GLOBAL VIEWAn overview of

RDSO &

its activities4th December ,2006

Research Designs & Standards Organisation• The sole R&D

organisation of Indian Railways.

• Established in 1957 • An ISO-9001

organization.• 3085 staff.• 22 Directorates.• Spread over 159

hectaresIndian Railways• A state-owned railway company of India.• One of the largest and busiest rail networks in the world, • Transporting over 5 billion passengers and over 650 million tons of freight

annually.• Gross Traffic Receipts estimated at Rs. 54,600 cr. (approx US$ 12 billion)• Operating Ratio - 83.7 %.

Functions of RDSO

Development of new & improved designs.Development, adoption and absorption of new technologies for use on Indian Railways.Development of standards for materials and products specially needed by Indian Railways.Technical investigations, statutory clearance, testing and providing consultancy services.Vendor approval and Inspection of critical & safety items of Rolling stock, Locomotives, Signaling and Telecommunications equipment and Track components.

Laboratories and other Laboratories and other Testing Facilities Testing Facilities

of RDSOof RDSO

Diesel Engine Development Laboratory• Four test beds capable of

testing diesel engines from 100 HP to 6000 HP

• Fully computerized system for recording over 128 test parameters at a time.

Brake DynamometerLaboratory

Testing of Brake blocks for different types of rolling stock.

Air Brake Laboratory

Facilities provided1. Simulating operation of air-brakes on

freight trains up to 192 wagons and 3 locomotives.

2. Simulation of operation of air brakes on passenger trains up to 30 coaches.

Fatigue Testing LaboratoryFacilities provided• Application of cyclic loads on bogies and other components.• Stress and fatigue analysis using computerized data acquisition systems.• Closed loop electro-hydraulic fatigue testing equipment• Hydraulic actuators from 9t to 25t capacity working at 2 to 40 Hz.

Track Laboratory• Measurement of stresses at

various locations of track components under simulated load conditions.

• Testing of full scale track panel under dynamic load patterns.

• Rail tensioning system for application of longitudinal forces on rail samples to simulate the thermal forces.

• Facility of fatigue testing of welded rail joints.

Signal Testing LaboratoryTesting of all types of Signaling equipments such as signaling relays, block instruments, power supply equipments, point machines, signaling cables, electromechanical signaling equipments and components.

Facilities provided• Environmental testing section equipped with testing facilitiesincluding programmable heat, humidity and cold chambers, mould growth, dust, rain chambers.• Working systems like; SSI, Universal Axle Counter, Audio Frequency Track Circuiting, Block instruments etc.

• Assessing critical psycho technical attributes of operating staff like; drivers, station masters.

• Assessment of psycho technical capabilities of operating staff like; drivers, switchmen and stations masters.

• Evolving criteria for on the job assessment of operating staff involved in safety of train operations.

Facilities provided• Laboratory is equipped with Bio-feedback system for assessment of GSR (Galvanic Skin Resistance), temperature pulse and respiration rate, used for stress management exercise. • Speed anticipation tester, Multiple Discrimination Reaction Tester for Vigilant behaviour of Drivers

Psycho- technical Laboratory

• Destructive and non-destructive testing of metals, polymers, composites, paints and petroleum products.

• Testing of entire range of components used in rolling stock and infrastructure.

• Testing of rails.Facilities provided• Scanning electron microscope, direct

reading spectrometer, ultrasonic flaw detector & other NDT equipment, polymer and composite evaluation facilities, thermal analyzer.

Metallurgical & Chemical Laboratory

• Corrosion engineering evaluation facilities, including weather meter.• Static 760hr test rig for grease testing.• Dynamic test rig for grease testing.

Bridge And Structures Laboratory• Testing of full scale models of beams,

slabs, columns, towers, shells & other concrete and steel component under static and dynamic loads.

Facilities provided• 6mx14m heavy-duty testing floor. • High frequency (250-700

cycles/minute) pulsator for applying pulsating loads from 2 to 20 tonnes.

• Static load of 40 tonnes on heavy duty testing floor.

• Switching and balancing units, acoustic emission equipment and data acquisition system.

• Multi channel dynamic strain recording system and analogue strain indicator.

Geo- technical Engineering Laboratory

Facilities provided• Sub-surface interface radar system• Laser based soil particle analyzer• Computerized consolidation test

apparatus• Computerized static tri-axial shear

apparatus to determine strength of soil and for design of embankment.

• Dynamic Tri-axial Shear Apparatus for soil testing under simulated field conditions.

• Portable Nuclear Compaction Gauge

• Determining strength parameter of soil in laboratory and fieldcondition .• Testing of sub-structure, embankment and formations in lab and field conditions.

Mobile Testing FacilitiesOscillograph carsTrack recording carsUltrasonic rail testing carOHE inspection-cum-test car

Inside view of TRC Lab

OHE inspection-cum-test car Track recording cars

Computer Aided Design FacilitiesUnigraphics including wave control, scenario for structure & motion, Ansys Multi-physics, NX Nastran.NUCARS ( AAR) ADAMSRAILAutoCAD on PCs

• High computing power Computer Cluster and two Work Stations.• Expertise in FEM Modeling and Crash Simulation has been developed.

Crashworthiness Design Centre

ADAMSRAIL Facilities

Telecommunication Laboratory• Equipment with testing facility for:

• Optical line terminal equipment• Digital multi-plexer equipment • Optical fibre accessories • Digital Microwave Equipment and Universal

Communication System equipment• Control telephone, wayside equipment etc.

Electrical and Traction Installation Lab• Testing equipment and capability to perform HV test

on electrical equipment up-to 50 kv• Vibration testing of electrical equipment

R&D activities undertaken in RDSO

R&D activities in Rolling Stock modernization• Bogie

– Track friendly bogie for wagons

– Higher axle load bogies: micro- alloying of wheels & axles

– Brake system• Intelligent brake system • Disc brakes with

microprocessor controlled anti-slip mechanism

• Bogie Mounted Brake system

• Composite brake blocks Improved Suspension

Sandwich Pad

…R&D activities in Rolling Stock modernization

• Wheel:Solid wheels for EMU

Wheels & axles of improved metallurgy

S Shaped wheel for locomotives for higher axle loads-24 T

…R&D activities in Rolling Stock modernization

•Suspension:– Air spring in secondary suspension– Capsule type shock absorber for Coach Dash pot– Metacone primary suspension of EMUs

…R&D activities in Rolling Stock modernization

• Couplers– High capacity buffer pack for

coaches– CBC with anti-climbing features in

Coaches– Crashworthy Buffers– Soft buffers to minimize jerks

…R&D activities in Rolling Stock modernization

• Superstructure– Stainless steel shell for

EMU stock– Aerodynamic profile of

DEMU– Crashworthy design of

coaches-honeycomb absorbers

Honey comb-before and after crash test

…R&D activities in Rolling Stock modernization•Superstructure

–Environment friendly toilet discharge system

–Fire retardant material for coach–Fire simulation on coaches –FRP modular toilet–Aluminium wagons

Area of 80° C isotherm

Special types of Wagons• Aluminum Body Wagons

BOBRAL & BOXNAL– Payload to tare ratio increased

to 2.63 from 2.17 for BOBRN and to 3.45 from 2.61 for BOXN

• Container Flat Wagon for 100 km/h

• Steel Coil Wagon BFNS

…R&D activities in Rolling Stock modernization

• Locomotives– to meet hotel loads

– Driver friendly cabs

– Aerodynamic profile– On Board

Diagnostics

Development of design for export of Diesel Locomotives to Sudan & Angola

• 1400 HP, 12t axle load, cape gauge locomotives to Sudan

• 2300 hp, 17 t axle load cape gauge locomotive to Angola.

R&D activities for development of an environment friendly system

• Bio Diesel blends• CNG based DEMU• Composite brake blocks to avoid

noise pollution• Eco-friendly refrigerant on under-

slung AC coaches- Replace CFC (R12)type refrigerant with HCFC/HFC (R22) refrigerant

• Measurement & Reduction of Emissions from engines of Diesel Locomotives

• Environment friendly toilet discharge system

R&D activities in Rail & Track Fittings• Corrosion Prevention of Rails• Anti Sabotage PSC Sleepers.• Elastic rail clip with improved toe

load & anti vandal features• Composite & FRP Sleepers for

Girder Bridges as a substitute for wooden sleepers.

R&D activities in Propulsion Systems• IGBT based propulsion system for

3 phase Electric Locomotive• Development of high Horse Power

traction motor for AC EMUs• Design & development of 3300HP

diesel-electric locomotive with hotel load facility

• Development of 8000 HP Electric Freight Locomotive

• Development of 6000HP Diesel Locomotive

• Self propelled Accident Relief Train

21417 OVER BODY14783 BOGIE CENTERS

2896

3357

1104

1282

28963277

952 DIA: Ø9153277

21337 OVER BODY

2896327714783 CRS OF BOGIES

1282

2896 ENGINE

21417 OVER BODY14783 CRS. OF BOGIES

28963277

1282

FUEL TANK

TRANSMISSION

3886

2896

3357AXLE DRIVE

952 DIA:

1104

MEDICAL VAN (TC)SUPERVISOR VAN(DPC-I) TOOL VAN (DPC-II)

R&D activities in Electrics

Electronic thermostat

• Development of microprocessor control for RMPUs (Roof mounted package unit)• Development of solid state temperature control for AC coaches • Development of composite insulators for electric traction installations

R&D activities in Signaling• Train Actuated Warning

Device• Anti-Collision Device (ACD)• Digital Axle Counter • Block Proving By Axle

Counter • LED Signals

View of Automatic Braking Unit (ABU) of ACD undergoing trials on NF Rly.

R&D activities in fault monitoring and detection systems

• Wheel Impact Load Detection System• Oscillation Monitoring System• Bridge foundation scour monitoring• Vibration Signature Analysis for Bridge

Health Monitoring

…R&D activities in fault monitoring and detection systems

• Trackside Bogie Monitoring System including dragging equipment detector

• Derailment Detection DevicesElectronic Detector for Passenger CoachesPneumatic Detector for Freight Stock

• Sensors for detecting Hot boxes, Hot WheelsTemperature of Axle box

Display of wheel & axle box temperaturesTemperature of Wheels

…R&D activities in fault monitoring and detection systems

Representative front panel template for aiding trouble shooting at shed level

• On-Board Diagnostics• Design & development of Measuring Wheel• Rail Flaw Detection Instrumentation - Use of Electromagnetic Acoustic Transducer technology with Phased array transducers

R&D activities in Operations• Satellite Imaging for Rail Navigation-

using GPS and GSM– Continuously track every train for its

location, speed and direction of movement.

– Dynamically disseminate information so gathered to passengers and to the general public

– Transfer data from running train to central server regarding the health of the locomotive and other vehicles in the train.

•Fog Vision Instrumentation• Increasing productivity through Heavy Haul operation

Delhi-HowrahDelhi-Mumbai

• Introduction of double stack container service on identified routes• Development of roll-on-roll-off door to door service.

Equipment installed in Locomotive

Double Stack Container Service

Future developments in Rail Transport in India

Dedicated Freight CorridorTrack Structure, Freight Stock

Higher Axle load Higher Payload to Tare ratio

MoU with TTCI for heavy haul operationMetro Trains in Cities High Speed Operation- 200kmph/250kmphMobile Communication System Train Protection and Warning System

MoU with TTCI for Heavy Haul Operation• Design and Development of 25 t & 32.5 t Axle Load

Wagons • Development of Testing Facilities for Higher Axle Load

Wagons • Design, Development and up-gradation of Track for

Heavier Axle Loads • Consultancy for Test Track • Capability Assessment and Condition Monitoring of

Bridges • Wayside Bogie Performance Detection System • Trackside Acoustic Bearing Detection System to

monitor and detect bearing defects in IR’s Train

Expectations from Global View

Similar Projects taken up on IRProjects similar to applications of Galileo- inteGRail• Satellite Imaging for Rail Navigation• Anti-Collision Device• Display and public announcement in running train• Integrated Passenger Information System• GPS based Synchronized digital clock for uniform time over IR • Video surveillance systemProjects similar to ERTMS,GSM-R• Train Protection & Warning System

– Pilot Project - New Delhi- Agra Cantt section –ERTMS level-1– Equipment procured from M/s Ansaldo Signal

• Mobile communication System– Sections identified: HWH-GHY,HWH-Jammu, NDLS-JHS (approx 3000km)– Equipment procured from: Siemens, Germany & Nortel, Finland

Similar Projects taken up on IRProjects similar to Green & Rail Energy• Reduction of emissions from Diesel Locomotives• Use of Biodiesel and CNG as fuel for Diesel Locomotives• Use of eco-friendly (HFC) refrigerant in AC coaches.• Removal of harmful gases from exhaust of power car.• CO/CO2 controlled Ventilation system for EMU Coaches

Projects similar to Silence• Noise reduction in power car• Noise reduction from Diesel Locomotives• Use of Composite brake blocks

Projects for Low cost passenger service• Head-on-Generation• Development of fuel cell/solar Panel for wayside station lighting.• Simplified version of 3-phase IGBT based AC Electrics for EMU

Usefulness of various projectsERTMS• GSM-R: standardization of hardware & software of GSM-R

network for easy maintainability.• ERTMS level-1: may be useful when high speed trains are

introduced.EUROPAC• Monitor the condition of overhead lines through on-board &

trackside monitoring systemINNOTRACK• Issues related with reduction in Life cycle cost of a conventional

line with mixed traffic duty.• Leading edge track system technologies esp for fastening

systems.

RAILCOM• Reduce the time & resources required to demonstrate EMC

compliance of rolling stock• Increase communication system capacity and availability through the

elimination of repeated messages due to corruption by electromagnetic interference

• Increase in track capacity/ occupancy and traction power throughrefinement of worst case scenarios and assumptions currently employed in EMC assessment of rolling stock and train detection system.

• Standardization of EMC/EMI for various signaling equipments.• Measurement techniques of EMC/EMIMODTRAIN• MODBRAKE:

– Computer controlled brake system• Different locomotive control processor; essential to interface

brake system microprocessor with locomotive control microprocessor.

• Develop Interchangeable modules for brake system• MODBOGIE: Development of new specification for EMU/DMU

motorized bogie, Tilting Bogies for Trains of Speed 200-250 kmph.

• GREEN: Reduce emissions from diesel locos– Combustion technology-training in the areas of combustion

modeling and CFD (Computational Fluid Dynamics)– Design of experiments on combustion system– Advanced fuel injection technology-development of common rail

systems for diesel locomotives– EGR (Exhaust Gas Recirculation) for diesel locomotives– After treatment devices for diesel locomotives like SCR (Selective

Catalytic Reduction), etc.• RAIL ENERGY:

– Use alternate fuels eg biodiesel & CNG - technological requirements

• inteGRail– Passenger information system– Development of TCN (Train Control Network) compatible vehicle

control for 3-phase drive locomotive– Predictive Maintenance and lean maintenance concept for track.– Rail Break prediction and broken rail detection– Detection of track locations needing immediate attention based on

ride quality monitoring.

Areas for Future Cooperation under FP 7Research Needs of Indian Railways

• Tilting Trains• Oil free compressor for Electric Locomotives• Locotrol for hauling heavier loads• IGBT based 3-phase traction propulsion system for Electric

Locomotives• Accelerated pre-cast/modular pre-cast construction techniques

for construction of new bridges.• Condition monitoring of Insulators for Traction Installations• Unified Power quality monitoring requirement on 25kV traction

power supply system• Maintenance free & corrosion resistant fittings for Traction

installations

Areas for Future Cooperation under FP 7Collaborative Projects

• Thermit Welding• Flaw Detection Techniques for rails.• Air raised high reach pantograph for high

horsepower locomotives (>7.4m)• Rail Fracture detection• Fog Vision

Thank You