TECHNICAL SPECIFICATION FOR ALTERNATE GEAR DRIVE … Gear spec_no_89_Rev_2.pdfTechnical...

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Issued in April’2009 Specification No. RDSO/2008/EL/SPEC/0089 (Rev’2’)

Prepared by Checked by Issued by

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

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

2. --- ,, 1

3. --- ,, 2

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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, 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 supply of following items of revised design will be done by the supplier –

SN Description Qty per loco

1 Axle 4

2 Main driving gear mounted on axle 4

3 Intermediate gear 4

4 Traction motor pinion 4

5 Coupling arrangement 4 sets

6 Gear box 4 sets

7 Other drive assembly components eg.

Labyrinth, seals, fasteners, mountings,

Bearings

As per requirement

3.0 Technical data:

Salient features of existing WAP5 Locomotive

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

Starting Tractive effort - 258 kN

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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 requirement is given

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.

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.

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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%.

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 a

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.

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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.

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 should be used.

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 complete drive gear assembly. During testing the

specified/designed load and working condition will be generated. The product shall

conform to the designed parameters with respect to its application, efficacy and

effectiveness. The scope of the type test will be decided as mutually agreed between

supplier and purchaser.

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 18 months. 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

√ √

7.1 Test Bench Setup:

The test bench set up is to be done using two test gear box in the way as mounted in the

existing bogie. These gear boxes arranged as to work against each other as to take gear of

the radial play. The drive shaft is connected at an angle through a carded shaft. Frequency

controlled DC motor drive system is used to drive the gear and takes care of the power loss

in the system at the required speed. The arrangement should be a distort circuit when the

distort torque introduced with an overhead planetary gear box and remains static in the pre-

load circuit during the test.

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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)

1.000 2.000

500 1.000

254 507.6

1.970 3.940

52.3 104.5

48.6 97.2

15 15

2 Run in (anti-clockwise)

1.000 2.000

500 1.000

254 507.6

1.970 3.940

52.3 104.5

48.6 97.2

15 15

3 Warm up (clockwise)

0-1.058±25 2.116±25 3.174±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)

0-1.058±25 2.116±25 3.174±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)

3.174 1.730 805.6 6.816 165.8 154.3 60

6 Continuous operation with max. speed (anti-clockwise)

3.174 1.730 805.6 6.816 165.8 154.3 60

7 Continuous operation with max. torque (clockwise)

1.585 6.930 402.3 27.304 82.8 77 30

8 Continuous operation with max. torque (anti-clockwise)

1.585 6.930 402.3 27.304 82.8 77 30

- 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

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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

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

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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.

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.

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8.0 Finite Element Analysis

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

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

The manufacturer must be certified with ISO 9001:2000 (the scope of the ISO certification has to specifically refer to the manufacturing of the full range of products).

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

Credentials/ Experience of manufacturer: The supplier shall provide reference of all those projects executed by them for various applications of the same or similar systems during the last 5 years wherein they have used same/similar type of drive gear assembly for traction application.

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.

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(iv) Testing procedure of each item (v) Write up on the working of drive gear system

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.

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

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

TECHNICAL SPECIFICATION FOR ALTERNATE GEAR DRIVE … Gear spec_no_89_Rev_2.pdfTechnical...

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