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BRAKE SYSTEM DESIGN OPTIMIZATION Volume II: Supplemental Data

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PB81-21470Z REPORT NO. FRA/ORD-78/20. II BRAKE SYSTEM DESIGN OPTIMIZATION Volume II: Supplemental Data L.L. Eshelman C.C. Shelleman J.P. Henderson A.T. Kearney. Inc. 100 South Wacker Drive Chicago IL 60606 APRIL 1981 FINAL REPORT DOCUMENT IS AVAILABLE TO THE PUBLIC THROUGH THE NATIONAL TECHNICAL INFORMATION SERVICE, SPRINGFIELD, VIRGINIA 22161 Prepared for U.S. DEPARTMENT OF TRANSPORTATION FEDERAL RAILROAD ADMINISTRATION Office of Research and Development Washington DC 20590 REPRODUCED BY NATIONAL TECHNICAL INFORMATION SERVICE u.s. DEPARTMENT OF COMMERCE SPRINGFIELD, VA 22161 NOTICE This document is disseminated under the sponsorship of the U.S. Departmentsof Defense and Transportation in the interest of information exchange. The U.S. Government assumes no liability for its contents or use thereof. NOTICE The U.S. Government does not endorse products or manufacturers. Trade or manufacturers' names appear herein solely because they are considered essential to the objectives of this repprt. Technical Report Documentatian Page 1. Report No. 2. Go"ern",en' Acce"ion No. 3. Recipient', Cololo, No. PB81 70 ~ FRA/ORD-78/20,II 214 4. Titl. and S.. btitl. S. Repor, Dote April 1981 BRAKE SYSTEM DESIGN OPTIMIZATION Volume II: Supplemental Data 6. P.r'orlllin, Or,onilohon Code h;--~:--:-:--------------------------""i8. P.r'ormin, O"onilotion Report No. 7. A..tltor/,lL. L. Eshelman, C. C. Shelleman, DOT-TSC-FRA-78-l,II J.P. Henderson 9. P.r'or"'in, O',oni lotion No",e ond Addr.u 10. Work Unit No. CTRAIS) A.T. Kearney, Inc.* RR128/R1309 100 South Wacker Drive 11. Contract or Gront No. Chicago IL 60606 DOT-TSC-l040 -2 12. Spon,orin, A,ency Na",e and Addr.u U.S. Department of Transportation Final Report Federal Railroad Administration April 1977 to March 197E Office of Research and Development 14. Spon,o,in, A,.ncy Cod. Washington DC 20490 15. S..pple",.ntory Not.' U.S. Department of Transportation Research and Special Programs Administration *Under contract to: Transportation Sy.stems Center Cambridge MA 02142 16. Ab,troct This report presents supplemental data which support Volume I, A Survey and Assessment, DOT-TSC-FRA-78-1,I,FRA/ORD-78/20,I, dated June 1978, 140 pages. A detailed description of the functional performance of each freight car air brake system component is provided. This is followed by a discussion of the operation, performance, and design of air brake systems. The results of a survey made to estimate the population of brake system components in service, and present operating problems with these components is presented. In addition, the problems which require immediate solutions from the perspective of the railroad industry are tabulated. A summary of recent research work performed to investigate ~reight car wheel thermal capacity is presented. 17. Key Word, 18. Di,tribution Stotelllont Rail freight braking systems DOCUMENT IS AVAILABLE TO THE PUBLIC THROUGH THE NATIONAL TECHNICAL Rail freight equipment technology INFORMATION SERVICE, SPRINGFIELD, Thermal capacity VIRGINIA 22161 .. 19. Security Clouil. (of this report) 20. S.curity Clouil. Co, thi I po,e) 21. No. of PotU 22. Price Unclassified Unclassified 156 Form DOT F 1700.7 C8-72) Reproduetio" of completed pOlle authorized PREFACE The work described in this report was carried out under the direction of the Transportation Systems Center of the u.S. De­ partment of Transportation in the context of an overall project of the Federal Railroad Administration (FRA) to provide a technical basis for the improvement of rail transportation service, effi­ ciency, productivity and safety. The work was sponsored by the FRA Office of Research and Development, Office of Freight Systems. This final report is organized into two volumes. Volume I describes the work performed and presents the results of the study and is a complete report. Volume II contains supporting materials developed in the course of the study which add substantially to the information base but are not essential to the object of the study. Kearney gratefully acknowledges the cooperation of the many railroads, rapid transit companies, manufacturers, research and development organizations, AAR Brake Equipment Committee members and staff, and other interested parties who provided the informa­ tion required to conduct a professional, objective study. We would also like to thank DOT personnel in the Transportation Systems Center and the Federal Railroad Administration for their cooperation and assistance throughout the course of -the study. - iii - ,. I.. !, .. 'i •• I .. -I Iii ..! i .J! o ;.....J pP w~ -I . : ~ Hil ill _hi11 1- • .o 'S .. o .. :: ~ •_ .. ! .. z ... c .. ~ ~... 1- • != :; ... "': ... ~ til! 1 I .. ~ ;~!U ... _1:1 ~ !:::: • 0_0 .... .... ..: o O,..j~O="'; : "i c .. :c SI '!· ~ ..c =- ...II: . a. •» • • ... •~ u• • : • j i I i· .. ! 0; : r r ~d ~ ~iiiH ­ ·.. i .:: .:. .= u u u. ~ j .. 1 i .......& ... .. .~- II: C ~ u c 01 ... cz n J" 1 51 II ,. ,. " tl CI IC\ II 0\ , .' , , • t C C '.0 z c iii II: 1I1111H11I1I11II 1111111111111111111111111111111111111 lIulllll 111111111111111111 111111111 1111111I 1111111I1111111111 1I1111111111l11U1 1I111H11 111I11111 111111111 111111111 1I11111u 1I11~IIIII1JuIlIlIlIIlIl ...> z 1 1 Cl 1 u '1'1'1'1"'1'1' '1'1'1'1"'1'" 'IT'T''I'I' '1'1'1'1"'1'1' '1'1'1'1"'1'1' ' '1'1'1"'1'1' '1'1'1'1'1'1'1' 11'.1'1'1"'1'1 11'1'1'1'1 11 '1 u a: t ~... =& .. 1.. ... - .. ~ L ..:: .... ...01- •.~ •; z .. ~ ...c : ~-::: • II: '~ ...•'" C ~ i u.. .. I i ';:;i .. .. I .. ~ )i c.. ,. - iv - TABLE OF CONTENTS Section 1. Introduction 1 2. Functional Performance of Brake 2 System Components and Subsystems 2.1 Brake Air Hose and Couplings 3 2.2 Angle Cock 6 2.3 Brake Pipes and Fittings 7 2.4 Brake Valves 15 2.5 Air Reservoir 22 2.6 Brake Cylinder 24 2.7 Brake Cylinder Release Valve 25 2.8 Retaining Valve 27 2.9 Brake Rigging 28 2.10 Hand Brakes 36 2.11 Slack Adjuster 38 2.12 Brake Shoes 41 3. Operations, Performance, and Design 50 of Freight Car Air Brake Systems 3.1 Introduction 50 3.2 Operations 50 3.3 Performance 63 - v - TABLE OF CONTENTS (Cont'd.) Section 3.4 Problems 72 4. Railroad and Private Car Owner Survey 80 4.1 Introduction 80 4.2 Data Requested in Railroad Survey 80 4.3 Data Requested from Private Car 81 Owners 4.4 Results of Survey 81 5. Thermal Capacity of Freight Car 101 Wheels 5.1 Introduction 101 5.2 Parameters to Consider 101 5.3 Summary 120 APPENDIX A Glossary of Terms 124 APPENDIX B References and Bibliography 134 - vi LIST OF FIGURES Figure 2-1 Arrangement of Brake System Components 3 on a Typical Freight Car 2-2 Air Hose and Air Hose 4 Coupling 2-3 Typical Angle Cock and Air Hose Location 7 for Cars with More than 5'6" Overhang 2-4 Piping Arrangement on a Typical Freight 8 Car 2-5 Brake Pipe Fittings 11 2-6 Approximate Brake Pipe Gradient versus 13 Temperature for "Typical" lOO-Car Train 2-7 Approximate Brake Pipe Leakage versus 14 Temperature for "Typical" lOO-Car Train 2-8 AB Brake Control Valve with QRB Brake 16 Cylinder Release Valve Exterior View 2-9 Air Brake Control Valve Exterior View 17 2-10 A-I Reduction Relay Valve 18 2-11 ABDW Brake Control Valve 19 2-12 Performance Comparison Between 19 ABD and ABDW Brake Valves 2-13 ZIA Brake Control 20 Valve 2-14 Functional Performance of the ZIA Brake 21 Control valve During Full Service Application and Release - vii· LIST OF FIGURES (Cont'd.) Figure 2-15 Air Reservoir 22 2-16 Sketch of AB-1 Type of Brake Cylinder Used 24 with Conventional Brake Rigging 2-17 Brake Cylinder Bushing Kit 25 2-18 Brake Cylinder Release Valve as 26 Integral Part of ABD Brake Valve 2-19 Four-Position and Three-Position 28 Retaining Valves 2-20 Four Configurations of Conventional 30 Brake Rigging 2-21 Brake Rigging Badge Plate 31 2-22 Truck Turning Moment 33 and Lateral Forces Produced by Two Configurations of Conventional Brake Rigging 2-23 Typical Truck-Mounted Brake Rigging 34 (One Truck Shown) 2-24 Force Distribution of Truck-Mounted 35 (Direct-Acting) Brake Rigging 2-25 vertical Wheel Hand Brake Assembly 37 2-26 Automatic Slack Adjuster Operation 39 2-27 Typical AAR Applications of Automatic 40 Slack Adjusters 2-28 AAR Reinforced Metal Brake Shoes 42 2-29 High Friction Composition Type Brake 44 Shoe -viii- LIST OF FIGURES (Cont'd.) Figure 2-30 Two Types of Brake Shoe 48 Keys 3-1 Typical Arrangement of Freight Car Brake 51 System Components 3-2 Typical Air Brake Piping Arrangement 52 3-3 ABDW Control Valve with 54 Integrated Continuous Quick Service 3-4 Three Types of Brake Rigging Arrangements 55 3-5 Brake Rigging Force Diagrams (Bottom View) 57 3-6 Brake Pipe Pressure Propagation Time versus 67 Train Length 3-7 Brake Pipe Reduction and Brake Cylinder 68 Buildup Propagation Time (6 psi B.P. Reduction) 3-8 Comparison of ABD and ABDW Full Service 70 Reduction Application Times 3-9 Time to Start Brake Release from 7 or 25 72 psi Reductions 3-10 Train Brake System Charging Time versus 74 Train Length 3-11 Leakage Location Effects on Train Brake 75 Pipe Pressure 3-12 Approximate Maximum Train Length (in Cars) 76 versus Ambient Temperature 3-13 Symbolic Representation of Train Being 78 Operated over Undulating Terrain - ix- LIST OF FIGURES (Cont'd.) Figure Page 5-1 Wheel Stresses Expressed in Terms of 103 Saw Cut Openings After Exposure to Various Car Brake Levels 5-2 Maximum Wheel Tread Temperature versus 105 Wheel Diameter After 60 Minutes at Constant Brake Horsepower 5-3 Coordinate System, Load Application and 107 Reference Planes to Analyze Wheel Stresses 5-4 Straight Plate Wheel Thermal Loading 108 5-5 Curved Plate Wheel Thermal Loading 108 5-6
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