An
air brake is a conveyance braking system actuated by compressed air. The Westinghouse system uses air pressure to charge air reservoirs
(tanks) on each car. Full air pressure signals each car to release the
brakes. A reduction or loss of air pressure signals each car to apply
its brakes, using the compressed air in its reservoirs.
Straight air brake
In the air brake's simplest form, called the straight air system, compressed air pushes on a piston in a cylinder. The piston is connected through mechanical linkage to brake shoes
that can rub on the train wheels, using the resulting friction to slow
the train. The mechanical linkage can become quite elaborate, as it
evenly distributes force from one pressurized air cylinder to 8 or 12
wheels.
The pressurized air comes from an air compressor in the locomotive and is sent from car to car by a train line
made up of pipes beneath each car and hoses between cars. The principal
problem with the straight air braking system is that any separation
between hoses and pipes causes loss of air pressure and hence the loss
of the force applying the brakes. This could easily cause a runaway
train. Straight air brakes are still used on locomotives, although as a
dual circuit system, usually with each truck having its own circuit.
Westinghouse air brake
In order to design a system without the shortcomings of the straight
air system, Westinghouse invented a system wherein each piece of
railroad rolling stock was equipped with an air reservoir and a
triple valve, also known as a
control valve.
The triple valve is described as being so named as it performs three functions: Charging air into an air tank ready to be used, applying the brakes, and releasing them. In so doing, it supports certain other actions (i.e. it 'holds' or maintains the application and it permits the exhaust of brake cylinder pressure and the recharging of the reservoir during the release). In his patent application, Westinghouse refers to his 'triple-valve device' because of the three component valvular parts comprising it: the diaphragm-operated poppet valve feeding reservoir air to the brake cylinder, the reservoir charging valve, and the brake cylinder release valve. When he soon improved the device by removing the poppet valve action, these three components became the piston valve, the slide valve, and the graduating valve.
- If the pressure in the train line is lower than that of the reservoir,
the brake cylinder exhaust portal is closed and air from the car's
reservoir is fed into the brake cylinder to apply the brakes. This
action continues until equilibrium between the brake pipe pressure and
reservoir pressure is achieved. At that point, the airflow from the
reservoir to the brake cylinder is lapped off and the cylinder is
maintained at a constant pressure.
- If the pressure in the train line is higher than that of the
reservoir, the triple valve connects the train line to the reservoir
feed, causing the air pressure in the reservoir to increase. The triple
valve also causes the brake cylinder to be exhausted to the atmosphere,
releasing the brakes.
- As the pressure in the train line and that of the reservoir
equalize, the triple valve closes, causing the air pressure in the
reservoir and brake cylinder to be maintained at the current level.
Unlike the straight air system, the Westinghouse system uses a
reduction
in air pressure in the train line to apply the brakes. When the engine
operator applies the brake by operating the locomotive brake valve, the
train line vents to atmosphere at a controlled rate, reducing the train
line pressure and in turn triggering the triple valve on each car to
feed air into its brake cylinder. When the engine operator releases the
brake, the locomotive brake valve portal to atmosphere is closed,
allowing the train line to be recharged by the compressor of the
locomotive. The subsequent increase of train line pressure causes the
triple valves on each car to discharge the contents of the brake
cylinder to the atmosphere, releasing the brakes and recharging the
reservoirs.
Under the Westinghouse system, therefore, brakes are applied by
reducing train line pressure and released by increasing train line
pressure. The Westinghouse system is thus fail safe—any
failure in the train line, including a separation ("break-in-two") of
the train, will cause a loss of train line pressure, causing the brakes
to be applied and bringing the train to a stop, thus preventing a
runaway train.
Modern systems
Modern air brake systems serve two functions:
- The service brake system, which applies and releases the brakes during normal operations, and
- The emergency brake
system, which applies the brakes rapidly in the event of a brake pipe
failure or an emergency application by the engine operator (generally
referred to as the automatic brake).
When the train brakes are applied during normal operations, the
engine operator makes a "service application" or a "service rate
reduction”, which means that the train line pressure reduces at a
controlled rate. It takes several seconds for the train line pressure to
reduce and consequently takes several seconds for the brakes to apply
throughout the train. In the event the train needs to make an emergency
stop, the engine operator can make an "emergency application," which
immediately and rapidly vents all of the train line pressure to
atmosphere, resulting in a rapid application of the train's brakes. An
emergency application also results when the train line comes apart or
otherwise fails, as all air will also be immediately vented to
atmosphere.
In addition, an emergency application brings in an additional
component of each car's air brake system: the emergency portion. The
triple valve is divided into two portions: the service portion, which
contains the mechanism used during brake applications made during
service reductions, and the emergency portion, which senses the
immediate, rapid release of train line pressure. In addition, each car's
air brake reservoir is divided into two portions—the service portion
and the emergency portion—and is known as the "dual-compartment
reservoir”. Normal service applications transfer air pressure from the
service portion to the brake cylinder, while emergency applications
cause the triple valve to direct all air in both the service portion and
the emergency portion of the dual-compartment reservoir to the brake
cylinder, resulting in a 20–30% stronger application.
The emergency portion of each triple valve is activated by the
extremely rapid rate of reduction of train line pressure. Due to the
length of trains and the small diameter of the train line, the rate of
reduction is high near the front of the train (in the case of an engine
operator-initiated emergency application) or near the break in the train
line (in the case of the train line coming apart). Farther away from
the source of the emergency application, the rate of reduction can be
reduced to the point where triple valves will not detect the application
as an emergency reduction. To prevent this, each triple valve's
emergency portion contains an auxiliary vent port, which, when activated
by an emergency application, also locally vents the train line's
pressure directly to atmosphere. This serves to propagate the emergency
application rapidly along the entire length of the train.
Working pressures
The compressor on the locomotive charges the main reservoir with air
at 125–140 psi (8.6–9.7 bar; 860–970 kPa). The train brakes are released
by admitting air to the train pipe through the engineer's brake valve. A
fully charged brake pipe is typically 70–90 psi (4.8–6.2 bar;
480–620 kPa) for freight trains and 110 psi (7.6 bar; 760 kPa) for
passenger trains. The brakes are applied when the engineer moves the
brake handle to the "service" position, which causes a reduction in
pressure in the train pipe. In normal braking, the pressure in the train
pipe does not reduce to zero.
Enhancements
Electro-pneumatic or EP brakes are a type of air brake that allows
for immediate application of brakes throughout the train instead of the
sequential application. Electro-pneumatic brakes are currently in testing in North America and South Africa in captive service ore and coal trains.
Passenger trains have had for a long time a 3-wire version of the
electro-pneumatic brake, which gives seven levels of braking force. In
most cases the system is not fail-safe, with the wires being energized
in sequence to apply the brakes, but the conventional automatic air
brake is also provided to act as a fail safe, and in most cases can be
used independently in the event of a failure of the EP brakes.
. On the conventional side, the control valve set a reference
pressure in a volume, which set brake cylinder pressure via a relay
valve. On the electric side, pressure from a second straight-air
trainline controlled the relay valve via a two-way check valve. This
"straight air" trainline was charged
(from reservoirs on each car)
and released by magnet valves on each car, controlled electrically by a
3 wire trainline, in turn controlled by an "electro-pneumatic master
controller" in the controlling locomotive. This controller compared the
pressure in the straight air trainline with that supplied by a self
lapping portion of the engineers valve, signaling all of the "apply" or
"release" magnets valves in the train to open simultaneously, changing
the pressure in the "straight air" trainline much more rapidly and
evenly than possible by simply supplying air directly from the
locomotive. The relay valve was equipped with four diaphragms, magnet
valves, electric control equipment, and an axle-mounted speed sensor, so
that at speeds over 60 mph (97 km/h) full braking force was applied,
and reduced in steps at 60 mph (97 km/h) 40 and 20 mph (64 and 32 km/h),
bringing the train to a gentle stop. Each axle was also equipped with
anti-lock brake equipment. The combination minimized braking distances,
allowing more full-speed running between stops. The "straight air"
(electro-pneumatic trainline),
anti-lock, and speed graduating portions of the system were not
dependent on each other in any way, and any or all of these options
could be supplied separately.
Later systems replace the automatic air brake with an electrical wire
(in the UK, at least, known as a "round the train wire") that has to be
kept energized to keep the brakes off.
Limitations
The Westinghouse air brake system is very trustworthy, but not
infallible. Recall that the car reservoirs recharge only when the brake
pipe pressure is higher than the reservoir pressure, and that the car
reservoir pressure will rise only to the point of equilibrium. Fully recharging the reservoirs on a long trian can require considerable time (8 to 10 minutes in some cases), during which the brake pipe pressure will be lower than locomotive reservoir pressure.
If the brakes must be applied before recharging has been completed, a
larger brake pipe reduction will be required in order to achieve the
desired amount of braking effort, as the system is starting out at a
lower point of equilibrium (lower overall pressure). If many brake pipe
reductions are made in short succession ("fanning the brake" in railroad
slang), a point may be reached where car reservoir pressure will be
severely depleted, resulting in substantially reduced brake cylinder
piston force, causing the brakes to fail. On a descending grade, the unfortunate result will be a runaway.
In the event of a loss of braking due to reservoir depletion, the
engine driver may be able to regain control with an emergency brake
application, as the emergency portion of each car's dual-compartment
reservoir should be fully charged—it is not affected by normal service
reductions. The triple valves detect an emergency reduction based on the
rate of brake pipe pressure reduction. Therefore, as long as a
sufficient volume of air can be rapidly vented from the brake pipe, each
car's triple valve will cause an emergency brake application. However,
if the brake pipe pressure is too low due to an excessive number of
brake applications, an emergency application will not produce a large
enough volume of air flow to trip the triple valves, leaving the engine
driver with no means to stop the train.
Solutions
Two-pipe air brake
Another solution to loss of brake pressure is the two-pipe system,
fitted on most modern passenger stock and many freight wagons. In
addition to the traditional brake pipe, this enhancement adds the main reservoir
pipe, which is continuously charged with air directly from the
locomotive's main reservoir. The main reservoir is where the
locomotive's air compressor output is stored, and is ultimately the source of compressed air for all systems that use it.
Since the main reservoir pipe is kept constantly pressurized by the
locomotive, the car reservoirs can be charged independently of the brake
pipe, this being accomplished via check valve
to prevent backfeeding into the pipe. This arrangement helps to reduce
the above described pressure loss problems, and also reduces the time
required for the brakes to release, since the brake pipe only has to
recharge itself.
Main reservoir pipe pressure can also be used to supply air for
auxiliary systems such as pneumatic door operators or air suspension.
Nearly all passenger trains (all in the UK and USA), and many freights,
now have the two-pipe system.
Accidents
There are a number of safeguards that are usually taken to prevent
this sort of accident happening. Railroads have strict
government-approved procedures for testing the air brake systems when
making up trains in a yard or picking up cars en route. These generally
involve connecting the air brake hoses, charging up the brake system,
setting the brakes and manually inspecting the cars to ensure the brakes
are applied, and then releasing the brakes and manually inspecting the
cars to ensure the brakes are released. Particular attention is usually
paid to the rearmost car of the train, either by manual inspection or
via an automated endofdevice,
to ensure that brake pipe continuity exists throughout the entire
train. When brake pipe continuity exists throughout the train, failure
of the brakes to apply or release on one or more cars is an indication
that the cars' triple valves are malfunctioning. Depending on the
location of the air test, the repair facilities available, and
regulations governing the number of inoperative brakes permitted in a
train, the car may be set out for repair or taken to the next terminal
where it can be repaired.
Standardisation
The modern air brake is not identical with the original airbrake as
there have been slight changes in the design of the triple valve, which
are not completely compatible between versions, and which must therefore
be introduced in phases. That said, the basic air brakes used on
railways worldwide are remarkably compatible.