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Piping diagram from 1920 of a Westinghouse E-T Air Brake system on a locomotive.
An air brake is a conveyance braking system applied by means of compressed air. Modern trains rely upon a fail-safe air brake system that is based upon a design patented by George Westinghouse on March 5, 1872. The Westinghouse Air Brake Company (WABCO) was subsequently organized to manufacture and sell Westinghouse's invention. In various forms, it has been nearly universally adopted.
Background
Prior to the introduction of air brakes, stopping a train was a difficult business. In the early days when trains consisted of one or two cars and speeds were low, the engineer (driver) could stop the train by reversing the steam flow to the cylinders, causing the locomotive to act as a brake. However, as trains got longer, heavier and faster, and started to operate in mountainous regions, it became necessary to fit each car with brakes, as the locomotive was no longer capable of bringing the train to a halt in a reasonable distance.
The introduction of brakes to railcars necessitated the employment of additional crew members called brakemen, whose job it was to move from car to car and apply or release the brakes when signaled to do so by the engineer with a series of whistle blasts. Occasionally, whistle signals were not heard, incorrectly given or incorrectly interpreted, and derailments or collisions would occur because trains were not stopped in time.
Brakes were manually applied and released by turning a large brake wheel located at one end of each car. The brake wheel pulled on the car's brake rigging and clamped the brake shoes against the wheels. As considerable force was required to overcome the friction in the brake rigging, the brakeman used a stout piece of wood called a "club" to assist him in turning the brake wheel.
The job of a passenger train brakeman wasn't too difficult, as he was not exposed to the weather and could conveniently move from car to car through the vestibules, which is where the brake wheel was (and still is, in many cases) located. In addition, passenger trains were not as heavy or lengthy as their freight counterparts, which eased the task of operating the brakes.
A brakeman's job on a freight train was a far different matter. He was exposed to the elements and had many more cars on which the brakes had to be operated. To set the brakes on a boxcar the brakeman would have to climb to the roof and walk a narrow catwalk to get to the brake wheel—while the car was swaying and pitching under his feet. Other than the brake wheel itself, there wasn't anything the brakeman could readily grasp to steady himself as he performed his duties. Setting the brakes on the next car required that he cross the gap between the cars—by jumping in some cases. Needless to say, a freight brakeman's job was extremely dangerous, and many were maimed or killed due to falling from moving trains.
Complicating matters, the manually operated brakes had limited effectiveness and controlling a train's speed in mountainous terrain was a dicey affair. Occasionally, the brakemen simply could not set enough brakes to a degree where they were able to reduce speed while descending a grade, which usually resulted in a runaway—followed by a disastrous wreck.
When adopted, the Westinghouse system had a major effect on railroad safety. Reliable braking was assured, reducing the frequent accidents that plagued the industry. Brakemen were no longer required to risk life and limb to stop a train, and with the engineer now in control of the brakes, misunderstood whistle signals were eliminated. As a result, longer and heavier trains could be safely run at higher speeds.
During his lifetime, Westinghouse made many improvements to his invention. The United States Congress passed the Safety Appliance Act in 1893 making the use of some automatic brake system mandatory. By 1905, over 2,000,000 freight, passenger, mail, baggage and express railroad cars and 89,000 locomotives in the United States were equipped with the Westinghouse Automatic Brake.
The introduction of brakes to railcars necessitated the employment of additional crew members called brakemen, whose job it was to move from car to car and apply or release the brakes when signaled to do so by the engineer with a series of whistle blasts. Occasionally, whistle signals were not heard, incorrectly given or incorrectly interpreted, and derailments or collisions would occur because trains were not stopped in time.
Brakes were manually applied and released by turning a large brake wheel located at one end of each car. The brake wheel pulled on the car's brake rigging and clamped the brake shoes against the wheels. As considerable force was required to overcome the friction in the brake rigging, the brakeman used a stout piece of wood called a "club" to assist him in turning the brake wheel.
The job of a passenger train brakeman wasn't too difficult, as he was not exposed to the weather and could conveniently move from car to car through the vestibules, which is where the brake wheel was (and still is, in many cases) located. In addition, passenger trains were not as heavy or lengthy as their freight counterparts, which eased the task of operating the brakes.
A brakeman's job on a freight train was a far different matter. He was exposed to the elements and had many more cars on which the brakes had to be operated. To set the brakes on a boxcar the brakeman would have to climb to the roof and walk a narrow catwalk to get to the brake wheel—while the car was swaying and pitching under his feet. Other than the brake wheel itself, there wasn't anything the brakeman could readily grasp to steady himself as he performed his duties. Setting the brakes on the next car required that he cross the gap between the cars—by jumping in some cases. Needless to say, a freight brakeman's job was extremely dangerous, and many were maimed or killed due to falling from moving trains.
Complicating matters, the manually operated brakes had limited effectiveness and controlling a train's speed in mountainous terrain was a dicey affair. Occasionally, the brakemen simply could not set enough brakes to a degree where they were able to reduce speed while descending a grade, which usually resulted in a runaway—followed by a disastrous wreck.
When adopted, the Westinghouse system had a major effect on railroad safety. Reliable braking was assured, reducing the frequent accidents that plagued the industry. Brakemen were no longer required to risk life and limb to stop a train, and with the engineer now in control of the brakes, misunderstood whistle signals were eliminated. As a result, longer and heavier trains could be safely run at higher speeds.
During his lifetime, Westinghouse made many improvements to his invention. The United States Congress passed the Safety Appliance Act in 1893 making the use of some automatic brake system mandatory. By 1905, over 2,000,000 freight, passenger, mail, baggage and express railroad cars and 89,000 locomotives in the United States were equipped with the Westinghouse Automatic Brake.
Overview
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 to a brake shoe that can rub on the train wheel, using the resulting friction to slow the train. 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 deficiency could easily cause a runaway train. Straight air brakes are still used on locomotives, although as a dual circuit system, usually with each bogie (truck) having its own circuit.
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 often described as being so named because it performs three functions. This is a widespread myth, as the triple valve simply performs two functions: it applies the brakes and releases them. In so doing, it supports certain other actions (i.e. it 'holds' or maintains the application, and it permits the reservoir to be recharged 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.
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 often described as being so named because it performs three functions. This is a widespread myth, as the triple valve simply performs two functions: it applies the brakes and releases them. In so doing, it supports certain other actions (i.e. it 'holds' or maintains the application, and it permits the reservoir to be recharged 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 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.
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.
Modern air brake systems are in effect two braking systems combined:
- 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 engineer.
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 engineer-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.
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. EP brakes have been in use in German high-speed trains (most notably the ICE) since the late 1980s, and in British practice since 1949, fully described in Electro-pneumatic brake system on British railway trains. 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.
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.
More recent innovations are electronically controlled brakes where the brakes of all the wagons (cars) and locomotives are connected by a kind of local area network, which allows individual control of the brakes on each wagon, and the reporting back of performance of each wagon's brakes.
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 train can require considerable time (8 to 10 minutes in some cases
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