FIELD OF INVENTION
The present invention relates to manufacturing of load test rig for load testing different
components of 280t wagon, inline with the Research design and standard organisation
requirements.
BACKGROUND OF THE INVENTION AND PRIOR ART
• BHEL Jhansi developed 24-axle, 280t especial wagon for BHEL Haridwar for
transportation of the stator of Turbo Generators from BHEL Haridwar to the
power plant site.
• Since this wagon loaded with the stator has to travel on Indian Railway track and
to get certificate from railway for running the wagon on Indian Railway track we
• have to follow all the testing norms of the wagon and its components laid by
Research design and standard organization (RDSO) the design department of
Indian Railway.
• The testing norms for the wagon and its components laid by RDSO are very
stringent because any failure during running will cause blockage of track and
shall affect the train movement.
• For testing the components/part assembly of wagon the test rig has been
designed and developed with the testing capacity of 300t.

• Thus the test rig design was proven practically and also to be correct.
• Using the test rig the load testing was performed successfully on following
parts/sub assembly of the 280t special wagon according to the testing norms
• defined by RDSO
a) Intermediate bridge (Inner)
b) Intermediate bridge (Outer)
c) Main Bridge
d) Bolster assembly
e) Bogie assembly
• Before the design and development of the test rig by BHEL Jhansi, the
following method of testing was in practice.
1) The component to be tested is supported on actual support.
2) Load is applied on loading points as per the scheme using the
steel plates and other material as dead load.
3) Noting the parameters to be recorded
4) Finally removal of load
• The above method of testing had the following demerits.
1) Can not achieve accurate load value using dead loads
2) Due to volume of dead weights the load gets applied on area
in place of point, thus we may not get the accurate results.
3) Putting the dead load without securing sometimes becomes
risky.

4) The loading and unloading process was very time consuming
5) The overall cost of testing was very high in terms of man
hours.
Therefore, there existed a need to develop a test rig for load testing of wagon
components which can eliminate the disadvantages of prior art.
OBJECTS OF THE INVENTION
Therefore it is an object of the invention to propose a load test rig for testing of
components of 280t special wagon which can eliminate the disadvantages of prior art.
Another object of the invention is to propose a load test rig for testing of components
of 280t special wagon which is cost effective in terms of time and manpower.
A still another object of the invention is to propose a load test rig for testing of
components of 280t special wagon which is capable of producing accurate test results
by applying the load at specific location.
A further object of the invention is to propose a load test rig for testing of components
of 280t special wagon which eliminates the risk involved during the load test.

A still further object of the invention is to propose a load test rig for testing of
components of 280t special wagon which is capable of testing the components other
than wagon like bogies of locomotive based on the requirement.
SUMMARY OF THE INVENTION
A load test rig was developed for load testing of different components of the 280t
wagon. As per RDSO requirement the components were to be tested at different loads
for components as specified in load test scheme shown in Table-1. The geometry and
overall dimensions of the test rig were finalized based on the maximum dimensions of
test piece.
The strength of test rig to withstand against the full capacity test load has been
calculated and verified using Finite Element Method (FEM) software. Design calculation
also done to examine and verify the strength of welding and during the manufacturing
of the test rig all weldments have been tested.
The unique feature of this test rig is that we can test two beams/components
simultaneously.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.1 - shows test rig assembly

Fig.2 - shows test set up for Main bridge and Intermediate bridge (Inner), with the help
of test rig
Fig.3 - shows test set up for Bolster and Intermediate bridge (Outer), with the help of
test rig.
. Fig.4 - shows the welded box section made of rolled plates.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
The test rig was manufactured/fabricated out of rolled steel plates thickness varying
from 16 mm to 32 mm. The material used for manufacturing is mild steel conforming to
IS 2062 grade B steel. The strength of the test rig was first verified by the finite
element analysis. The use of box section (12) gives more strength to test rig with lesser
weight. Also the placement of girders for testing is made easy with box section (12).
The sketch of test rig is shown in Fig.1. The construction of test rig is as below:
1. SIDE SILL ASSEMBLY (1): The 2 nos. side assemblies are
used one at either end, these are constructed welded
box section (12) using the rolled plates (13, 14). Box
section (12) has been designed such that it can
withstand the forces coming on it, when the pressure on
girders is applied by hydraulic jack (4).

2. BOTTOM BASE ASSEMBLY (2): The bottom base
assembly is constructed through welded box section (12)
using the rolled plates (13,14) the provision is made for
fixing the support required for test piece on top of the
bottom base assembly (2). Box section (12) has been
designed such that it can withstand the forces coming on
it, when the pressure on girders is applied by hydraulic
jack (4). Also the width of box section (12) has been kept
such that the girders can be properly placed in the test
rig.
3. TOP BASE ASSEMBLY (3): The top base assembly is
constructed through welded box section (12) using the
rolled plates (13,14). The provision is made for fixing the
hydraulic jack (4) of 300t capacity for applying the
required load on test piece as per the test scheme. Also
the width of box section (12) has been kept such that the
hydraulic jacks can be properly fixed in the test rig.
4. HYDRAULIC JACK (4): One no. hand operated hydraulic
jack of 300t capacity operated vertically mounted on top
base assembly of the test rig. It is equipped with the load
display device to facilitate application of desired load on
test piece/girders. Use of hydraulic jack made the load

application methodology very much under control. The
hydraulic jack is bolted to the top base assembly.
5. INSTRUMENTATION: Based on the test requirement no.
of dial gauges are provided to record the displacement of
the test piece. Dial indicators were placed by supporting
them from side sill assembly (1).
6. STOOL ASSEMBLY (15, 16): The stools were used in such
a fashion that similar load conditions are met for both top
and bottom girders (to be tested). The stool sizes were
kept suiting to the gap available between girders and test
rig. The stools were positioned in location where load or
reaction is to be applied on girders (G1, G2).
The test rig has been designed in such a fashion that two girders can be tested with
.similar load application simultaneously. The load is applied through hydraulic jack (4) on
suitably placed stool assembly (15, 16). The stool assembly is placed on girder (G1) (on
top) to be tested, centre pivot location. Two other stool assemblies are placed on
extreme ends of the girder (on top) below the end pivot locations. The other girder (G2)
to be tested is kept in inverted position below the top girder (G1) in such a fashion that
the stool assemblies (16) kept at extreme end pivot location for top girders shall touch
the bottom girder also the same location. The another stool is kept below the centre
pivot location of the bottom girder and the other end of this stool touches the test rib
bottom base assembly. This stool transfers the same load (reaction force) on centre

pivot of bottom girder also as a reaction to the force applied on top girder by hydraulic
jack (4).
Thus the same load conditions are made for both top and bottom girders to be tested.
This is made possible by the newly designed test rig to uniquely test both rigs
simultaneously with lesser effort and lesser time as described above.
In earlier load test practices, loads were applied by putting steel plates/blocks physically
on the centre pivot or any other loading area. Putting such a heavy load on the girders
at any particular area and balancing them was a very tough and hectic activity. This
used to involve a very high risk of loads sliding down or toppling of whole set-up. The
loading of plates and balancing them on girders needed too many persons and a lot of
time. Also the precision in controlling the load application was not there. Once the
testing used to get completed equal amount of time and manpower were needed to
remove the loading blocks/steel plates. Thus for testing only one girder used to take
too much of time. While with the present test rig it is possible to test two girders
simultaneously with significantly less time and manpower. Also the control in application
of load is very much in control in load testing with this test rig (8).
Once the test set-up is ready for load application dial gauges are mounted in such a
manner that these can measure the deflection of girders (both top and bottom) on
application of load.
For testing of different types of girders different combination of stool assemblies are
used according to the requirement.

WE CLAIM
1. A load test rig (8) for testing of components of 280t special wagon comprising:
a plurality of side sill assembly (1) constructed in welded box section (12) with
rolled plates (13,14) for withstanding the forces coming on it;
a bottom base assembly (2) constructed in welded box section (12) with rolled
plates (13,14) for withstanding the forces coming on it and for fixing the support
required for test piece on top of it;
a top base assembly (3) constructed in welded box section (12) with rolled plates
(13,14) for withstanding the forces coming on it and for fixing the hydraulic jack
on it;
a hydraulic jack mounted vertically on top base assembly (3) with load display
device for facilitating application of desired load on test piece;
a plurality of dial gauges provided for recording the displacement of the test
piece;
a plurality of stool assembly (15,16);
characterized in that,
the stool is kept in the gap available between girders and test rig (8) wherein the
stools are positioned in location where load or reaction is to be applied on girders
(G1, G2) and when same load conditions are maintained for both top and bottom
girders to be tested.

2. A load test rig as claimed in claim 1, wherein the width of box section (12) is
kept such that the hydraulic jacks can be properly fixed in the test rig (8).
3. A load test rig as claimed in claim 1, wherein the capacity of hand operated
hydraulic jack (4) is 300t.
4. A load test rig as claimed in claim 1, wherein the thickness of rolled steel plates
varies from 16 mm to 32 mm.
5. A load test rig as claimed in claim 1, wherein the hydraulic jack (4) is bolted to
the top base assembly (3).
6. A method for testing of components of 280t special wagon comprising:
applying the load through hydraulic jack (4) on suitably placed stool assembly
(15, 16);
placing the stool assembly on girder (G1) top to be tested at centre pivot
location;
placing a plurality of stool assemblies on extreme ends of the girder (G1) on top
and below the end pivot locations;
keeping the other girder (G2) to be tested in inverted position below the top
girder (G1) when the stool assemblies (16) kept at extreme end, pivot location
for top girders touching the bottom girder also the same location;

keeping another stool below the centre pivot location of the bottom girder (G2)
and other end of the stool touching the test rib bottom base assembly (2);
characterised in that,
the said stool transfers the same load on centre pivot of bottom girder (G2) as a
reaction to the force applied on top girder by hydraulic jack making the same
load conditions for both top (G1) and bottom (G2) girders to be tested, when the
displacement of the test pieces are recorded by the dial gauges.

A load test rig (8) for testing of components of 280t special wagon consists a plurality
of side sill assembly (1) constructed in welded box section (12) with rolled plates
(13,14), a bottom base assembly (2) constructed in welded box section (12) with rolled
plates (13,14), a top base assembly (3) constructed in welded box section (12) with
rolled plates (13,14), a hydraulic jack mounted vertically on top base assembly (3) with
load display device for facilitating application of desired load on test piece, a plurality of
dial gauges provided for recording the displacement of the test piece and a plurality of
stool assembly (15, 16). The stool is kept in the gap between girders and test rig. The
stools are positioned in location where load or reaction is to be applied on girders (G1,
G2) so that same load conditions are maintained for both top and bottom girders to be
tested.