OVERVIEW OF COACH FURNISHING by CHIEF INSTRUCTOR 1
OVERVIEW OF COACH FURNISHING by CHIEF INSTRUCTOR 1
Main Features Of Furnishing • • Larger windows – provides panoramic view. Bigger size emergency exit windows (4 nos. per coach) Higher speed potential – Fit for 160 Kmph Good riding quality due to improved suspension –less fatigue to passengers. Good sound insulation inside the coach (60 Decibel). Good air conditioning system (Micro Processor Controlled AC Unit with fresh air intake) Controlled discharge toilet system (Electronically controlled)- More hygienic. 2
Main Features Of Furnishing • Higher carrying capacity – FAC 24 instead of 18 – AC-2 T 52 instead of 46 – AC-3 T 72 instead of 64 • Good modular aesthetics (FRP) - presents pleasant look • Moulded cushions in seats in chair car and berths for better comforts. • Glow type stickers for better visibility of “Notices for passengers” during night. • Wider entrance passage area than conventional coaches. • Hopper windows in toilets – For proper ventilation. • Use of fire retardant material. 3
Flow of Shell in Furnishing Shop Coach Entry to Furnishing Shop Flooring PVC Elect. Stage-III Partition Frame Paneling Window & Ceiling Lavatory Molding Elect. Stage-IX Plumbing Seat & Berth Coach Lowering Air Brake testing Shower Testing QC Inspection Final Inspection Coach Ready for Dispatch 4
Stages of Furnishing 5
Coach Entry to Furnishing Shop Interior View 6
Flooring & PVC Ø Floating Floor board (Makore 19 mm) Rubber element (D-Coupling Rubber) Metallic Back piece Metallic floor support member (D-Coupling Element) Floor board resting on rubber (D-Coupling) element 7
Flooring & PVC Ø Flooring boards – cork sandwiched between compreg to absorb noise 8
Flooring & PVC • Process of PVC Pasting and welding similar as conventional coaches • Pasting with Dendrite adhesive for better adhesion. • Skirting of PVC with side wall for better aesthetics and easy cleaning. 9
Electrical Stage-III Ø Wiring in roof, sidewall and under frame for electrical equipments Ø Loading and wiring of power panels 10
Partition Frame Ø Honey Comb Partition Frame ü Improved aesthetics ü Very good surface finish ü Corrosion resistance ü Better rigidity ü Higher strength to weight ratio ü Mounted with stainless steel. partition pillar 11
Window & Ceiling Ø Sealed Window Glass Three types of windows have been used in LHB coaches: • Fixed window - 14 Nos. • Emergency open-able window- 4 Nos. • Hopper type window for lavatory - 4 per coach The sealed window units consists of 8. 4 mm outer laminated and 4 mm tempered inner glass with 6 mm Krypton/Argon gas filled. 12
Window & Ceiling Gluing of window frame to shell body - gluing with sikaflex glue - holding with frame for 24 hrs Glass secured by rubber profiles from inside - fixing or locking rubber - sealing rubber 13
Window & Ceiling Emergency open able windows Handle pulls out rubber profile so that glass can be removed Hopper Window for Lavatory 14
Window & Ceiling Ø AC Duct ü Modular design- easy fitment. ü No loss of cooling air ü Superior thermal /sound insulation ü No direct blast of cool air (supply through diffusers) 15
Window & Ceiling Ø Ceiling Panel ü ü ü Improved aesthetics Ability of FRP to be molded into intricate shapes/curved surfaces, avoid joints Better strength to wt ratio No visible screws No corrosion 16
Paneling ü ü ü ü Improved aesthetics Ability of FRP to be molded into intricate shapes/curved surfaces, avoid joints Better strength to wt ratio No visible screws No corrosion Scratch resistance Resilience to small dents 17
Paneling • HPL used instead of LP where FRP is not being used. • FRP trough for AC unit instead of steel. • Loading and fixing of RMPU. 18
Moulding Ø Fixing of various types of moulding e. g. ü Flat moulding ü H-Extrusion ü J moulding ü Z moulding ü Curtain moulding ü Other complex extrusions for ceiling and ducting fixing. 19
Moulding • Various types of Doors – Body side doors – End Wall sliding doors – Compartment doors (both sliding and hinge type). 20
Moulding Ø Body side doors – 04 nos. ü Pivoted type swing sandwich doors ü Stainless steel body filled with phenolic resin for better heat insulation. ü Inside panel of door made of FRP ü Provided with sealed window glass unit. 21
Moulding Ø End wall sliding doors – 02 nos ü Double flap sliding door ü Manual opening and auto closing type door ü Provided with rubber sealing at the door leaf for hand safe feature ü Stainless Steel body filled with phenolic resin for better heat insulation and security of the coaches ü Fitted with 6 mm glass for viewing 22
Moulding Ø Compartment doors – 02 nos. Sliding type in Chair Cars & Swing type in Sleeper coaches 23
Plumbing Ø Water Tanks fixing ü Under slung water tanks module: 685 liters-02 nos and 450 liters 1 no. : Passenger coaches 450 liters- 01 no. : Generator car Under slung water tanks 24
Plumbing ü Fixing detail of under slung water tanks 25
Plumbing ü Auxiliary water tanks of 30 liters capacity: One in each lavatory in the roof 26
Lavatory Ø FRP Modular Toilets ü Improved aesthetics ü No visible screws ü No corrosion üControlled Discharge Toilet System üHidden plumbing üNow Pre-assembled 27
Lavatory Ø Alucobond Lavatory Ceiling Panel Aluca bondsandwiched construction of Aluminium and plastic 28
Lavatory Ø Waste Retention Tank of CDTS 29
Electrical Stage-IX Ø All Electrical accessories fixing e. g. ü Fan ü Tube Light ü Night Light ü Berth reading light etc. 30
Seat & Berth Ø Ø Seat cushion & backrest moulded Fitted with better quality of upholstery AC Chair Car 31
Seat & Berth Magazine Bag Ladder Curtain AC 3 -Tier 32
Seat & Berth SS Luggage Rack Curtain Bottle Holder Snack Table AC 2 -Tier 33
Coach Lowering Ø Lowering of Coach on bogies Ø To Maintain bogie dimensions 34
Air Brake Axle Mounted Disc Brake System with Wheel Slide Protection Unit 35
Air Brake Ø Features of Air Brake System ü Compact panel mounted brake control equipment ü Axle mounted discs ü Brake actuator with integrated slack adjuster ü WSP 36
Shower Testing Ø Water leakage Testing of coach after complete furnishing Ø Roof leakage testing Ø Side wall leakage testing Ø End wall leakage testing Ø Leakage testing from various furnishing interface like glass window frames, AC trough and AC unit, AC bellows etc. 37
QC Inspection Ø Initial inspection of coach by Q/C Staff Ø Defects noticed distributed to various stages of Furnishing for attending and after proper rectification coach re-offered for inspection. 38
Final Inspection Ø Final inspection of coach by Q/C Staff Ø Final clearance of coach by quality after - attention to all quality points - inspection of all stage quality documents like air brake testing. - Shower testing and Electrical testing clearance. - Recieval of coach folder from previous group. 39
Coach ready for dispatch THANK YOU 40
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