Modernization of the braking system of freight railcars

Modernization of the braking system of freight railcars

Logistics and Transport
Reconstruction and Construction

JSC “Ukrzaliznytsia”

Problem

Due to the imperfect design of the brake lever transmission, uneven brake shoe wear occurred, which led to:

 

  • increased rolling resistance and excessive fuel consumption;
  • loss of braking efficiency;
  • premature replacement of brake shoes (service life was reduced by a factor of 3);
  • wheel damage, increased repair costs, and disposal expenses.

 

Solution:

An engineering-based modification of the triangle linkage kinematics was implemented, eliminating the harmful torque. The system was enhanced with a guiding mechanism that equalizes the gaps between the brake shoes and the wheels when the brake is released. The solution was tested in a pilot on 10 wagons, confirming its scalability.

Result
  • wedge-shaped (klinodual) wear eliminated;
  • brake shoe lifespan increased from 70,000 km to 210,000 km;
  • reduced repair and replacement costs;
  • reduced diesel fuel and electricity consumption;
  • improved operational safety.
Economic effect:
  • ₴727,725 in savings per wagon over the estimated service life (22 years).
  • ₴62.7 billion — potential savings for the entire fleet of freight wagons (over 86,000 units).
  • ₴4,155 per wagon annually — the effect of reduced harmful emissions and fuel consumption in diesel locomotive traction (environmental efficiency component).