JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 35

Application - The tank should have a good life span; - Apart from fitment on new coaches, the new undercarriage water tank module design should be suitable for retrofitting on existing coaches. It was a real challenge to design a composite pressure vessel for train undercarriage applications without compromising the tank water holding capacity, while meeting the space constraint and ballast protection requirements. Conventional undercarriage water tanks are in metal with flat ends (unlike filament-wound pressure vessels) and a number of other undercarriage components are fitted beside the tanks. Being undercarriage, the tank is considered a safety item and also has to maintain the stipulated safety dimension from rail level. During the design phase, the tank was subjected to a number of changes to reach an optimized design fulfilling all the necessary criteria. The composite water tank module developed saved 120 kg per coach. The undercarriage water tank module assembly consists of the following main parts: Thermoplastic liner A food-grade thermoplastic liner which also acts as mandrel was designed with sufficient thickness to withstand the winding tension while allowing the fixing of the central shaft. Depressions/niches were provided on the thermoplastic liner for additional padding (around the metal supports) and nozzle fitting. Structural shell with integral dish ends The structural composite shell was designed as a glassreinforced polyester construction (E-glass rovings and isophthalic acid-based unsaturated polyester resin system) with the necessary thickness. It was manufactured using filament winding, combining helical winding at + 15 degrees to the longitudinal axis and balance hoop winding at 90 degrees in the straight portion. Hoop winding was also used around the metal supports that hold the two tanks together and fix them to the coach underframe. Technical specifications, constructional details and manufacturing The vessel was designed considering filament winding on a rotomoulded thermoplastic liner with integral dish ends which doubles up as the mandrel for winding. As it needs to offer optimum performance, the dome has to be designed with a geodesic shape providing a non-slip fibre path. This helps balance the internal pressure by stretching along the fibre direction. The shape of the dish end is nearly semi-ellipsoidal. The layered analysis of the shell was carried out using specialized software. The nozzles were designed according to relevant design standards and joined with proper reinforcement at the cut-outs.The composite undercarriage water tank was designed in compliance with BS 4994:1987 to fulfil the following technical specifications and requirements: Tank fixing arrangement The tank fixing arrangement was designed to allow both retrofitting and fitting to new coaches. The two tanks are held together and mounted to the coach underframe with a specially designed stainless steel (SS 304) fixing arrangement. The suspension arrangement and fixing brackets are analyzed for specific loads. Protective shield A specially designed polypropylene protective shield is fixed to the lower half of the undercarriage tank module with a certain gap, thus allowing the main shell to protect the tank from ballast hits while the train is running on the tracks. Testing and field trials A prototype tank was fabricated and tested for all basic material properties. All the welded metal joints were tested using the diepenetration test while the complete tank was subjected to hydro testing. On successful completion of fabrication/testing and clearance from RDSO, the prototype tank was mounted on a train for field trials. It has now completed over two and a half years of extensive field trials. In view of the highly satisfactory and successful field trials, RDSO has already approved the new composite undercarriage water tank and Indian Railway is in the process of introducing it on a mass scale. More information: www.kinecogroup.com No36 October - November 2007 / JEC Composites Magazine
http://www.kinecogroup.com

JEC COMPOSITES MAGAZINE - Issue #36 - October 2007

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #36 - October 2007

- Trends
FEATURE: TRANSPORTATION
- Measurement
Edito
BUSINESS
- Innovations
- Niche markets
- Companies
- Application
- Successful partners
- Composites in the world
CONTENTS
KNOW-HOW
- Process
USERS’ PLATFORM
- Market
- Market survey
NEWS WORLDWIDE
- Prototyping
- Agenda of events
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 1
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 2
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - Edito
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 4
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 5
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - CONTENTS
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 7
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - NEWS WORLDWIDE
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 9
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 10
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 11
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 13
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Innovations
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 15
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 16
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Market survey
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 19
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 20
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 21
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 22
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 23
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 24
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 25
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Trends
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 27
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Niche markets
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - FEATURE: TRANSPORTATION
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Market
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 31
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 32
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 33
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Application
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 35
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 36
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 37
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 38
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 39
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 40
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 41
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 42
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 43
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 44
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 45
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 46
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 47
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 48
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - USERS’ PLATFORM
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 51
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Successful partners
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 53
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 54
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 55
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 56
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Prototyping
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 59
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 60
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 61
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Process
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 63
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 64
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - - Measurement
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 66
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 67
JEC COMPOSITES MAGAZINE - Issue #36 - October 2007 - 68
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