The disc brake system consists of actuators in the form of brake cylinders, caliper units, integrated slack adjusting arrangement, and wheel slide protection device (WSP). The system has a panel-mounted brake equipment consisting of DV, manifolds, etc. The WSP is approved by UIC which protects the wheels from sliding. The system is meeting the performance of semi highspeed trainsets of operating speed of 160kmph.
LHB Brake Caliper
The LHB brake caliper is a key component of the modern disc brake system used in LHB and Double Decker coaches. It provides efficient braking at high speeds (up to 180 km/h). It provides improved safety at high speeds due to controlled braking with reduced wear and tear compared to other systems. It provides better passenger comfort with smoother braking. Modern high-speed rail operations has high reliability on this type of brake calipers.
Panel Mounted Brake System (PMBS)
- • Brake control equipments are integrated in the panel for better maintainability.
- • Compact and modular design.
- • Brake reservoirs and Brake isolating cocks are integrated in the panel.
- • Feature for mechanical indication of brake status.
- • Distributor Valve (DV) with Relay Valve function with Built-in Quick Release Valve (QRV).
- • 6L integrated Control Reservoir (CR).
- • Adjustable Brake Cylinder (BC) pressure control.
- • Test points like BP and FP for easy troubleshooting on train.
- • Compatible with dual pipe architecture.
- • Pressure governor for WSP sleep mode.
Wheel Slide Protection (WSP)
Salient Features:- • Intelligent microprocessor-based Wheel Slide Protection (WSP) system with real-time wheel speed monitoring and rapid anti-skid brake modulation.
- • Advanced adhesion management algorithm optimizes braking effort while preventing wheel lock and wheel flats under low adhesion conditions.
- • Integrated high-capacity event logger continuously records operational data, fault history, wheel-slide events, date/time stamp and train operating conditions.
- • Wide-range galvanically isolated potential-free input/output interfaces suitable for rolling stock electrical environments.
- • Continuous monitoring of internal and external relay contacts enhances operational reliability and fault detection capability.
- • Independent watchdog safety timers ensure high system integrity and secure operation during processor or communication anomalies.
- • Integrated USB and SD card for event logging, software update and operational data retrieval.
- • LCD Display and Navigation control for easy operation and system interfacing.
- • 4 Speed sensor inputs for efficient speed sensing.
- • 3 Analog Inputs, 5 Digital Inputs, 5 digital relay Outputs and 1 power output for seamless signal sensing and control.
LHB Brake Disc
The brake disc used in LHB coaches is an axle-mounted disc, offering superior braking efficiency, heat dissipation, and safety compared to conventional systems. It is made of grey cast iron with cooling ribs, ensuring durability and consistent performance under demanding service conditions.
Features:- • Directly mounted on the wheelset axle for stability and uniform braking.
- • Reduces wear compared to tread brakes.
- • Provides high mechanical and thermal capacity, resisting cracks and deformation.
- • Crosswise ribs improve heat dissipation.
- • Prevents overheating during repeated or emergency braking.
- • Allows limited scoring, concave wear, and rib breakage within specified limits.
- • Residual thickness of friction surface must remain ≥ 14 mm.
Split Type LHB Disc
The split-type brake disc used in LHB coaches is a specialized design that improves maintainability and performance compared to the conventional disc. It is particularly useful for high-speed trains where braking efficiency and ease of replacement are critical.
Features:- • The disc is split into two halves, bolted together around the axle.
- • Eliminates the need to dismantle the wheelset for disc replacement.
- • Ensures interchangeability across LHB rakes.
- • Allows quick removal and replacement during POH (Periodic Overhaul), saving time compared to single discs, which require wheel pressing.
Main Features
- • Electro-Pneumatic system
- • Integrated Automatic Advanced Wheel Slide Protection System – Safety
- • Emergency Braking – Safety
Product Status
Sub systems are in various stages of approvals.
Major Sub Systems
- • Panel Mounted Brake System - Proven
- • Wheel Slide Protection System - Proven
- • Indigenous Brake Caliper - Approved for field trial
- • Brake caliper unit along with brake cylinder
- • Brake caliper units with different rigging ratio for coach application
- • Wheel slide protection unit with latest features to avoid wheel sliding
- • Brake pads with excellent friction and wear rate
- • Compatible with Single and Twin-pipe architecture.
- • Adaptable to Load Dependent brake application.
- • Compatible with different sizes of brake actuators.
- • Almost No Brake Rigging.
- • Microprocessor based WSP.
- • Wheel Turning frequency Reduced.
- • Centralised control for complete Coach.
- • Use of Emergency Brake Accelerator for sharp emergency application in complete train set.
- • Semi-high speed passenger coaches (LHB)
- • Double decker coaches