ENGINEERING EXCELLENCE AWARDS-2013BEML LIMITEDWELCOMES
TO THE PRESENTATION ON DESIGN & DEVELOPMENT OF
STAINLESS STEEL EMU
7th OCT 2013
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.
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
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
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
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
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.
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
CAD model of interiors, driver’s desk & cab mask prepared
Interferences checked
DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS
DESIGN OF INTERIORS
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
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
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
DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS
MANUFACTURING INFRASTRUCTURE
ROBOTIC SPOT WELDING
5 AXIS SERIES SPOT WELDING
CNC PROGRAMMED STRETCH FORMING
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
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.
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
DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS
Testing of furnished SSEMU rake in test track witnessed by RDSO/RITES.
INHOUSE TESTING
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
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
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
DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS
VIDEO
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
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
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
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
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
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
CUSTOMER FEEDBACK
DESIGN & DEVELOPMENT OF STAINLESS STEEL EMU FOR INDIAN RAILWAYS
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
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
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
THANK YOU