i

Bogie Differential Design Proposal

J.A. Kruger

March 2014

ii

Abstract

The purpose of this report is to describe a proposed bogie design which utilises differentials in order
to be able to negotiate turns and bends on the railway more efficiently. Conventional bogies make
use of a method where the front and rear wheels are connected, when the front wheels start
turning in the bend it forces the rear wheels to turn as well making it easier to negotiate bends and
reduces wear on the wheels and rails. The proposed differential design would allow bogies to
negotiate tighter bends and reduce wear on the wheels and rails as well as reducing the risk of
derailing in bends. This type of system may cause additional wheel slip in bends and carry a greater
risk of failure due to the added number of moving components, these factors should be investigated
further before a final conclusion can be made as to the feasibility of such a system.


iii

Table of Contents
1. Introduction .................................................................................................................................... 1
1.1. Objective ................................................................................................................................. 1
1.2. Scope ....................................................................................................................................... 1
1.3. Background ............................................................................................................................. 1
1.3.1. Bogies .............................................................................................................................. 1
1.3.2. Steering ........................................................................................................................... 2
1.3.3. Differentials ..................................................................................................................... 3
2. Design Concept ............................................................................................................................... 4
3. Discussion ........................................................................................................................................ 5
4. Conclusions & Recommendations .................................................................................................. 5




iv

Table of Figures

Figure 1 3D Drawing of a Bogie in the Bo-Bo Configuration ................................................................... 2
Figure 2 Bogie Steering System ............................................................................................................... 3
Figure 3 Differential Commonly Found in Cars ....................................................................................... 3
Figure 4 Conventional Bogie Drive Train Layout ..................................................................................... 4
Figure 5 Proposed Design Concept ......................................................................................................... 4


1. Introduction

1.1. Objective

Currently the wheels of the bogie is driven directly from the traction motor using only a spur gear
reduction gearbox and steering is only done on the Bo-Bo configuration (two axles per bogie) using a
forced articulation system.
The objective of this project is to briefly investigate the possibility of using differentials on the axles
of the bogie in order to allow the wheels on the inside and outside rails in a bend to rotate at
different speeds thereby increasing stability and decreasing wear on the wheels and rails. A design
concept is also to be generated and briefly described.
Conclusions and recommendations will then be made regarding the feasibility of this system and
areas for further investigation will be identified.

1.2. Scope

The project includes a brief investigation into current methods and practices with regards to the
drive train of a bogie. A concept for the use of differentials on bogies will be included.
The project will not include any design or research on driving methods for bogies, or any other part
of the bogie apart from the drive train.

1.3. Background

1.3.1. Bogies

A bogie is a sub assembly used in rolling stock to which the wheels and motors are mounted. It is
essentially the chassis a locomotive, coach or wagon and come in many different configurations.
Coaches and wagons generally have two bogies where locomotives can have three or even four in
some cases. Bogies almost always contain a suspension, the type of suspension varies depending on
the purpose of the bogie (Loco, wagon, coach etc.). Bogies are attached to the loco or wagon by a
centre pin allowing the bogie to rotate independently.
2


Figure 1 3D Drawing of a Bogie in the Bo-Bo Configuration
Bogies have more than one axle depending on its use, usually 2 to 3 axles. Locomotive bogies
generally have three axles and wagon bogies two axles. Bogies with two axles (as shown above) are
known as the Bo-Bo configuration and bogies with 3 axles are known as the Co-Co configuration.
The wheels of a bogie are driven by means of a spur reduction gearbox and a traction motor, the
type of motor depends on the railway voltages on which the bogie is to be used and can be a 3 kV
DC motor or a 25 or 50 kV AC motor.

1.3.2. Steering

In the Bo-Bo configuration the two bogies on the locomotive, wagon or coach can be steered since
the bogies are free to rotate about the centre pin. In this situation the front and rear wheels are
connected to each other using a linkage system known as forced articulation as shown below:
3


Figure 2 Bogie Steering System

1.3.3. Differentials

A differential is a type of planetary gearbox where the average rotational velocity of the two output
shafts is equal to the velocity of the input shaft. In cars the differential acts as a final gear reduction
from the gearbox to the wheels.

Figure 3 Differential Commonly Found in Cars
The figure above shows the components and layout of a differential found in a car.


4

2. Design Concept

The proposed design concept involves replacing the solid axles and reduction gearboxes currently
being used with differentials which could also be used to facilitate the gear reduction from the
motor. The figure below shows a schematic layout of the conventional bogie and drive train:

Figure 4 Conventional Bogie Drive Train Layout

A schematic layout of the new concept is shown in the figure below:

Figure 5 Proposed Design Concept
In this concept the solid axles are replaced with separate axles running from each wheel into the
differential. The differential is then connected to the traction motor using a helical bevel gear mesh,
a bevel gear mesh is chosen since the output shaft of the traction motor and the input shaft of the
differential is at a 90 degree angle to each other and helical gears provide a more efficient mesh
5

than spur gears. This gear pair or the differential can then be used to achieve the required gear
reduction, which eliminates the need for an additional reduction gear box.
It should be noted that apart from the components mentioned above none of the other parts are
replaced or modified except for additional mounting points that need to be added to the bogie
frame for the differential.
The axles on the undriven bogies can be updated so that each wheel has its own separate axle which
would allow these bogies to be able to negotiate the bends more efficiently as well.
3. Discussion

This concept would provide more stability and reduce wheel and rail wear when going into bends
and can be implemented in tow and three axle bogies.
This concept is based on the assumption that there would be sufficient space in the bogie frame to
incorporate the differential without having to use smaller size motors or requiring major
modifications to the bogie frame.
The disadvantage of this concept is that it would increase the manufacturing and maintenance costs
of the bogie and would require more maintenance due to the larger number or moving parts. But
would eliminate the need for the forced articulation linkage system.
4. Conclusions & Recommendations

It is recommended that a costing analysis is done in order to determine if this design would be
financially feasible considering the reduction in wheel and rail wear but the increase in bogie
manufacturing and maintenance costs. The costs of the differential type design should also be
compared to the forced linkage system, but it is expected that the linkage system would cheaper
since it is a less complex design.
Detailed data and specifications on the current bogie design is required in order to determine if this
system can be used in the existing bogies without requiring major redesigns or modifications to
existing components. Size is a key factor in this type of design since the bogies cannot be made
wider due to rail width constraints and fixed traction motor sizes.
In conclusion this concept has the potential of being a viable upgrade to existing bogies but the
feasibility would greatly depend on the effect the new design would have on costs. At the very least
more time should be spent on researching the design and the costs involved to gain a better insight
into what the long term feasibility would be. This concept can be considered when designing a new
bogie if intellectual property law and agreements do not allow modifications to the current design.