LOCOMOTIVE TESTING SHOP

1. Introduction
Locomotive based vehicle systems are among the most commonly and widely used
methods of transportation, both for passengers and goods. Therefore, safety and
precaution are an important objective regarding operation for locomotive based vehicle.
Thus, various test such as Air Brake test, Pantograph balancing test, leakage test etc.
performed to locate defects and reduces chances of failure.

Fig. New Locomotive testing shop

In locomotive testing shop, there are three tests perform respective to find mechanical
defects:

1.1 Air Brake Test

In the earliest days of railways, braking technology was primitive. Viz, locomotives were
slowed or stopped by the application of manually applied brakes such as vacuum brake
and steam power brakes.

Nowadays locomotive braking system is pneumatic in nature i.e., The compressed air is
used for obtaining brake application. In Air Brake system compressed air is used for
opening the brake system. The locomotive compressor charges the feed pipe and the brake
pipes throughout the length of the train. The feed pipe is connected to the auxiliary

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reservoir and the brake pipe is connected to the brake cylinder through the distributor
valve. Brake application takes place by dropping the pressure in the brake pipe.

1.1.1 Components of Vacuum Brake Systems:

Pressure Pneuma c System Brake Cylinder

Air Compressor Air Compressor

Step down transformer DC Battery

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 Air reservoir Air Blower

1.1.2 Air Brake Test Parameters

 Main Reservoir Pressure
 Brake Pressure
 Feed Pressure
 Brake Cylinder Pressure (auto A9)
 Brake Cylinder Pressure (auto SA9)

1.1.3 Working of Air Brake System

In locomotives air brake system function in 3 stages:

(a) Charging Stage

Charging stage is primary stage of air brake test in which charged air delivered to pipe
duct from compressor in form of compress air. During this stage, brake pipe is charged to
5kg/cm2 pressure which in turn charges control reservoir and auxiliary reservoir to 5
kg/cm2 pressure via distributor valve. At this stage, brake cylinder gets vented to
atmosphere through passage in Distributor valve.
(b) Application Stage

For application of brakes, the pressure in brake pipe has to be dropped. This is done by
venting air from driver`s brake valve. Reduction in brake pipe pressure positions the
distributor valve in such a way that the control reservoir gets disconnected from brake
pipe and auxiliary reservoir gets connected to brake cylinder. This results in increase in
air pressure in brake cylinder resulting in application of brakes. The magnitude of braking
force is proportional to reduction in brake pipe pressure.

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(c) Release Stage

For releasing brakes, the brake pipe is again charged to 5 kg/cm2 pressure by compressor
through driver’s brake valve. This action positions distributor valve in such a way that
auxiliary reservoir gets isolated from brake cylinder and brake cylinder is vented to
atmosphere through distributor valve and thus brakes are released.

1.2 Pantograph
A pantograph is a device used in locomotives and electric trains to collect power from an
overhead electric line. When the locomotive moves beneath the electric field section of
the track, the pantograph is raised, and collector shows come into contact with the
overhead wire. The contact between the shoes and wire allows electrical power to flow
from the wire to locomotive`s electrical system.

Fig. Pantograph
The pantograph is designed to maintain a consistent contact force with the overhead wire.
It achieves this through a combination of mechanical and pneumatic system. The
mechanical linkage allows the pantograph to follow the contours of the overhead wire,
while the pneumatic system applies the necessary force to maintain good electrical
contact.

The electrical power collected by the pantograph is then transmitted to the traction motors
of the locomotive. Which drive the wheels and propel the train forward. In this way, the
pantograph enables electric locomotives and trains to operate without the need for an
onboard power source like an internal combustion engine.

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1.2.1. Pantograph balancing test
Pantograph balancing test is mechanically performed test used to ensure the proper
alignment and balance of the pantograph device on locomotives or electrical trains.

These tests are crucial for maintaining reliable contact between the pantograph and
overhead wire, optimizing power collection, and reducing wear and tear during the
balancing test, the pantograph is subjected to various positions and load to assess its
performance and make necessary adjustments. Generally, balancing test can be performed
in three stages:

Stage 1: Positioning

The locomotive or train is positioned under the overhead wire, and the pantograph is
raised to make contact with the wire. The position of the pantograph is critical, as it should
align properly with the wire to achieve optimal contact and minimize wear.

Stage 2: Static Balancing

The pantograph is first tested for static balancing. In this test the pantograph is positioned
at different heights and angles to determine if it remains stable and balanced. Adjustments
are made to pantograph`s mechanisms, such as the counterweights or spring tension, to
achieve proper balance.

Stage 3: Dynamic Balancing

Once the pantograph is statically balanced, dynamic balancing tests are conducted. This
involves energizing the overhead wire with electrical power, simulating real real-world
operating conditions. The pantograph is then subjected to various speeds, acceleration and
track conditioned to assess its stability and performance.

During the dynamic balancing tests, engineers monitor the pantograph`s behaviours
closely. They look for any signs of bouncing, excessive vibrations, or irregularities in
contact with the overhead wire.

If any issues are observed, adjustments are made to the pantograph`s mechanical
components to correct them.

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1.3 Shower Test
Tightness of locomotive in terms of water proofing is an important factor that have a
specific impact on the performance of locomotive in several conditions such as during
rainy season. Water proofing by shower testing method is a traditional method of tightness
testing used to detect leakage in locomotive engine.

Shower test typically refers to a test conducted on a locomotive to check its water tightness
and assess any potential leaks. This test is undertaken to detect leakages around windows,
doors, cabins, covers, etc.

In this method, a shower facility is designed. This shower facility is set up to create an
artificial shower on the Locomotive engine to be tested.

Fig. Shower Test

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