DESIGN OF HYDRUALIC RAIL CAR MOVER

Submitted in partial fulfilment of the requirements For the degree of Bachelor of Engineering
In

Mechanical Engineering
By

Chakravarti Atole Avinash Bagul Deepak Khabale Shalom Varghese

Guide

Prof. Ashok Patole

Department of Mechanical Engineering MESs Pillais Institute of Information Technology, Engineering, Media Studies and Research, New Panvel, Navi Mumbai 410 206 2011-12

Department of Mechanical Engineering MESs Pillais Institute of Information Technology, Engineering, Media Studies & Research New Panvel 410 206

Certificate
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

(Internal guide)

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 Ss Pillais Institute of Information Technology, Engineering, Media Studies and Research, New Panvel, Navi Mumbai 410 206

EXAMINERS

1) ---------------------------------------------

2) ----------------------------------------------

Principal M E Ss Pillais Institute of Information Technology, Engineering, Media Studies and Research, New Panvel, Navi Mumbai 410 206

ABSTRACT

Indian Railways is one of the largest railway networks in the world. It operates both long distance and suburban rail systems. Indian railway workshop at Matunga carries out Periodical Overhaul (POH) and heavy corrosion repairs of main line as well as EMU coaches. The Yard engine, Traverser, overhead cranes are used to move the coaches from one place to another. These means have their own advantages and disadvantages.

Overall these systems are bulky requires proper maintenance, electricity consumptions is high, operations are noisy and requires more than one person to do task, workers attention is needed for safety. The time required for shunting operation is more.

Hydraulic rail car mover can be use for better, efficient and safe work at workshop, requires no major alterations in the workshop for installation. The rail car mover can provide higher productivity because the person controlling the movements stands next to where work is being done, making it easy to position cars right where they need to be.

The design of Hydraulic rail car mover includes design of hydraulic cylinder, dog arm, bearing and the modeling of parts using CAD Software and analysis of Hydraulic rail car mover components.

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

INTRODUCTION 1.1 Background 1.2 Aim and Objectives 1.3 Report Layout LITERATURE REVIEW 2.1 Introduction to Hydraulics 2.2 Rephasing Cylinder System 2.3 Trends in Hydraulics 2.4 Computer Application in Hydraulics DESIGN AND CALCULATIONS 3.1 Introduction 3.2 Operation of The System 3.3 3.4 3.5 3.6 Operation of Direction control Check Valve Calculations of Hydraulic Rail Car Mover Design of Roller Bearing Justification of Assumptions

MODELLING USING PRO ENGINEER 4.1 Introduction 4.2 Hydraulic cylinder Model 4.3 Models of parts of Hydraulic Cylinder 4.4 Cross section of Hydraulic Cylinder

Chapter 5

Title ANALYSIS OF ARM USIGN PATRAN/NASTRAN 5.1 Introduction 5.2 Design of Arm 5.3 Results CONCLUSION AND FUTURE SCOPE REFERENCES

Page 28 28 29 31 32 33

6 7

LIST OF FIGURES

Figure
1.1 1.2 1.3 2.1 2.2 2.3 3.1 3.2 3.3 3.4 4.1 4.2 4.3 4.4 4.5 4.6 5.1 5.2 5.3 5.4 5.5

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

LIST OF TABLES

Table
1.1 3.1

Title
Symbols of Value stream map Cost of Hydraulic rail car mover

Page
2 23

NOMENCLATURE

D L dpr d l dp lp da la F P Q H g C Peq

Cylinder bore diameter, m Length of cylinder, m Piston rod diameter, m Piston inner tube diameter, m Length of piston rod, m Pass tube diameter, m Length of pass tube, m Axle dog cylinder bore diameter, m Length of Axle dog cylinder, m Force, kN Power, kW Flow rate, m3/sec Pressure head, m Acceleration due to gravity, m/s2 Dynamic capacity, kgf Equivalent load, N

Greek
oil Efficiency, % Density of oil, kg/m3

Subscripts
pr p a r a Piston rod Pass tube Axle dog Radial load Axial load

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, Central railway, Matunga. 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.

First of all I would like to thank Mr. A. R. TUPE (C.W.M.), Mr. M. K. KAREKAR (A.P.L.E. training officer) and Mr. C. SHETTY (C.I, B.T.C.) for giving me an opportunity to take training in this historic workshop.

I express my heartily gratitude to Mr. S. K. SAYYED ( Jr. Inst, B.T.C.), Mr. RANE (Sr. Inst, B.T.C. ) and Mr. P. PATIL (D.V.) for their unstinting support and suggestions which gave me direction to work.

Special thanks to Prof. ASHOK PATOLE (Internal guide), Dr. R. I. K. MOORTHY (Principal, PIIT) and Prof. SANDEEP JOSHI (HOD, Mechanical Dept.), Prof. M. D. NADAR (Project In-charge) for all their support and suggestions and invaluable guidance.

We would also like to thank all Railway workshop officials, shop superintendents and PIIT Professors, Staff members and faculty members of Mechanical Department for invaluable help at all the time.

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.

CHAPTER 1

INTRODUCTION

Indian Central Railway is the leading passenger carrying system. It carries more than 4 lacs passengers every day to each nook and corner of the country through Mail/Express /Passenger trains. Mumbai Suburban Train System is the life line of the Metropolitan City. More than 3 million passenger travel every day in 1573 suburban trains, moving across 77 stations.

The Carriage Workshop, Matunga covers a triangular piece of land/area of 35 hectares, including a covered area of about 11 hectares. There are 23 mechanical sections and 7 electrical sections. The electrical consumption is 6 lacs units/month.

Fig 1.1 Layout of carriage workshop Matunga

The workshop carries out Periodical Overhaul (POH) and heavy corrosion repairs of main line as well as EMU coaches. The target is to attend 269 coaches per month but actual average attended is 243 coaches per month.

Fig 1.2 Value Stream Mapping of workshop activities

Table 1.1 Symbols of value stream map SR No CATEGORY SYMBOL SUB CATEGORY Unavailability of equipment operator Unavailability of Tools, parts and workspace Unavailability of appropriate maintenance personnel

DELAY 1

DELAY 2

DELAY 3

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. 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. The disadvantages of overhead care are as follows.

Disadvantages of Overhead Crane

Instability Crane is unstable under unsecured load and if load capacity exceeded from crane load carrying capacity Communication - 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 - Contact with power lines, Overturns, Falls, Mechanical failures Risk - 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.

Fig 1.3 Photo of Rope puller

Disadvantages of Rope puller

Small Capacity

Used for short distance movement only Uncontrolled motion Difficulty in moving from one place to another Noisy operation

Need of Modification

Fig 1.4 Cause Effect Diagram

1.2 Aim and Objective of the Project

Aim
To Design the Hydraulic Rail Car Mover for better, efficient and safe work at railway workshop

Objective
By utilizing leading edge technology to effectively provide rail car moving solution at railway yard.

Using modern technology minimizing the potentials of risk and increasing the efficiency of railway workshop.

To learn and practice new things.

1.3 Report Layout

Chapter 2 includes literature review on hydraulics in general, rephasing hydraulic system. The design and analysis process of hydraulic system and recent trends and computer application in the field of hydraulics.

Chapter 3 provides the details of the operation of Hydraulic rail car mover and Calculations of Hydraulic rail car mover force, speed, pressure and power pack, calculations of the roller bearings. 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 5 presents the introduction to the CAE software Patran and Nastran. 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.

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction to Hydraulics

The machines which are used to move the rail car in workshop are diesel engine, overhead crane, Traverser, and rope puller. Even though these are not the most efficient or productive methods, this equipment has been the traditional solution. The procedure also requires using more than one person, regular maintenance, and is not as safe as more modern methods.

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. Hydraulics totally dominated certain types of equipment in their development.

Fig 2.1 Hydraulic power equipment trends

Hydraulic systems are widely used in the industry. The system components like pumps, valve, and cylinders are always became investigation topic in the history. Hydraulic cylinders are one of the most common component of the hydraulic system used in many engineering applications like; automatic manufacturing, heavy construction, control systems, sensitive measurements and test systems. They are used in producing linear motion in hydraulic systems and they convert hydraulic energy into mechanical energy.

2.2 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, equal, simultaneous, actuation of each cylinder in the system. As the volumes of each cylinder cannot economically, be identically matched, 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. This indexes all cylinders of the system to the same position, then upon retraction (extension) positive sealing is engaged and synchronized operation continues.

Rephasing cylinders combine the functions of flow dividing/combining components with that of actuators, saving space and weight. In addition, accuracy reportedly equals or exceeds that of more-costly methods. Other advantages include lower parasitic power losses, pressure intensification, and the ability to transfer power between actuators. The same principle of Rephasing cylinder is used in Collinear Cylinder assembly. But instead of external bypass tube inner pass tube through the piston is used to avoid external fluid lines. The Collinear cylinders are used in indexer type rail car mover by Calbrandt Inc., Delano.

2.3 Recent Trends in hydraulics

The technological trends are confirmation of the general consensus of industry. 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. It provides the basis for self-compensation that is self-adjusting, self-lubricating, and self-limiting type of an operation.

Contaminant monitoring is a large part of every maintenance. The techniques like portable contaminant monitors which can do analysis and measurement of particulate contamination have been brought out of clean room. The assessment of the degree of antiwear protection provided by hydraulic fluid has made good progress in the last years. Through the gamma rating for hydraulic fluids, it is now possible to not only select a fluid which will adequately protect system components, but also ascertain the degradation of that fluid and pin point fluid change periods.

The use of microcomputers for data acquisition has been overwhelming in most power fluid laboratories. The major function of the microcomputer tends to be nothing but a monitor for multiple sensors and data logger. The trend is in extending its use to do diagnosis and troubleshooting which are parts of real time condition control.

2.4 Design and Analysis Process

Fig 2.2 Hydraulic system design and analysis process

The generalized hydraulic Design and analysis process is illustrated in the above figure. From the design goals, 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. Once these tasks are completed the component sizing and selection process will enter. A hydraulic system is composed of interacting elements and components. Therefore once the element component models are developed, the system model becomes mathematical description of the way these elements and components interact. Components model analysis is done using computer Software.

The actual performance characteristics are evaluated through laboratory and field tests using the system prototype. Optimization is a function of process which is normally called as cut and try.

2.5 Computer Application in Hydraulics

In early days of computer modeling and simulation, the design engineer had not to only be intimately familiar with fluid power components and systems, but he needed to be a mathematical whiz and proficient computer programmer. But recent trend is to provide designers with powerful PC based software to aid in their design mission. They only need to know what software does and are not required to know how it does it.

Fig 2.3 Graph of modeling and simulation trends

Computational fluid dynamics, usually abbreviated as CFD, is a branch of fluid mechanics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows. Computers are used to perform the calculations required to simulate the interaction of liquids with surfaces defined by boundary conditions. The commercial used CFD solvers are Ansys fluent and CFX, CD-Adapco, Aerosoft Inc., etc.

ANSYS is engineering simulation software. Companies in a wide variety of industries use ANSYS software. ANSYS offers a comprehensive range of engineering simulation solution sets providing access to virtually any field of engineering simulation that a design process requires. ANSYS ICEM CFD used as Pre/Post processor for solving fluid system. It has tools for repair and to fix CAD complex geometries. It is first and foremost meshing tool, significant mesh editing add power to meshing options. It is oriented towards experienced users.

A sophisticated Knowledge base Electronic Catalogue software which is available allows the distributor to design a system, analyze the performance, select components, provide circuit and element drawings, issue quotations etc. all on a PC.

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. However, 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.

CHAPTER 3

HYDRUALIC RAIL CAR MOVER: DESIGN AND CALCULATIONS

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, 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. The rail car mover also requires less maintenance compared to using overhead cranes for positioning 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 stroke raises an axle dog from the floor to engage the axle of the rail car, and then the collinear cylinders extend to move the car. The axle dog then drops back below floor level, and the cylinders retract back to their home position.

Fig 3.1 Axle dog model

3.2 Operation of the System

Hydraulic rail car mover consists of five cylinders mounted end-to-end in a collinear arrangement. The first cylinder is stationary, from second cylinder, cylinders are mounted on rollers and when its rod extends, it pushes on the cap end of the second cylinder. Likewise, the rod of the second cylinder pushes on the cap end of the third cylinder, and so on. This means that, theoretically, the rod end of the second cylinder moves at twice the relative ground velocity as the first one. This is because the body of the second cylinder (which is mounted on rollers, as are the third, fourth, and fifth cylinders) moves at the speed of the first cylinders rod, and the rod of second cylinder extends at that same speed. Therefore, the rod end of the fifth cylinder moves at five times the ground velocity as the first one. In actuality, the stroke speed of any given cylinder varies. The piston acting against the least resistance will move. However, the net result is uniform motion from the cylinders sharing fluid routed in parallel.

Fig 3.2 Operational sequence schematic representation

Fig 3.4 Schematic of Cylinder

When the control valve handle is moved toward the extend cylinder position, hydraulic fluid under pressure is allowed to flow from the hydraulic pump to the piston side of the cylinder 1. 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. The extend fluid is restricted to pass through outer pass tube using directional control check valve. 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 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. 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. Hence retracting all the cylinders and pushing the oil on top of the cylinder 1 back to the reservoir.

3.3 Operation of Direction Control Check Valve

Spring loaded direction control check valves are used to guide the fluid inside the Hydraulic cylinder. The check valve senses the pressure and gets actuates and allows fluid to pass in one direction only. The Schematic diagram of check valve is given below.

Fig 3.5 Check valve diagram

In Hydraulic rail car mover at two position direction control check valves are used. One is inside piston inner tube entrance and another is at each pass tube entry. The valve inside piston rod gets actuate at the pressure 2167.688kN/ m2 and allows fluid to pass in forward direction. The valve at pass tube gets actuated at pressure 3545.91kN/m2 allows fluid to pass in retraction motion.

3.4 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

= 0.165m = 4.4m = 0.11m = 0.05m = 4.5m = 0.05m = 4.5m = 0.03m = 0.5m

Axle dog cylinder bore diameter (da) = 30mm = 500mm = /4 * D2

= /4 * 0.1652
= 0.02138 m2

Volume of one Cylinder

= area * length = 0.02138 * 4.4 = 0.09407 m3 = /4 * d2 * l = /4 * 0.052 * 4.5 = 0.008639 m3 = /4 * dp2 * lp = /4 * 0.052* 4.5 = 0.008639 m3 -------- C -------- B -------- A

Volume of Piston inner tube

Volume of Pass tube

Volume of axle dog cylinder

= /4 * 0.032 * 0.5 = 0.000353 m3 -------- D

Total Volume

= A * 5+ B * 5 + C * 4 + D * 2 = 0.5488 m3

Total volume in liters Time required Flow rate Pump required capacity

= 548.8 lit = 3 min = 4.5733 * 10-3 m3/sec = 182.93 lit/min = 72.43 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 = 0.122 m/s2

Assume motion is pure rolling motion and 15% extra load for design.

Force required to move the rail car

= mass * acceleration = (300 * 103 + 0.15 * 300 * 103)* 0.122 = 42090 N

Pressure required

= Force/ Area = 42090/0.01187 = 3545.91 KN/m2

Pressure head

= pressure/ density of water* 9.81 = (3545.91*103)/ (1000*9.81) = 361.45m

Selecting SAE 30 oil, density of oil is 830 kg/m3 Assume overall efficiency () = 82% Power required = (oil * g * H * Q)/ (1000 * ) = (830*9.81*361.45*4.5733*10-3)/ (1000*0.82) = 16.41kw

Select 18kw motor and 75gpm pump 75gpm = 0.004731m3/ sec Maximum operating pressure of pump = (P*1000* )/ (oil *g* Q) = (18*1000*0.82)/ (830*9.81*0.004731) = 383.16m of water = 3758.78kN/m2 = cross section area of cylinder area of piston inner tube = 0.02138 0.001963 = 0.019417m2

Pushing area

Pressure required in extension= (42090/0.019417) = 2167.688kN/ m2

Max Force in extension

= Pushing area * operating pressure = 0.019417 * 3758.78 = 72984.23N > 42090N = Hence OK = cross section area of cylinder area of piston rod = 0.02138 0.009503 = 0.01187m2

Pulling area

Pressure required in retraction= (42090/0.01187) = 3545.91kN/m2

Max force in retraction

= Pulling area * operating pressure = 0.01187 * 3758.78 = 44616.7N > 42090N

Hence Design is ok.

Weight of an axle dog

= 100 kg

Cross section area of dog cylinder

= /4 * da2 = /4 * 0.032 = 7.068 * 10-4 m2

Pressure required to operate axle dog = (100 * 9.81)/ (7.068 * 10-4) = 1387.94kN/m2

Velocity in forward direction

= flow rate/ pushing area = 0.004731/ 0.019417 = 0.2436 m/sec

Speed of rail car in forward direction = Velocity in forward direction * 4 = 0.974 m/sec

Theoretical time required to move the coach in forward direction is 21.44 sec

Velocity in retraction

= flow rate/ pulling area = 0.004731/ 0.01187 = 0.3985 m/sec

Speed of rail car in reverse direction = Velocity in retraction * 4 = 1.594 m/sec

Theoretical time required to move the coach in reverse direction is 35.06 sec

3.5 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. = 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, b P07 P10 L10 = constant for ball bearing = 1.34 from PSG data book = 0.93 = 0.90 = (ln(1/P07)/ ln(1/P10))1/b

= 253.59 mr

Calculation of approximate equivalent load Using excess radial load factor Peq Where, V X S Kr Kt = 1 for outer race bearing = 1 radial load factor = 1.1 service factor = 1.3 excess radial load factor = 1.06 temperature factor for operating temp 130 degree = (V*X* Fr *S*Kt)* Kr

Peq

= (1*1*1.1*1.3*1.06*1750) = 2652.65 N

Calculation of Dynamic capacity Using load life relationship C Where, K C = 3, constant ref PSG data book = (253.59)1/3 * 2652.65 = 16788.93 N = 1711.41 kgf = (L10)1/k * Peq

Ref PSG design data book Select SKF 6011 deep groove ball bearing with dynamic capacity 2200 kgf.

3.6 Justification of assumptions

Alloy Steel is used as cylinder material because of its high strength and corrosion resistance properties. Ease of Manufacturing is also criteria for selection of material. 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. There are no external fluid lines in the system except main line from source to the first fixed cylinder.

Operability of the system is very easy. It does not require any special training for using the machine. It requires only one person and the person operating the rail car mover can take safe position and monitor the operation. 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.

The use of PLC circuits permits remote control operation. Operator can keep eye on operating pressure indicated on pressure dial. The initial cost of the hydraulic rail car mover is

Table 3.1 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. The power requires for hydraulic rail car mover is 18kw but power consumption of the overhead crane is 25kw. Hence the operating cost of hydraulic rail car mover is less than overhead crane for same number of working hours. The numbers of parts which require maintenance are less hence the maintenance cost is also less than the overhead cranes.

CHAPTER 4

MODELLING USING PRO ENGINEER

4.1 Introduction to Pro/E

Pro/ENGINEER is a feature based, parametric solid modeling program. As such, its use is significantly different from conventional drafting programs. In conventional drafting (either manual or computer assisted), various views of a part are created in an attempt to describe the geometry. Each view incorporates aspects of various features (surfaces, cuts, radii, holes, protrusions) but the features are not individually defined. In feature based modeling, each feature is individually described then integrated into the part. The other significant aspect of conventional drafting is that the part geometry is defined by the drawing.

If it is desired to change the size, shape, or location of a feature, the physical lines on the drawing must be changed (in each affected view) then associated dimensions are updated. When using parametric modeling, the features are driven by the dimensions (parameters). To modify the diameter of a hole, the hole diameter parameter value is changed. This automatically modifies the feature wherever it occurs - drawing views, assemblies, etc. Another unique attribute of Pro/ENGINEER is that it is a solid modeling program. The design procedure is to create a model, view it, assemble parts as required, then generate any drawings which are required.

The assembly model of Hydraulic Cylinder is created in ProE by using different parts of cylinder created in ProE. These ProE models can be used for doing analysis using Ansys software with ICEM CFD solver. The analysis will give the pressure in the cylinders, speed of the system, operating temperature, and cylinder can be tested for buckling etc.

4.2 Hydraulic Cylinder Model

Fig 4.1 Hydraulic cylinder Assembly model

4.3 Models of Parts of Hydraulic Cylinder

Fig 4.2 Model of Front end and Back end

Fig 4.3 Model of Piston and piston rod

Fig 4.4 Model of Piston rod end

4.4 Cross sections of Hydraulic Cylinder model

Fig 4.5 Cross section of Front part of cylinder

Fig 4.6 Cross section of Rear part of cylinder

CHAPTER 5

ANALYSIS OF ARM USING PATRAN/NASTRAN

5.1 Introduction
Patran is the world's most widely used pre/post-processing software for Finite Element Analysis (FEA), providing solid modeling meshing facility which facilitates the placement
of loads and restraints,

analysis setup and post-processing for multiple solvers including

MSC Nastran, Marc, Abaqus, LS-DYNA, ANSYS, and Pam-Crash.

Fig 5.1 Steps in analysis

MSC Nastran is the world's most widely used Finite Element Analysis (FEA) solver. When it comes to solving for stress/strain behavior, dynamic and vibration response and thermal gradients in real-world systems, MSC Nastran is recognized as the most trusted multidiscipline solver in the world. The model of the axle dog arm is created using the ProE software. Then it is imported to the Patran for finite element analysis where it is meshed using meshing tools. The load and constraints are applied. Later processing is done using Nastran solver. The results of Nastran are access in Patran.

5.2 Design of Axle Dog Arm

The Axle length of the rail car is 1524mm. 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. So the arm is design in U shape. And the other end of the arm is hinged to the platform so it can rotate about the pin. There are two arm positioned opposite to each other in the system. These arms hold the axle shafts of trolley. While one arm is pushing the rail car the other arm is used for controlling the motion of the rail car. They are operated by different hydraulic cylinders. The pressure required to operate the hydraulic arm is 1387.94kN/m2. The maximum stress in the arm is 1.42 * 103 N/mm2 calculated using Nastran.

Fig 5.2 Model of axle dog

Fig 5.3 Meshing and load applied using Patran

5.3 Results of Nastran

Fig 5.4 Result constraint forces

Fig 5.5 Result Stress and Displacement

CHAPTER 6

CONCLUSION AND FUTURE SCOPE

Indian railway workshop is most busy place for 365 days and still workload is increasing continuously. The demand for frequent and faster railway service is increasing. Therefore there is need for modern better, safe techniques to replace conventional methods which are also creating more pollution.

The Hydraulic rail car mover is better option to use for movement of the rail cars under workshop. Hydraulic rail car mover will save the time required in workshop by eliminating interference of shunting department in the movement of the rail car. It doesnt require skill person to operate the machine. And the cost of installation and maintenance is also less compared to overhead carne.

It is more safe and convenient for the peoples working in workshop than threat of overhanging load. Hence Hydraulic rail car mover system is better.

Further this systems performance can be analyze using computer engineering Software like Ansys ICEM CFD. Check the reliability of the Hydraulic rail car mover using the computer testing Software. By changing the parameters like pressure, power, dimensions systems performance can be optimize. And by making prototype of the system more performance parameters could be understand.

CHAPTER 7

REFERENCES

JOURNAL
Dr E. C. Fitch, Dr Richard K. Tessmann, Dr Ing T. Hong (1999), Fluid Power Goals and Trends, FES Technology publication Paul Johnson (2011), Aggressive hydraulic machinery, Magazine Hydraulics and Pneumatics July 2011, page no. 26-30

BOOK
R. S. Khurmi , Fluid Mechanics and Hydraulic Machines, S Chand publications V. B. Bhandari , Design of Machine Elements, Fourth edition, McGraw Hill publications R. S. Khurmi, J. K. Gupta, Machine Design, S Chand publications Design Data Book of Engineers, PSG college of Technology

WEB
http://www.aggressivehydraulics.com/products/cylinder-component-parts/ http://www.calbrandt.com/products/axle-type-railcar-mover#1 http://www.ehow.com/about_5403188_parts-hydraulic-cylinder.html http://en.wikipedia.org/wiki/patran_nastran http://www.bardyne.com/Publications/Literature.htm#11