Presentation
on
LHB Coach
Design Features
By : Balwant Singh - SME/Design/RCF
Shotcomings with existing IR Coach technology
Higher Tare weight to pay load ratio.
Proneness to corrosion.
Low availability and reliability due to frequent
requirement of maintenance .
Poor Ride comforts.
Restricted operating speed.
Passanger Amenities not modular type.
By : Balwant Singh - SME/Design/RCF
LHB Coaches Contract
M/s. ALSTOM LHB/Germany
Supplied 24 coaches
consisting of 19. AC chair cars,
2 AC Executive Class Chair cars and
3 Generator cum Brake vans.
The bogies supplied by M/s. FIAT -SIG
Switzerland.
By : Balwant Singh - SME/Design/RCF
Main design Features of LHB Coach
Corrosion Free Coach
Extensive use of Stainless steel and surface protection measures
Longer Coach
Longer By Approx. 2.2 Meters than Conventional Coaches.
Light Weight Coach
10% lesser weight per meter length lesser than conventional coach
Better Pay to Tare Ratio
Higher passenger comfort:
Ride Index 2.5 ( Not exceeding 2.75)
Suitable To Higher Speed potential –160 kmph
upgradable to 200 Kmph
By : Balwant Singh - SME/Design/RCF
Main Features of LHB Coach
Superior Shell and furnishing Design
Complete shell interlocked
Better Acoustic and Vibration Measures
Superior Insulation
Damping elements
Axle Mounted Disc Brakes With WSP
Centre Buffer Coupler
Controlled Discharge Toilet Systems,
Now replaced with DRDO
Bio retention tanks filled with
Anerobic Bacteria .
By : Balwant Singh - SME/Design/RCF
Main Features of LHB Coach
Auto Closing Sliding Doors
Wider Windows
Modular Interiors
Improved Air Conditioning System with micro processor
controlled.
Use of Fire Retardant Materials .
By : Balwant Singh - SME/Design/RCF
At a glance comparison of
Weight and passanger carrying Capacity
No Weight Capacity Weight Capacity
t t
LHB/EOG ICF/EOG
FAC 1 43.3 24 FAC 46.2 18
ACCW 4 44.6 52 ACCW 44.8 48
ACCN 7 45.6 72 ACCN 48.3 64
CB 2 40.9 0 CB 47.9 0
WLRRM 2 53 0 WLRRM 60 0
16 728.7 736 779.3 658
LHB Weighs Less by 50.6 t Capacity more By 78 passengers
By : Balwant Singh - SME/Design/RCF
Passenger Concerns Sound Control Measures –
within 65 db Achieved
Inside The Passenger Area
• Sound Insulating Paint
• Rubber D-coupling –Floating Floor
• Sandwich Floor Board - 4mm cork
• Melamine foam Insulation for Ducting
All Round the duct
• Non-Metallic Interiors - FRP
• Sealed Auto closing Vestibule
•No direct opening of lavatories pans.
By : Balwant Singh - SME/Design/RCF
Passenger Concerns
Vibration Control Measures
• Dampers in Bogies
• Rubber metal bonded parts In bogies
•Floating Floor
•Pillars mounted on Rubber elements
•Non-Metallic Interior -such as FRP
• Higher passenger comfort:
• Ride Index 2.5 (Not exceeding 2.75)
By : Balwant Singh - SME/Design/RCF
PASSENGER CONCERNS
Safety Aspects
• Superior Braking System
•Emergency Openable Window
•Fire Retardant Materials
•Anti Climbing Feature
•Fire Alarm System
•Proper Coach Earthing
•Public Address System
•Emergency Accident light
By : Balwant Singh - SME/Design/RCF
Passenger Concerns
• Wider windows for Panoramic View
• Screwless Modular interiors
By : Balwant Singh - SME/Design/RCF
Passenger Concerns
Coach Interior Environment
Thermal Insulation Measures
• Bary Skin V 60 DB
• Cork-sandwich floor board
• PVB Film in Window
• Melamine foam in duct
• Phenolic foam in doors
• Non metallic interior
• Glass wool
By : Balwant Singh - SME/Design/RCF
Maintenance Aspects
• Corrosion free
•Extensive Use Of Stainless Steel
• Better Design Concepts
•Better rigidity and dimension control
• Reliable Hi-Tech Systems:
•Axle mounted disc brake system
with wheel slide protection device
• Modular units
• Superior Mounting of under slung
equipment
• Fail safe mounting due to interlocked members
By : Balwant Singh - SME/Design/RCF
Extensive use of Stainless Steel
By : Balwant Singh - SME/Design/RCF
Steels used in LHB Coaches
Shell Sub Steels used and their %age UTS Yield
Assemblies compositions N/mm2 Stress
N/mm2
Side wall, End X2 Cr12 Ferritic Steel 450- 320
wall and Roof ( C < .03%, Cr 10-12%, Si 1%, 600
structure Mn 1.5%, Ni 0.3- 1.0 %) --409M
Roof sheet and X5 Cr Ni 18 10 Austenitic Steel 700- 235
Trough floor ( C < .07%, Cr 18%, Ni 10 % Si 1%, 850
Mn 2%) --- 304
Underframe IRS M-41 440- 320
( C < .01%, Cr .35 -.6%, Ni .2 - .4% 480
Cu .3 - .6% Si .3 - .7%, Mn .25%) –
Corten Steel
By : Balwant Singh - SME/Design/RCF
ANTI TELESCOPIC , LIGHT WEIGHT, HIGH STRENGTH
TUBULAR INTEGRAL STAINLESS STEEL SHELL
Stainless Steel Shell
By : Balwant Singh - SME/Design/RCF
Sole Bar Sidewall Connection
Conventional Design
Body pillar with LHB Design
turn under
Elimination of pockets
Turn Under Has Been Eliminated
Clear Approach For Sand Blasting And Painting
No Accumulation Of Water And Muck
Pillar Rests On Solebar As Compared To Load Transfer
Through A Vertical Welded Joint In Conv. Coaches
By : Balwant Singh - SME/Design/RCF
Interlocking of members
Interlocking between the
horizontal and vertical
stiffening members of sub-
assemblies like sidewall,
endwall, underframe, etc.
Reduction of side wall width
from 90 mm to 60mm
Better geometrical integrity
By : Balwant Singh - SME/Design/RCF
Roof
Corrugated roof sheet spot
welded to z-section roof arches
Uniform height of arches
along it’s length
Roof weighs only about
1000kg
Spot welded austenitic steel
cladding
Pocket free
By : Balwant Singh - SME/Design/RCF
End Wall
Vertical Z- stiffeners for
absorption of accidental loads.
Holes provided in all stiffeners
of end wall to reduce weight
By : Balwant Singh - SME/Design/RCF
End Wall
End wall overhangs
beyond head stock
-Releasing more space
inside
-Reducing space and
hence wind resistance
due to turbulence
between coaches.
-Gap between end walls of two coupled
coaches is 300 mm only
By : Balwant Singh - SME/Design/RCF
Vestibule Foot Plate
• Vestibule Fall Plate Can take
later movement
• Vestibule fall plate can slide
and also lift up.
• When fall plate is up, the
vestibule door can not be
By : Balwant Singh - SME/Design/RCF opened more than 150mm
Underframe
Underframe front
part is made by
joining together
head stock and body
bolster
By : Balwant Singh - SME/Design/RCF
UNDERFRAME
Spot welding of
austenitic trough floor
with cross bearers
Aluminium based weld
able primer used for
welding Corten steel to
SS to prevent bi-metallic
corrosion
By : Balwant Singh - SME/Design/RCF
Underframe
Provision for CBC as well a side
buffer mounting in head stock
Flooring Support Members
On Underframe
By : Balwant Singh - SME/Design/RCF
Underframe
Water Tank Mounting Bracketts
Welded On The Under Frame
Yaw Damper Brackets
Welded On The Underframe
By : Balwant Singh - SME/Design/RCF
Body Shell
•Separate Door Frame
• Easy shell manufacture
•No Camber provided .
By : Balwant Singh - SME/Design/RCF
Modern Manufacturing
Techniques
By : Balwant Singh - SME/Design/RCF
Manufacturing Techniques
Laser Profile Cutting Of Components
Sidewall/Roof Spot Welding
Magnetic Skin Tensioning Of Shell
By : Balwant Singh - SME/Design/RCF
Manufacturing Techniques
Gluing Of Window Frame To Shell
Body
Use Of MIG/MAG welding with
Argon mix (90% Argon, 5% Co2,
5% O2) Shielding Gas
Robotic Garnet Blasting Of Shell
By : Balwant Singh - SME/Design/RCF
Superior Insulation
By : Balwant Singh - SME/Design/RCF
Heat Insulation
GLASS WOOL
ON ROOF AND SIDE WALL
PROVIDE HEAT INSULATION
.
GLASS WOOL PADS HELD BY
PINS, WELDED ON THE ROOF
By : Balwant Singh - SME/Design/RCF
Sound Insulation Paint
“Baryskin v60dB” or eq. Sound insulation
PU paints on full coach shell interior,
provide anti drumming sound insulation
as well as corrosion resistance
Coating of 2-3 mm thickness in the coach
interior, 6-8 mm in body bolster area
Extremely good fire retardant.
By : Balwant Singh - SME/Design/RCF
Rubber De-coupling Elements In Flooring
Floor board with sand
witched cork layer
Rubber element
Metallic floor support
member
By : Balwant Singh - SME/Design/RCF
Rubber De-coupling
Elements In Flooring
Flooring boards resting on rubber
de-coupling elements
Flooring boards - cork
sandwiched between compreg to
absorb noise
By : Balwant Singh - SME/Design/RCF
USE OF COMPOSITE MATERIALS
“ALUCOBOND” LAVATORY CEILING PANEL &
ALUMINIUM HONEY COMB PARTITION PANELS
IMPROVED AESTHETICS
VERY GOOD SURFACE FINISH
CORROSION RESISTANCE
BETTER RIGIDITY
HIGHER STRENGTH TO WEIGHT RATIO
By : Balwant Singh - SME/Design/RCF
AC DUCT
• Superior 2 tier design
• No loss of cooling air
• Superior thermal insulation
• Better sound dampening
• No direct blast of cool air
By : Balwant Singh - SME/Design/RCF
FRP ITEMS
A NO. OF FIRE RETARDANT FRP ITEMS HAVE BEEN
USED IN THE INTERIORS FOR:
IMPROVED AESTHETICS
ABILITY OF FRP TO BE MOULDED INTO INTRICATE SHAPES/CURVED
SURFACES, AVOID JOINTS
BETTER STRENGTH TO WT RATIO
SCRATCH RESISTANCE
RESILIENCE TO SMALL DENTS
EASY REPAIRABILITY
NO VISIBLE SCREWS
BETTER MAINTAINABILITY
NO PROBLEM OF
CORROSION
By : Balwant Singh - SME/Design/RCF
CORUNDUM GRAINS IN FRP RESIN
FLOOR IN LAV FOR ANTI-SLIP
PROPERTIES AND WEAR RESISTANCE
BRACKETS FOR MOUNTING LIGHT
FITTINGS
By : Balwant Singh - SME/Design/RCF
Window Glass unit characteristics
- Aluminum frame glued to car body
- Window glass secured by rubber profiles
8.4 mm outer laminated and 4 mm tempered
inner glass with 6 mm Argon gas filling
Thermal conductivity not more than 1.6 W/M2K
Transparency more than 39 %
Reflection more than 40
Total energy absorption less than 21%
By : Balwant Singh - SME/Design/RCF
Emergency
open able
window
Four units are provided each
coach to allow emergency
evacuation of passengers
A handle connected to the
rubber profile opens the glass
unit of the emergency window
By : Balwant Singh - SME/Design/RCF
HOPPER WINDOW FOR LAVATOTRY
By : Balwant Singh - SME/Design/RCF
Luggage rack (Chair Car)
Made from aluminium extrusions lengths
and tempered safety glass
Can with stand distributed load of 1000 N
(100 kgs) per meter length and pint load of
850 N (85 Kgs) as per UIC 566.
Halogen reading lights, for individual seats,
fitted into outer extrusion and wiring
hidden by polycarbonate cover
Provided with movable coat hooks
43
44
SAFER DUE TO CBC
LHB COACHES HAVE BEEN PROVIDED WITH TIGHT LOCK CENTRE
BUFFER COUPLERS INSTEAD OF SCREW COUPLING.
COUPLERS ARE AAR H-TYPE AND HAVE ANTI CLIMBING
FEATURES BECAUSE OF VERTICAL INTERLOCKING
COUPLERS HAVE ADEQUATE
STRENGTH FOR THE FOLLOWING:
•SATISFACTORY HAULING OF
A TRAIN OF 26 COACHES AT
110 KMPH
•SATISFACTORY HAULING OF
A TRAIN OF 18 COACHES AT
160 KMPH
By : Balwant Singh - SME/Design/RCF
.
FIAT BOGIE
By : Balwant Singh - SME/Design/RCF
By : Balwant Singh - SME/Design/RCF
Summary Of Steels Used In SS Coaches
MATERIAL THICKNESS WEIGHT in kg
Austenitic Steel 1.25 mm 1380
Total 1380
Ferritic Steel 2 mm 2800
-do- 3 mm 300
-do- 4 mm 60
Total 3160
Corten Steel 4 mm 725
-do- 6 mm 2000
-do- 8 mm 600
-do- 10 mm 200
Total 3525
Grand Total 8065
Stainless steel pipes: 10/12/15/18/22/28 mm - 385m
(DIN2391-C- DIN17456 Grade 1.4301 X5CrNi 18 10)
By : Balwant Singh - SME/Design/RCF
Details of SS used in Stainless Steel coach
Main Assembly Application area Steels used Thickness Qty of
finished
product
Side wall Side wall sheets X2 CrNi 12 Ferritic Steel 2 mm 979 kg
Vertical pillars -do- 2 mm 425 kg
Horizontal member -do- 2 mm 288 kg
Roof flange -do- 2 mm 270 kg
Roof Roof sheet X5 CrNi 18 10 1.25 mm 654 kg
Austenitic Steel
Carlines X2 CrNi 12 Ferritic Steel 2 mm 160 kg
End parts -do- 2 mm 380 kg
Final roof arch -do- 4 mm 56 kg
End wall End wall sheets -do- 2/3 mm 98 kg
End wall frames -do- 2/2.5/3/4/6/10 mm 260 kg
U/frame Trough floor X5 CrNi 18 10 1.25 mm 680 kg
Austenitic Steel
Sole bar IRS M41 Corten steel 6 mm 645 kg
Cross bearers -do- 4 mm 645 kg
Body bolster -do- 6 mm 750 kg
Head stock -do- 4/6/8 mm 1280 kg
Coupler -do- 10 mm 200 kg
carrier/Center sill
Vendor supplied Water tanks SS 316 Ti 2 mm 300 kg
items Roof ventilators X5 CrNi 18 10 1.25 mm 49 kg
Austenitic Steel
By : Balwant Singh - SME/Design/RCF
ACCZ
ACCW
FAC
By : Balwant Singh - SME/Design/RCF
