Wagon repair workshop Jhansi, North Central Railway (NCR) has invented an open freight wagon having a detachable upper body that can be separated from and re-assembled on to the under frame through a specially designed locking and guiding arrangement.
The invention enables the side walls, end walls and floor structure (upper body) to be detached from the wagon under frame whenever major body repairs are required. The under frame can immediately be fitted with another serviceable upper body, thereby considerably reducing wagon detention time.
The invention is particularly useful in wagon repair workshops, accident restoration sites, freight terminals and maintenance depots where faster restoration and increased wagon availability are of utmost importance. The total potential annual savings through this detachable wagon concept is –Rs 184.7 crore. Jhansi Division has sent the detachable wagon invention to RDSO for approval.
Existing Technology
At present, Indian Railways freight wagons are manufactured with the wagon body permanently welded to the under frame. Whenever major body repairs such as replacement of side panels, floor plates, end walls, stanchions or structural members become necessary, the complete wagon must be withdrawn from service and sent to a workshop.
Although the under frame often remains structurally sound, it cannot be utilized independently because the body is inseparable. Similarly, during accidents, damaged wagons block railway lines until the complete wagon is removed by cranes or restoration equipment, thereby increasing traffic disruption.
The average repair cycle of freight wagons undergoing heavy body repairs is approximately six days, resulting in reduced wagon availability and loss of freight earning capacity.
Drawbacks / Problems /Challenges in Existing Technology
The existing wagon design suffers from several limitations:
• Permanent attachment of wagon body to under frame.
• Entire wagon becomes unserviceable even when only the body is damaged.
• Long repair cycle of approximately six days.
• High workshop occupancy.
• Increased manpower requirement.
• Reduced freight wagon availability.
• Delayed restoration during railway accidents.
Accordingly, there exists a need for a wagon structure that allows the damaged body to be replaced independently while retaining the serviceable under frame in operation.
Invention done by the workshop:
The proposed invention provides an Open Freight Wagon having a completely detachable upper body.
The detachable body comprises:
• Sidewalls
• End walls
• Floor assembly
The body is mounted on the under frame through six specially designed locking mechanisms,three on each side. To ensure proper positioning during installation, guiding posts are provided at both ends of the wagon.
Whenever the wagon body requires extensive repair, the locking system is released and the complete upper body is lifted using cranes. A repaired or spare upper body is then lowered over the existing under frame, guided accurately by the guide posts, and secured through the locking arrangement. Thus the under frame immediately returns to service without waiting for body repairs.
Details of the invention
The invention provides a modularfreightwagonconstructioninwhichtheupperbodyisdetachablefrom the under frame. Instead of repairing the complete wagon, only the damaged body is removed and replaced by another ready upper body.
The invention significantly reduces repair time, increases wagon availability, minimizes workshop congestion and greatly improves accident restoration. The system is entirely mechanical and can be manufactured using conventional fabrication techniques.
Working Principle
Normal Operation
The detachable body remains securely locked to the under frame through six locking assemblies. Both locking systems function together to behave as a conventional wagon body.
During Repair
When heavy body repair becomes necessary:
• Locking mechanisms are released.
• Upper body is lifted using overhead crane.
• Under frame becomes immediately available.
• Spare upper body is lowered.
• Guide posts ensure alignment.
• Locking systems are engaged.
• Wagon is returned to service.
Accident Restoration
In case of accident:
Only the damaged upper body is removed.
The under frame may be re-used after inspection.
This considerably reduces restoration time and line blockage.
Advantages
The proposed invention offers the following advantages:
• Completely detachable wagon body.
• Modular wagon construction.
• Reduced repair cycle from 6 days to approximately 3 days.
• Increased wagon availability..
• Faster body replacement.
• Simplified maintenance.
• Improved accident restoration.
• Increased freight throughput.
• Significant reduction in revenue loss.
• Improved fleet utilization.
• Improved operational efficiency.
• Lower life cycle maintenance cost.
Industrial Applicability
The invention can be implemented in all Open wagons in Indian Railways.
Tentative savings in revenue:
•It is estimated that one wagon produces revenue of around Rs 12600 per day while in service.
•At present, approximately 680 wagons are marked sick per day, all over Indian Railways due to want of routine maintenance, which are taken into workshops for repair.
•Out of these 680 wagons, around 255 are those which require maintenance of the body part only
•By introducing the concept of detachable wagons, there will no need of taking entire wagon for maintenance, only the upper part will be taken for maintenance and the underframe will be utilized with a fit upper body immediately. This will lead to prevention of daily revenue loss on account of unloadable open wagon.
•Since the maintenance time will also be reduced from existing 6 days to 3 days or even lesser, more financial gain will accrue on account of reduced cycle time.
•Financial analysis indicates a potential annual earnings improvement of approximately ₹106.99 crore through reduced repair detention, while the detachable design also has the potential to reduce embedded wagon revenue losses by approximately ₹77.748 crore annually.
