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Submitted in partial fulfilment of the requirements For the degree of Bachelor of Engineering
Chakravarti Atole Avinash Bagul Deepak Khabale Shalom Varghese
Prof. Ashok Patole
Department of Mechanical Engineering MES‟s Pillai‟s Institute of Information Technology, Engineering, Media Studies and Research, New Panvel, Navi Mumbai 410 206 2011-12
Department of Mechanical Engineering MES’s Pillai’s Institute of Information Technology, Engineering, Media Studies & Research New Panvel – 410 206
This is to certify that the requirement for the project entitled „Design of Hydraulic Rail Car Mover‟ has been carried out by
Name Chakravarti Ramesh Atole Avinash Devidas Bagul Deepak Tanaji Khabale Shalom Sunny Varghese
Roll No. 802 804 824 867
In the partial fulfillment for the award of degree in Mechanical Engineering for Mumbai University in the academic year 2011-2012.
Prof. Ashok Patole
Mr. S. K. Sayyad (External Guide)
Prof. Sandeep Joshi
(Head of Department)
Dr. R. I. K. Moorthy (Principal)
REPORT APPROVAL SHEET FOR B.E. PROJECT
The Project report entitled “Design of Hydraulic Rail Car Mover” (Chakravarti Atole (802), Avinash Bagul (804), Deepak Khabale (824), and Shalom Varghese (867)) is approved for the partial fulfillment of the award of the degree of Bachelor of Mechanical Engineering.
(Prof. Sandeep Joshi) HEAD Department of Mechanical Engineering
(Prof. Ashok Patole) GUIDE Department of Mechanical Engineering
M E S’s Pillai’s Institute of Information Technology, Engineering, Media Studies and Research, New Panvel, Navi Mumbai 410 206
Principal M E S’s Pillai’s Institute of Information Technology, Engineering, Media Studies and Research, New Panvel, Navi Mumbai 410 206
workers attention is needed for safety. overhead cranes are used to move the coaches from one place to another. The rail car mover can provide higher productivity because the person controlling the movements stands next to where work is being done. dog arm. Traverser. making it easy to position cars right where they need to be. bearing and the modeling of parts using CAD Software and analysis of Hydraulic rail car mover components. It operates both long distance and suburban rail systems. efficient and safe work at workshop. The design of Hydraulic rail car mover includes design of hydraulic cylinder. Hydraulic rail car mover can be use for better. The Yard engine. operations are noisy and requires more than one person to do task. Indian railway workshop at Matunga carries out Periodical Overhaul (POH) and heavy corrosion repairs of main line as well as EMU coaches.ABSTRACT Indian Railways is one of the largest railway networks in the world. These means have their own advantages and disadvantages. Overall these systems are bulky requires proper maintenance. . requires no major alterations in the workshop for installation. The time required for shunting operation is more. electricity consumptions is high.
3 Trends in Hydraulics 2.3 Models of parts of Hydraulic Cylinder 4.2 Hydraulic cylinder Model 4.3 Report Layout LITERATURE REVIEW 2.4 Computer Application in Hydraulics DESIGN AND CALCULATIONS 3.5 3.2 Aim and Objectives 1.4 Cross section of Hydraulic Cylinder .1 Introduction 4.2 Rephasing Cylinder System 2.4 3.1 Background 1.6 Operation of Direction control Check Valve Calculations of Hydraulic Rail Car Mover Design of Roller Bearing Justification of Assumptions 2 3 4 MODELLING USING PRO ENGINEER 4.2 Operation of The System 3.1 Introduction 3.CONTENTS Chapter Title ABSTRACT LIST OF FIGURES LIST OF TABLES NOMENCLATURE ACKNOWLEDGEMENT Page i iv vi v vii 1 1 5 6 7 8 9 10 11 13 13 14 16 28 21 23 24 24 25 25 27 1 INTRODUCTION 1.3 3.1 Introduction to Hydraulics 2.
2 Design of Arm 5.1 Introduction 5.Chapter 5 Title ANALYSIS OF ARM USIGN PATRAN/NASTRAN 5.3 Results CONCLUSION AND FUTURE SCOPE REFERENCES Page 28 28 29 31 32 33 6 7 .
2 2.2 4.1 3.3 5.6 5.4 4.1 5.LIST OF FIGURES Figure 1.5 Title Layout of carriage workshop Matunga Value Stream Mapping of workshop activities Cause Effect Diagram Hydraulic power equipment trends Hydraulic System Design and Analysis Process Graph of Modeling and simulation trends Axle dog model Operational Sequence Schematic Representation Schematic of Cylinder Check valve diagram Hydraulic cylinder Assembly model Model of Front end and Back end Model of Piston and piston rod Model of Piston rod end Cross section of Front part of cylinder Cross section of Rear part of cylinder Steps in Analysis Model of Axle dog arm Meshing and Load applied using Patran Result constraint forces Result stress and Displacement Page 1 2 4 7 10 11 13 14 15 16 25 25 26 26 27 27 28 30 30 31 31 .4 5.3 2.3 3.1 4.4 4.2 3.1 1.2 1.3 3.5 4.1 2.3 4.2 5.
1 3.LIST OF TABLES Table 1.1 Title Symbols of Value stream map Cost of Hydraulic rail car mover Page 2 23 .
m Axle dog cylinder bore diameter. m Piston inner tube diameter. kN Power. kg/m3 Subscripts pr p a r a Piston rod Pass tube Axle dog Radial load Axial load .NOMENCLATURE D L dpr d l dp lp da la F P Q H g C Peq Cylinder bore diameter. % Density of oil. m Length of pass tube. m Piston rod diameter. m/s2 Dynamic capacity. m Length of cylinder. N Greek η ρoil Efficiency. kW Flow rate. m Force. m Acceleration due to gravity. kgf Equivalent load. m3/sec Pressure head. m Pass tube diameter. m Length of piston rod. m Length of Axle dog cylinder.
We would also like to thank all Railway workshop officials. B. SANDEEP JOSHI (HOD. PIIT) and Prof. I express my heartily gratitude to Mr. C.T.I.W. shop superintendents and PIIT Professors. I. SHETTY (C. RANE (Sr. R. D. KAREKAR (A. K. SAYYED ( Jr. MOORTHY (Principal.T. Inst.ACKNOWLEDGEMENT We would like to use this medium to express our sincere feelings of gratitude to all those people who have selflessly taken pains to make this project training part successful at Carriage workshop. M. P. Prof. B.) for giving me an opportunity to take training in this historic workshop.C. training officer) and Mr. Mr.M. Dr. PATIL (D.) for their unstinting support and suggestions which gave me direction to work. Last but not the least we would like to thank all my colleagues and workers of railway workshop for all the co-operation and for their direct and indirect help during the phase of project training. Special thanks to Prof. ) and Mr.C. Staff members and faculty members of Mechanical Department for invaluable help at all the time. Mr. M. ASHOK PATOLE (Internal guide). Matunga. B.).V. K.P. . NADAR (Project In-charge) for all their support and suggestions and invaluable guidance. Inst. Mechanical Dept.C.). S. R.E. First of all I would like to thank Mr. It is very worthwhile and value added experience take this opportunity to express our gratitude to all the individual whose contribution have helped us in undergoing training.T. Central railway. K.). A. TUPE (C.L.
. It carries more than 4 lacs passengers every day to each nook and corner of the country through Mail/Express /Passenger trains.CHAPTER 1 INTRODUCTION Indian Central Railway is the leading passenger carrying system. The Carriage Workshop. Fig 1. The target is to attend 269 coaches per month but actual average attended is 243 coaches per month. including a covered area of about 11 hectares. More than 3 million passenger travel every day in 1573 suburban trains. moving across 77 stations. There are 23 mechanical sections and 7 electrical sections.1 Layout of carriage workshop Matunga The workshop carries out Periodical Overhaul (POH) and heavy corrosion repairs of main line as well as EMU coaches. Mumbai Suburban Train System is the life line of the Metropolitan City. The electrical consumption is 6 lacs units/month. Matunga covers a triangular piece of land/area of 35 hectares.
So railway will able to provide good service to its passengers. Overhead Cranes are used for moving the coach from one place to another in the workshop. . parts and workspace Unavailability of appropriate maintenance personnel 1 DELAY 1 2 DELAY 2 3 DELAY 3 4 TIME LINE NVA -Non value added time VA -Value added time If the non-value added time is reduced then the efficiency of the workshop will increase and target can be accomplish on time.2 Value Stream Mapping of workshop activities Table 1.Fig 1.1 Symbols of value stream map SR No CATEGORY SYMBOL SUB CATEGORY Unavailability of equipment operator Unavailability of Tools. The disadvantages of overhead care are as follows.
Operators and persons at crane site are under risk Cost – High installation and maintenance cost Rope puller is the small machine used for short distance movement of the coaches in the workshop.The point of operation is a distance from the crane operator or not in full view of the operator Training – Skilled and experienced crane operators only required Maintenance or inspection – Daily proper inspection is needed and regular maintenance is must Major causes of accidents .3 Photo of Rope puller Disadvantages of Rope puller Small Capacity .Disadvantages of Overhead Crane Instability – Crane is unstable under unsecured load and if load capacity exceeded from crane load carrying capacity Communication .Contact with power lines. Overturns. Falls. Mechanical failures Risk . Fig 1.
4 Cause Effect Diagram . Used for short distance movement only Uncontrolled motion Difficulty in moving from one place to another Noisy operation Need of Modification Fig 1.
2 Aim and Objective of the Project Aim To Design the Hydraulic Rail Car Mover for better.1. Using modern technology minimizing the potentials of risk and increasing the efficiency of railway workshop. . To learn and practice new things. efficient and safe work at railway workshop Objective By utilizing leading edge technology to effectively provide rail car moving solution at railway yard.
. rephasing hydraulic system.1. speed. Chapter 5 presents the introduction to the CAE software Patran and Nastran. The design and analysis process of hydraulic system and recent trends and computer application in the field of hydraulics.3 Report Layout Chapter 2 includes literature review on hydraulics in general. pressure and power pack. Also it includes the justification of assumptions. Chapter 4 presents introduction to the pro engineer software and the model created using pro engineer and details of hydraulic rail car mover cylinder parts. Chapter 3 provides the details of the operation of Hydraulic rail car mover and Calculations of Hydraulic rail car mover force. And the analysis of the axle dog arm using Patran and Nastran. Chapter 6 draws general and specific conclusion from the research work documented in this thesis. calculations of the roller bearings.
Hydraulics totally dominated certain types of equipment in their development.CHAPTER 2 LITERATURE REVIEW 2. Fig 2. Hydraulics was chosen for this application because it is the only form of power transmission that can fit into the narrow confines of the application and still generate more than 40 tons of thrust.1 Hydraulic power equipment trends . and is not as safe as more modern methods. The procedure also requires using more than one person. Even though these are not the most efficient or productive methods. overhead crane. and rope puller. this equipment has been the traditional solution.1 Introduction to Hydraulics The machines which are used to move the rail car in workshop are diesel engine. Traverser. regular maintenance.
In addition. As the volumes of each cylinder cannot economically. sensitive measurements and test systems. Other advantages include lower parasitic power losses. saving space and weight. be identically matched. accuracy reportedly equals or exceeds that of more-costly methods. Hydraulic cylinders are one of the most common component of the hydraulic system used in many engineering applications like. control systems.Hydraulic systems are widely used in the industry. valve. a bypass port is provided that upon full extension (or retraction) a metered amount of fluid bypasses the piston seal to the next adjacent cylinder in the system. Rephasing cylinders combine the functions of flow dividing/combining components with that of actuators. and cylinders are always became investigation topic in the history. This indexes all cylinders of the system to the same position. and the ability to transfer power between actuators. actuation of each cylinder in the system. They are used in producing linear motion in hydraulic systems and they convert hydraulic energy into mechanical energy.2 Rephasing Cylinder System Synchronized operation of two or more hydraulic cylinders can be attained by plumbing volumetrically matched cylinders adjacent to each other where the displaced fluid produces. then upon retraction (extension) positive sealing is engaged and synchronized operation continues. 2. 2. simultaneous. The Collinear cylinders are used in indexer type rail car mover by Calbrandt Inc. But instead of external bypass tube inner pass tube through the piston is used to avoid external fluid lines. The system components like pumps.3 Recent Trends in hydraulics . The same principle of Rephasing cylinder is used in Collinear Cylinder assembly. pressure intensification. equal.. Delano. automatic manufacturing. heavy construction.
It provides the basis for self-compensation that is self-adjusting. self-lubricating. but also ascertain the degradation of that fluid and pin point fluid change periods. it is now possible to not only select a fluid which will adequately protect system components.4 Design and Analysis Process . and self-limiting type of an operation. The assessment of the degree of antiwear protection provided by hydraulic fluid has made good progress in the last years.The technological trends are confirmation of the general consensus of industry. The techniques like portable contaminant monitors which can do analysis and measurement of particulate contamination have been brought out of clean room. The major function of the microcomputer tends to be nothing but a monitor for multiple sensors and data logger. Contaminant monitoring is a large part of every maintenance. 2. Through the gamma rating for hydraulic fluids. The trend is in extending its use to do diagnosis and troubleshooting which are parts of real time condition control. The goals of fluid power which are successfully attainted to suit industrial trends are categorized as Energy conservation Leakage control Fluid stability control Proactive maintenance Contamination control Computer aided engineering Microcomputer control The maintenance strategies of hydraulic systems preventive maintenance and predictive maintenance are well developed. New strategies such as proactive maintenance techniques where the root causes of failure are continuously evaluated to provide an alert before the system is damaged by some failure mode are being developed. The use of microcomputers for data acquisition has been overwhelming in most power fluid laboratories.
2 Hydraulic system design and analysis process The generalized hydraulic Design and analysis process is illustrated in the above figure. . From the design goals. Components model analysis is done using computer Software. Optimization is a function of process which is normally called as cut and try. A hydraulic system is composed of interacting elements and components. The actual performance characteristics are evaluated through laboratory and field tests using the system prototype. Therefore once the element component models are developed.Fig 2. Once these tasks are completed the component sizing and selection process will enter. the design concept to be integrated into the hydraulic system must be established and system schematic must be developed along with the operational specifications for the system. the system model becomes mathematical description of the way these elements and components interact.
. usually abbreviated as CFD. It is oriented towards experienced users. Computers are used to perform the calculations required to simulate the interaction of liquids with surfaces defined by boundary conditions. the design engineer had not to only be intimately familiar with fluid power components and systems. Aerosoft Inc. ANSYS is engineering simulation software. CD-Adapco. It is first and foremost meshing tool.3 Graph of modeling and simulation trends Computational fluid dynamics. Companies in a wide variety of industries use ANSYS software. ANSYS ICEM CFD used as Pre/Post processor for solving fluid system. is a branch of fluid mechanics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows. ANSYS offers a comprehensive range of engineering simulation solution sets providing access to virtually any field of engineering simulation that a design process requires. . The commercial used CFD solvers are Ansys fluent and CFX. but he needed to be a mathematical whiz and proficient computer programmer. Fig 2.2. significant mesh editing add power to meshing options. They only need to know what software does and are not required to know how it does it.5 Computer Application in Hydraulics In early days of computer modeling and simulation. etc. But recent trend is to provide designers with powerful PC based software to aid in their design mission. It has tools for repair and to fix CAD complex geometries.
analyze the performance. . issue quotations etc. The Tie rod collinear cylinders connected end to end are selected for hydraulic rail car mover to cover the required long distance. A telescoping cylinder could have performed functionally similar to the collinear cylinders. select components. provide circuit and element drawings. the multiple stages of motion and the large piston area needed to generate the high thrust would have required a telescoping cylinder too large to fit between the rails. all on a PC. However.A sophisticated Knowledge base Electronic Catalogue software which is available allows the distributor to design a system.
The rail car mover also requires less maintenance compared to using overhead cranes for positioning the rail car. the person controlling the movement right next to where the work is being done. making it easy to position cars right where they need to be. and the cylinders retract back to their home position. Fig 3.1 Introduction Hydraulic car mover can move 5 cars of 60 ton each at time at speed of 15 meter per minute. The car mover provides higher productivity than overhead crane because only one person can handle the system.1 Axle dog model .CHAPTER 3 HYDRUALIC RAIL CAR MOVER: DESIGN AND CALCULATIONS 3. and then the collinear cylinders extend to move the car. The stroke raises an axle dog from the floor to engage the axle of the rail car. An indexer type pushes the axle of a rail car using a single length assembly of hydraulic cylinders mounted end-to-end and positioned parallel to the rail. The axle dog then drops back below floor level.
In actuality. The first cylinder is stationary. the rod of the second cylinder pushes on the cap end of the third cylinder. as are the third. cylinders are mounted on rollers and when its rod extends. theoretically. This is because the body of the second cylinder (which is mounted on rollers. the rod end of the fifth cylinder moves at five times the ground velocity as the first one.2 Operation of the System Hydraulic rail car mover consists of five cylinders mounted end-to-end in a collinear arrangement. and fifth cylinders) moves at the speed of the first cylinder’s rod. the stroke speed of any given cylinder varies. and the rod of second cylinder extends at that same speed.3. However. the net result is uniform motion from the cylinders sharing fluid routed in parallel. it pushes on the cap end of the second cylinder. the rod end of the second cylinder moves at twice the relative ground velocity as the first one. fourth. from second cylinder. This means that. Likewise. Fig 3. Therefore. The piston acting against the least resistance will move.2 Operational sequence schematic representation . and so on.
3 Operation of Direction Control Check Valve . hydraulic fluid under pressure is allowed to flow from the hydraulic pump to the piston side of the cylinder 1. the pressurized oil is sent to the rod side of the cylinder 1 from the hydraulic pump and the part of the fluid pass thorough the hole on the piston rod to the end cap of next cylinder. 3. Hence retracting all the cylinders and pushing the oil on top of the cylinder 1 back to the reservoir. While the oil under the piston by the rod side of the cylinder 1 is allowed to flow from the cylinder and back to the reservoir. If the handle is pushed to the retract position. The check valve gets actuated at predefined pressure and part of the fluid passes to the end cap of next cylinder through the inner tube.4 Schematic of Cylinder When the control valve handle is moved toward the extend cylinder position. The extend fluid is restricted to pass through outer pass tube using directional control check valve.Fig 3. Then at retract fluid pressure the check valve at entry of the pass tube in each moving cylinder gets actuated and fluid the passed to the rod side piston of the cylinders mounted on the rollers.
688kN/ m2 and allows fluid to pass in forward direction. One is inside piston inner tube entrance and another is at each pass tube entry. Fig 3.Spring loaded direction control check valves are used to guide the fluid inside the Hydraulic cylinder.5 Check valve diagram In Hydraulic rail car mover at two position direction control check valves are used. The check valve senses the pressure and gets actuates and allows fluid to pass in one direction only. The valve inside piston rod gets actuate at the pressure 2167. . The valve at pass tube gets actuated at pressure 3545. The Schematic diagram of check valve is given below.91kN/m2 allows fluid to pass in retraction motion.
4 = 0.05m = 4.D .5 = 0.3.5 = 0.A Volume of Piston inner tube Volume of Pass tube Volume of axle dog cylinder = π/4 * 0.05m = 4.052* 4.000353 m3 -------.032 * 0.008639 m3 = π/4 * dp2 * lp = π/4 * 0.02138 m2 Volume of one Cylinder = area * length = 0.165m = 4.1652 = 0.C -------.4 Calculations of Hydraulic Rail Car Mover Cylinder bore diameter (D) Length of cylinder (L) Piston rod diameter (dpr) Piston inner tube diameter (d) Length of piston rod (l) Pass tube diameter (dp) Length of pass tube (lp) Length of Axle dog cylinder (la) Cross section area of cylinder = 165 mm = 4400mm = 110mm = 50mm = 4500mm = 50mm = 4400mm = 0.11m = 0.008639 m3 -------.5m = 0.4m = 0.B -------.5 = 0.052 * 4.02138 * 4.5m = 0.5m Axle dog cylinder bore diameter (da) = 30mm = 500mm = π/4 * D2 = π/4 * 0.03m = 0.09407 m3 = π/4 * d2 * l = π/4 * 0.
91*103)/ (1000*9.45*4.43 gallons/min Weight of rail car Number of rail car Total weight of rail car Total distance to be covered Acceleration = 60 ton =5 = 300 ton = 22 m = 0.41kw . density of oil is 830 kg/m3 Assume overall efficiency (η) = 82% Power required = (ρoil * g * H * Q)/ (1000 * η) = (830*9.01187 = 3545.81 = (3545.93 lit/min = 72.5733 * 10-3 m3/sec = 182. Force required to move the rail car = mass * acceleration = (300 * 103 + 0.15 * 300 * 103)* 0.45m Selecting SAE 30 oil.91 KN/m2 Pressure head = pressure/ density of water* 9.5733*10-3)/ (1000*0.82) = 16.81) = 361.5488 m3 Total volume in liters Time required Flow rate Pump required capacity = 548.Total Volume = A * 5+ B * 5 + C * 4 + D * 2 = 0.8 lit = 3 min = 4.81*361.122 = 42090 N Pressure required = Force/ Area = 42090/0.122 m/s2 Assume motion is pure rolling motion and 15% extra load for design.
688kN/ m2 Max Force in extension = Pushing area * operating pressure = 0. Weight of an axle dog = 100 kg .01187 * 3758.019417) = 2167.81*0.009503 = 0.78kN/m2 = cross section area of cylinder – area of piston inner tube = 0.78 = 44616.01187m2 Pulling area Pressure required in retraction= (42090/0.Select 18kw motor and 75gpm pump 75gpm = 0.02138 – 0.23N > 42090N = Hence OK = cross section area of cylinder – area of piston rod = 0.16m of water = 3758.78 = 72984.001963 = 0.004731) = 383.91kN/m2 Max force in retraction = Pulling area * operating pressure = 0.004731m3/ sec Maximum operating pressure of pump = (P*1000* η)/ (ρoil *g* Q) = (18*1000*0.7N > 42090N Hence Design is ok.019417m2 Pushing area Pressure required in extension= (42090/0.019417 * 3758.02138 – 0.82)/ (830*9.01187) = 3545.
068 * 10-4 m2 Pressure required to operate axle dog = (100 * 9.2436 m/sec Speed of rail car in forward direction = Velocity in forward direction * 4 = 0.004731/ 0.068 * 10-4) = 1387.974 m/sec Theoretical time required to move the coach in forward direction is 21.032 = 7.06 sec .44 sec Velocity in retraction = flow rate/ pulling area = 0.3985 m/sec Speed of rail car in reverse direction = Velocity in retraction * 4 = 1.94kN/m2 Velocity in forward direction = flow rate/ pushing area = 0.594 m/sec Theoretical time required to move the coach in reverse direction is 35.004731/ 0.019417 = 0.81)/ (7.01187 = 0.Cross section area of dog cylinder = π/4 * da2 = π/4 * 0.
1 service factor = 1. = 93% Life in million revolutions for 93% Probability of survival Lmr = (Lh*60*N)/ 106 = 192 mr Life in million revolutions for 93% Probability of survival L07/L10 Where.59 mr Calculation of approximate equivalent load Using excess radial load factor Peq Where.3. V X S Kr Kt = 1 for outer race bearing = 1 radial load factor = 1. b P07 P10 L10 = constant for ball bearing = 1.3 excess radial load factor = 1.34 from PSG data book = 0.90 = (ln(1/P07)/ ln(1/P10))1/b = 253.5 Design of Roller Bearing Number of bearing Total load carried Radial Load on each bearing (Fr) Axial load on each bearing (Fa) Speed (N) Life required (Lh) Probability of survival = 24 = 42000 N = (42000/24) =1750 N = 500 N = 200 RPM = 16000 hrs.06 temperature factor for operating temp 130 degree = (V*X* Fr *S*Kt)* Kr .93 = 0.
Peq = (1*1*1.59)1/3 * 2652.41 kgf = (L10)1/k * Peq Ref PSG design data book Select SKF 6011 deep groove ball bearing with dynamic capacity 2200 kgf.06*1750) = 2652.3*1. K C = 3.93 N = 1711.65 N Calculation of Dynamic capacity Using load life relationship C Where.1*1.65 = 16788. . constant ref PSG data book = (253.
1 Cost of Hydraulic Rail Car Mover Hydraulic rail car mover Part 17kw motor 75gpm pump 5 cylinders Other cost Total approximate value Cost of the part (INR) 50000 150000 300000 400000 900000 The initial cost of hydraulic rail car mover is less than initial cost of overhead crane it costs almost 25-30 lacs per unit. It requires only one person and the person operating the rail car mover can take safe position and monitor the operation.6 Justification of assumptions Alloy Steel is used as cylinder material because of its high strength and corrosion resistance properties. The power requires for hydraulic rail car mover is 18kw but power consumption of the overhead crane is 25kw. The use of PLC circuits permits remote control operation. There are no external fluid lines in the system except main line from source to the first fixed cylinder. The numbers of parts which require maintenance are less hence the maintenance cost is also less than the overhead cranes. . As compare to overhead crane where controls are at a height. operator have to climb to platform to operate the crane hydraulic rail car mover controls are simple. Operability of the system is very easy. The system is design to fit under rail car within available space. The length of the system in home position is 27m and fully extended position length is 50m. It does not require any special training for using the machine. Hence the operating cost of hydraulic rail car mover is less than overhead crane for same number of working hours. The initial cost of the hydraulic rail car mover is Table 3. Ease of Manufacturing is also criteria for selection of material.3. Operator can keep eye on operating pressure indicated on pressure dial.
4. speed of the system. radii. cuts. and cylinder can be tested for buckling etc. holes. operating temperature. the hole diameter parameter value is changed. Another unique attribute of Pro/ENGINEER is that it is a solid modeling program. view it. various views of a part are created in an attempt to describe the geometry. The assembly model of Hydraulic Cylinder is created in ProE by using different parts of cylinder created in ProE. The design procedure is to create a model. etc. If it is desired to change the size. its use is significantly different from conventional drafting programs. This automatically modifies the feature wherever it occurs . shape. The other significant aspect of conventional drafting is that the part geometry is defined by the drawing. or location of a feature. Each view incorporates aspects of various features (surfaces. the features are driven by the dimensions (parameters).2 Hydraulic Cylinder Model .drawing views. assemblies.CHAPTER 4 MODELLING USING PRO ENGINEER 4. protrusions) but the features are not individually defined. the physical lines on the drawing must be changed (in each affected view) then associated dimensions are updated. The analysis will give the pressure in the cylinders. each feature is individually described then integrated into the part. In conventional drafting (either manual or computer assisted). These ProE models can be used for doing analysis using Ansys software with ICEM CFD solver. When using parametric modeling. To modify the diameter of a hole. then generate any drawings which are required. parametric solid modeling program. In feature based modeling.1 Introduction to Pro/E Pro/ENGINEER is a feature based. As such. assemble parts as required.
2 Model of Front end and Back end .Fig 4.1 Hydraulic cylinder Assembly model 4.3 Models of Parts of Hydraulic Cylinder Fig 4.
4 Cross sections of Hydraulic Cylinder model .4 Model of Piston rod end 4.Fig 4.3 Model of Piston and piston rod Fig 4.
5 Cross section of Front part of cylinder Fig 4.Fig 4.6 Cross section of Rear part of cylinder .
LS-DYNA.CHAPTER 5 ANALYSIS OF ARM USING PATRAN/NASTRAN 5. Fig 5. Marc. and Pam-Crash. providing solid modeling meshing facility which facilitates the placement of loads and restraints. Abaqus.1 Introduction Patran is the world's most widely used pre/post-processing software for Finite Element Analysis (FEA). analysis setup and post-processing for multiple solvers including MSC Nastran. ANSYS.1 Steps in analysis .
The load and constraints are applied. And the other end of the arm is hinged to the platform so it can rotate about the pin. MSC Nastran is recognized as the most trusted multidiscipline solver in the world. These arms hold the axle shafts of trolley. When it comes to solving for stress/strain behavior. The pressure required to operate the hydraulic arm is 1387. dynamic and vibration response and thermal gradients in real-world systems. .MSC Nastran is the world's most widely used Finite Element Analysis (FEA) solver. There are two arm positioned opposite to each other in the system.42 * 103 N/mm2 calculated using Nastran. The straight arm was enough to push the rail car but there is difficulty in operation of the arm because of the brake linkages restricting the motion of the arm. 5. The maximum stress in the arm is 1. Then it is imported to the Patran for finite element analysis where it is meshed using meshing tools. While one arm is pushing the rail car the other arm is used for controlling the motion of the rail car. The model of the axle dog arm is created using the ProE software.94kN/m2. They are operated by different hydraulic cylinders. Later processing is done using Nastran solver.2 Design of Axle Dog Arm The Axle length of the rail car is 1524mm. The results of Nastran are access in Patran. So the arm is design in U shape.
2 Model of axle dog Fig 5.3 Results of Nastran .Fig 5.3 Meshing and load applied using Patran 5.
Fig 5.5 Result Stress and Displacement .4 Result constraint forces Fig 5.
And the cost of installation and maintenance is also less compared to overhead carne. power. The demand for frequent and faster railway service is increasing. Further this systems performance can be analyze using computer engineering Software like Ansys ICEM CFD. And by making prototype of the system more performance parameters could be understand. Therefore there is need for modern better. safe techniques to replace conventional methods which are also creating more pollution. It is more safe and convenient for the peoples working in workshop than threat of overhanging load. Check the reliability of the Hydraulic rail car mover using the computer testing Software. The Hydraulic rail car mover is better option to use for movement of the rail cars under workshop. . It doesn’t require skill person to operate the machine. Hence Hydraulic rail car mover system is better. dimensions systems performance can be optimize. Hydraulic rail car mover will save the time required in workshop by eliminating interference of shunting department in the movement of the rail car.CHAPTER 6 CONCLUSION AND FUTURE SCOPE Indian railway workshop is most busy place for 365 days and still workload is increasing continuously. By changing the parameters like pressure.
K.com/products/axle-type-railcar-mover#1 http://www. Khurmi . Bhandari .aggressivehydraulics. C. “Aggressive hydraulic machinery”.bardyne. S. Hong (1999). Fourth edition. “Fluid Mechanics and Hydraulic Machines”. Dr Ing T. J.org/wiki/patran_nastran http://www. B. “ Machine Design”.html http://en.com/products/cylinder-component-parts/ http://www. Tessmann.ehow.com/Publications/Literature.wikipedia. Fitch. S.calbrandt. 26-30 BOOK R. Dr Richard K. S Chand publications V. “Design of Machine Elements”.htm#11 . page no. Khurmi. McGraw Hill publications R.com/about_5403188_parts-hydraulic-cylinder.CHAPTER 7 REFERENCES JOURNAL Dr E. FES Technology publication Paul Johnson (2011). “Fluid Power Goals and Trends”. S Chand publications “Design Data Book of Engineers”. PSG college of Technology WEB http://www. Magazine Hydraulics and Pneumatics July 2011. Gupta.
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