Mechanical Design Wing
1.0 Design wing setup:
MCF Mechanical Design Wing has been setup with advance design capabilities;.
3 Verticals in Design wing i.e. Shell design, Bogie design and Interior design and equipped with 26 Nos. Workstations with NX 11.0 & PLM software, Walkthrough, FEA & Ergonomic analysis, Electrical cabling , Train/Coach Dynamic simulation(SIMPACK software) etc. CAD software is used for design of all coaches and its components with all the relevant EN / ISO specification available with MCF design wing
2.0 Setting up of Centre of excellence in Design:
Virtual Reality-Setup, IETM (Interactive engineering technical manual), Digitization of drawings of other LHB variants (3D parametric model)
3.0 Developments and Achievements :
3.1 Humsafar Express coaches
Humsafar rakes is being turned out with improved features like-
• Improved aesthetics: Exterior colour scheme presenting futuristic look with vinyl sheets with anti graffiti feature.
• Improved aesthetics: Interior colour scheme with Gel coated granular FRP moulded panel in side wall and roof with anti graffiti feature.
• Improved aesthetics: Gel coated FRP lavatory modules with anti graffiti feature.
• GPS based passenger information display system: LED panels above both compartment doors.
• Passenger announcement system
• Fire and Smoke detection and suppression system.
• CCTV System with display monitor
• Integrated Braille display
• Increased Mobile charging points; USB /charging points for each berth
• Fire retardant curtains on windows & aisle. Improved Curtain pattern
• Automatic vending machine
• Cleanable Vinyl flooring
• Better upper berth climbing arrangement
• Lower side berth with comfortable single piece sliding top
• Improved toilets : Two level floor, Urinal, Baby nappy changing seat, Touch less fittings
• Automatic odour control dispensers
• Reading light for every berth
• Dustbin in every cabin.
3.2 Antyodaya coaches
2 rakes of Antyodaya coaches has been turned out (1st rake in April, 2017) with improved features like-
· Cushioned luggage racks which can serve as seat during rush.
· Additional hand hold in doorway area.
· Vestibuled ends for inter coach movement.
· Water Purifier- Potable water similar to Aqua guard type water filtration system.
· Bio-toilets. Modular toilet: FRP lavatory module, Gel coated Anti graffiti coating
· Enhanced number of Mobile charging points.
· Fire extinguishers with anti-theft arrangement.
· More pleasing colour scheme for interior and exteriors with anti-graffiti measures.
· Sidewall & Roof panels : FRP Gel coated Anti graffiti
· Honey comb sandwiched pre-panelled partition frame with FRP sheets on both sides with steel inserts, Gel coated, anti-graffiti.
· Bolted Pillar assembly like LWACCN coaches
· J-hooks near longitudinal luggage racks.
3.3 Deendayalu coaches
Deendayalu (LHB GS) coaches developed using GFRE & DGFRP panels instead of NFTC & LP sheets respectively. Other improved features of Antyodaya coaches are provided in these coaches.
3.4 AC 2Tier in AC 3Tier shell:
Design developed for LHB AC-2T coach using of LHB AC-3T Roof profile. These developments resulting 260mm more headroom for upper berths. First coach turned out in March, 2018 to Firozpur division, Northern Railway.
3.5 SMART coach
First smart coach of Indian railways [NCR -18155/C (LWACCN)] manufactured at MCF furnished with Passenger Information Coach Computing Unit (PICCU) with various amenities like PAPIS, CCTV surveillance, OBCMS (Onboard coach monitoring system ,Water level indicator, Control of HVAC parameters and digital destination board ,Wi-Fi & Infotainment ,automatic fire detection and alarm system has been turned out on June,2018. It has started giving its preliminary report and going to eliminate on line failure and will facilitate preventive to predictive maintenance and thus will result into saving in terms of reduced maintenance and less down time and thus proposed for regular adoption. With the introduction of diagnostic system and also regular fitment of fire detection and alarm system, it is possible by Indian Railways to adopt superior technology such as articulated bogie and tilting coach technology which will facilitate reduced forces and stresses on fixed infrastructure (track and bridges) and will improve comfort and reduce the journey time on existing infrastructure. In fact, this will be the least expensive option for the existing infrastructure.
Second Smart coach NR 182737 (LWACCN) has been flagged off by Hon’ble Prime Minister on 16 Dec’18.
SMART Power car:
First of its kind power car has been rolled out by MCF which has been developed with M/s Kirloskar in Nov’18.
3.6 Review of design tolerances
In order to improve accuracy and quality of product tolerances are reduced from ±14 mm to ±2 mm in Body shell, Under frame, sidewall & roof
3.7 PU based Wet on Wet application on exterior painting
In wet on wet painting system after application of surfacer wet on wet top coat applied. In this process; No primer application, reduced painting cycle time and 6 years warranty for gloss and colour retention. It results in improvement in painting system to achieve high production. The painting will be done as per specification no. MMDTS 18034 Rev-04 and complete cycle time for painting of coaches is about 30 Hrs.
3.8 LHB DSLR Coach
Modern Coach Factory (MCF) has rolled out its first LHB DSLR Coach on 11.01.2019.
This coach has under slung a 500 KVA Diesel Generator Set releasing space on board accommodating passengers and luggage. The coach has seating arrangement of 6 differently abled with a specially design lavatory keeping in mind the special requirement of these persons.
Besides this, the coach will accommodate 30 general passengers in a separate area with a dedicated lavatory.
The coach has also a luggage area with 4 ton capacity.
3.9 Projects in pipeline
3.9.1 Manufacture of DPRS (Distributed power Rolling stock) & Metro coaches:
Propulsion System for DPRS
It has been decided to procure propulsion system for DPRS ( with complete Knowhow) through store tender.
Scope covers “Design, Development, Manufacture ,Supply, Integration, Testing and Commissioning of complete propulsion system and other subsystems including electrics for BG AC DPRS (Operational speed 160 KMPH)”
Manufacturing of Metro Coaches at MCF
Kolkata SG Metro: 7x6= 42 coaches
3.9.2 Aluminium Body coaches
MCF is interested to manufacture Aluminium body coaches and a DPR for manufacture of 500 Aluminium body coaches per annum at MCF/RBL.was sent to Railway Board for sanction of additional infrastructure & TOT required for Aluminium car body fabrication at MCF. Railway Board has added the work “TOT for Design, Development. Manufacturing and testing of Aluminium Body passenger coaches” under umbrella work “Up gradation of critical work centre of workshops of Indian Railways”. Further process in this regard is in progress at MCF.
Aluminum has high strength to weight ratio, high resilience and inherent corrosion, reduce the energy consumption. Aluminium is one of the materials for light weight passenger coaches which has high potential to substitute steel used conventionally in passenger coaches.
Other advantages in Rail car body manufacture are low haulage cost resulting higher payload, better fuel efficiency & lower pollution level, reduced Axle load to increase speed of train, less wear and tear on the fixed infrastructure (i.e. Rails and fittings etc), less maintenance cost, Ease of manufacturing, easier to machine than the steel improving tool life, Modular interiors, Possibility of easily removing the components during the maintenance and retro fitment in future.
3.9.3 Modular seat and berths
To over-come the time consuming activity of replacement of Seats and Berths in a coach in service which requires it to be dismounted from the coach for replacing the cushion and stripping of upholstery Modular design concept of Seats and Berths has been developed. In this design complete set of Seats and Berths arrangement can be replaced without dismounting it from the coach. The integral and Modular Seats consisting of Upholstery & Cushion gets replaced without removing the Berth-frames from the coach.
3.9.4 Manufacturing of High Speed Bullet Train:
National High Speed Rail Corporation Limited (NHSRCL) has planned 18 rakes of High speed trains from Japan and remaining 6 rakes will be manufactured/assembled at MCF. The speed of these trains will be 300 + KMPH with most modern features in safety and comfort. MCF has proposed NHSRCL to get remaining 6 rakes manufactured/assembled at MCF as the part of Make in India and ToT (Transfer of Technology).
3.9.5 World class interiors
As per directive of Railway Board to utilize global expertise in the field of interior furnishing, materials/manufacturing technologies for developing State of the Art World Class Interiors for various LHB coaches manufactured by Indian Railways. Accordingly EOI/Technical Bid was published and 4 firms are working on this project. After evaluation of furnished prototype coaches , approval of interiors to be done, revised technical specification shall be drawn for inviting technical & financial bids of Supply & Apply tender (Stage-II) to award the contract for interior furnishing. This supply and apply furnishing turnkey work covers complete interior furnishing of 1000 LHB design newly manufactured coaches .
3.10 Export coaches:
· Mozambique Railways
MCF is interested to manufacture 90 nos. Cape gauge (1067 mm) Railway coaches (Six variants) for Mozambique Railways. Accordingly MCF has sent the Techno commercial offer for the same to M/s RITES in Jan’19.
Further Representatives of Mozambique Railway Mr. M.J.Matabel, Chairman/CFM Board along with its other members visited MCF on 06.03.2019 and inspected the capabilities and facilities at MCF. During inspection the officials of Mozambique Railways were briefed regarding various production activities going on, coach quality and various standards being followed in MCF.
The confirm order for supply of 90 passenger coaches to Mozambique Railways has been received from RITES on 29.05.2020.
· Sri Lanka Railways
MCF has planned for revenue generation through export of passenger coaches. MCF has adequate infrastructure for making coaches not only for Indian Railways but also for Non-Railway customers. Techno commercial offer for development of 100 Nos. Short length Broad gauge coaches on LHB platform with coach length of 15.8 metre has been sent to M/s RITES in Oct’18, as such hardly any new Jigs and fixtures may be required, minor modification/provisions in existing equipments may serve the purpose.
· Etihad Rail
Delegates of Etihad Rail (UAE) visited MCF on 13.12.2018 to assess the capability of MCF/RBL to manufacture passenger coaches for Etihad Rail.