Technical Seminar

Axle Mounted Disc Brake System

Mumbai Date: 23 May 2024

AS PER RDSO LETTER

Agenda
Wheel slide Protection System
• Types of WSP & Brief Description
• Version of WSP Software and action plan for improvement to be
implemented
• Illustrative use of software for each types of WSP
• Self-testing protocol for each types of WSP
• Data downloading
• Software Availability to all depots and plan to provide on demand
• Action plan to address failure of MIL grade connectors and junction boxes
• Action plan for simplification of Software
• Modifications & Retrofits

Air Brake System

• Various Issues in C3W DV
• Maintenance of Brake system
• Modifications and data downloading
Types of WSP & Function

Data Download

Monitoring Software

Self-Test
 WHEEL SLIDE PROTECTION SYSTEM
Different types of WSP supplied – Issue date and Upgradation status
2 types of WSP used

KES type WSP(SWKP) – Supplied till 2019 FT WSP (AEFG2) – Supplied after 2019
Coach wise Populations
SWKP ~ 7500 nos
Software Version and Issue date
AEFG2 ~ 8900 nos
• KES WSP – SW version 2.1, Released on 06.04.2020
• FT WSP – SW version 1.04, Released on 21.09.2021

Upgradation status
• KES WSP – No further updates
• FT WSP – D05 test SW is in Field trail expected to get the SW update end May’2024
Wheel Slide Protection System
FT-WSP AEFG2 – FOR LHB COACHES
/// OVERVIEW OF COMPONENTS
WSP - AEFG2
Overview of components & Architecture

WSP System Consists of :

WSPCU – 1 No
Speed Sensor – 4 Nos
Dump Valves – 4 Nos
Phonic Wheel – 4 Nos
Connector Assemblies
(Wiring Harnesses / Junction box /
Cable assemblies) – 1 set

7
Confidential & Proprietary
/// SELF TESTING & FAULT CODES
 WSP Self-Test – AEFG2)

To test the functionality of WSP, please

follow the below steps: CPU board has 2 Push buttons to
1. Apply brake. Ensure through the initiate Static test and other functions
brake indicator status is RED. as per the menu from the front panel
2. Check WSP status is showing 0099
in CPU display. apart from connecting Monitoring
3. Initiate the TEST: software through RS232.
➢ Select P3; Go to “TEST” option in
the menu by P1-P2; Choose “TEST”
option by P4. Test will occur.
4. Ensure all Dump valves are
actuating sequentially.
5. After Test, the WSP will show T_OK
and status will be 0099.
/// MONITORING TOOL & DOWNLOADING OF DATA
WSP - AEFG2
WSP – Monitoring software tool
➢ Hardware and System Requirements
▪ To install and use MONLHBWSP(monitoring software tool), the computer must satisfy certain
hardware and software requirements
▪ Hardware
Personal Computer equipped with at least a 120 MHz PENTIUM (or equivalent)
microprocessor.
Hard disk with at least 200 MB free space (further disk space is required for the storage of
files
created during the use of MONLHBWSP)
▪ VGA colour display.
▪ A free serial port (9-pin male connector) or USB port.
▪ Software
Microsoft Windows versions
(Windows XP, Windows 7, Windows 10)

11
Confidential & Proprietary
WSP - AEFG2
WSP – Monitoring software tool

➢ Power On the Laptop

➢ Connect the RS232 cable between the Laptop and the WSP unit
➢ Switch ON the Power supply to the WSP unit
➢ From the programs menu select MonLHBCoachesWSP monitoring tool as shown

12
Confidential & Proprietary
WSP - AEFG2
WSP – Monitoring software tool

➢ From “Gemini” menu select “Panel”

13
Confidential & Proprietary
WSP - AEFG2
WSP – Monitoring software tool

➢ The above screen appears on selecting ”Panel” menu

14
Confidential & Proprietary
WSP - AEFG2
WSP – Monitoring software tool

Shows the
status of Digital
Shows output signals
active
faults if
any

WSP
status

Buttons to initiate WSP

test
15
Confidential & Proprietary
WSP - AEFG2
WSP – Monitoring software tool

➢ From the menu select “Errors” and then “EEPROM” submenu

16
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

➢ From the menu select “Errors” and then “EEPROM” submenu

17
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

➢ Select “RX Errors”

18
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

➢ Wait for “read error successfully ended” message

19
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

➢ Select “Save Errors” and save the file with a name

20
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

➢ Select “View Errors”

21
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

➢ Select the error file saved

22
Confidential & Proprietary
WSP - AEFG2
W S P – E r r o r l o g s d o wn l o a d f r o m M o n i t o r i n g s o f t wa r e t o o l

Error list with Date

Statistical data of
, Time &
errors from the list
Odometer stamp
logged
23
Confidential & Proprietary
Wheel Slide Protection System
KES SWKP AS20R – FOR LHB COACHES
/// OVERVIEW OF COMPONENTS
WSP – SWKP AS20R
Overview of Components

WSP System consists of

WSPCU – 1 No
Speed Sensor – 4 Nos
Dump Valves – 4 Nos
Phonic Wheel – 4 Nos
Associated cables, connectors, etc
26
Confidential & Proprietary
/// STATIC TESTING AND DATA DOWNLOAD
WSP – SWKP AS20R
S t a t i c Te s t

➢ CPU board has 5 Push button

➢ Push Button 1 => to read Diagnostic fault code
➢ Push Button 2 => for test purposes when pushed for 3s, the
display will indicate “89” and CPU will enter into the test program
to test WSP System
➢ Push button 3 => to clear the history of fault code when pressed
for 3s and also will display clear
➢ Push button 4 => when pressed for 3s will check all the door
control (Not used)
➢ Push button 5 => when pressed for 3s will display total km run in
the form of 8 digits. First press will show first four part of 8 digits.
Second press will indicate the last four digits

28
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d
➢ Power On the Laptop. Connect the USB to RS232 converter to the USB port in the
Laptop if laptop do not have RS232 port
USB TO RS232 COMMUNICATION CABLE
CONVERTER

USB to Male D-Connector 9- Connect 9-Pin Male D-SUB

Laptop Pin Connector to WSP

29
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ Connect the other end of the communication cable to the WSP unit Female 9-Pin
D-Connector
➢ Ensure that the WSP is Powered ON and laptop is connected
➢ Open the software AS20 from laptop
30
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ From the program menu select and click the SAB WABCO KP and then the
Diagnose application software
31
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ The below screen will appear after the application program opens

32
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ Select “Operational Data” from the Dialog Box

33
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ Select “Operational Data” window is displayed as below. Also please note that
“Menu Bar” also changes accordingly
➢ From the menu select “Process” and click on “Failure History”

34
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ The “Failure History” window is displayed as below

35
Confidential & Proprietary
WSP – SWKP AS20R
E r r o r L o g D o wn l o a d

➢ Click “Load Failure History” button as shown as below. The failure history will be listed in the
window as below. Click “Save History” button. This will save the error log file as *.txt file
➢ The data is ready for analysis
36
Confidential & Proprietary
WHEEL SLIDE PROTECTION SYSTEM
CAUTION on Cards

CAUTION :
➢ Removal of any of the WSP Cards with Power Supply ON
condition is strictly prohibited to avoid damages to the
Electronic boards.
➢ The K05 relay in the coach manages the Power saving
feature for the WSP. Hence it is not recommended to by-
pass this relay in the coach.
➢ The fuse rating shall be maintained as per the
recommended value.
37
Confidential & Proprietary
/// COMPARISON OF KES SWKP & AEFG2 WSP MODELS
WHEEL SLIDE PROTECTION SYSTEM
D I M E N S I O N A L C O M PA R I S O N - 1 9 ” R A C K
SWKP AS20R – CONSISTS OF 8 ELECTRONIC CARDS

FT AEF G2 – CONSISTS OF 6 ELECTRONIC CARDS

39
Confidential & Proprietary
WHEEL SLIDE PROTECTION SYSTEM
AEFG2 SYSTEM ARCHITECTURE

KES SWKP AS20R FT-WSP AEFG2

1. N1 POWER CARD 1. POWER SUPPLY CARD
2. N2 POWER CARD 2. WHEEL BOGIE INTERFACE CARD_1
3. OPTO COUPLER INPUT CARD(OP) (WBI 1)
4. RELAY CARD(RL) 3. WHEEL BOGIE INTERFACE CARD_2
5. MAGNET VALVE CARD(MV) (WBI 2)
6. LED STATUS DISPLAY CARD(ST) 4. DIGITAL OUTPUT CARD(DO)
7. CPU WITH 7-SEGMENT DISPLAY & 5. ANALOGUE OUTPUT CARD(AO)
RS232 INTERFACE 6. CPU WITH 7-SEGMENT
8. SPEED SENSOR SIGNAL INTPUT & DISPLAY,RS232 & ETHERNET
ANALOG OUTPUT(GE) INTERFACE

40
Confidential & Proprietary
WHEEL SLIDE PROTECTION SYSTEM
D U M P VA LV E

SWKP FT-WSP
Coil Resistance (SWKP-DV)
Pin1 & Pin2 = 74.94Ω
Pin1 & Pin3 = 74.72Ω

Coil Resistance (FT-DV)

Pin1 & Pin2 = 238.2Ω
Pin1 & Pin3 = 234.8Ω

41
Confidential & Proprietary
WHEEL SLIDE PROTECTION SYSTEM
SPEED SENSOR

FOR KES SWKP AS20R MODEL

▪ Voltage Signal type
▪ Frequency range 1Hz – 12kHZ
▪ Recommended gap between sensor and phonic
wheel 1.5±0.5 mm

FOR AEFG2 MODEL

▪ Current Signal type
▪ Frequency range 0 – 3.5kHZ
▪ Recommended gap between Sensor & Phonic
wheel 0.5 to 1.5 mm

42
Confidential & Proprietary
WHEEL SLIDE PROTECTION SYSTEM
Fault codes RDSO requirement Vs KES & AEFG2
FT WSP
Fault Name RDSO Requirement KES WSP
software version D05

Speed Sensor Failure (Open/Short Circuit)

0011 / 0021/ 0031 / 0041 11 / 21 / 31 / 41 0011 / 0021/ 0031 / 0041
Axle 1/ Axle 2/ Axle 3 / Axle 4

Speed Sensor Failure (Gap / Frequency)

0012 / 0022 / 0032 / 0042 -
Axle 1 / Axle 2 / Axle 3 / Axle 4 0012 /0022 / 0032 / 0042

Dump Valve Failure (Short Circuit) 0013 / 0023 / 0033 / 0043

13 / 23 / 33 / 43 0013 / 0023 / 0033 / 0043
Axle 1 / Axle 2 / Axle 3 / Axle 4

Dump Valve Failure (Open Circuit)

0014 / 0024 / 0034 / 0044 14 / 24 / 34 / 44
Axle 1 / Axle 2 / Axle 3 / Axle 4 0014 / 0024 / 0034 / 0044

Error log-0001
Transient Error 0001 (0095) 0095
Display code -0095

OK 0099 – There are no errors recorded

(No error present- in the WSPCU.
0099 99
Display code) 0095 – There was a failure in the
past.

43
Confidential & Proprietary
Retrofits & Improvements

Plan for Simplification of

Software

Failure of MIL Grade

connectors
 Software Simplifications
Plan for development of software with common output data and support using pen drive with
USB connection, to be analysed on any laptop/computer
FTRTIPL Remarks
➢ Presently Data download in the WSP control unit is through serial Cable
➢ No provision in the electronic HW for the USB interface

Continuous recording of speeds of all axles during trip and dump valve operation
FTRTIPL Remarks
➢ Presently we have error and event logs for 80 seconds in the EEPROM
➢ Continuous recording of every 30 minutes will be implemented with SD card on the CPU which is a design
change
Software Availability to all depot and plan to provide on demand
FTRTIPL Remarks
➢ Software installed in railway laptops & demonstration provided.
➢ In case of any requirement, the same can be given immediately.
➢ PDF copy of details procedure of data download will be provided on demand.
 Retrofits & Improvements
1. INIHIBIT Cable removal and WSP Software Update
Modifications are undergoing, 64% completed. FTRTIPL will speed up the retrofits to
complete by Aug’24

2. Main Valve Finish of DV

90% of the suspected batch replaced. 106 coaches are pending due to unable to trace
the location of coaches. Materials for 106 coaches are handed over to concerned
depots. Location of 94 coaches provided by RDSO and will be completed by the end of
Jun’24 (Update: 16 completed, rest under progress)

3. Brass Plug of DV
Modified brass plug implemented in OE supply on 10/2022. DV SI. No. # 10.22.5635 &
LHB Panel No, 10.22.125 B AC/NAC. Action plan for existing fleet retrofit will be given by
30 May 2024
 Other Issues – Discussed during meeting

1. Joint investigation with RDSO – Coach no 236057, ER/Malda depot.

2. Wiring Issue – Coach no 163410, NR/LKO POH at Alambagh

Modification not done by FTRTIPL. Released from POH shop.

3. WSP Monitoring Software – Given to all Depot.

4. AEFG2 revised software release by end of May 2024.

5. Endurance testing – DV overhauled under AMC.

1 sent from ER/LLH, Test report shared with LLH, 2 DVs will be dispatched from Matuanga by 25th May
6. Speed sensor Cable – Light weight. Implementation in new supply : End of Jun
Continuous Improvement Plan
C3W DV WITH STEP DOWN RELAY
D e s i g n Imp r o veme nt

▪ BC fluctuating issue will get eliminated.

▪ By maintaining DV output as per UIC requirement of 3.8 Kg/cm2.
▪ Using step down relay valve BC pressure reduces to 3.0 Kg/cm2 to meet RDSO
Pressure Plate
specification.
DV with Step-down Relay
▪ Diaphragm control design will stabilize the BC output in step down relay valve.
▪ Implemented in Standardized Panel.

49
Confidential & Proprietary
 Failure of Junction box & MIL grade connectors and speed sensor cable
Water Ingress
Issue description: Water ingress into junction box leading to short circuit and failure in WSP

Root cause analysis:

▪ Junction box and wiring harness are IP65 protected by design

▪ It is observed that, mounting holes provided in junction box are NOT being used for assembly

▪ Two additional holes are being drilled at the center of junction box for mounting, Junction box will no longer be IP65

▪ As shown in the image, holes have been drilled in junction box and water marks are visible. It is also observed that, the
water is entering connectors from the Junction box

Containment Action: Connectors /Speed sensors are replaced on a goodwill basis

Recommended corrective Action:

▪ Junction box to be mounted using the mounting holes provided in junction box with our drilling additional holes to keep
the IP65 protection
Junction Box & Speed Sensor connector orientation revised
MCF & RCF Coaches – Speed Sensor Orientation at Bottom side casing breakage of connector.
Whereas in ICF it is oriented on the top of the Junction box
Orientation in MCF & RCF Coaches Orientation in ICF Coaches

Outer Junction Box with Inner Junction Box with Outer Junction Box with Inner Junction Box with
Speed Sensor Speed Sensor Speed Sensor Speed Sensor
connector connector connector connector
Speed Sensor connector ICF has provided fitted the
was in bottom side of speed Sensor connector
Junction Box on top side of junction Box
51
Confidential & Proprietary
Speed Sensor connector & junction box broken
- Improper routing,
- External hitting

52
Confidential & Proprietary
Speed Sensor Routing
O b s e r v e d S p e e d S e n s o r h o s e d a m a g e . T h i s i s d u e t o t h e h o s e e n t r a p m e n t b e t we e n t h e
s i d e f r a m e a n d t h e B o g i e s s t o p p e r.

53
Confidential & Proprietary
/// RECOMMENDATIONS
Speed Sensor - Routing
Issue description: Connector of Speed Sensor cable assembly getting damaged

Root cause analysis:

▪ Stress on the MIL grade connector at the junction box end due to the slackness and loading effect of the Speed Sensor
cable assembly

▪ Movement of the Speed Sensor cable assembly along with the connector at the junction box end during dynamic
movement of the coach at curves.

▪ Due to lack of support along the length of cable and improper routing of hose, there is additional stress on the speed
sensor connector leading to breakage

▪ Observed that, speed sensor hoses are damaged due to hose entrapment between side frame and bogie stopper.

▪ Speed Sensor cable tied up using the cable ties on the Bogie frame assembly as shown in the following pictures

▪ It is also observed that, Speed sensor connectors are also damaged due to external hitting

Containment Action: Connectors /Speed sensors are replaced on a goodwill basis

Recommended corrective Action:

▪ Proposed modification in speed sensor routing and orientation of connectors.

- FT has taken trials in routing modification, coach 202891 at SBC depot on Apr’21

55
Confidential & Proprietary
Speed Sensor Routing
Clamps provision before Modification Clamps provision after Modification

Earlier only 02 clamps were Now, ICF has provided 02 more

there to hold the speed sensor additional clamps to secure
cable speed sensor cable from jerks

➢ Improvement in provision of additional clamps for Speed Sensor cable

56
Confidential & Proprietary
ICF Drawing

ICF has provided 02 more

additional clamps to secure
speed sensor cable from jerks

57
Confidential & Proprietary
SUMMARY & WABTEC RECOMMENDATION – Improve reliability of WSP
Key Points to be taken care during assembly:

1.Speed sensor Hose should be support across the length of hose

2. To ensure Speed sensor Hose is not entrapped between side frame and bogie stopper
3. No New holes should be drilled on junction box for mounting to ensure IP65 Protection
Proposal - Speed
sensor Routing

Letter to RCF &

MCF - JB Letter to MCF and
RCF on Junction box &

Letter to MCF/RCF

58
Confidential & Proprietary
WabtecCorp.com