Hot Axle Hot Wheel Detector (HAHW)

Hot Box and Hot Wheel detectors are trackside devices designed to monitor axle, wheel,
brake temperatures and to indicate any overheating which could lead to derailments and
transmits this data to the traffic control and monitoring section. This is an unmanned system,
which consists of high speed pyrometers installed at axle box level to check the temperature
in near axle and far axle and at the track level to measure the wheel temperature. These
pyrometers are connected with real time embedded data acquisition system that wakes up on
train arrival to capture and analyze the data from all pyrometers.

The real time software possesses the intelligence to process the recorded data and produces
the report with axle wise temperature information and transmits the data to Traffic Control or
Monitoring Station. The cut-off limits and the alarm limits can be set by the user for flagging
the hot axles, hot wheel & cold wheels.

The system was developed along with IIT-Kanpur as a part of Technology Mission
for Railway Safety

Salient Features
Automatic Identification of Hot Axle Box, Hot Wheel & Cold Wheel
Detailed report with data of axle box and wheel temperature at two sides of an axle
for complete train
Automatic Identification of the train
Automatic Transfer of report & analysis to railway control office through
GPRS/Existing OFC Line
Identification of train type, number of engines, wagons/coach, brake vans
IP 65 grade cabinet to house data acquisition system & pyrometers
Reliable 24X7 operation without Manual Intervention
Notification of Alarms & reports through SMS and e-mail
 Solar power as secondary power
Audio Visual Alarm for given alarm condition

Track Side Bogie Monitoring System (TBMS)

Track Side Bogie Monitoring Systems (TBMS) monitors & provides data about the health of
bogies. The forces acting in the vertical & lateral directions of the wheel-rail contact zone
will represent the true health status of the bogie. Bogies with poor health are identified and
isolated from the fleet for immediate repair & rectification.
The system was developed along with IIT-Kanpur as a part of Technology Mission
for Railway Safety

Salient Features
Automatic train detection
Measures Vertical Load, Lateral Load & Angle of Attack
Calculates L/V Ratio, Tracking Error, Inter Axle Miss-Alignment
Secondary power - solar power
Reliable 24X7 operation without Manual Intervention
Automatic Identification of Trains and Automatic Measurements
Automatic Transfer of Report & Analysis to Railway Control Office or Train
Examining Station through GPRS
Notification of Alarms & reports through SMS and e-mail

Wheel Impact Load Detector (WILD)

Impact load occurs on rail when a defective portion of wheel falls on rail head. Impact
load is transferred to rail head from wheel through combination of any or all of the
following defects like
1. Wheel having a flat / Out of roundness
2. Overloaded Axles
3. Defect in suspension system
4. Miss-alignment of bogies
5. Skew in the car body etc

Wheel Impact Load Detector (WILD) is a Safety System used to identify the
defective wheel due to any of the above defects by measuring the dynamic impact on
the track at a very early stage and thereby protect the Rail Infrastructure, avoid
 derailments and catastrophic failures. WILD is also to reduce service failures and
unplanned maintenance cost of Rolling Stocks and Tracks.
WILD System was initially developed along with RDSO & IIT-Kanpur
Salient Features
Wayside system with reliable 24x7 operation without Manual intervention
Automatic Identification of Train and Automatic Measurements
Impact Load Measurement & Impact Load Factor (ILF) Measurement of all Wheels
Automatic Transfer of Report & Analysis to Railway Control Office/Train Examining
Station through GPRS
Transferring of data through OFC link
Intimation of alarms through SMS
Automated Alarm Notification based on Load levels & ILF
Speed Measurement of each axle and average train speed measurement
Bidirectional Traffic
Provides Wagon/Coach Wheel & Axle Information
Instrumentation optimized for capturing full Wheel Circumference data
More Number of Measurement zones to provide greater accuracy
Self-Calibration of Channels to maintain accuracy
Self-Diagnostics
Programmed software available at website for easy analysis of defective wheels

LOCK BOLTS

Almost all new wagons specially stainless steel wagons are provided with lock bolting
instead of riveting. In repair/maintenance CP top of all wagons irrespective of materials are to
be lock bolted. Entire lock bolting is to be done with zinc plated/galvanized lock bolts (grade-
8) having a minimum yield strength of 250 N/mm2.
Lock Bolts have been introduced in the fabrication of Wagons. Lock bolt fasteners consist of
Lock bolt pin and collar, and are installed with the help of special installation tools, as
follows-
Lock bolt pin is placed in drilled hole, and collar is placed onto the lock bolt pin.
Installation tool engages and pulls the lock bolts pin.
Tool swages the collar onto lock bolt grooves.
Pin tail breaks off the lock bolt pin.

Advantages:-

High strength
Vibration resistant
Fast and easy installation
Maintenance free

Proper Installation of lock bolts:-
It should be ensured that:
(i) The collar of lock bolt is completely swaged. The collar of lock bolt fasteners not
completely swaged may be causes of improper tool operation or worn anvil in nose.
(ii) The pintail of fastener break without fail. The pintail of fastener fails to break due to
improper installation/incorrect fasteners.
(iii) After breaking of pintail, the extruded/projected portion of lock bolt should be in the
range of 2.00 to 10 mm and collar should always be on annular groove of lock bolt.
(iv) Mismatch of holes to be reamed properly to align and gas cutting to match holes is
strictly prohibited.

Clamp Force or PreLoad:

In the initial stages of the installation process, the tool engages and pulls on the pintail. The
joint is pulled together before the conical shaped cavity of the nose assembly is forced down
the collar. This progressively locks (swages) it into the grooves of the harder bolt. The bolt
and swaged collar combine to form the installed fastener.
The squeezing action reduces the diameter of the collar, increasing its length. This in turn
stretches the bolt, generating a clamp force over the joint.

1. Pin inserted into prepared hole -- collar spun into pin

2. Tool is applied to annular pull grooves and activated
Nose assembly draws pin into the tool
The swaging anvil presses on collar
Draws up sheet gap
3. Anvil begins to swage collar into lock grooves
Collar and pin elongate, developing precise clamp
4. Tool ejects fastener and releases puller -- installation complete