(BECU) with WSP
Sona Comstar has developed a comprehensive brake system to meet the requirements of the Semi-High Speed 'Vande Bharat' Express Train. This brake system integrates advanced electronic control systems, pneumatic components and wheel-mounted friction brake discs, all designed to fulfill the performance and safety standards essential for semi-high-speed rail operations.
- • Advanced Digital Controlled brake application
- • Brake electronics redundancy
- • Configurable to different communication protocol, IP-TRDP, MVB, PWM
- • CAN communication between Brake Electronics
- • CAR and BOGIE Control Solution
- • Wheel Slip/Slide Control with wheel diameter calibration
- • Detection of Non-Rotating Wheel
- • Load Compensated Brake system
- • Jerk limited Brake Blending, optimized LCC
- • Compact Tread Brake Unit (TBU) and Brake Calliper
- • Wheel mounted and axle mounted brake disc
- • Integrated brake control unit (BCU) for easy accessibility and maintainability
- • Fail-safe backup brake system for train safety
- • Safety Integrity Level (SIL)
- • Emergency Brake – SIL4
- • Service Brake – SIL2
- • Equipment for supplement function like Horn control, Third rail actuator, Pantograph control, WFL Control, Coupler control etc.
- • Advanced Digital closed loop brake electronics with redundancy for better train availability and performance
- • Configurable system for CAR and BOGIE control architecture
- • Advanced IP-TRDP protocol to enhance cyber security
- • Internal reliable CAN communication among Brake Electronics
- • Both Tread Brake Unit (TBU) and Caliper solution for different train speed configuration
Brake Electronics Control Unit (BECU)
The Brake Electronic Control Unit based on the microprocessor-controlled system carries out the braking calculation to control the required service brake of each car through the electric pneumatic blending considering load weight from air spring pressure detected through a pressure transducer.
- • Intelligent microprocessor-based brake control with electro-pneumatic and regenerative brake blending.
- • Smart brake effort pattern generation with real-time traction coordination through TCMS integration.
- • Advanced jerk-limited brake application for improved passenger comfort.
- • Automatic variable load compensation using air spring pressure feedback.
- • High-precision brake cylinder pressure control with hysteresis compensation.
- • Integrated Wheel Slide Protection (WSP) for improved adhesion utilization.
- • Continuous self-diagnostics, health monitoring and fault recording.
- • Real-time fault status and event logging for centralized monitoring.
- • Modular and fail-safe architecture for improved availability and safety.
- • RDSO specifications applicable for EMU/MEMU/Trainset brake control equipment.
- • 14 Analog Inputs, 24 Digital Inputs and 12 Digital Outputs for signal sensing and control.
- Microprocessor-based Brake Electronic Control Unit (BECU) for distributed power EMU/Trainset applications in Indian Railways.
- Suitable for AC EMU, MEMU, Train-18/Vande Bharat type rolling stock and trainsets operating up to 180 km/h.
- SIL-2 compliant Service Brake and WSP function and SIL-4 compliant Emergency Brake function.
- In-built Service Brake and WSP redundancy.
- If one BECU fails, another BECU takes over instantly for braking and WSP application.
- Dual-channel speed sensor outputs routed to two BECUs for signal redundancy.
- TRDP-Ethernet based TCMS communication network.
- CAN-FD communication for BECU internal and inter-BECU communication.
Integrated Brake Control Unit
- Compact and modular design for better maintainability.
- Configurable to BOGIE / CAR control brake architecture.
- Mechanically controlled fail-to-crush brake application.
- Digital controlled loop for brake modulation.
- Integrated parking brake feature.
- Back-up brake for train rescue.
- Integrated brake reservoirs.
- Ingress protection class IP54.
- Operating condition -40°C to +70°C.
- RoHS Compliant.
- Fire Safety level EN45545 - HL3.
- Driver's control panel for horn and BP control.
- Separate integrated units for suspension control and feedback.
- Separate integrated unit for Auxiliary Compressor control for Pantograph operation.
- Axle detection and correction for wheel slide control.
Wheel Mounted Brake Caliper – Compact
The Wheel Mounted compact brake caliper unit is a high-performance, lightweight assembly designed for precision braking at high speeds (optimized for speeds up to 160–200 km/h) while minimizing maintenance and space requirements. It integrates advanced pneumatic and mechanical features for both service and parking brake functions. It has modular construction consisting of separate brake cylinder and slack adjuster assemblies.
- • Compact, lightweight design occupying minimum space in the bogie.
- • Integrated spring actuator for the parking brake in the housing.
- • Spring actuator can be mechanically released by manual operation through release cable.
- • Parallel links to better guide the brake pad holders.
- • Caliper provides low wear of brake pads and low noise.
Tread Brake Unit
Tread Brake Units (TBU) are used where braking force is applied directly to the wheel tread. They are robust, simple and reliable for moderate-speed operations.
- • Simple, rugged and cost-effective.
- • Easy to maintain with accessible brake shoes.
- • Well suited for heavy freight trains and moderate passenger services.
Wheel Mounted Brake Disc
Wheel-mounted brake discs are a modern railway braking solution where the disc is directly attached to the wheel, allowing calipers to apply friction for controlled braking.
This design is widely used in high-speed rolling stock because it offers superior performance compared to traditional brakes.
- • Ventilated discs with cooling ribs dissipate heat effectively.
- • Prevents wheel tread damage and thermal cracks.
Axle Mounted Brake Disc
The axle-mounted brake disc is designed for railway braking applications where the brake disc is directly mounted on the wheelset axle, providing stable and uniform braking performance.
- • Directly mounted on the wheelset axle for stability and uniform braking.
- • Reduces wear compared to tread brakes.
- • High mechanical and thermal capacity for demanding service conditions.
- • Crosswise cooling ribs improve heat dissipation.
- • Helps prevent overheating during repeated or emergency braking.
- • Grey cast iron construction with cooling ribs for durability and consistent performance.
- • Limited scoring, concave wear and rib breakage permitted within specified limits.
- • Residual thickness of friction surface must remain ≥ 14 mm.
- Disc is split into two halves and bolted together around the axle.
- Eliminates the need to dismantle the wheelset for disc replacement.
- Ensures interchangeability across LHB rakes.
- Enables quick removal and replacement during POH.
- Saves maintenance time compared to single-piece discs requiring wheel pressing.
- Intelligent microprocessor-based WSP 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 records operational data, fault history and wheel-slide events.
- Wide-range galvanically isolated potential-free input/output interfaces suitable for rolling stock electrical environments.
- Continuous monitoring of internal and external relay contacts for enhanced reliability and fault detection.
- Independent watchdog safety timers for high system integrity.
- 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 signal sensing and control.