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ENGINEERING EXCELLENCE AWARDS-2013 BEML LIMITED WELCOMES TO THE PRESENTATION ON DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU 7 th OCT 2013

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Page 1: Beml limited

ENGINEERING EXCELLENCE AWARDS-2013BEML LIMITEDWELCOMES

TO THE PRESENTATION ON DESIGN & DEVELOPMENT OF

STAINLESS STEEL EMU

7th OCT 2013

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The present existing Electrical Multiple Units (EMU’s) running on sub-urban

rail network in metropolitan cities, are 3.66 m wide coaches manufactured with

Mild Steel material and painted.

These EMU’s are prone to corrosion, especially in harsh environmental

conditions in coastal cities of Mumbai, Chennai & Kolkata.

This results in frequent body repairs, increased down time and less availability

thereby reducing the revenue to Indian Railways.

PROJECT BACKGROUND

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

With the above background, a pro-active step was taken up by M/s BEML Ltd, Bangalore Complex, R&D team

Re-design the conventional mild steel body coaches with corrosion resistant austenitic stainless steel material (life of 35 years).

Carbody design which is modern, clean, aesthetically appealing and more importantly which does not require any painting

With world-class interiors.

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PROJECT HIGHLIGHTS:

Development order from Indian Railways.

Quantity: 2 rakes of 9 coaches each.

Order Value: INR 40 crores for 2 rakes.

Order received : 2008-09

Scope: Design, Development, Manufacture, Testing, Commissioning & supply.

Technical Requirements:

• 3.66 m wide Stainless Steel Carbody,

•World Class Interiors,

•Provision of forced air ventilation with ducting.

Prototype completed: 2011-12

Trials completed & put into revenue service : 2012-13

PROJECT BACKGROUND

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

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BRIEF SPECIFICATIONS:

Track Gauge-Broad Gauge: 1676 mm,

Max Speed : 100 kmph

Coach length over body: 20726 mm,

Max. width over body side: 3660 mm,

Coupler height from rail level: 1035mm,

Height of coach from rail level: 3618 mm,

Maximum permissible axle load (Driving Motor coach & Trailer coach): 20.32 T,

Max. height of the comp. floor from rail level under tare condition: 1230 mm,

Rake Formation-9 Coaches: B-C-D-B-C-C-D-C-B

(B- Driving Motor Coach, C- Trailer Coach with Ladies Comp, D- Trailer Coach with Vendor Comp)

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

DETAILS OF PRODUCT

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SUB SYSTEMS:

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

DETAILS OF PRODUCT

Sub – system Features

Carbody Austenitic Stainless Steel carbody with unpainted exteriors

Coupler arrangement High capacity semi permanent coupling (Schaku couplers)

Bogie Primary Coil Spring & Secondary Air suspension for good riding comfort

Propulsion System Electric propulsion system

Brake System Electro pneumatic brake system.

Front end FRP cab mask and cab skirt which provides a modern aesthetic appeal to the coach.

InteriorsDesigned to be on par with that of the world-class coach interiors. FRP panels have been used extensively to provide pleasant ambience for the passengers

Seat Ergonomically designed passenger seats with polycarbonate material and with dual tone shade to match the FRP interiors

Flooring Anti-skid stainless steel floor cover sheets

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Design of wide bodied SS carbody structure with 16 passengers / sqm loading (double of International & Indian metro standards) was a challenging task

Interior design was made with aesthetics & cost effectiveness in mind, FRP panels used

New design of window with wider opening. Design is having provision for converting to Air-conditioned type with minimal changes

Passenger seats with polycarbonate material & dual tone shade to match the interiors.

FRP cab mask incorporated in the front to give a better look. FRP driver’s desk ergonomically designed.

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

DESIGN INNOVATIONS

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

DESIGN & DEVELOPMENT EFFORTS

Design effort involved: Development effort involved:

Analysis of customers requirements, Manufacturing drawings

Conceptual Design, Procurement technical specifications

Detail design calculations Quality Documents.

3D modeling Manufacturing of Prototype carbody

Structural Integrity & Strength Analysis Design validation by squeeze testing

Manufacturing, Furnishing & In-house testing

Testing and commissioning at customers location.

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Complete carbody modeled using CATIA V5 software.

Carbody section to be within the allowable maximum moving dimensions.

Weight reduction by 2 Tonnes

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

DESIGN MODELING OF CARBODY

TRAILER COACH

MOTOR COACH

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CAD model of interiors, driver’s desk & cab mask prepared

Interferences checked

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

DESIGN OF INTERIORS

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Structural Integrity & Strength Analysis of the carbody checked

To meet UIC 566 standard,

Analyzed using MSC Nastran software,

Super dense passenger loading of 16 passengers / sqm

Stress levels within acceptable limits.

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

STRUCTURAL STRENGTH VERIFICATION

MOTOR COACH

TRAILER COACH

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Validation of carbody carried out by squeeze testing as per

UIC-566 standard with the following loadsVertical Load L1: 75 Tonne Compressive Load L2: 1200KNCombined Load: L1+L2

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

CARBODY DESIGN VALIDATION – PHYSICAL TESTING

PROTOTYPE TRAILER COACH CARBODY

PROTOTYPE MOTOR COACH CARBODY

DATA ACQUISITION UNIT

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To meet the requirement of developing a world class coach, BEML has

established all the infrastructure required for manufacturing carbody and it’s

assemblies for SS EMU cars.

Robotic spot welding technology,

5 axis series spot welding,

CNC programmed Stretch Forming,

Dedicated special Jigs & Fixtures.

Custom built test facilities like water leak test, bogie load testing and test

tracks to ensure quality requirements.

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

MANUFACTURING INFRASTRUCTURE

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

MANUFACTURING INFRASTRUCTURE

ROBOTIC SPOT WELDING

5 AXIS SERIES SPOT WELDING

CNC PROGRAMMED STRETCH FORMING

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

MANUFACTURING INFRASTRUCTURE

UNDERFRAME MAIN ASSY JIG ROOF MAIN ASSY JIG

SIDE BLOCK ASSY JIG SIDE WALL MAIN ASSY JIG

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

CARBODY MANUFACTURE

TRAILER COACH CARBODY

MOTOR COACH CARBODY

Manufacturing of Stainless steel

EMU carbody in production line.

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

Furnishing of Stainless Steel EMU in

production line.

CAR FURNISHING & ASSEMBLY

INTERIOR VIEW

DRIVER DESK

EXTERIOR VIEW

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

Testing of furnished SSEMU rake in test track witnessed by RDSO/RITES.

INHOUSE TESTING

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

First Rake Stainless Steel EMU rolled out from BEML Limited, Bangalore

Complex to Eastern Railways, Sealdah, Kolkata

FIRST PROTOTYPE RAKE

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

SSEMU has successfully undergone all the extensive tests & trials by the customer, Eastern Railways, Sealdah, Kolkata

COMMISIONING & FIELD TRIALS

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

This product was extensively tested by the user railways and after successful completion of trials for a period of six months, this innovative product is running successfully in revenue service at Sealdah, Eastern Railways from Oct 2012 onwards.

REVENUE SERVICE

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

VIDEO

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

COMPARISION OF SSEMU WITH EXISTING MILD STEEL EMU

EXISTING MILD STEEL EMU STAINLESS STEEL EMU

STAINLESS STEEL EMU & EXISTING MILD STEEL EMUSTAINLESS STEEL EMU & EXISTING MILD STEEL EMU

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

COMPARISION OF SSEMU WITH EXISTING MILD STEEL EMU

EXISTING MILD STEEL EMU WINDOWSTAINLESS STEEL EMU WINDOW

EXISTING MILD STEEL EMU WINDOW INSIDE VIEWSS EMU WINDOW INSIDE VIEW

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

COMPARISION OF SSEMU WITH EXISTING MILD STEEL EMU

INTERIORS IN EXISTING MILD STEEL EMUINTERIORS IN STAINLESS STEEL EMU

EXISTING MILD STEEL EMU SEATSSTAINLESS STEEL EMU SEATS

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

COMPARISION OF SSEMU WITH EXISTING MILD STEEL EMU

INTERIORS IN EXISTING MILD STEEL EMUINTERIORS IN STAINLESS STEEL EMU

SS PANELLED PARTITIONS IN EXISTING MILD STEEL EMU

FRP PANELLED PARTITIONS IN STAINLESS STEEL EMU

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DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

COMPARISION OF SSEMU WITH EXISTING MILD STEEL EMU

STRAP HANGER IN EXISTING MILD STEEL EMUSTRAP HANGER IN STAINLESS STEEL EMU

LP SHEETS PANELLED CEILING IN EXISTING MILD STEEL EMUFRP CEILING IN STAINLESS STEEL EMU

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The indigenously designed & developed SS EMU has successfully undergone all the stringent tests & trials of the customer, IR

User satisfactory performance certificate received.

Based on the successful user trials, further order of 4 rakes (36 cars) has been received from IR

MD, MRVC (Mumbai Rail Vikas Corporation) after his visit to BEML had made the following observations

“ We were extremely happy to observe the international standard achieved by BEML in the design & manufacture of stainless steel coaches for Metro & Suburban railway system in India. “

CUSTOMER FEEDBACK

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

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CUSTOMER FEEDBACK

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

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SS EMU designed & developed for Indian Railways for the first time through

in-

house R&D efforts without any foreign collaboration.

Stainless steel carbody joining / manufacturing process established which will

be helpful for other projects.

Stainless steel raw material of desired specification developed by indigenous

sources.

Interior furnishing items developed through indigenous sources.

Future requirements of rolling stock variants with stainless steel carbody can

be developed within the country.

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

CONTRIBUTION TOWARDS SELF RELIANCE

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With introduction of SS EMU latest stainless steel carbody similar to the

metro cars brought in IR.

Use of Stainless steel will increase the life of the coaches (25 to 35 yrs) & also

reduces maintenance time, thereby reducing the life cycle cost.

Use of austenitic stainless steel has eliminated painting, making it eco friendly.

Common man can have the pleasure of travelling in a better coach at the same

cost.

Product well accepted, IR placed additional order for SS EMU & MRVC floated

requirement for 153 nos. SS cars.

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

KEY IMPACTS

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Based on the successful commercial service of prototype rake, Indian

Railways have placed additional supply order for 4 rakes of SSEMU valuing

about 84 crores.

Indian Railways plans to replace the existing 3000 no’s of Mild Steel EMU

coaches with the newly developed Stainless Steel EMU’s. Total business

expected from SSEMU is about INR 1000 crores per year.

Mumbai Rail Vikas Corporation (MRVC) were impressed by unique features of

the SSEMU prototype rake and have floated requirement for 153 SSEMU

coaches for their harbour line.

Considering the benefits of stainless steel carbody, future production of other

EMU’s is expected to be manufactured with SS.

Tier – II cities can adapt this technology with minimal changes for low cost

metro rolling stock.

FUTURE READINESS

DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS

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THANK YOU