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AIR DISTRIBUTOR
483M
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 piston and rod movement.
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 is 240 mm.
3.7
The release spring shall be compressed six times until the coils touch and, during control compression, shall not exhibit residual deformation.
The surface of the springs shall have no cracks or signs of overheating.
The end coils of the spring shall be pressed so that the spring maintains a stable position when placed vertically on a horizontal surface (plate).
3.8
Metric and pipe threads on the cylinder parts shall comply with the requirements of the design documentation (DD).
3.9
Permissible dimensional deviations of the parts shall not exceed the values specified in the DD.
3.10
After machining, and on unmachined casting surfaces, no cracks, hairlines, or chips are allowed.
3.11
Before assembly, all cylinder parts shall be cleaned of contamination, moisture, packaging material, and preservation materials.
3.12
Friction surfaces of the cylinder parts shall be lubricated with the oil specified in the DD.
4. Coating Requirements
4.1
Unmachined surfaces of the cylinder parts shall have a protective paint-and-lacquer coating.
The color and type of coating shall comply with the DD and applicable regulatory documents.
Shipping cylinders in primed condition is permitted.
4.2
The type and grade of the paint-and-lacquer coating must be indicated in the DD.
4.3
The release 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 are not coated, except those intended for preservation, shall be lubricated with the oil specified in the DD.
5. Requirements for Materials and Purchased Products
5.1
Materials used in the manufacture of the cylinders shall comply with applicable standards and these Technical Specifications (TS).
The quality of materials must be confirmed by certificates of conformity (quality certificates) issued by the material manufacturers.
5.2
The cylinder body, front and rear covers, piston, and rod head shall be produced by casting from gray cast iron grades SCh150, SCh200, SCh250, SCh300 according to DSTU 8833; or cast iron grades GJL-150, GJL-200, GJL-250, GJL-300 according to DSTU EN 1561, as specified in the DD.
5.3
Castings shall be cleaned of molding sand, scale, and burn-on.
Flash, fins, shrinkage cavities, risers, and runners shall be removed by any method. Removal areas shall be cleaned or dressed.
5.4
Castings shall not contain cracks, blowholes, local looseness, porosity, slag inclusions, or foreign inclusions.
5.5
The release spring and retaining ring shall be manufactured from steel wire according to DSTU ISO 8458-2.
5.6
The expander ring blank and its lugs shall be produced from steel strip made of steel grade 65G in accordance with DSTU 8429.
5.7
The tube and thrust ring shall be manufactured from seamless cold-drawn tube according to DSTU 8939.
5.8
All other metal parts shall be made from rolled quality carbon structural steel according to DSTU 7807 and DSTU 7809.
5.9
Rubber seals, cuffs, and gaskets shall be manufactured from oil-resistant rubber mixture according to the DD and must comply with applicable standards.
5.10
Materials used to manufacture the cylinders shall ensure operability under limiting temperatures.
6. Completeness
6.1
The delivery set shall include:
– cylinder assembly complete according to specification 188B.000;
– operating manual;
– passport (for the batch of products) according to DSTU GOST 2.601.
6.2
Each delivery batch of cylinders shall be accompanied by documents containing:
– name and/or trademark of the manufacturer;
– cylinder designation number;
– designation of these TS;
– manufacturing date (month, year);
– quantity of cylinders in the batch;
– quality control department (QCD) stamp.
7. Manufacturability Requirements
7.1
The design of the cylinder and its parts shall be technologically suitable and controllable during production, operation, and repair.
7.2
When repairing railway wagons, the cylinders shall be interchangeable with cylinders from other manufacturers.
8. Marking
8.1
Marking shall comply with these TS and the DD for the product.
8.2
Each cylinder body, at the locations specified in the working drawings, shall bear the following markings:
– manufacturer’s trademark;
– manufacturer’s code;
– cylinder model name;
– cylinder diameter;
– serial number from the beginning of the year;
– month and last two digits of the year of manufacture;
– QCD stamp.
8.3
Marking shall be applied by stamping or casting.
8.4
Marking must remain legible throughout the entire service life of the cylinder.
9. Packaging Requirements
9.1
Packaging of the cylinders shall protect them from direct atmospheric precipitation, water splashes, and solar ultraviolet radiation, and limit the penetration of dust, sand, and aerosols.
It shall also prevent damage during transportation and storage.
Transportation of cylinders without packaging is permitted 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 another lubricant according to the DD.
The guaranteed storage period without re-preservation is one year from the date of manufacture.
9.3
Through openings of the cylinder bodies shall be closed with plugs (stopper and load screw according to the DD).
9.4
Preserved cylinders shall be packed on a pallet or, at customer request, in wooden crates according to applicable standards.
9.5
Shipped products shall be accompanied by the documents specified in section 1.6 of these TS.
The documents shall be placed in a hermetically sealed polyethylene bag.