smoke Mode
In this mode , system shuts off the fresh air intake and provides full recirculation of
return air within the saloon.

4. Vent mode
air is supplied inside saloon without any cooling
 Cool-1 mode:-air is supplied with cooling only 50% of cooling capacity is
used
 Cool-2 mode:-air is supplied with cooling (100% cooling capacity is used.
DOORS
 Types of Door

1. Saloon Door

2. Cab Side Door

3. Partition Door

4. Emergency Door

Saloon Door Numbering

 Saloon door number is fixed & not changed with cab activation.

Salient Features

• Obstruction detection
• Door isolation
 • Emergency operation

• Fault diagnosis

Major components of saloon door

Electrical items Mechanical items

 DCU  Center hook casting & Eccentric pin.

 Solenoid  Transmission belt & gear box

 Motor  Spindle shaft

 Encoder  Spindle nut and holder

 Close limit switch  Drive bracket

 Lock limit switch  Cover actuator plate

 Emergency switch

 Isolation switch

Components

DCU(Door control unit): Electronic unit that process all input commands,
control door actions and report door status and faults and provide communication with
TIMS.
 DCU

Solenoid:

Solenoid controlled by DCU and with its plunger activation center hook casting moved
up&down (mechanical lock lock/unlock )according to door open/close movements.

Solenoid

Motor :-Motor controlled by DCU and according to command gives door

movements open/close.
 Motor

Lock limit switch:-Lock limit switch operated by center hook casting and gives signal
to DCU for lock/unlock status of door.

Lock limit
switch

Emergency switch:-

Emergency switch is activated by emergency handle operation and gives signal to DCU for
door opening in emergency situation
 Emergency switch

Isolation switch
Isolation switch is manually operated & with operation electrically isolate the DCU &
mechanically locked with double hook plate

Isolation switch

DOORS OPERATING CHART

 Door Close
Door Open
push button push Button
ATP ZVAR Close Limit
relay Switch

DCU
Lock Limit
Switch
Emergency
S/W
Solenoid

Motor Encoder

Spindle Shaft

Spindle Nut

Drive Bracket

Door Panel

Door Open/ Close