LREE-9313H.pdf

lree-9313h

MASSACHUSETTS

BAY

TRANSPORTATION

AUTHORITY

TECHNICAL SPECIFICATION

LREE - 9313

SPECIFICATION FOR RESILIENT WHEELS

ISSUED:

REVISION A:

REVISION B:

REVISION C:

REVISION D:

REVISION E:

REVISION F:

REVISION G:

REVISION H:

10/28/93

12/20/93

01/27/94

02/04/94

03/07/94

04/13/94

06/01/94

02/08/95

LIGHT RAIL EQUIPMENT ENGINEERING

LREE - 9313H

TABLE OF CONTENTS

DESCRIPTION PAGE #

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

3.0 VARIATIONS

3.1 Conflicts

3.2 Oral Statements

4.0 REQUIREMENTS

4.1 General

4.2 Quality

4.3 Handling

4.4 Workmanship

4.5 Performance

4.6 Wheel Design

4.7 Mechanical

4.8 Rubber Blocks

4.9 Assembly/Disassembly

4.10 Tire Slippage

4.11 Material

4.12 Electrical

4.13 Vibration and Shock

4.14 Environmental

4.15 Speed

4.16 Noise

4.17 Wear

4.18 Deflection

4.19 Wheel Trueing

4.20 Corrosion Protection

4.21 Identification

4.22 Warranty

4.23 Technical Support

4.24 Quality Assurance

4.25 Delivery

5.0 PREPARED BY

6.0 APPROVALS

7.0 REVISIONS

ADDENDA ........................................................................................................................ 12-14

ATTACHMENTS ............................................................................................................. 15-17

1.0 SCOPE

1.1 This specification establishes the requirements for the manufacture of resilient wheels used on the Type 7 SRC.

2.0 APPLICABLE DOCUMENTS

2.1 The following documents form part of this specification to the extent specified herein:

MBTA Documents Description

47530 Shunt for Resilient Wheel (See page 15)

47638 Wheel Components (See page 16)

47639 Wheel Profile (See page 17)

3.0 VARIATIONS

3.1 Conflicts

Any conflicts shall be referred in writing to Light Rail Engineering for resolution.

3.2 Oral Statements

Oral statements by any person or persons shall not be permitted in any manner or degree to modify or otherwise affect the requirements of any portion of this specification.

4.0 REQUIREMENTS

4.1 General

4.1.1 Subject to the MBTA's standard maintenance practices and operating procedures, the Resilient Wheels shall be designed for normal revenue service use and a minimum service life of 25 years in the Boston environment.

4.1.2 Proposals offering equipment not meeting the entire scope of this specification shall not be acceptable.

4.1.3 The resilient wheel shall be referred to as wheel throughout this

4.1.4 The wheel shall have six (6) principle components. A wheel center, a tire, rubber blocks, compression ring, current conductors (shunts), locking bolts. Refer to MBTA Drawing 47638. (See page 16)

4.1.5 Wheel replacement components, such as rubber blocks, shunts and o-

(D1)

(D2) rings, excluding failure caused by misuse, shall not require replacement prior to the useful life of the tire as defined in section 4.17 of this

4.1.6 The wheel shall be resilient and provide both noise damping and shock absorbing qualities.

4.2 Quality

4.2.1 Wheels shall be processed in a careful and workmanlike manner in accordance with good design and sound practice and shall be free from defects that affect life, serviceability and/or appearance.

4.2.2 All workmanship shall be of high grade and shall conform to the best machine tool industry practices in all respects for railway passenger cars and surface rail vehicles.

4.2.3 All surfaces shall be smooth, free from burrs, fins and other sharp projections.

4.3 Handling

4.3.1 The wheels shall be adequately protected during shipping, handling and storage to prevent damage.

4.3.2 The wheels shall be packaged in sets of four (4) and matched in diameter to within 0.012 inches. The diametric measurement shall be made on the taping line of the tire. Reference Drawing No. 47639. (See page 17)

4.4 Workmanship

4.4.1 The wheels shall be delivered clean with all cutting oils and grease removed.

Any chemical used to clean the wheels shall not cause damage to the wheel material.

4.4.2 Wheels shall not be reworked without prior notification and approval by

Light Rail Engineering.

4.5 Performance

The wheels shall have a service proven performance history of five (5) years minimum on revenue service light rail vehicles.

4.6 Wheel Design

4.6.1 The rubber cushioned single ring resilient wheel design shall consist of an annular arrangement of equally spaced individual rubber blocks between the tire and the wheel center. The design shall allow for spring travel of the

(G1)

(B1)

(C1) rubber blocks in the radial, axial and tangential direction. The design of the wheel shall be such that the rubber blocks are deformed, under normal operating conditions, over the total cross sectional area and are able to withstand the high shear and compression forces of MBTA service. The design shall not place high tensile loading on the rubber blocks.

4.6.2 The compression ring, used to secure the rubber blocks and the tire on the wheel center, shall have a tapered fit for the purpose of securing the tire to the wheel center. The compression ring shall be assembled by use of four

"power" bolts, and when completely assembled with an adequate number of locking bolts shall have a press fit against the wheel center sufficient to insure the integrity of the wheel.

4.6.3 This specification describes an acceptable resilient wheel design. An approved equal resilient wheel design may be considered providing the design meets all of the other requirements and the intent of this specification. In all areas of non compliance the bidder must provide documentation proving the alternate design is equal to or better than the specified design. The Authority will be the sole judge in determining if the alternate design is acceptable. All documentation must be submitted at the time of the bid submission.

4.6.4 All bids must include a drawing and technical description of the proposed wheel to be considered responsive.

4.7 Mechanical

4.7.1 The wheel diameter shall be 26 inches nominal. The tolerance limits of the wheel diameter shall be + 0.25/- 0 inches. The flange width shall be 1+1/32-

0 inch. Wheels shall be supplied in marked sets of four (4) matched in diameter to within 0.012 inches. The wheel condemning limit diameter shall be 24-0 inches.

4.7.2 The total width of the tire tread, including the flange, shall be four (4) inches as defined in MBTA Drawing 47639. The wheel, under all wear conditions, must not interfere with the existing MBTA track system.

4.7.3 The following two (2) requirements describes the wheel-axle interface and an acceptable axle that is within tolerance:

4.7.4 When the wheel/axle assemblies are rolled on the journals, treads shall not show total indicator readings greater than 0.020 inches in a radial direction nor greater than 0.024 inches in a direction parallel to the axle center line.

4.7.5 The rough machined inside diameter of the wheel center shall be 4.875

+0.005/- 0.000 inches.

(D3)

(F1)

(D4)

(D5)

(G2)

(C2)

(F2)

(D6)

(D7)

4.7.6 The finished inside diameter of the wheel center (5.089/5.090") shall be related to the diameter of the seat on the axle (5.095/5.096") so as to obtain a press fit in accordance with the Authority's standard practice of ten tons per inch of seat diameter (minus 0 + 20 tons) for wheels. The MBTA will be responsible for the final inside finish diameter and surface finish.

4.7.7 The surface finish of the wheel center shall be 63 micro inches.

4.7.8 The width of the seat on the axle shall be 5.650 0.020 inches.

4.7.9 The wheels must fit on the existing axles without requiring any modifications or extra machining of the axles.

4.8 Rubber Blocks

4.8.1 The elastomeric rubber blocks shall be compressed by approximately 30% when assembled with an interference fit between the compression ring and the wheel hub. Every rubber block shall be tested by the supplier for back pressure at service load prior to use on a wheel assembly. The rubber blocks shall be matched to use on a wheel assembly. The rubber blocks shall be matched in each tire by back pressure. Each rubber block shall be identified so that the blocks can be matched in wheel assemblies by MBTA maintenance personnel. The rubber blocks shall be made of heat resisting natural rubber grade FHFN 80 capable of withstanding temperatures of

230F maximum during continuous operation. The resilience of the rubber blocks shall be optimized for maximum shock absorption and noise reduction. The rubber blocks shall not be secured to the wheel assembly by use of fasteners or adhesives.

4.8.2 Deterioration, in any form, of the rubber blocks is unacceptable.

4.8.3 The rubber blocks shall have a useful service life of at least the service life of the tire.

4.8.4 The supplier shall provide proof that surface cracking of the rubber blocks is not detrimental to the performance of the wheel.

4.9 Assembly/Disassembly

4.9.1 The tire must be removable and installable while on the vehicle with the use of simple hand tools and a minimum amount of disassembly/reassembly time with a minimum expenditure of manpower.

4.9.2 The compression ring shall have a hydraulic or equivalent assist for ease of

(D8)

(F3)

(D9) removal.

4.9.3 The wheel center shall have a hydraulic or equivalent assist to aid in the removal from the axle. The assist shall include an internal annular groove in the hub, a threaded connection for the pressure application device at the outer end of the port, and a secure closure for the threaded connection. The threaded connection shall be removable with standard tools and be of a non-metallic, non corrosive material.

4.10 Tire Slippage

4.10.1 Slippage of the tire in relation to the wheel center in either the clockwise or the counter clockwise direction is unacceptable under any conditions.

Slippage of the tire in relation to the wheel center will be monitored by

MBTA personnel during periodic inspection intervals. Witness mark alignment on the tire and wheel hub, will be the criteria used for monitoring slippage. The supplier shall be responsible for marking each wheel with witness marks in 2 places. Witness marks shall be a 1 inch by 3 inch stripe using permanent white paint.

4.10.2 The tire shall be able to withstand a vehicle weight of 142,500 pounds without slippage. The static weight distribution over each wheel shall be as follows:

A-Truck 13,181 lbs/wheel

B-Truck 13,500 lbs/wheel

C-Truck 8,944 lbs/wheel

4.10.3 Tire slippage shall not be induced by the spin/slide system.

4.11 Material

4.11.1 The tire shall have a hardness of 321 to 363 BHN.

4.11.2 The tires shall be rolled steel and meet the requirements of AAR M-107, Class C with a carbon content of 0.67 to 0.72 weight percent.

4.11.3 The conical compression ring shall be AISI-1045 forged steel.

4.11.4 The wheel center shall be AISI-1045/1055 forged steel.

4.11.5 The locking bolts shall be commercially available property Class 10.9 or

12.9.

(D10)

(D11)

(F4)

(D12)

(E1)

4.12 Electrical

4.12.1 Each wheel assembly shall have a minimum of two (2) external shunts to provide conductive paths for current around the resilient rubber material from the wheel center to the wheel tire.

4.12.2 The wheel shunts shall be made of #4 AWG tin copper flexible cable according to Drawing 47530 (See page 15). The supplier has the option of providing an equivalent wheel shunt.

4.12.3 The shunts on each wheel assembly shall be capable of carrying 300 amps of current without overheating.

4.12.4 Each wheel assembly shunt shall be secured to the wheel center and the wheel tire with removable steel screws.

4.12.5 The shunts shall be reusable on wheel assemblies unless damaged in service.

4.12.6 No internal shunts may be utilized.

4.12.7 The electrical resistance between the wheel center and tire with shunts in place shall be less than 10 milli-ohms. The electrical resistance of a wheel assembly that has been in service shall not exceed 100 milli-ohms.

4.13 Vibration and Shock

4.13.1 The wheels shall be designed to withstand vibrations of not less than 10g at frequencies up to 100Hz in all directions and shock loads of not less than

15g in each major axis.

4.13.2 The wheels shall reduce impact acceleration at rail curve and rail joints by approximately 40% when using a solid wheel as a reference.

4.13.4 Upon request the wheel supplier shall provide test data on impact acceleration reduction.

4.14 Environmental

4.14.1 The wheels shall be able to operate satisfactorily in an operating temperature environment of -30 to 120F. Satisfactory operation includes no slippage of the tires.

4.14.2 Rain, snow, humidity, cleaning detergents and snow melting chemicals shall not effect any of the wheel materials.

(D13)

(D14)

(D15)

4.15 Speed

The wheels with any condition of wear within the non-condemnable range shall be capable of withstanding constant operating speeds of 0 to 65 miles per hour with the capability of withstanding speeds of 85 miles per hour for one (1) hour.

4.16 Noise

4.16.1 The wheels shall reduce air borne noise caused by curve squeal at a distance of 10 feet from the center of the vehicle by 20 d B/A minimum when using a rigid wheel as a reference when operating on tight radius curves and dry track.

4.16.2 The wheels shall reduce air borne noise inside the vehicle caused by curve squeal by 5 d B/A minimum when using a solid wheel as a reference.

4.16.3 Upon request the wheel supplier shall supply test data verifying noise reduction.

4.17 Wear

Tire wear life at minimum shall be equal to or greater than the existing Green Line wheels. It is expected that tire wear life shall be 300,000 miles minimum.

4.18 Deflection

The resilient wheels shall have a radial deflection of 0.024 to 0.035 inches under five (5) ton wheel loads.

4.19 Wheel Trueing

4.19.1 The resilient wheels shall be designed for reprofiling of tread and flange by use of conventional underfloor contour machines. No special tooling or procedures will be required.

4.19.2 The wheels shall be profiled according to MBTA Drawing 47639

(See page 17).

4.20 Corrosion Protection

4.20.1 A protective coating shall be applied to the tire to prevent corrosion and/or rust during shipment and storage. The protective coating shall not effect the braking rate of the vehicle.

(D16)

(D17)

4.20.2 The inner diameter of the wheel tire and the outer diameter of the wheel center, where the rubber block is in contact, shall be painted with a completely solid layer of zinc dust paint.

4.20.3 'O' ring seals shall be provided to prevent corrosion of the retaining ring/wheel center interface.

4.21 Identification

Tire markings shall be in accordance with Figure 4 and center markings shall be in accordance with Figure 5 of the AAR Specification M-107. Both the tire and wheel center shall be serialized. The list of serial numbers shall be provided by the supplier to the MBTA. The documentation shall indicate wheel center and tire serial numbers. Traceability to material and manufacturing details of the above components is also required.

4.22 Warranty

4.22.1 The supplier shall warrant the wheels against defect in design, materials or workmanship for a period of six years from the date of each installation on revenue service vehicles. The supplier shall not be responsible for defects caused by normal wear.

4.22.2 Upon MBTA notification in advance to the supplier, wheels exhibiting defects which are determined by the MBTA to be the responsibility of the supplier, shall be repaired or replaced at the suppliers expense. The supplier will be required to replace all defective material at no cost to the MBTA and to compensate the MBTA for all warranty labor at the MBTA's prevailing labor rate, including overhead loading, up to a maximum of 20% of the wheel cost. Wheels requiring full removal and replacement will be billed for labor at the full 20% of the wheel cost. Replacement items shall be warranted for the full term of the warranty period from the date of the replacement installation.

4.22.3 Wheel defects which occur on 5% or greater of the total quantity of installed wheels still under warranty shall constitute a design defect. Under these circumstances the supplier shall be required to submit a design change for

MBTA approval for correction of the defect. Upon MBTA approval, the supplier shall be responsible to supply the redesigned component or assembly at no cost to the MBTA and pay the MBTA's labor as described herein to correct all wheels, including those out of warranty and those not yet installed.

4.23 Technical Support

4.23.1 Three (3) complete sets of tooling, fixturing and equipment for the assembly and disassembly of the wheel shall be provided by the wheel supplier.

(A1) (A2)

(B2) (C3)

(D18)

(G3)

4.23.2 The supplier shall provide 3 sets of manuals and 3 sets of drawings describing the use and care of tooling, fixturing and equipment.

4.23.3 The supplier shall provide 25 sets of an assembly and disassembly procedure, and 4 sets of an assembly and disassembly video.

4.23.4 The supplier shall provide 5 sets of drawings and technical documentation describing the wheel assembly.

4.23.5 The supplier shall be available for timely visits to MBTA facilities for technical discussions, demonstrations and corrective action to problems that may arise.

4.23.6 The supplier shall provide specifications for special materials such as screws, gaskets, and o-rings used in the wheel assembly.

4.23.7 The supplier shall be responsible for supplying materials, tooling, fixturing, equipment, drawings, documentation and support over the life of the wheel assembly. In the event the supplier is unable to provide support, the supplier shall provide to the MBTA all detailed manufacturing drawings and documentation required for the manufacture of components necessary for the continued use of the wheel assembly.

4.24 Quality Assurance

4.24.1 The MBTA reserves the right to conduct destructive and non-destructive testing and mechanical measurements of the wheels and to reject a wheel lot if a sample wheel from that lot does not meet the requirements of this

4.24.2 The usage of the wheel is a safety sensitive application and therefore ultimate wheel integrity is required.

4.24.3 Certificates of Compliance verifying characteristics (chemical, physical) of the wheels must be supplied with each shipment.

4.24.4 Acceptance of the wheels is based upon a first article inspection of a wheel that is in strict compliance with this specification.

4.25 Delivery

Delivery shall commence 18 to 22 weeks maximum after notice to proceed.

Delivery shall be 50 wheels per month over a two year period for a total of 1200 wheels.

(C4)

(D19)

(B3) (C5)

(D20)

(G4)

5.0 PREPARED BY

Original Issue Signed By: Date: 10/28/93

Louis A. Tobio, Jr.

Engineer

6.0 APPROVALS

Original Issue Signed By: Date: 10/28/93

Edward A. McDonald

Acting Manager

Light Rail Equipment Engineering

Original Issue Signed By: Date: 10/29/93

James E. Thys

Superintendent

Green Line Maintenance

7.0 REVISIONS

SECTION DATE DESCRIPTION REVISION

Updated specification to current format H

ADDENDA

Addendum numbered 1-42 have been incorporated into the text of this specification.

The identifying number of the applicable Addendum has been placed in the right hand margin of the page adjacent to each revision by Addendum.

ADDENDA DATE DESCRIPTION REVISION

Addendum No. 1 (A1) December 20,1993 removed premature A

Addendum No. 2 (A2) December 20, 1993 before failure A

Addendum No. 3 (A3) December 20, 1993 added statement A

Addendum No. 4 (A4) December 20, 1993 added 25 sets A added 4 sets

Addendum No. 5 (A5) December 20, 1993 added statement A

Addendum No. 6 (A6) December 20, 1993 added statement A

Addendum No. 7 (B1) January 26, 1994 added statement B

Addendum No. 8 (B2) January 26, 1994 added statement B

Addendum No. 9 (B3) January 26, 1994 added statement B

Addendum No. 10 (C1) February 4, 1994 removed second sentence C

Addendum No. 11 (C2) February 4, 1994 added statement C

Addendum No. 12 (C3) February 4, 1994 changed warranty C

Addendum No. 13 (C4) February 4, 1994 added statement C

Addendum No. 14 (C5) February 4, 1994 changed delivery C

Addendum No. 15 (D1) March 7, 1994 added statement D

Addendum No. 16 (D2) March 7, 1994 added statement D

Addendum No. 17 (D3) March 7, 1994 remove bolt quantity D

& reworded statement

Addendum No. 18 (D4) March 7, 1994 added statement D

ADDENDA (cont.)

Addendum No. 19 (D5) March 7, 1994 added condemning limit D

Addendum No. 20 (D6) March 7, 1994 corrected spelling D

Addendum No. 21 (D7) March 7, 1994 added statement D

Addendum No. 22 (D8) March 7, 1994 added final finish statement D

Addendum No. 23 (D9) March 7, 1994 added equivalent statement D

Addendum No. 24 (D10) March 7, 1994 added equivalent statement D

Addendum No. 25 (D11) March 7, 1994 added marking statement D

Addendum No. 26 (D12) March 7, 1994 added wheel loading weights/truck D

Addendum No. 27 (D13) March 7, 1994 added statement D

Addendum No. 28 (D14) March 7, 1994 reworded statement D

Addendum No. 29 (D15) March 7, 1994 changed temperature range D

Addendum No. 30 (D16) March 7, 1994 revised statement D

Addendum No. 31 (D17) March 7, 1994 revised & added statement D

Addendum No. 32 (D18) March 7, 1994 changed warranty D

Addendum No. 33 (D19) March 7, 1994 revised & added statement D

Addendum No. 34 (D20) March 7, 1994 added delivery statement D

Addendum No. 35 (E1) April 12, 1994 rev. vehicle weights & distribution E

Addendum No. 36 (F1) June 1, 1994 added statements F

Addendum No. 37 (F2) June 1, 1994 changed statement to include F flange & total width

Addendum No. 38 (F3) June 1, 1994 added statement for fit and F machining

Addendum No. 39 (F4) June 1, 1994 added static to statement F

ADDENDA (cont.)

Addendum No. 40 (G1) February 8, 1995 added statement for packaging G

Addendum No. 41 (G2) February 8, 1995 changed pairs to marked G sets of four (4)

Addendum No. 42 (G3) February 8, 1995 changed warranty from G

5 to 6 years

Addendum No. 43 (G4) February 8, 1995 changed delivery from 100 G wheels/mo over 1 year to

50 wheels/mo over 2 years