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To Reduce the Maintenance Cost in Transportation System by Using Air Spring

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Published IJAER, International Journal of Applied Engineering Research ...
  TO REDUCE THE MAINTENANCE COST IN TRANSPORTATIONSYSTEM BY USING AIR SPRING Jinesh Jain 1  , Suraj Kumar  ! Dhananja Chauhan # ! 1 Department of Mechanical Engineering, Govt., engineering college  , Ajmer 2Department of Mechanical Engineering, Bhagwant University  , Ajmer   Department of Mechanical Engineering, G.E.!  , Ajmer  2 Emai$%& gmps  Emai$ $%& AB'()A!( (he main p rpose of the air spring is to restrict the vi*ration at a &esira*le *eca se with increase& the spee&,&ynamic performance of the vehicles is negatively affecte&. (he tren& towar&s higher rail vehicle spee&sgenerally res lts in increase& vi*rations in the car *o&y, which has a negative impact on ri&e comfort .(hes spension of the vehicle has to *e mo&ifie& in or&er to compensate vi*ration as well as wor+ life sho l&have long i.e. maintenance cost is too low. n fact, most helical spring possess low inherent &amping there*yca sing serio s pro*lems which will impair the f nction an& life of str ct res lea&ing to their ltimate fail reas &istortion which have *a& impacts on economical con&ition * t air spring have more life as an& as well asalso re& ce the vi*ration as per &esire& level.(his research paper entitle&  ' to re& ce the maintenance cost in transportation system *y sing air spring-gives the analysis regar&ing cost i.e. how m ch cost is re& ce& after sing air spring in place of helical spring.t is recognie& *y the railways &ept to re& ce the cost in transportation system as well as wor+ing life sho l& *e long respective to helical spring . Ke ()r* $% mportance of air spring, maintenance cost, life & ra*ility I+INTRODUCTION n the general competition *etween &ifferent means of transportation the main s *ject is afast, safe an&comforta*le jo rney. /or railway vehicles active technology enlarges the 0ossi*ilities of improving thevehicles &ynamic performance compare& to what the conventional passive sol tion has to offer.mprovements of ri&e comfort, r nning *ehavior an& c rving a*ility have, of co rse, a positive impact on thevehicles &ynamic performance, which, in t rn, may ena*le higher vehicle spee&s.   (o re& ce the maintenancecost in transportation system *y sing air spring is an interesting topic which shows that how cost is&ecrease& after increasing the spee& of vehicles.Active technology in rail vehicles can *e tilie& in or&er to achieve one or more of the following goals a, mprove passenger ri&e comfort, -, Maintain goo& ri&e comfort altho gh vehicle spee& is increase&, ., Maintain goo& ri&e comfort altho gh trac+ con&itions are worse, *, )e& ce wheel an& rail wear *y means of improve& c rve negotiation, e, 'ec re r nning sta*ility at higher vehicle spee&. A+ Cur/e ne0)iai)n 3hen negotiate a c rve at an e4cessive spee&, vehicles will roll over an& a tomo*iles will lose traction an&sla+e o t of a c rve instea& of rolling over. (he more top%heavy a vehicle is, the more li+ely it will roll over than sla+e o t of a c rve. f the ri&e comfort is alrea&y goo&, f rther improvement at nchange& vehicle spee&an& trac+ con&itions is generally not j stifie& & e to the high costs of implementing active s spension.5owever, goals *6  an& e6 allow large possi*ilities for cost%efficient improvements, since vehiclespee& can *e increase&. Moreover, goals 7c an& &6 have goo& potential of *eing worth the investment of active technology, since *ogie maintenance will *e save& .n or&er to achieve this control loop in the  s spension of a rail vehicle, act ators, sensors an& a controller m st *e a&&e& to the mechanical system . /ig1.(he concept of an active s spension systemB Three 2arameers ) re*u.e he mainenan.e .)s n &isc ssing vi*ration protection as well as to re& ce the maintenance cost in transportation, it is sef l toi&entify the three *asic elements of &ynamic systems$1. (he e8 ipment 7component, machine motor, instr ment, part, etc. ...6 2. (he s pport str ct re 7floor, *ase plate, concrete fo n&ation, etc...6 an& . (he resilient mem*er referre& to as an isolator or mo nt 7r **er pa&,air col mn, spring, etc.6 C+ Chara.erisi.s )3 s2rin0 maeria$s /ig2$%characteristic c rve of spring material II+ 4ITERATURE RE5IE6 A+ He$i.a$ s2rin0s (he helical springs are ma&e p of a wire coile& in the form of a heli4 an& (he cross%section of the wire fromwhich the spring is ma&e may *e circ lar, s8 are or rectang lar an& the heli4 angle is very small, s ally lessthan 19 :. /ig2$ 5elical spring  (he main &isa&vantage of this spring is & e to & mping *ogie str ct re got &amage& ; crac+s. D e to whichthis is change after every three months ma4im m p to months. /or passenger vehicles, the air spring hasnormally a preloa& of <9%1<9 => 7<%1< tons6. (he 8 ality of ri&e, e4perience& *y passengers, is pre&ominantly controlle& *y the &esign of the secon&ary s spension. )esearch con& cte& *y the nternational'tan&ar&s organiation has shown that the h man *o&y is least s scepti*le to vertical vi*rations in the 1 to 25 range./ig. 2n&ry s spension(he material se& to constr ct mechanical springs has a limite& energy%storage capacity per nit vol me of the material. (herefore, a spring, which m st carry large loa&s an& provi&e large static &eflections, ten&s to *ecome e4cessively * l+y. A pne matic spring is a spring, which employs gas as its resilient element. 'incethe gas is s ally air, s ch a spring is often calle& an air spring. (he gas in the air spring can *e compresse& tothe press re re8 ire& to carry the loa& an& therefore air springs &o not re8 ire large static &eflection. /or anytype of spring, the important characteristics are loa&e& capacity, spring rate an& transmissi*ility. 0ne maticsprings are partic larly note& for their low transmissi*ility coefficients an& their a*ility to vary loa&capacities easily *y changing only the gas press re within the springs. Another impressive characteristic of  pne matic springs is the a*ility to provi&e a controlle& varia*le spring rate, which can *e tailore& to a specificnee&. (hey also offer simple an& ine4pensive a tomatic leveling. /ig.?$%. Bogie with air springs III+ PARTS O7 AIR SPRING 1. Mattel parts $ % (op cover 2. ) **er parts$ % ) **er *ell. ) **er @ Mattel parts$ % Emergency spring(hese are the main three parts in air spring on which this &esign is *ase& on. Emergency spring wor+s& ring the fail re of Mattel an& r **er parts, an& whose capacity is a*o t 1999 =M.-Base plate is ma&e p of 7'292! 6, which have least r st an& less tensile property. C.  6ORKING PRINCIP4E O7 PNEUMATIC SUSPENSION it enclose& press rie& air in a pre%&efine& cham*er calle& air spring, ma&e p of r **er *ellow  emergencyr **er spring, provi&es vario s s spension characteristics incl &ing &amping. air springs are height%controlle& loa& leveling s spension &evices. with changing loa&s, air spring reacts initially *y changing the&istance *etween air spring s pport an& vehicle *o&y. the air springs replace only the secon&ary s spension,  whereas primary s spension contin es to se steel coil springs. an a 4iliary air reservoir of 1<9 litre capacityis provi&e& *elow each coach which is fe& from fee& pipe thro gh a non%ret rn valve. maintains  *ar  press re in loco compressor an& air springs operate at a limiting press re of  +g;cm2 5I+AD5ANTAGES O7 AIR SUSPENSION i. !apa*le to s stain ' per Dense !r sh Foa&s typical of s * r*an traffic. ii.Maintain constant floor height of coach.iii. 0rovi&e s perior ri&e comfort. iv. Cirt ally !onstant nat ral fre8 ency from tare to f ll loa&s,re& cing passenger fatig es. solation of str ct re *orne noise, this improving mprove&relia*ility, re& ce& maintenance effort. Cii /le4i*ility to choose characteristics as per re8 irement at &esignstage./ig<$fi4e& height of air spring 5II+ COMMON AIR SUSPENSION PROB4EM A+ Air -a0 )r air sru 3ai$ure   B+ Air $ine 3ai$ure C Air 3iin0 3ai$ure   D+ C)m2ress)r 3ai$ure I8+SCOPE (his sche& le lays &own the technical re8 irements for the &esign an& s pply of air spring assem*ly for fitment in the e4isting two a4le *ogies of EMU;DMU coach *ogies of n&ian railways. (his shall cater to theincrease& payloa& &eman&s an& weight im*alances inherent to the &esign of EMU;DMU stoc+, partic larlythe motor coaches. (he scope of s pply shall generally *e as per cla se  of this sche& le of technicalre8 irements 7'()6. 8+ CHARACTERISTICS TESTS  Air Be$$)( $ (a*le no1characteristics tests '.>o0ress re in +g;cm2 'pecific loa& in =>H o*serve& loa& in =>1. 1 +g;cm2 9.? to .9 => 1.2< =>(a*le no2 specifie& inspectionsFot sie pto192<<9<199 >o of samples2?<(a*le  chec+ list for inspection of air spring
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