JIS JAPANESE INDUSTRIAL STANDARD Translated and Published by Japanese Standards Association JIS E 7105: (JARI/JSA) Rolling stock—Test methods of static load for body structures mber : JIS E 7105 : 2006 (E) PROTECTED BY COPYRIGHT 8sE 7105 : 2006 Foreword ‘This translation has been made based on the original Japanese Indus- trial Standard revised by the Minister of Land, Infrastructure, Trans port and Tourism through deliberations at the Japanese Industrial Standards Committee as the result of proposal for revision of Japanese Industrial Standard submitted by Japan Association of Rolling Stock Industries (IRD/Japanese Standards Association (JAS) with the draft being attached, based on the provision of Article 12 Clause 1 of the In- dustrial ‘Standardization Law applicable to the case of revision by the provision of Article 14, Consequently JIS E 7105:1989 is replaced with this Standard. Attention is drawn to the possibility that some parts of this Standard may conflict with a patent right, application for a patent after opening to the publig, utility model right or application for registration of utility model after opening to the public which have technical properties. The relevant Minister and the Japanese Industrial Standards Committee are not responsible for identifying the patent right, application for a patent after opening to the public, utility model right or application for rogistration of utility model after opening to the public which have the said technical properties. Date of Establishment: 1989-02-22 Date of Revision: 2006-02-06 Date of Public Notice in Official Gazette: 2006-02-06 Investigated by: Japanese Industrial Standards Committee Standards Board ‘Technical Committee on Railways and Rolling Stock JIS E.7105 : 2006, First English edition published in 2010-05 ‘Translated and published by: Japanese Standards Association 4-1-24, Akasaka, Minato-ku, Tokyo, 107-8440 JAPAN In the event of ary doubts arising as to the contents, the original JIS is to be the final authority. © 8A 2010 All rights eseeved. Unless otherwise specified, no part ofthis publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying. and microfilm, without permission in writing from the publisher. Printed in Japan HI/HN PROTECTED BY COPYRIGHTRoe 5.2 53 5.4 5.5 5.6 Scope *~ Normative references **" ‘Terms and definitions *- Test type ‘Test method Measurement item -- Instrument Selection of measurement point Load applied «+++: Pressure in air-tight chamber Supporting method of body sxrueture and eopig ‘method of test load - Evaluation method of test result Contents @ PROTECTED BY COPYRIGHT E7105: 1 so aT “2 2 2 2006 Page Bako “10JAPANESE INDUSTRIAL STANDARD JIS E7105: 2006 Rolling stock — Test methods of static load for body structures 1 Scope This Japanese Industrial Standard specifies the test methods of static load thereafter referred to as “test’) for confirming strength, rigidity and the like of body structures for passenger stock such as electric railcars, internal-combustion railcars and passenger cars principally. 2 Normative references The following standards contain provisions which, through reference in this text, constitute provisions of this Standard. The most recent editions of the standards (including amendments) indicated below shall be applied. JIS B0153 Glossary of terms used in mechanical vibration and shock JIS B0155 Industrial-process measurement and control — Terms and definitions JIS B 7505 Bourdon tube pressure gauges JISB7516 Metal rules JIS E4001 Railway rolling stock — Vocabulary JIS E4208 Test methods of static load for truck frames and truck bolsters of rail- way rolling stock JIS E7106 Holling stock — General requirements of carbody structures for pas senger car JIS Z2300 Terms and definitions of nondestructive testing 3 Terms and definitions For the purposes of this Standard, the definitions given in JIS E 4001 and JIS B 0153, and the following definitions apply. a) body structure for testing assembly of main body structures such as underframe, side body structure, end body structure and roof body structure, and other compo- nents which affect the strength and rigidity Regarding 6.6.7, the assembly whose opening is sealed with genuine parts or temporary caulking components so that the homogencous sctting pressure is main- tained inside the air-tight body structure during the measurement, b) strain gauge in accordance with 6 (8) of JIS Z 2300 © load cell in accordance with 2.C) 2.2) of JIS B 0155 d) stress product of the strain measured by strain gauge and the modulus of clastie- ity of the component on which the strain gauge is attached PROTECTED BY COPYRIGHT2 E 7105 : 2006 NOTE: It is fundamentally impossible to measure the stress directly; however in this Standard, such an expression of “stress” measurement in common use is used instead o? “strain” measurement. 4 Test type The tests shall usually be classified into the following seven types. When different tests are necessary, the test methods shall be upon the agreement be~ tween the purchaser and the supplier. a) Vertical load test }) Cumpressiun load Lest at carbudy end. c) Torsion load test d) Three-point support test e) Measurement (test) of natural frequency of bending f) Measurement (test) of natural frequency of torsion g) Air-tightness strength test (1) Note () Applicable to the rolling stock of air-tight structure upon the agree- ment between the purchaser and the supplier. 5 Test method 5.1 Measurement item The measurement item for each test type shall be as shown in table 1 Table1 Measurement item ‘Test type Measurement item Stress Displace- Natural Load Pressure in ment frequency | applied airtight chamber 3 o Vertical load test ‘Compression load test at carbody end Torsion load test Three-point support test Measurement (test) of natural frequency of bending “Measurement (test) of natural frequency ° of torsion ‘Air-tightness z strength test o 2 as Q Jo} o Jo ojo} o fe) oO ° fe} PROTECTED BY COPYRIGHT3 E7105: 2006 5.2 Instrument An example of instrument for each measurement item is shown in table 2. Table 2 Instrument (example) ‘Measurement item Instrument Stress Strain gauge ‘Displacement Displacement meter, metal rules specified in JIS B 7616 Frequency Strain gauge, displacement meter, acceleration sensor and fe quency analyser ‘Load applied Load cell Pressure is Pressure gauge spouilied in JI5 D 7508 or manometer airtight chamber NOTE: Using method of stra:n gauge shall be in accordance with 6.3 of JIS E 4208, 5.8. Selection of measurement point 5.8.1 Measurement point of stress ‘The measurement point of stress shalll be as fol lows, a) Area of basic component where comparison between calculated stress and meas- ured stress is easy b) Area where generation of high stress is expected according to the result of strength calculation c) Area where the stress concentration is expected such as an area at which the shape and/or cross section change sharply and the end of a welding bead 4) Arca where attention io required in welding or machining at tho time of manufac turing the body structure 5.3.2 Measurement point of displacement The measurement point of displacement shall be as follows. a) Displacement in longitudinal direction of rolling stock (®) 1) Supporting point of the body structure or the application point of the load applied if it is defined 2) Point where the deformation mode shows the flexion point of the body structure such as both ends of doorway . 3) Point where the deformation mode shows almost equal interval in an observable pitch Note @) Also expressed as “Ceflection”. b) Horizontal displacement in ercss-section of rolling stock(’) The point where it gives some effects on the body structure functions, such as an area where shape and/or section change sharply Note (3) Also expressed as “deformation”. PROTECTED BY COPYRIGHT4 E 7105 : 2006 5.3.3 Measurement point of frequency The measurement point of frequency shall be a point where the natural vibration mode appears most clearly. 5.4 Load applied The magnitude of load applied shall be in accordance with JIS E 7106. 5.5 Pressure in air-tight chamber ‘The magnitude of air pressure applied to the chamber in an air-tightness strength test shall be in accordance with JIS E 7106, 5.6 Supporting method of body structure and applying method of test load 5.6.1 Vertical load test ‘The vertical load Lest shall be as fulluws. a) Supporting method of body structure The supporting position of the body struc ture shall be the portion supported by the truck. The structure of supporting por- tion shall be as follows. 1) Temporary air spring seat for the rolling stock which has air spring directly con nected to the car body 2) Temporary coil spring seat for the rolling stock which has coil spring directly con” nected to the car body 3) ‘Temporary centre pivot or temporary auxiliary side bearer for the rolling stock which is supported by the centre pivot or side bearer An example of the body structure supporting method is shown in figure 1. Body structure ‘Peat load —— ee | } i (ey ydd \ Usshape upper roller holder 7 Supporting fixture (1) Flat upper roller holder Ss ~ Roller Seaiabecupper dalek naldaes +o Load cell ©“ Flat upper roller holder Support base, Notes (*) Any one of 1) to 3) of 5.6.1 a). () Instrument for measuring the test load. It may be omitted when the determined load is appliad. Figure 1 Supporting method of body structure in yertical load test (Example) b) Applying method of load ‘The applying method of load shall be as follows. 1) The test load shall be evenly distributed over the floor surface. Using hydraulic pressure, air bags, water tanks, sand bags, iron blocks, pig iron for casting or others, the vertical load shall be increased to/decreased from the pre-determined maximum load in stepwise, and the measurement shall be carried out at each step (). In general, this test load is caleulated by subtracting the mass of the body structure for testing and the testing apparatus multiplied by the gravitational PROTECTED BY COPYRIGHT5 E7105: 2006 acceleration from the maximum loed specified in table of JIS E 7106. 2) For the rolling stock equipped with a device having large mass, the measurement shall be carried out by applying a concentrated load corresponding to the mass of the device to its attaching place. Note() — In the preliminary test, it shall be confirmed that the relations be~ tween stress and load as well as between deflection and load are linear. If the relation is not linear, the cause shall be determined. If hysteresis in measured values is found between the upward and downward load- ing processes, any structural cause inthe product for testing or the test jig and the like shall be determined. Furthermore, the stress and the deflection after removal of the load shall be confirmed to be almost equal to those before applying the test load. 5.6.2 Compression load test at carbody end The compression load test at carbody end shall be as follows. a) h) Supporting method of body structure The supporting method of the body struc ture shall be in accordance with 5.6.1 a). The flat upper roller holder and the flat lower roller holder shown in figure 1 shall be used on the compression load applica~ tion side so that they will not inhibit the compression deformation of the body structure. Applying method of load The applying method of load shall be as follows, 1) The load applied shall be a compression load by a hydraulic jack. 2) In order to stabilize the position of the body structure, the perpendicular load shall be applied in the vertical direction by the method specified in 5.6.1 b). The magnitude of load is not specially specified; however, the load equivalent to the mass of an emply ear is generally used. 3) ‘Temporary pushing rods for testing shall be attached to the coupler attaching po- sitions on both ends of the body structure as shown in figure 2. Using a hydraulic jack, the compression load shall be applied from one end of the body structure by increasing to/decreasing from the pre-determined maximum load in stepwise, and measurement shall be carried out at each step (®). PROTECTED BY COPYRIGHT6 E 7105 : 2006 Pulling rod Reaction Reaction force beam force beam Body structure est load Uy \ Pushing rod Pulling Pushing ro \ for testing rod for testing Hydrate jack \Spherical seat Sphorieal eat] | oad call Note (7) Instrument for measuring the load applied. It may be omitted when the load applied is calculated by the pressure supplied to the hydraulic jack then measured with a pressure gauge. Figure 2 Applying method of test load in compression load test at carbody end (example) 5.6.3 Torsion load test The torsion load test shall be as follows a) Supporting method of body sxucture The supporting method of the body struc: ture shall be so that it is supported at the two places on the centre line of one of the bolsters of the body structure (8) and fixed with a fixing beam or with vertical load applied in the vicinity of the e1pporting point, while the centre position of the other bolster is supported by a support base having a knife edge or a roller of a small diameter via a torsion beam as shown in figure 3. Note@® For the rolling stock which has air springs or coil springs dizectly con- nected to the car body, the supporting points shall be in the positions of the air springs or coil springs. For the rolling stock which is sup- ported by the centre pivot, the supporting points shall be in the posi- tion of the side bearer. b) Applying method of load The load shall be applied so that only the torsion mo- ment by a couple of force is ayplied to the body structure as shown in figure 3. The load shall be increased to/decreased from the determined maximum load in step wise, and the measurement shall be carried out at each step (°), PROTECTED BY COPYRIGHTm E 7105: 2006 Fixing bolt Fixing beam Torsion beam Doorway {~ we Biuppart Load cell age Hydraulic jack ~}| + + ‘Test load ATES Fixing bolt Hydraulic jack beam rE fase LS Hydraulic jack Support basd Figure 3 Applying method of test load and supporting method of body structure in torsion load test (example) 5.6.4 Three-point support test The three-point support test shall be carried out as follows. a) Supporting method of body structure ‘The body structure shall be supported hori: zontally at four jack holders in the vicinity of the bolster of the body structure by using the load cell with a spherical seat or ball on the top as shown in figure 4, One of the four supporting points (on the rear side in figure 4) shall be a hydraulic (or screw) jack with a load cell on the top. b) Applying method of load The epplying method of load shall be as follows. 1) The load applied shall be in accordance with 6.6.1 b) 1). ‘The magnitude cf load shall be calculated by subtracting the mass of the body structure for testing mul- tiplied by the gravitational acceleration from the load equivalent to the empty mass of the subject car. 2) At the supporting point where the jack is set, the jack height shall be decreased from/increased to the height in stepwise, where the load cell and the body struc: ture separates. Measurement shall be carried out at each of the steps (®). However, in the case of the body structare featuring small torsion rigidity, the load cell and the body structure will not separate even if the jack height is decreased. In such a case, the maximum decrease in the jack height shall be upon the agreement. be~ tween the purchaser and the supplier. PROTECTED BY COPYRIGHT8 E7105 : 2006 Body structure Front ‘Rear Body structure os load Test i Load cell — Load cell Support base { | if i Hydraulic jack Figure 4 Supporting method of body structure in three-point support test (example) 5.6.5 Measurement (test) of natural frequency bending The measurement (test) of nutural frequency bending shall be carried out as follows. a) Supporting method of body structure ‘The body structure shall be supported by the support bases similar to that in 6.6.1 a). b) Vibrating method Although various methods for vibrating the body structure are available, the following methods are widely used in general. 1) Instantaneous weight cutoff method A method to cause the free vibration of body structure by instantaneously cutting off the weight being hung from the cen- tre of the body structure floor bottom face, as shown in figure 5. 2) Impact vibration method A method to vibrate a body structure by dropping a weight such as a sand bag or a ballast, instead of the weight in figure 5, onto the underframe floor in the centre of the hady stricture 3) Forced vibration method A method in which a forcing vibration machines at lahed to the ventre of the body structure instead of the weight of figure 5, or a method of applying a vibration force to the centre of the body structure by a wire connected lo a vibration machiues placed un Uhe ground 4) Impact hammer method A method to cause the bending vibration to the body structure, without fitting the weight in figure 5, by giving a vertical impact blow to the underframe using an impact hammer ©) Measurement of frequency The method shall be such that the output signal from an acceleration sensor attached to the body structure is recorded on a recording chart and the natural frequency of bending is obtained from the waveform, or out~ put from the acceleration sensor is analyzed by a frequency analyzer. PROTECTED BY COPYRIGHT.9 E7105: 2006 Body structure cat Ripa aac VE support me “JT | 1 \ wash oat nd Figure 5 Example of weight cutting off method in natural frequency of bending measurement test 5.6.6 Measurement (test) of natural frequency of torsion The measurement (test) of natural frequency of torsion shall be carried out as follows. 2) Supporting method of body structure The body structure shall be supported in a manner that the fixing bolts, fixing beam, hydraulic jack and load cell are removed from figure 3 of 6.6.3 a). b) Vibrating method Although various methods for vibrating the body structure are available, the following metho’s are widely used in general. 1) Instantaneous weight cutoff method A method to cause the free vibration of body structure by instantaneously cutting off the weight being hung from one end of the torsion beam as shown in figure 6 2) Forced vibration method A method in which a forcing vibration machine is at- tached to one end of the torsion beam instead of the weight of figure 6, or a method of applying a vibration force to the end of the torsion beam by a wire cone nected to a vibration machine placed on the ground 3) Impact hammer method method to cause the torsion vibration of body struct ture by giving a vertical impact blow, using an impact hammer, to the side of the underframe supported by a knife edge without fitting the torsion beam and weight in figure 6 ©) Measurement of frequency ‘the method shall be such that the output signal from an acceleration sensor attachad to the body structure is recorded on a recording chart and the natural frequency of torsion is obtained from the waveform, or output from the acceleration sensor is analyzed by a frequency analyzer, PROTECTED BY COPYRIGHT10. E 7105 : 2006 Body structure Torsion beam Cutoff equipment eight ™~ ~~ Knife edge ‘Test lond ‘Support base Figuro 6 Gonoral test method of natural froquoney of torsion measurement (example) 5.6.7 Airtightness strength test. The air-tightness strength test shall be as follows. a) Supporting method of body structure The body structure shall be supported at four places of the bolsters by the support base. b) Applying method of pressure ‘The pressure shall be applied by supplying the com- pressed air in stepwise from the air supply port provided at the temporary sealed area of the body structure for testing. The pressure in the air-tight chamber shall be increased stepwise to tke determined maximum value and the measurement shall be carried out at each step. When decreasing the pressure, the pressure shall be reduced to zero without intermediate steps in general, because it is difficult to reduce and adjust the pressure in stages (*). 6 valuation method of test result The test results shall be evaluated in accordance with 4.3 and 4.4 of JIS E 7106. PROTECTED BY COPYRIGHTBrrata for JIS (Gnglish edition) avo printed in Standsrdization Journal, published monthly by the Japanese Standards Association, and also provided to subscribers of JIS (Knglish edition) in ‘Monthly Information, Errata will be provided upon request, please contact! Standards Publishing Department, Japanese Standards Association 41-24, Akasaka, Minato-ku, Tokyo, 107-8440 JAPAN TL, 08-3589-8002 FAX. 08-58-0462 PROTECTED BY COPYRIGHT