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LEVER GEAR REGULATOR RGVP-300T
1. Main parameters and characteristics
1.1 The cylinder must comply with the requirements of DSTU GOST 31402, these technical specifications and the set of design documentation (CD) in accordance with specification 188B.000.
1.2 When supplied for export, cylinders must additionally comply with the requirements of the supply agreement (contract), the requirements of international, regional and national standards of consumer countries, as well as the legislative acts of Ukraine on the supply of products for export.
1.3 The main parameters and dimensions of the cylinders must comply with those specified in Table 1.
Table 1.
2. Indicators (characteristics) of functional purpose
2.1 Reliability indicators
2.1.1 The intended service life of cylinders is not less than 20 years.
The decision on the possibility of further operation is made separately for each cylinder after examining its technical condition.
2.1.2 Mean time between failures – 120,000 braking cycles.
2.1.3 Installed failure-free service life – 12,000 braking cycles.
2.1.4 The specified service life of the cuffs, seals and cylinder gaskets is 6 years.
2.1.5 The failure criterion for cylinders is:
– breakage or failure of parts and components;
– cylinder leak.
2.1.6 Limit state criteria:
– wear of the inner diameter of the cylinder body is more than 359 mm;
– presence of chips on the cylinder body flanges, if the chipped part covers the bolt holes;
– the presence of cracks in the housing that extend to the working surfaces.
2.2 Technological processes for manufacturing cylinders must ensure the economical use of raw materials, materials, fuel, energy and labor resources.
3. Design requirements
3.1 Cylinders consist of the following main parts and assemblies:
– hull;
– rear covers;
– front covers;
– piston assembly;
– release springs;
– other parts and standardized products according to specification 188B.000.
3.2 Cylinders must remain operational at temperatures from minus 60 °C to plus 60 °C. Short-term (no more than 4 hours) operation at temperatures of plus 80 °C is possible.
3.3 The cylinder assembly must be leak-proof at a working pressure of 0.6 MPa (6.12 kgf/cm2).
3.4 The movement of the piston to its full stroke should be smooth, without jerks or stops.
At sub-zero test temperatures, a jolt is allowed at the beginning of the movement of the piston with the rod.
3.5 The movement of the piston in the cylinder must take place under the air pressure specified in Table 2.
At sub-zero ambient temperatures, a pressure deviation of ±0.005 MPa (±0.05 kgf/cm2) from the values specified in Table 2 is allowed.
Table 2
3.6 The maximum piston stroke shall be 240 mm.
3.7 The return spring shall be compressed six times until the coils touch and, during the control compression, shall not exhibit any permanent deformation.
No cracks or overheating shall be present on the spring surface.
The end coils of the spring shall be ground/pressed so that the spring has a stable position when installed with its end on a horizontal surface (plate).
3.8 The metric and pipe threads on the cylinder parts shall comply with the requirements of the design documentation (DD).
3.9 The permissible limit deviations of the dimensions of the parts shall not exceed the values specified in the DD.
3.10 After machining, and on the unmachined surfaces of castings, there shall be no cracks, hairline cracks, chips.
3.11 Before assembly, all cylinder parts shall be cleaned of contaminants, moisture, packing materials and preservation materials.
3.12 The rubbing (mating) surfaces of cylinder parts shall be lubricated with the oil specified in the DD.
4. Requirements for Coatings
4.1 Unmachined surfaces of cylinder parts shall have a protective paint-and-lacquer coating. The colour and type (grade) of the coating shall comply with the requirements of the DD and applicable regulatory documents (RD) for them.
Supply of cylinders in primed condition is allowed.
4.2 The type and grade of paint-and-lacquer coating shall be specified in the DD.
4.3 The return spring shall have an anti-corrosion coating as specified in the drawing.
4.4 Surface preparation for coating shall be carried out in accordance with DSTU ISO 12944-4 (ISO 12944-4, IDT).
4.5 Surfaces of cylinder parts that do not have protective coating, except those subject to preservation, shall be lubricated with the oil specified in the DD.
5. Requirements for Materials and Purchased Components
5.1 The materials used in the manufacture of the cylinders shall meet the requirements of the applicable RD for them and of these Technical Specifications (TS).
The quality of the materials shall be confirmed by certificates of conformity (quality certificates) of the material manufacturers.
5.2 The cylinder body, front and rear covers, piston, and rod head shall be manufactured by casting from grey cast iron grades SCH150 or SCH200, SCH250, SCH300 in accordance with DSTU 8833; or cast iron grades GJL-150, GJL-200, GJL-250, GJL-300 in accordance with DSTU EN 1561, as specified in the DD.
5.3 Castings shall be cleaned of moulding sand, scale and burn-on.
Laps, fins, shrinkage marks, foundry allowances and runners shall be removed by any method. The places of removal shall be ground or chipped.
5.4 Castings shall not have cracks, blowholes, local looseness, porosity, slag inclusions or foreign inclusions.
5.5 The return spring and the retaining ring shall be made from steel wire in accordance with DSTU ISO 8458-2.
5.6 The blank for the expanding ring and its lugs shall be made from steel strip of steel 65G in accordance with DSTU 8429.
5.7 The tube and the thrust ring shall be made from seamless cold-deformed tube in accordance with DSTU 8939.
5.8 All other metal parts shall be made from rolled stock of quality carbon structural steel in accordance with DSTU 7807 and DSTU 7809.
5.9 Rubber seals, cups and gaskets shall be manufactured from oil-resistant rubber compound in accordance with the DD and shall comply with the requirements of the applicable RD for it.
5.10 The materials from which the cylinders are manufactured shall ensure operability at the limiting temperatures.
6. Completeness
6.1 The delivery set shall include:
– a cylinder assembly complete in accordance with specification 188Б.000;
– operating manual;
– product data sheet (for a batch of products) in accordance with DSTU GOST 2.601.
6.2 A batch of cylinders supplied shall be accompanied by documents containing:
– the name and/or trade mark of the manufacturer;
– the cylinder designation;
– designation of these TS;
– date of manufacture (month, year);
– quantity of cylinders in the batch;
– stamp of the Technical Control Department (TCD).
7. Requirements for Manufacturability
7.1 The design of the cylinder and its parts shall be manufacturable and suitable for inspection and control during production, operation and repair.
7.2 During wagon repair, the cylinders shall be interchangeable with cylinders of other manufacturers.
8. Marking
8.1 The marking shall comply with the requirements of these TS and the DD for the product.
8.2 The following marking symbols shall be applied on each cylinder body in the places specified by the working drawings:
– trade mark of the manufacturer;
– code number of the manufacturer;
– model name of the cylinder;
– cylinder diameter;
– serial number of the cylinder from the beginning of the year;
– month and last two digits of the year of manufacture;
– TCD stamp.
8.3 Marking shall be applied by stamping or casting.
8.4 The marking shall remain legible throughout the entire service life of the cylinder.
9. Requirements for Packaging
9.1 Packaging of cylinders shall protect them from direct exposure to atmospheric precipitation, water splashes and solar ultraviolet radiation, and limit the ingress of dust, sand and aerosols. At the same time, damage to the products during transportation and storage shall be excluded.
Transportation of cylinders without packaging is allowed by agreement with the customer, in accordance with DSTU GOST 31402.
9.2 Surfaces of cylinders not coated with paint shall be preserved with gun grease or other grease in accordance with the DD. The guaranteed storage period without re-preservation is one year from the date of manufacture.
9.3 Through holes of the cylinder bodies shall be closed with plugs (a plug and a load screw) in accordance with the DD.
9.4 Preserved cylinders shall be packed on a pallet or, at the customer’s request, in wooden boxes in accordance with the applicable RD.
9.5 Shipped products shall be accompanied by documents in accordance with clause 1.6 of these TS. The documents shall be placed in a polyethylene bag, which shall be hermetically sealed (heat-sealed, etc.).