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lR;eso t;rs

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR

ALTERNATE GEAR DRIVE ASSEMBLY FOR WAP5 AC ELECTRIC LOCOMOTIVES

Specification No. RDSO/2009/EL/SPEC/0089 (Rev ‘2’)

ISSUED ON ---------

Approved by Signature

Sr. EDSE

Issued by

ELECTRICAL DIRECTORATE RESEARCH DESIGNS AND STANDARDS ORGANISATION

LUCKNOW-226011

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Status of Revision SN Date of

Revision Page No. Revision Reasons for Revision

1. ----- ----- 0 First Issue (March’ 2008).

2. 16.04.2010 ,, 1 Inclusion of important technical suggestions regarding scope, coupling, sealing, gear box housing and type test to improve the design of system

3. ,, 2 Modification of purchase specification in technical specification on the basis of successfully developed system with incorporating design as well as testing procedure, physical properties like temperature/vibration measurement etc.

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Contents

SN Description Page no.

1. Foreword 4

2. Scope 4

3. Technical Data 4

4. Operating Environmental Condition 5

5. Salient Features 6

6. Inspection & Testing 7

7. Test 8

8. Finite Element Analysis 12

9. Documentation, Records and Suppliers Responsibility:

12

10. Marking & Packing 13

11. Annexure-I 14

12. Annexure-II 15

13. Annexure-III(sketch of the drive gear system)

16

14. Annexure-IV(drawing of Rotor Shaft) 17

15. Annexure-V(Sketch of Gear box Housing)

18

16. Annexure-VI(Drawing of WAP5 axle) 19

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Technical Specification for Alternate Gear Drive Assembly for WAP-5 AC Electric Locomotive

1.0 Foreword:

The driving gear system for WAP5 locomotive consists of hurth coupling, main driving gear, intermediate gear, pinion, aluminium gear case and other drive assembly components. The present system is suitable for a maximum train speed of 160 kmph. The reliability of the existing arrangement has been a source of concern due to breakage of lug of aluminium gear case, oil leakages from gear case/hurth coupling, seizure of coupling and failures of other components. There have been improvements through development of new design in the drive gear system for traction application.

2.0 Scope: Therefore, this specification is meant for drive gear system which should not only

be reliable at the present speed of 160/200 kmph but also should be able to serve at a test speed of 180/225 kmph. The complete new system containing all gears, gear case, couplings and other assembly components and revised mounting arrangement will be designed and supplied by them. However, the wheel and bogies of the existing design shall remain the same. The same traction motor without any changes in dimension or design will also be used.

The supplier shall supply completely assembled driving gear system consisting of following components:

SN Components Qty per loco

1 Axle 4

2 Main driving gear mounted on axle 4

3 Intermediate gear 4

4 Input Pinion 4

5 Coupling arrangement 4 sets

6 Gear box including torque arm 4 sets

7 Other drive assembly components eg.

Labyrinth, seals, fasteners, mountings,

Bearings

As per

requirement

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3.0 Technical data:

Salient features of existing WAP5 Locomotive are as below:

Max. Service Speed - 160 kmph and a test speed of 180 kmph

Starting Tractive effort - 258 kN

Continuous rated tractive effort - 220 kN (0-50 kmph)

Continuous rated power at wheel rim - 4000 kW (80-160 kmph)

Axle arrangement - Bo-Bo

The data of the existing system as well as the operational/working requirements are given as below:

Axle load -19.5 t

Max corresponding train speed -160 kmph

Gear ratio -3.94 (67:35:17)

Wheel dia -1092 mm (new), 1016 mm (fully worn)

Motor power -1150 KW at 1585 RPM

Max allowable radial misalignment -±16 mm

Max allowable axial misalignment -±35 mm

The above technical parameters are identical of the present design of WAP5 locomotives which is having 4 axles i.e. Bo-Bo type with fully suspended traction motor.

4.0 Operating environmental condition:

The environmental condition will be:

a) Maximum temperature } Stabled Locomotive under sun : 70º C

} On board working loco under sun : 55º C

b) Minimum temperature : - 4º C

Humidity: Up to 100% during rainy season.

Altitude : Up to 1750 m above mean sea level.

Rainfall : Very heavy in certain areas.

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Atmospheric condition during hot weather: Extremely dusty and desert terrain in certain areas. The dust concentration in air may reach a high value of 1.6 mg/m3.

Coastal area: The drive system shall be designed to work in coastal area in humidity and salt laden and corrosive atmosphere. The maximum values of the condition will be as follows: a) Maximum pH value : 8.5.

b) Sulphate : 7 mg per liter.

c) Max. Concentration of chlorine : 6 mg per liter.

d) Maximum conductivity : 130 micro siemens/cm

The level of shock and vibrations to be withstood by Drive gear system shall be as per IEC 61373 for bogie mounted / axle mounted equipments. Specific values will be decided at the time of design approval depending on the system offered.

5.0 Salient features: 5.1 Dimensions: The broad dimensions of the bogies, traction motor, wheel sets, axle and available

space for drive assembly is given in annexure-I and annexure II. The supplier shall design the system to enable fitment in the available space only, as the bogies, wheel sets and other locomotive structures will remain same. An indicative sketch of the drive gear system is shown in annexure-III.

5.2 Coupling:

i) The effective distance between the two parts of the coupling (motor end & gear end) should be maximized and increased to reduce the teeth angle at contact between the two parts of the coupling to the maximum of 2.5 deg. This is required to reduce and minimize the axial movement due to radial misalignment.

ii) The dynamic stresses on the drive system should be minimum to absorb more shocks/impacts at higher speeds.

iii) The two parts of the couplings should be either grease lubricated or

maintenance free i.e. without lubrication.

iv) The maximum operational speed should be 3600 RPM with a provision of over speed of 20%.

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v) The coupling shall be of split design so that the axle with the complete gear box can be dismounted from the bogie.

vi) The coupling should be able to withstand the maximum level of frequent

and infrequent shocks of magnitude of 30 KN-m.

vii) The weight of the coupling shall not exceed 90 kg. 5.3 Sealings:

i) The sealing system should be adequate to prevent dirt/dust and water into the couplings.

ii) A non-contact type sealing between the two couplings should be designed.

iii) All other labyrinth should also be non-contact type.

iv) All rubber sealings, ‘O’ rings etc should be made of oil and weather resistant composition of synthetic rubber.

v) There should be no rubber or synthetic material membrane between two

parts of the coupling. This should be maintenance free.

5.4 Gears & Pinion:

i) Presently, 67 teeth main gear, 35 teeth intermediate gear and 17 teeth pinion with an overall gear ratio of 3.94 are used.

ii) The gears and pinions shall be of 18crNiMo7-6 1.6587 high quality steel with case hardening and complying with the international standard of gears and pinions being used in traction application.

iii) 59 teeth main gear, 35 teeth intermediate gear and 19 teeth pinion with an

overall gear ratio of 3.105 will be used for 200 kmph.

iv) The serviceable limits of gear & pinion should be minimum 18 lakh km.

5.5 Axle:

The axle shall be as per Indian Railway standard specification no. R 43-92. Drawing of WAP5 axle is enclosed as annexure-VI for guidance only. However, the position of the gear box assembly could be change suitably as per requirement of manufacturer.

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5.6 Gear box housing:

i) The gear box housing shall be of Spheroidal graphite cast iron (SGCI) as per DIN EN GJS 400-15. The housing should be tough and robust so as to withstand the heating of small object like ballast during run.

ii) The oil lubrication arrangement inside the gear box without necessitating the provision of oil pump shall be designed. This type of splash lubrication should be adequate to eliminate blockages of path during run for a considerable period of time without any intermittent maintenance.

iii) The quantity of oil in the housing and its sealing arrangement shall be designed in such a way that the oil replenishment is not required for 6 months.

iv) Cylindrical Roller bearings or tapered roller bearings should be used. v) L10 life of bearing should be more than 12 lakh km. vi) Shall be designed so as not to have a finite fatigue life.

5.7 Mounting & suspension arrangement:

i) Suitable anti-vibration mountings shall be designed for suspension of gear box housing.

ii) The mountings spheriblocks/studs shall be accessible for easy mountings and dis-mounting during maintenance.

6.0 Inspection & Testing: 6.1 In general, the prototype & routine test will be carried out in accordance with the

relevant international standards for individual items. However, the manufacturer shall have in-house testing jig/arrangement for testing complete drive gear assembly. During testing the specified/designed load and working condition shall be generated. The product shall conform to the designed parameters with respect to its application, efficacy and effectiveness.

6.2 The supplier shall develop one no. prototype unit for prototype testing and

approval by RDSO. This prototype unit shall be made after receipt of order and clearance by RDSO. Bulk supply will commence after successful commissioning of the prototype unit in locomotive and successful field trial of 12 months for either design (160/200 Kmph). During the prototype testing the adjustments/alterations will have to be done by the supplier as advised by Railways in consultation with RDSO.

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7.0 Test

SN Test Description Clause no. Type Test Routine Test

1 Run Test/Temperature Rise

Test

7.1 √

2 Sound Level 7.2 √

3 Vibration Test 7.3 √

4 Oil Level Test 7.4 √

5 Material of Gear & Shaft 5.4 & 5.5 √

6 Gear Box Housing 5.6 √

7 Mechanical parameters of Gear , Housing & Shaft

Internal

Report

√ √

8 Tooth Control(Involute, Longitudinal, Pitch, Radial Run Out, Tangent)

Internal

Report

√ √

9 Surface Hardness of Gear Internal

Report

√ √

10 Grinding Burning Test Internal

Report

√ √ *

11 Crack Detection Internal

Report

√ √

12 Overall Dimension As per assembly drawing of supplier

√ √

* The test will be conducted on 20% of the sample only.

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7.1 Test Bench Setup:

The test bench set up consists of two test gear box mounted on support point on welded construction as per the arrangement existing on the bogie. The gear boxes are arranged in such a way as to work against each other. Cardan shaft is used to connect the driven shaft with the angle gear. The propulsion is provided by a frequency controlled DC motor that must supply the power loss that occur in the circuit and simultaneously supply the required speed. The arrangement should be a distort circuit wherein the distort torque is introduced with an overload planetary gear box and remains static in the pre-load circuit for the duration of the test.

7.1.1 The test run scheme will be as below:

SN Test Run Input speed (rpm)

drive torque (Nm)

output speed (rpm)

output torque (Nm)

Speed (Km/H)

*New

wheel

Speed (Km/H)

**Worn

out wheel

Duration (min)

1 Run in (clockwise)

1000 2000

500 1000

254 507.6

1.970 3.940

52.3 104.5

48.6 97.2

15 15

2 Run in (anti-clockwise)

1000 2000

500 1000

254 507.6

1.970 3.940

52.3 104.5

48.6 97.2

15 15

3 Warm up (clockwise)

0-1058±25 2116±25 3174±25

500 268.5 537 805.6

788 55.26 110.5 165.8

51.4 102.8 154.3

10 10 10

4 Warm up (anti-clockwise)

0-1058±25 2116±25 3174±25

500 268.5 537 805.6

788 55.26 110.5 165.8

51.4 102.8 154.3

10 10 10

5 Continuous operation with max. speed

(clockwise)

3174 1730 805.6 6.816 165.8 154.3 60

6 Continuous operation with max. speed

(anti-clockwise)

3174 1730 805.6 6.816 165.8 154.3 60

7 Continuous operation with max. torque

(clockwise)

1585 6930 402.3 27.304 82.8 77 30

8 Continuous operation with max. torque

(anti-clockwise)

1585 6930 402.3 27.304 82.8 77 30

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- *Wheel diameter of new wheel - 1092 mm

- **Wheel diameter of worn out wheel - 1016 mm

- Test run item 3 and 4 up to steady temperature = rise of temperature ≤ 50C

within 15 min

7.1.2 Records:

i) Before setting up the test, weight of the test gearboxes, the input coupling, and torque arms must be measured separately.

ii) After every test run following parameters will be recorded:

SN Parameter Acceptance criteria

1 Oil Quantity The oil level should be in middle position on the oil sight glass

2 Ambient temperature -

3 Bearing Temperature Temperature of the Roller bearing areas on the housing / outer bearing cover should not be exceeded from 1200C.

Max. acceptable temperature - 1500C

4 Oil sump temperature

Oil sump temperature limit should not be exceeded from 130'C

5 Input and Output speed and direction of rotation

As per test run scheme

6 Input and Output torque

As per test run scheme

iii) During the visual and auditory inspections for each run following parameters will be recorded if found abnormal:

- Oil supply

- Oil tightness

- Noise level

- Vibration behavior

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iv) After conclusion of each test run the following parts should be checked:

SN Part Check Points

1 Power Transmission

Labyrinths of input and output shaft, Bearing cover and other covers, Sealing screws, breather Oil leaks, abnormal noises or vibrations should not occur during the test runs. Spares of oil mist are acceptable.

Use the inspection cover to check whether there is adequate oil supply of the oil collection pockets and oil collection channel is provided.

2 Roller bearing

Damage or recognizable wear are not acceptable.

Visible wear of the running tracks, roller bearings, and cages is not acceptable. Only possible when dismantling a test gearbox.

3 Running Gears

Pitting, Scoring and cracks are not acceptable

7.1.3 Temperature Measurement

After every test run, temperatures of the gearbox for bearings, labrynth and oil sump will be measured via thermal elements. The oil drain plug will be fitted with a thermocouple that measures the oil sump temperature. The measured temperature values must be recoded continuously. The relative winds will be simulated with an electric fan in the direction of travel. Wind speed approx. 1/3 of the running speed associated with the speed.

7.2 Sound Level Measurement The class 1 sound level measurement will be taken in accordance with the international standard IEC/ANSI SPM standards TYPE / class 1. Measured value of the sound level should be max. 90 dB(A) at a distance of 1m.

7.3 Vibration Test

Vibration acceleration will be measured in axial and radial direction on the suspension points of the gearbox. Acceleration sensors will be used for measurement.

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7.4 Oil Level Test The oil supply within the gearbox will be tested visually through the cover. The minimum and maximum oil level will be measured on the oil sight glass.

7.5 Visual inspection

After concluding the test the contact pattern of the gears will be evaluated through the inspection covers. Further the tightness of the gearbox housing and the labyrinth seals will be evaluated.

8.0 Finite Element Analysis

The manufacturer shall submit FEA report of sub components of the drive gear assembly.

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9.0 Documentation, Records and Suppliers Responsibility:

The manufacturer shall submit the following documents along with their offer and ensure their compliance.

9.1 Certificates/Approvals/Experience of the product/ manufacturer to prove credibility.

i) The manufacturer must be certified with ISO 9001:2008 (the scope of the ISO certification has to specifically refer to the manufacturing of the full range of products).

ii) Test Reports/certificates from accredited laboratory/institute for the similar or identical design system shall be submitted.

iii) The supplier shall provide reference of all those projects executed by them for similar applications during the last 5 years wherein they have designed and manufactured same/similar type of drive gear assembly for traction application. The firm should submit various technical parameters credential of supply of similar drive system to Railways for the purpose of verification.

9.2 The supplier shall supply detailed instructions for proper installation of the equipment inside the locomotive. For this purpose, the supplier shall depute his engineers/supervisors to purchaser site during installation of the equipment in the locomotive.

9.3 The supplier shall associate themselves during commissioning, testing and field trials of the equipment in locomotive and depute team of engineers/supervisors for this purpose for first two sets at one place of supply.

9.4 The supplier shall arrange required instrumentation and carry out detailed tests and field trials jointly with RDSO.

9.5 The supplier will also offer special tools and instruments separately which may be required for maintenance.

9.6 The supplier shall recommend list of spares required for satisfactory maintenance and operation of drive gear system for a period of five years.

9.7 The supplier will submit design manual for the system containing following details:-

(i) The dimensional diagram with technical data.

(ii) Assembly drawing with part list.

(iii) The detail functioning of each item and its sub-assembly.

(iv) Testing procedure of each item

(v) Write up on the working of drive gear system

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9.8 The supplier will supply the user's manual containing instruction for assembly/dis-assembly during maintenance. The instructions for inspection and trouble shooting shall be clearly given.

9.9 The supplier shall be responsible for carrying out improvements and modifications at his own expense on all the equipments supplied, provided such modifications/improvements are decided to be necessary for meeting the requirements of reliability, performance and safety etc, jointly between contractor and purchaser.

9.10 For the purpose of technical decisions on improvements/ modifications etc. on equipment, the final authority from the purchaser’s side will be RDSO.

9.11 The supplier shall provide training of 50 man days per 10 locomotives of order

quantity or part-thereof on drive gear system – for CLW/RDSO and Zonal

Railways.

9.12 The supplier shall supply commissioning tools & alignment checking gauges with

prototype unit – one set each for CLW and loco shed.

9.13 The supplier shall apply necessary spares which are prone to wear/damage during

service. One set of spares shall be supplied per 5 loco sets of PO quantity or part-

thereof.

10.0 MARKING & PACKING:

10.1 The following information shall be clearly marked at a suitable place on each component:

a) Name and Address of the manufacturer. b) Year of the manufacturer.

c) Serial number of component d) Specification number (RDSO SPEC NO. 0089, Rev. ‘2’)

10.2 The equipment and its sub assemblies shall be packed in a wooden case of sufficient strength so that it can withstand bumps and jerks encountered in a road/rail journey.

---------X--------

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Annexure-I

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Annexure-II

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Annexure IV

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Annexure V

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Annexure-VI