KKE 900 : Automatic Train Wash Equipment

This is special spray arch, equipped with low discharge nozzles.

The Pre Wash Arch sprays water initially over the train to soak the hard mud stains, smoke marks, water marks, dust, etc. Pre wash station consists of an arch fabricated from heavy steel sections. The columns are painted with water resistant paint. Stainless Steel (SS304) pipes have SS nozzles mounted on it. The nozzle arches are fixed on the columns with clamps.

There are two water spray banks. One water banks is used for normal service and another is kept idle and used only when the first water bank is under nozzle maintenance. This is done manually using a ball valve.

The water to the pre wash station is supplied by pump and injected on the coach surface through the nozzles. The excess water flow of pump is returned to tank through the by pass circuit and flow is adjusted by operating the valve. The train is sensed using a photo-eye sensor.

Soap or cleaning fluid is pumped directly and mixed in water using automatic proportional dosing system. The pipelines and the nozzles are made of stainless steel. Since the pipes and nozzles are made of stainless steel, the equipment can handle chemicals in wide pH range.

This station consists of a Stainless Steel bank with Foaming type soap spray nozzles. The nozzles are made of Brass or Stainless Steel. The detergent nozzles are mounted on the stainless steel pipes (SS 304) and the nozzles direct the detergent on the brushes. The water is supplied by the pump and the detergent is dosed into it by the automatic proportional dosing mechanism. The excess water is returned to the tank through by pass circuit. This is done by operating the cock.

There are two soap spray banks. One soap bank is used for normal service and another is kept idle and used only when the first soap bank is under nozzle maintenance. This is done manually using a ball valve.

The under – coach area is washed by this station consists of series of nozzles on the sides and the bottom. The train wheels are sensed by a photo-eye sensor. A multi stage high pressure pump is used to wash the bogie parts.

There are two water spray banks. One water arch is used for normal service and another is kept
idle and used only when the first water banks is under nozzle maintenance. This is done manually
using a ball valve.

This station is located at some distance from the detergent arches , giving some time for it to soak the dirt.

There are two sets of vertical brushes for washing the sides and two sets of tilting roof brushes to wash the top of the coach.

When the wash system is switched off or the train is moving in reverse direction, the vertical brushes are retracted and the roof brushes which have a tilting mechanism, straighten upwards so that the brush bristles do not touch the train surface. This feature has been added for safety of the coach and the wash system.

The brushes are continuously sprayed with water to remove the dirt on the rotating brushes. There are two water banks. One water bank is used for normal service and another is kept idle and used only when the first water bank is under nozzle maintenance. This is done manually using a ball valve.

The train is sensed using a photo-eye sensor

The control system consists of a control panel and an operating panel. The control system houses the PLC and switch gear.

The operating panel has indications of all the pumps and motors of the equipment. The status of sensors are also indicated on the operating panel. The equipment works in two modes.

In AUTOMATIC mode, the equipment works automatically without any manual intervention, In MANUAL mode all the parts of the equipment can be manually activated by selecting switches on the operating panel. MANUAL mode is very helpful in snag rectification and maintenance activities.

EMERGENCY Switch : The equipment has got an EMERGENCY switch which is active in AUTOMATIC as well as MANUAL mode. The complete equipment stops and comes to safe position automatically if the emergency switch is pressed.

The complete control system works on 24V DC.

Two traffic lights, installed at the entry and exit area of the wash bay, to control the entering of the wash bay. The traffic lights are equipped with a green and one red light . Green : drive through or ready to start a wash cycle Red : no entry allowed.

All the arches of the equipment have a maintenance platform for ease of maintenance to be carried out.

All the stations of the equipment have two nozzle arches. When one nozzle arch is in use, maintenance operations can be carried out on the other arch.

All equipment is built in built in corrosion resistant material or coated with corrosion resistant treatment. The water piping is stainless steel on the equipment and connecting pipe lines are of galvanized iron pipes or HDPE pipes..