DESAIN, PRODUKSI DAN

COMMISSIONING/TESTING

SARANA KA

Yunendar Aryo Handoko ST., PhD

Fakultas Teknik Mesin dan Dirgantara

DEFINISI – UU No 23 Th 2007

PerkeretaapianSatu kesatuan sistem yang terdiri atas prasarana, sarana dan sumber daya manusia, sertanorma, kriteria, persyaratan, dan prosedur untuk penyelenggaraan transportasi kereta api

Kereta apiSarana perkeretaapian dengan tenaga gerak, baik berjalan sendiri maupun dirangkaian dengansarana perkeretaapian lainya, yang akan ataupun sedang bergerak di jalan rel yang terkaitdengan perjalanan kereta api

Sarana perkeretaapianKendaraan yang dapat bergerak di jalan rel

SISTEM PERKERETAAPIAN: SARANA DAN PRASARANA

Centralized

power train

Distributed

power trainUnconventional

Train

Railway Rolling Stock

Spektrum Sarana Kereta Api

Passenger Coach

Freight Wagon

Motive power unit

(Locomotive)

Centralized power train

Steam Loco

Diesel Loco

Electric Loco

Mechanic

Hydraulic

Electric 6 Axle

4 Axle

Bulk Wagon

Box Wagon

Flat Wagon

Solid

Liquid

Gas

Container

Trailer

Open top

Sliding

Single Deck

Double Deck

Intercity

Tourist

Dining

Bagage

Sleeping Power

Tank

Hopper

SPEKTRUM SARANA KERETA API

CENTRALIZED POWER TRAIN

Push-Pull Locomotive

Electric Rail Car

Diesel Rail Car

Distributed power train

D.M.U

Rail Bus

Urban

Suburban

High speed

Metro

LRV

Tramway

Intercity

High Speed

Intercity

Surface

Underground

Elevated

SPEKTRUM SARANA PERKERETAAPIAN

DISTRIBUTED POWER TRAIN

A.G.V

Rubber EMU

Monorail

Unconventional Train

SPEKTRUM SARANA PERKERETAAPIAN

Maglev

Trackless/Autonomous Tram

UNCONVENTIONAL TRAIN

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INTERIOR & EQUIPMENT CARBODY SHELL BOGIEPROPULSION & BRAKING

PRODUK KERETA

1

Rail VehicleProduct Structure

Bogie

Bearing

Bogie Frame

Air Spring

Primary Suspension

Roda

Carbody

Al Ekstrusi cm

Composite

Stainless Steel

Interior

Lighting

Seat

Door System

Panel

Traction Motor

VVVF Driver

Air Conditioner

Compressor

Brake Control Unit

Brake Actuator

Propulsi & Brake System

Static Inverter

RAIL VEHICLES PRODUCT STRUCTURE

Train Control and Management

System

Firmware

Hardware/ Sensor

Coupler

Toilet & Sanitary Eq.

Locking Device

Battery

Misc. Components

Mild Steel

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3

ENTRANCE DOOR PINTU MASUK

BOGIE & BRAKE SYSTEM

RUANG PENUMPANG - SALOON

ATAP

UNIT AC LAMPU SEMBOYAN

GANGWAY BELLOWS

ALAT PERANGKAI -

COUPLER

PLAT PENYEBERANG

- APRON

TOILET -LAVATORY

JENDELA - FIXED WINDOWS

STRIPING IDENTITYJENDELA – EMERGENCY WINDOWS

STAND HAND GRIP

PASSENGER DOUBLE SEAT REVOLVING -

RECLINING

WATER TANK

A- V PUBLIC ADDRESS

GANG - AISLE

VESTIBULE BORDES

EMERGENCY HAND BRAKE

SALOON DOOR

GANGWAY DOOR

PRODUCT STRUCTURE PASSENGER COACH

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4 STRUKTUR PRODUK (STRUKTUR UMUM GERBONG BARANG)

MECHANICAL COUPLER

END BEAMBOLSTERCENTER SILL

END CENTER SILL

CHEKERED PLATE FLOOR

SIDE SILL

TWIST LOCK POINT

EMERGENCY HAND WHEEL

THREE PIECE BOGIE

DISTRIBUTOR VALVE

AIR RESERVOIR

SLACK ADJUSTER

CROSS BEAM

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Sarana kereta api merupakan produk yang “customized” dan spesifikdiperuntukkan untuk kondisi operasional tertentu - yang sangatberhubungan erat dengan kondisi prasarana jalan rel

Diatur oleh regulasi / standard

Outline

specification

Technology

evaluation

Study phase

Component

SpecificationArrangement

Drawing,

Component Layout

Basic design phase

Detail design, Mnf. Drawing

Design phase

Production phase

Fabrication Finishing

Testing & CommissioningPurchasing

Time

OPERATION &

MAINTENANCE

INDUSTRIAL PRODUCT LIFE - CYCLESCOPE OF WORK OF AN INTEGRATED MANUFACTURING INDUSTRY

Quality Assurance Dalam Industri Manufaktur

Customer

Requirement

Marketing for

contract

review

Engineering

for design

process

Design for

ManufacturingProduction

Planning Control Quality Assurance

Management Review

Internal quality Audit

Corrective & Preventive

Action

Control of NC product

Logistic for

Procurement &

storage

Production

Logistic for

Delivery

Service for

after sales

Human resource

for training

Desain Sarana KA

DEPARTEMEN

DESAIN DAN

REKAYASA

Requirement

(Spesifikasi)

•Jadwal desain

•Spesifikasi produk

•Spesifikasi komponen

•Laporan verifikasi desain

•Gambar desain

•Produk manual

•Standard

•Procedure

•Tool

•Resources

Master Schedule

DIAGRAM INPUT-OUTPUT PROSES DESIGN DAN REKAYASA

DESIGN & ENGINEERING FLOW PROCESS • TRAIN PERFORMANCE

CALCULATION

• INTERIOR & EXTERIOR ARRANGEMENT

• ERGONOMIC STUDY

• QUALITY STANDARD REFERENCE

• GOVERNMENT REGULATION

• MAIN COMPONENT SELECTION - DESIGN & SPECIFICATION

• SCHEMATIC : BRAKE, PROPULSION, AUXILLARY SYSTEM, INTERFACE WITH OCC EQUIPMENT

• CLAUSE PER CLAUSE COMMENTARY

• TECHNICAL CALCULATION : STRUCTURAL STRENGTH, BRAKE & PROPULSION PERFORMANCE,

BASIC DESIGN

• BRIEF DESCRIPTION OF PRODUCT CONCEPT

• TECHNICAL SPECIFICATION & ARRANGEMENT DRWG PROPOSED

• VERIFICATION : DESIGN COMPARISON

• ESTIMATION PRICE

• TENTATIVE SCHEDULE

PROPOSAL/ CONCEPT DESIGN

• DESIGNING DETAIL DRAWING

• MANUFACTURING DRAWING

• INSPECTION & TEST REQUIREMENT

• TECHNICAL CALCULATION : AC, PRIMARY & SECONDARY STRUCTURE, BOGIE STRUCTURE, DYNAMIC ANALYZE, AIR CONSUMPTION, BATTERY

• INTERFACE SYSTEM :

• BRAKE & PROPULSION,

• INTERLOCK DOOR

• HV & LV SUPPLY SYSTEM,

• ATO –ATP – BRAKE –PROPULSION

• BOGIE TO BODI

• BOGIE COMPONENT

• DRIVER CONTROL

DESIGN DETAIL

Reability, Availability, Maintainability & Safety

Source: EN 50126 Standard

RAMS must be planned and engineered

Carbody Design Requirements

❖ Operational Characteristic (strength, durability, etc.)

❖ Safety (e.g crashworthiness)

❖ Aesthetics (good in appearance) and Comfort

❖ Economic (Low Cost, Energy Efficient)

Material Selection Construction Design

CARBODY DESIGN ATTRIBUTES AND THEIR IMPACTAttribute Impacts

Lightweight • Increased payload, high acceleration from propulsion, energy saving, lower emission, reduce track maintenance cost

• Higher initial cost --> expected to be repaid within several years of operation

Stiff Structure & Durability • Passenger Safety• Comfort, reduce structural vibration and noise• Lower maintenance, high salvage value

Corrosion resistance • Long service life, low maintenance• Reduces or eliminates painting

Fabricability (including extrudeability, formability, weldability, etc)

• Novel design• Integrally stiffened section with decreased weight• Improved side wall design, reduce labour• Reduces number of components• Reduces need for welding / machining

Recycleability • Retains high value at end-of-life• Support a sustainable industry

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Teknologi Konstruksi Badan Kereta

Pertimbangan Dalam Merancang Badan Kereta

Daya Angkut Besar

Hemat Konsumsi Bahan

Kekakuan Tinggi

Harga Tegangan Kecil

Konstruksi

Besar & BeratKonstruksi

Kuat

Konstruksi

Lemah

Konstruksi

Ringan

Desain &

Pemilihan Material

Light Weight Carbody Design Process

Car Body

Weight Reduction

Construction

Monocoque Structure

(Layout, dimension, panels, doors,

windows, etc)

Material

Material Selection:

High tensile steel

Stainless steel

Aluminium Alloy

FRP / Composite

Etc

Stress Analysis

And Confirmation

Strenght and Rigidity

Construction

Re-arrangement & Re-modelling

(including dimension, number of

components and panels, doors,

windows, etc.)

Stress flow & consentration

Partial reinforcement

Material

Rational application according to

function and position

Miscellaneous

Thinner sheeting, weight saving,

perforation, etc, which is consistent

to the design parameters

Evaluation

Cost

Maintainability

Serviceability

etc

Lightweight Car Body

MATERIAL SELECTION

• Light weight

• Strength & Stiff Structure

• Durability

• Corrosion Resistance

• Fabricability• Formability

• Extrudability

• Weldability

• Recyclability

• STAINLESS STEEL

• ALUMINIUM

• COMPOSITE

CONSIDERATION:

Konstruksi Badan Kereta: Steel / Baja

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Konstruksi Badan Kereta: Stainless Steel

Konstruksi Badan Kereta Aluminium

ENGINEERING

ANALYSIS

DESIGN FOR

MANUFACTURING

PROTOTYPING

& TESTING

FE ANALYSIS

ENGINEERING DESIGN FOR CARBODY DEVELOPMENT

Aerodynamics Analysis

Parameter Desain Bogie• Kondisi Prasarana:

• Ruang Bebas (loading gauge)• Lebar Sepur (track gauge)• Radius Lengkung (curve radius)• Ketidakrataan Jalan Rel (track irregularity)

• Dimensi Utama Bogie:• Jarak gandar (bogie wheel base)• Jarak journal spring, damper & bearing/axle box (primary suspension)• Jarak secondary spring, vertical & lateral damper• Posisi traction rod, mechanical brake (tread brake/disc brake), dan

komponen lainnya seperti motor traksi, leveling valve, speed sensor dll.

• Berat Bogie dan Komponen

• Performansi Operasional: • Kecepatan operasi di track lurus dan di jalur lengkung• Kenyamanan (ride index/quality)

• Dan lain-lain kondisi operasi seperti kondisi lingkungan, fasilitasdan interval perawatan.

Ketidakrataan jalan rel

• Gage

• Lateral /alignment

• Vertical

• Cross Level

Verifikasi Dan Kalkulasidalam Rancang Bangun dan Rekayasa Bogie

• Kekuatan Struktur Rangka Bogie• Static

• Fatigue/Dynamic

• Performansi dinamik bogie• Stability / critical speed

• Curving performance

• Derailment Sensitivity

• Ride quality

• Gaya-gaya pengereman dan traksi

Perhitungan Kekuatan Struktur Rangka BogieSTATIC ANALYSIS BY FEA

Typical Task Analysis & Calculation Method in Train Dynamics Simulation

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Trai

n B

rake

Sys

tem

AUTOMATIC AIR BRAKE

ELECTRIC DIGITAL COMMAND AIR BRAKE

ELECTRIC ANALOGUE COMMAND AIR BRAKE

ELECTRIC AND REGENERATIVE BRAKE (DYNAMIC BRAKE)

Pengereman Kereta Api

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• Umumnya menggunakan sistem udara tekan• Aktuator dapat berupa brake cylinder atau brake caliper

Disc BrakeThreadBrake

Actuator Komponen friksi

Brake Pad

Brake Block

Pengereman Kereta Api

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• Transmisi yang menggunakan fluida untuk menyalurkan daya dari Mesin diesel ke Roda

• Terdiri dari : • Mesin Diesel

• Turbo Transmision / Transmisi

• Cardan Shaft / Poros Gardan

• Gear Box

PROPULSI (Transmisi Diesel Hidrolik)

12

• Merubah daya putar Mesin Diesel menjadi daya listrik menggunakan Generator Listrik yang akan dipakai oleh Motor Listrik untuk menggerakkan Roda

• Pengaturan kecepatan dilakukan dengan mengubah parameter daya listrik dari generator / alternator yang masuk ke motor

Skematik diagram Transmisi Diesel Elektrik AC-AC :

Mesin Diesel sama dengan yang digunakan untuk Transmisi Diesel Hidrolik

PROPULSI (Transmisi Diesel Elektrik)

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• Merubah daya listrik kabel LAA menjadi energi gerak melalui motor listrik

• Ada 2 macam yaitu sistem AC - AC dan sistem DC - AC

PROPULSI (Transmisi Elektrik, KRL

Diagram sistem AC-AC

Diagram sistem DC-AC

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Pantograph

Inverter

Motor ListrikGear Box

Rectifier

Main Transformer

14

• Transformator menurunkan tegangan arus AC kabel aliran atas yang tinggi (25KV) menuju level yang lebih rendah

• Rectifier mengubah tegangan AC menjadi tegangan DC• Inverter merubah tegangan DC kembali menjadi tegangan AC namun dengan frekuensi yang diatur untuk

mengatur putaran motor listrik

PROPULSI (Transmisi Elektrik, KRL AC-AC)

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PantographInverter

Motor ListrikGear Box

Inverter merubah tegangan DC kembali menjadi tegangan AC namun dengan frekuensi yang diatur untuk mengatur putaran motor listrik

PROPULSI (Transmisi Elektrik, KRL DC-AC)

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Merupakan suatu unit AC terpusat Agar distribusi pendinginan merata penyaluran udaramenggunakan sistem ducting

Air-conditioners for Greater Cairo Metro Line No.3

System Configuration

AC Kereta Api

Proses Produksi

FINAL INSPECTION

CARBODYPAINTING

INTEGRASI PROSES PRODUKSI

DESIGNENGINEERING

LOGISTIK FABRIKASI FINISHINGTEST &

COMMISIONINGPURNA JUAL &PERAWATAN

CUTTINGWELDINGSUB-ASSEMBLINGON JIG

CARBODYFINALASSEMBLING

INTERIORTRIMMINGWIRING

EQUIPMENTFITTING

BOGIEMOUNTING

BOGIEWELDINGMACHINING & ASSEMBLING

TESTING COMMISIONING

2

Carbody Manufacturing – Aluminium Carbody

Aluminium billet

Sub-assembly panel:

- Underframe

- Side wall

- Roof

- End wall

- Nose

Aluminium

extrusion panel

Finished carbody shell

Finished car

SUB ASSEMBLY IN ASSEMBLING WORKSHOP

SETTING JIG, MATERIAL PREPARATION

SUB ASSY WELDING, JOINING, BONDING ON JIG

CARBODY ASSEMBLY IN ASSEMBLING WORKSHOP

Carbody Assembling Line Process of Carbody Assembling

EQUIPMENT INSTALLATION IN FINISHING WORKSHOP

Line Equipment Fitting

Using Tack system

On Roof Eqp fitting

Wiring & Interior fitting

Beneath U/F Eqp fitting

BOGIE MOUNTING & INTERIOR FITTING IN FINISHING WORKSHOP

Lifting Jack, pit, line for pipe-bogie connection

Bogie Mounting

Interior fitting

Air piping & connection to eqp beneath U/F

PEMERIKSAAN, PENGUJIAN DAN SERTIFIKASI SARANA KA

Definisi

• Pemeriksaan adalah aktifitas untuk memastikankondisi suatu komponen atau sarana KA secarakeseluruhan sesuai dengan yang dipersyaratkan

• Pengujian adalah aktifitas untuk memastikan / menvalidasi bahwa performansi (unjuk kerja), sifat dan karakteristik suatu komponen atausarana KA secara keseluruhan sesuai denganyang dipersyaratkan

• Sertifikasi adalah suatu rangkaian aktifitas / proses untuk memberikan sertifikat layakoperasi/layak guna terhadap suatu tipekomponen atau terhadap suatu tipe sarana KA secara keseluruhan.

Dokumen Acuan

• Standar dan Regulasi

• Spesifikasi Teknis

• Manual/Petunjuk Pengoperasian

• Manual Perawatan

• Dokumen lain yang disepakati oleh para pihak(Mis: Notulen rapat, Laporan pengujianterdahulu, dll)

Macam-macam Pemeriksaan Sarana KA

• Pemeriksaan pertama saat barang keluar pabrik

• Pemeriksaan untuk keperluan uji pertama dan sertifikasi

• Pemeriksaan utuk keperluan uji berkala

• Pemeriksaan saat perawatan rutin/berkala atau insidentil

• Pemeriksaan harian:• Saat sarana KA akan dioperasikan (pre-departure inspection)

• Saat beroperasi (di stasiun/pos tertentu)

Macam-macam Pengujian Sarana KA

• Uji Pertama dan Uji Berkala

• Uji Statik dan Uji Dinamik

• Uji Beban (Statik) dan Uji Lelah (Fatigue)

• Uji Merusak / Tak Merusak

• Uji Komposisi material

TESTING AT ASSEMBLY WORKSHOP: CARBODY STRUCTURE TEST

COMPRESSION LOAD TEST ON U/F AS PRIMARY STRUCTUREVERTICAL LOAD IN CRUSH LOAD

CONDITION, EACH CRITICAL POINT WILL BE MEASURED USING PRECISION STRAIN GAUGE

STATIC TEST WITH ACTUAL LOAD VALUE AS DESIGN REQUIREMENT

BOGIE FRAME & POWERPACK FRAME FATIGUE TEST

Fatigue Test dengan beban dynamic

Bekerja sama dengan LUK Serpong

TESTING IN FINAL INSPECTION WORKSHOP: EQUIPMENT PERFORMANCE TEST

FINAL INSPECTION PIT

ELECTRICAL SYSTEM TEST

BOGIE AND AIR PRESSURE SYSTEM TEST

DRIVER CONTROL AND LIGHTING TEST

TESTING AT FINAL INSPECTION WORKSHOP: WEIGHT MEASUREMENT, LOADING GAUGE, RAIN TEST, DYNAMIC TEST

RAIN TEST, WEIGHT MEASUREMENT EQUIPMENT AND LOADING GAUGE

1.500 KVA POWER SUPPLY & SUB STATION FOR DYNAMIC TEST

• BRAKE SYSTEM : BRAKING TIME, STOPPING DISTANCE

• DRIVING SYSTEM

• ANTI SKID SYSTEM

• ELECTROMAGNETIC INTERFERENCE

• FAIL SAFE CONCEPT : ATP INTERFACE, POWER FAIL, FLAT TYRE, DOOR INTERLOCK, TMS COMMUNICATION

• RESCUE SIMULATION

SAFETY :

COMFORT

PERFORMANCE

• LIGHTING PERFORMANCE / LUX VALUE

• TEMPERATURE, HUMIDITY, HOMOGENOUS AIR FRESH DISTRIBUTION

• VIBRATION LEVEL AND NOISE

• DRIVER ERGONOMIC

• PASSENGER INFORMATION DISPLAY

• ACCELERATION AND DECELERATION

• MAXIMUM SPEED

• CURVE MANUVER

• PASSENGER CAPACITY & HANDICAP ACCESIBILITY

OPERATIONAL TEST

IN MAIN LINE

(DYNAMIC TEST)

THANK YOU