recent experience on coach interiors and future opportunities integral coach factory, chennai, india...
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Recent Experience on Coach InteriorsAnd
Future Opportunities
Integral Coach Factory, Chennai, India
10-10-2015
ICF - 1955 to 2015….
• 1955 First coach
• 1962 EMU Train set
• 1981 Underground Metro Train for Kolkata
• 1994 DEMU Train set
• 2001 EMU with 3-phase propulsion system
• 2008 Stainless Steel Coach
• 2013 DEMU with 3-phase propulsion system
• 2015 50,000th Coach
Variety of Builds
Stainless steel coaches Mainline express coaches
EMU Train set – 3 phase propulsion DEMU Train set – 3 phase propulsion
Variety of Builds
Kolkata Underground Metro Air Conditioned Train set
Kolkata Underground Metro – 3 phase Propulsion
Governing Specifications
• Raw materials for Interior furnishing of Indian Railway Coaches should comply with:
– Spread of Fire UIC 564-2 OR ( Class B )
– Loss of visibility due to Smoke UIC 564-2 OR (Class A )
– Toxicity NCD1409 (toxicity index <1)
– Limited Oxygen Index IS:13360 (Min 32)
– Heat release rate R1(HL2) of EN:45545-2
• IR is working towards migration to EN:45545 standards.
Interior Panelling
FRP
Aluminium Composite Panel (ACP)
Polycarbonate
POLYESTER RESIN
PHENOLIC RESIN
EPOXY RESIN
Interior Panelling
FRP PanellingUsed in Stainless steel body mainline coaches On 3-phase EMU train sets and DEMU Train sets.
•Aesthetic finish
•Mouldable
•Longer lead time
•Non-recyclable
Interior Panelling
ACP Panelling• Core: Inorganic oxide of
Aluminum• Used on Kolkata Metro coaches,
a few rakes of 3-phase EMU and a few mainline coaches.
•Aesthetic finish•Not mouldable , but formable•Used with Alu extrusions•Recyclable.•Non-availability of ACP meeting Railway FST requirements (A2 grade –EN -13501) in India.
Interior Panelling
• Polycarbonate ABS blend material for paneling
Mouldable RecyclableLight weight (500 kg less per coach)Longer lead time
Interior Panelling
Future requirements
FRP for all AC and Non-AC Stainless steel body mainline coaches and 3-phase EMU Train sets.
ACP in Diesel Train sets and metro coaches
Polycarbonate on trial basis on Mainline coaches.
Seating System for Commuter Trains
Polycarbonate thermoformed seat
Cushioned SeatUsed in Intercity coaches like DEMU and day coaches
•Extensively used in 130 EMU train sets and Kolkata Metro coaches
•High rate of production
•Glued to SS frame and endcapped
•Non-uniform thickness due to thermoforming.
•Difficult to replace broken seat top
•Extensively used in intercity trains
•DTPB or PU foam cushion
Seating System for Commuter Trains
Polycarbonate Injection-Moulded seat
• Currently used used in 3-phase EMU train sets
• Better dimensional control
• Varied colours and more aesthetic.
• Inserts are moulded in to the polycarbonate sheet for better structural integrity.
CUSHIONING MATERIAL
– PU foam – Good cushioning comfort. Does not meet stringent FST standard with respect to Toxicity (<1 toxicity index). Used along with fire barrier cloth on day coaches
– Densified Thermal Bonded Polyester blocks (DTPB) – Meets FST and widely used in IR.
– Silicone Foam – Meets FST. Better cushioning comfort. Developed and under trials .
Seating
Future requirements
Polycarbonate seats for commuter trains FRP/polycarbonte seats for Metro trains Cushioned seats for intercity trains Revolving seats for tourist cars and high end applications
Experience on Thermoplastics
Commuter Coach Window
Door glass
Look out Glass
– Silicon hard coated Polycarbonate used for look out glass (Taber abrasion 1000 cycles, % haze < 12)
Thermoplastics - Polycarbonate
• Light weight
• Good mouldability
• Recyclabel
• Performance is good – window glass, door glass, snack table and hand holds.
• Scratch formation on look out glass of driver cab
• PC raw material not available in India.
• Long Lead time.
• Product design and process engineering left to the fabricator.
• With ABS combination, meeting Toxicity requirement is difficult.
Lighting and PIS
IR is changing over to LED system from existing Fluorescent Lights.
• Compartment lights• Emergency light• Passenger alarm light• Tail light• Berth reading lights• Berth indication lights• Lights for toilet/ wash basin
GPS based Public Information System
LED for Commuter trains LCD on Metro Trains currently production
Luggage Rack
• Stainless steel luggage racks are for commuter trains and general coaches.
• Luggage racks made from Aluminum extruded section is used in AC chair cars. Aesthetic. Will be provided in all day coaches.
Aluminum Extruded Luggage Rack Stainless Steel Luggage Rack
Cork sandwiched between layers of Macore boards is used for sub floor with PVC top floor in Stainless steel body AC coaches.
Aluminum Honeycomb sub floor with PVC top flooring is being tried for air conditioned electric train sets.
Flooring – Sub layer
Flooring- Top Layer
Slip-free Stainless steel flooring
PVC top floor is provided in all main line coaches
PVC flooring
Stainless Steel ‘slip free’ top floor is provided for commuter trains viz. EMU and DEMU as well as doorways of conventional mainline coaches.
Halogen free rubber-on-rubber flooring on Metro coaches – under implementation
Modular Toilets
• FRP Modular toilets and Stainless steel Modular toilets in AC Coaches
• It is planned to adopt Modular toilets in non-AC coaches also.
• FRP Modular toilet – Loss of lusture over time.
• Stainless steel Modular toilet – formation of water stains.
Bio-toilet• Hygenic disposal of toilet waste.• Anaerobic Bacteria degrades fecal
matter into gas & liquid.• Track and station premises will be kept
clean.• 100% implementation on Conventional
coaches from March 2013.• All new coaches are turned out with Bio
toilets from current year. 11,000 nos fitted at ICF so far.
• Future Plan: Vacuum Toilets with bio-digester tanks
FULLY SEALED GANGWAYS
• Used on Kolkata Metro air conditioned train sets
• Currently being used on Fully Air Conditioned Electric Train set for Mumbai Suburban
• Functionally performance is good
• Turnbuckles holding the vestibules giving up
• Will be used on all Air Conditioned trainsets and Metro coaches
AIR CONDITIONING
The tonnage of Roof Mounted Package Unit (AC) for various trains
• 6.5 tons on Main line AC coaches – 800 coaches/annum• 11 tons on Metro Coaches – Project based• 15 tons on AC trainsets for suburban - Project based
FORCED AIR CIRCULATION
• Mumbai Suburban trains operate under super dense crush loads
• For comfort of passengers, Forced Air Circulation system was introduced which pumps 16000 m3/hr fresh air
• Reduction of 1000 PPM of CO2 levels from the existing highest levels of 2450 PPM
Air Handling Unit
Diffuser Grills
Insulation
• Sound Insulation
• Sound insulation paint coated on whole interior of Stainless steel Coaches
• Floor board made of cork sandwiched between compreg sheets, and laid over rubber decoupling elements.
• The above insulation Increases weight by 500 kg per coach.
Floor board laid over rubber decoupling elements
Sound insulation Paint
Insulation
• Thermal Insulation
• Glass wool cladded with aluminum foil is pasted on walls and ceiling for heat insulation.
• Additional layer of cross linked polyoiefin foam (Resonoflex) is provided upto window level in LHB AC coaches.
Resonoflex Thermal InsulationGlass wool Thermal Insulation
Insulation
Future Requirements
• Water based and eco friendly
• Coatings that provide sound as well as heat insulation planned for development.
• Light weight
Transview Tourist Coaches
• Large windows on side walls, end wall as well as roof for panoramic view
• Roof glasses glazed for opalescence through electric controls, for making opaque when necessary
• On board entertainment facility and LCD display
• Revolving chairs that can be oriented in train running direction.
• Automatic doors at compartment entry
• Modular pantry
Anubhuti Super Luxury Coaches
Superior Interior Paneling Designer toilets
• IR planning to manufacture Anubhuti Super Luxury coaches with Improved interiors for higher travel comfort
• Plush upholstery, designer toilets, diffused lighting, better ergonomics, LCD screens, personalized pantry
• LCD TV behind each seat with Armrest keypad control
• Wi-Fi facility
Diffused Lighting
Smart display
Foldable Arm restSnack Table
SLIDING DOORS
• Electrically operated• Pocket doors• Provided in air conditioned EMU
and Kolkata Metro.
• Manually operated• Pocket doors• Provided in all commuter trains.
P I P
I
Automatic Pivoted DoorFuture Requirement
• Manually operated pivoted doors provided in all types of mainline passenger coaches presently.
• Automatic Pivoted doors are required for main line coaches to replace existing manual operated doors.
door actuator
FIRE SUPPRESSION SYSTEM
• Fire suppression system currently being installed in power cars• Fire/smoke detection and high pressure water mist suppression system• To be tried out in AC and NON-AC coaches in a big way.• System yet be proven in Non AC environment
CCTV Camera
• Planned to provide in Ladies compartment of EMU, DEMU, SLRD and all AC coaches – on a large scale
• Network video recorder (NVR) having 2 TB hot swappable hard disk• 30 days recording• IP Cameras having infra red sensors for recording even during dark.• GPS antenna for real time location and speed.
GPS CoordinatesSpeed & Time
CCTV Video Stream
To Conclude
• Current coach production on IR ~ 4000 /Annum • Will go upto ~ 5000 /Annum• Large variety of coaches – around 50 variants produced each
year• Large scale up-gradation of interiors is planned • Lead time needs to be reduced • Local Engineering support and manufacturing base needed