Instrumentation system for 27,000 lb drop-weight tup hammer machines used in qualifying high-capacity draft gears (M-901 series) for Indian Railways — per RDSO specification WD-71-BD-15.
Applicable Standards
M-THI Series
RDSO specification WD-71-BD-15 requires that high-capacity draft gears (M-901 series) for Indian Railways be qualified on a 27,000 lb drop-weight tup hammer. The instrumentation must capture reaction forces up to 900 Tons and coupler travel up to 125 mm at a minimum of 1,000 samples per second.
The M-THI instrumentation system is designed to meet every measurement and reporting requirement of RDSO WD-71-BD-15 Clause 4.3 — from force transducer linearity and temperature compensation to automatic work-done calculation and multi-record display.
Capabilities
Complete draft gear qualification — from official capacity and endurance tests to sturdiness and energy-absorption analysis per RDSO WD-71-BD-15.
Verifies the draft gear absorbs the minimum specified energy in a single drop per RDSO WD-71-BD-15. Peak reaction force and peak travel are recorded graphically and numerically. Pass/fail is determined automatically.
Repeated drop impacts accumulating 25 million ft-lb of absorbed energy. The system logs energy per impact and running cumulative total, flagging when the gear fails to recover or meet the minimum absorption threshold.
High-energy single-drop impacts to assess structural integrity of the draft gear under extreme load conditions. Peak force is recorded and compared against the maximum permissible reaction force limit.
Real-time graphical output of reaction force versus coupler travel with work done (energy absorbed) computed as the area under the curve — the primary deliverable for RDSO submission.
Peak reaction force and peak coupler travel presented as both graphical waveforms and numeric values per Clause 4.3 of RDSO WD-71-BD-15. Multiple test records displayed simultaneously on a single interface.
Software automatically computes work done (energy absorbed by the draft gear) from the load-displacement graph. Results are stored with automatic backup and formatted for RDSO submission.
Technical Data
| Parameter | Value |
|---|---|
| Tup Hammer Capacity | 27,000 lb (12,247 kg) |
| Force Transducer Capacity | Up to 900 Tons |
| Force Transducer Linearity | ±1% of full scale |
| Temperature Compensation | Yes — force transducer |
| System Accuracy (Static Cal.) | ±2% |
| System Accuracy (Dynamic) | ±5% |
| LVDT Travel | Up to 125 mm |
| DAQ Sampling Rate | Minimum 1,000 cycles/second |
| DAQ Backup | Automatic |
| Signal Conditioner | Removes electrical / magnetic noise |
| Software Output | Peak force, peak travel, load-displacement-energy graph |
| Power Supply | Single-phase, 230 V, 50 Hz |
Specifications per RDSO WD-71-BD-15 Clause 4.3. Custom configurations available on request.
Standard Equipment
Measures reaction forces up to 900 Tons with ±1% full-scale linearity and built-in temperature compensation — meeting the exact transducer specification mandated by RDSO WD-71-BD-15 Clause 4.3.
Captures full coupler travel throughout the drop event. LVDT range of 125 mm matches the RDSO-specified displacement measurement requirement for high-capacity draft gear qualification tests.
Dedicated signal conditioning eliminates electrical and magnetic noise from the high-current tup hammer environment, converting raw mV transducer outputs into clean, calibrated engineering units.
Data acquisition at the RDSO-mandated minimum of 1,000 samples per second, with automatic data backup after every test — no data loss even in the event of a power interruption.
Dedicated software module computes work done (energy absorbed) from the load-displacement curve. Multiple test records are displayed on a single screen for direct comparison across drops.
Auto-generated test reports include peak force (graphical + numeric), peak travel (graphical + numeric), and the load-displacement-energy graph — exactly as specified in RDSO WD-71-BD-15.
What's Included
Our Customers
Trusted by India's leading wagon manufacturers, RDSO-approved foundries, and global railcar component suppliers.
Amsted Rail
Railcar components & systems
Om Besco Rail Products
Wagon & rolling stock manufacturer
Hindusthan Engineering (HEIL)
Freight wagon manufacturer
Titagarh Rail Systems
Wagons, coaches & metro trains
Texmaco Rail & Engineering
India's largest wagon manufacturer
Frontier Alloy Steels
RDSO foundry — couplers & draft gears
Jupiter Wagons
Freight wagons & alloy castings
Atul Engineering Udyog
RDSO foundry — railway castings
Product Range
After Sales
On-site and in-house calibration of testing machines and sensors
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Application engineering, test method development, and lab planning
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Safe disassembly, transport, and re-commissioning of testing machines
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Modernise legacy or imported test rigs with new controls and sensors
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Annual maintenance contracts (AMC) for all testing machines
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Share your tup hammer capacity, draft gear type, and test standard — our engineers will configure the right force transducer, LVDT, DAQ, and reporting software for RDSO submission.
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