DESIGN AND FABRICATION OF FOOT BOARD ARRANGEMENT IN TRAIN
R.S UTHAYAN, P.S HARIRAM, M. NAVEEN BARATH
DEPARTMENT OF MECHANICAL ENGINEERING
VELAMMAL COLLEGE OF ENGINEERING AND TECHNOLOGY - MADURAI
GUIDE NAME: Mr. R. EZHILVANAN M.E.
DEPT OF MECHANICAL ENGINEERING
PROJECT OUTLINE
1. ABSTRACT
2. INTRODUCTION
2.1. THE ACCESSIBILITY OF TRAINS
IN INDIA
2.2. ACCESSIBILITY OF TRAINS IN
OTHER COUNTRIES
3. LITERATURE SURVEY
4. PRINCIPLE OF OPERATION
5. DESIGN OF PROJECT
6. FABRICATION
7. BILL OF MATERIALS
8. RESULTS AND DISCUSSION
9. CONCLUSION
1. ABSTRACT
Indian Railways is a fast growing network for transportation. Presently, the Indian Railway Coaches are manufactured by ICF (Integral Coach Factory) with consideration for safety. But due to variation in platform heights in various stations the accessible becomes a tedious process considering low level platforms since the steps are vertical and does not have any inclination.
“FOOT BOARD ARRANGEMENT is nothing but one of the lifting system to the aged people at the time of emergency. In this foot board arrangement system pneumatically operated one. Here the additional pneumatic cylinder and control valve
is provided in the automobile itself.
In this project, the push type valve is used to activate/deactivate the control valve in the bus. The compressor air is go to the cylinder at the time of emergency; so that the compressed goes to the pneumatic cylinder. Then the compressed air passes through the tube, and then pushes the pneumatic cylinder, so that the foot board is lifting down position at the time of valve “forward” position and foot board is lifting up position and the time of valve “backward” position.
2. INTRODUCTION
Integral Coach Factory (ICF) is the only manufacturer of rail coaches located in Chennai, Tamil Nadu, India . It was established in 1952, is owned and operated by the Indian Railways. The coach factory primarily manufactures cars for Indian Railways but also exports railway coaches to other countries. Integral coach factory
was established in 1952 and started production on 2 October 1955. The first items produced were third class shells for Southern Railway.
The Integral Coach Factory consists of two main divisions - shell division and furnishing division. The shell division manufactures the skeleton of the rail coach, while the furnishing division is concerned with the coach interiors and amenities. An ancillary unit to the Integral Coach Factory is being built in Haldia, West Bengal for furnishing diesel multiple units. ICF manufactures more than 170 varieties of coach including first and second class coaches, pantry and kitchen cars, luggage and brake vans, self-propelled coaches, electric (EMU), diesel (DMU) and mainline electric multiple units (MEMU), metro coaches and diesel electric tower cars, accident relief medical vans (ARMV), inspection cars (RA), fuel test cars, track recording cars and luxury coaches.
The plant employs about 13,000 people and manufactures about 1500 coaches per year. ICF churned out 1,503 coaches in 2010 and in August 2011, ICF was sanctioned a project for manufacturing stainless steel shells and high speed bogies and an increase in capacity from 1,500 to 1,700 coaches. In 2013-14, it built 25 LHB Coaches, 248 air-conditioned and 1185 non-ac coaches. It has set a target to manufacture 300 LHB coaches in 2014-15 and reach a capacity of 1000 LHB coaches by 2016-17. A total of 50,000 coaches had been produced till 18 Aug 2015
by ICF since its inception.
Rail Coach Factory, Raebareli
Rail Coach Factory, Kapurthala
2.1. THE ACCESSIBILITY OF TRAINS IN INDIA
The current coaches manufactured by IFC have vertical steps as mentioned earlier. These steps are kept at a distance of 225 mm from each other. The length of each step is 650mm and is mostly made of Steel to withstand heavy loads and to improve ruggedness. Due to technical constraints the gap between the platform and the coach is approximately equal to 300mm or a foot length.
2.2. ACCESSIBILITY OF TRAINS IN OTHER COUNTRIES The Trains in other countries, accessibility is made simpler by keeping the door level in level with platform. The Doors are operated by power operation, Power Door Operation, where drivers enable the operation of door. Once the station is reached the doors are opened by drivers by pressing of a button. Since there are no steps in such trains the passengers can entrain/detrain without much difficulty and therefore improving the time and reducing accidents of passengers falling off in gaps between platforms and trains. These kinds of accessibility is commonly employed in countries like United States, European Union, China etc.,
3. LITERATURE SURVEY
4. PRINCIPLE OF OPERATION
INFORMATION ABOUT STEPS
In Indian railways, there are three different types of levels of platforms
They are
High Level Platform
Medium Level Platform
Low Level Platform
In Our Project We Have Used Double Acting Pneumatic Cylinders
4.1.1 First Step
According to Indian platform construction there is no need of any additional changes.
4.1.2 Second Step
In second step, foot board arrangement in trains is mainly used in the middle level platform and also in low level platform by the help of the pneumatic cylinder slider mechanism. Once they are ejected out it will be helpful in accessing the trains and thus reducing the gap between platform and trains.
4.1.3 Third Step
It is used only in the low level platform and it is not used in other platforms by the use of pneumatic cylinder slider mechanism once they are ejected out it will be helpful in accessing the trains and thus reduce the gap between platform and trains.
5. DESIGN OF PROJECT
5.1. FOOT STEP DESIGN
FRONT VIEW
SIDE VIEW
FINAL DESIGN OF OUR PROJECT
DESIGN CALCULATION
The force exerted by a single acting pneumatic cylinder can be
expressed as
F = Pπ d2 l / 4
where
F = force exerted (N)
p = gauge pressure (N/m2, Pa)
A = full bore area (m2)
d = full bore piston diameter (m)
The Load depends upon given amount of pressure deliver to the
cylinder
Cylinder 1
Diameter = 40m
Stroke Length = 120m Pressure = 4 x 106 N/m2
F = (105 x3.14 x 0.42 x 0.120) / 4
F = 150.72 N
6. FABRICATION OF PROJECT
ISOMETRIC VIEW
According to Indian platform construction there is no need of any
additional changes. In second step, foot board arrangement in trains is mainly used in the middle level platform and also in low level platform by the help of the pneumatic cylinder slider mechanism. Once they are ejected out it will be helpful in accessing the trains and thus reducing the gap between platform and trains. It is used only in the low level platform and it is not used in other platforms by the use of pneumatic cylinder slider mechanism once they are ejected out it will be helpful in accessing the trains and thus reduce the gap between platform and trains.
DURING MIDDLE LEVEL PLATFORM
DURING LOW LEVEL PLATFORM
DURING HIGH LEVEL PLATFORM
7. ADVANTAGES
It eliminates the gap between the platform and train thus reducing the percentage of passengers from trapping in
It also makes sure that the doors in train should be closed while travelling thus ensuring safety
It will be useful for accessibility for senior citizens and thus making it easy to entrain/detrain.
Since the steps are independent it can be used for both high level as well as low level platforms.
It is also economic and any damage can be easily replaced.
Simulation results proved that it can withstand weights upto 150 kg, which is 75 kg more than average human weight.
8. CONCLUSION:
The project on Design and Fabrication of Foot Board Arrangement in Train system is working fine, getting the parameter envisaged during the conceptual stage. During the design, as well as during the construction, greater care has been put into avoid hiccups at the final stage. The circuit is made as simple as to our knowledge. Also components were selected keeping in mind their availability and cost. It was a very interesting process of developing the prototype, stage by stage and testing the same. We have to go through fairly large pages of data related to the components etc. It was a useful and fulfilling assignment to get the project completed in time. This gave us a sense of satisfaction and accomplishment.
The Indian Railways is envisioning a greater future with much importance to safety of the passengers. It is a proud feeling that our project serves this purpose and will also improve the passenger comforts.
9. REFERENCE
1. https://en.wikipedia.org/wiki/Integral_Coach_Factory
2. https://innovate.mygov.in/challenges/innovation-challenge-for-easy- accessibility-to-trains-from-low-level-platforms/
3. https://en.wikipedia.org/wiki/Indian_Railways
4. http://www.indianrailwaysecrets.com/2012/10/indian-railways-types-of- coaches.html
5. http://www.thebetterindia.com/39189/make-in-india-railway-coach
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