DESIGN AND MANUFATURE OF METRO CAR BODY

DESIGN AND MANUFACTURE OF METRO CAR BODY 2019-20
Dept. of Mechanical Engineering, SVCE, Bengaluru-57 Page 1
Chapter 1
COMPANY PROFILE
BEML Limited (formerly Bharat Earth Movers Limited) is public sector undertaking under
ministry of defence (Govt. of India) with headquarters in Bangalore. BEML’s products meet the
requirement sectors of economy viz. urban transportation, construction and mining, defence
equipment etc.
Fig. 1.1 BEML Symbol
BEML was incorporated in 11th May 1964 and commenced its operations on 1st January
1965 as the wholly owned company of Govt. of India under the administrative control Ministry of
Defence. After an initial divestment of 25% in 1992 the company’s holding progressively reduced
and at present stands at 54%. BEML is now Asia’s second largest manufacturer of earth moving
equipment and also a major supplier of state-of-the-art stainless steel metro cars to cities like Delhi
and Bangalore and is ready to take further plunge in this market.
BEML is ranked as “The Largest and Most Profitable Construction Equipment Company”
by Construction World – NICMAR, 2007 and has emerged in the forefront of heavy engineering
industry with a track record of growth and revenues for over four decades. For its innovative

management practices, the company has been awarded “Golden Peacock Innovation Management
Award”. BEML has also been rated as “The Fourth Largest Wealth Creator in the Country” by Dalal
Street Magazine.
BEML Limited, a ‘Miniratna – Category-1’ company, plays pivotal role and serves India’s
core sectors like Defence, Rail, Power, Mining and Infrastructure. The company started with a
modest turnover of Rs.5 crore during 1965 and today, thanks to its diverse business portfolio, the
company has been able to achieve a turn over more than Rs.3000 Cr. during the financial year 2012-
13. It has three major business verticals viz., Mining and Construction, Defence and Rail & Metro
and are serviced by its 9 manufacturing units located at Bangalore, Kolar Gold Fields (KGF),
Mysore and PalakkadKGF unit is the main unit accounting for the manufacture and assembly of a
wide array of earth-moving equipment such as bulldozers, mining shovels, loaders and excavators.
The Rail and metro coaches are made in Bangalore complex and Mysore facility makes dump trucks
and diesel engines of various capacities for its captive requirement. The new division at Palakkad
turn out rail components and defence equipment.
The company plans to diversify into varied activities including underground storage for
petro-products, leasing and financial services and joint ventures abroad. BEML’s products are
exported to more than 25 countries. As a part of company’s globalization strategy, the company has
its global reach by opening local companies at Indonesia and Brazil.
BEML operates on three major business verticals for associated equipment manufacturing:
 Mining and construction.
 Defence.
 Rail and Metro.
In addition to the above, there are three strategic business units (SBUs):
 Technology Division for providing end-to-end engineering solutions.
 Trading Division for dealing in non-company products.
 International Business Division for export of company products & services.

1.1 Mining and Construction Business.
BEML Limited offers a comprehensive and diverse range of mining machinery for both
opencast and underground mines. BEML products in this domain are:
Electric Rope Shovels, Hydraulic Excavators, Bulldozers, Wheel Loaders, Wheel Dozers,
Dump Trucks, Motor Graders, Pipe Layers, Tyre Handlers, Water Sprinklers and Backhoe Loaders.
Besides, BEML also manufacturers mammoth Walking Draglines for cost-effective operations in
the opencast mines. BEML has ventured into underground mining with products such as Side
Discharge. It has also established marketing offices and service centre networks throughout the
country.
1.2 Defence Business.
Being India’s leading Defence equipment manufacturer, BEML Limited keeps the Indian
Army and other defence forces abreast with state-of-the-art military equipment. The company
manufactures variants of heavy duty Tatra vehicles for all terrain operations including Bridge Layer,
Field Artillery Tractor, Medium and Heavy Recovery Vehicle, Pontoon Mainstream Bridge
Systems, Crash Fire Tenders, Mobile Mast Vehicle etc. BEML also supplies engineering Mine
Ploughs, Tank Transportation Trailers, Weapon Loading equipment, Armored Recovery Vehicle,
Milrail Coaches and Wagons apart from Aircraft Weapon Loading Trolley and Aircraft Towing
Tractor. BEML plays a stellar role in the country’s Integrated Guided Missile Development Project
by supplying ground support vehicles. The company has also created a world class test track at its
KGF complex to test Defence Equipment and vehicles.
1.3 Rail and Metro Business.
In recent years, BEML Limited has also forayed into manufacture and supply of high-tech
metro trains deployed for intra-city commuting. BEML is expanding its infrastructure to meet the
greater needs of metro projects coming up in the country. Also, BEML supplies equipment to Indian
Railways which include Integral Rail Coaches, Overhead Electric Inspection Cars(catenary
cars),Postal Vans, AC/DC Electric multiple units, Diesel EMUs, Utility Track Vehicles, Track
Laying Equipment, Broad-Gauge Rail bus, Treasury Vans, Spoil disposal Units etc.

1.4 International Business Division.
BEML Limited has an expanding international presence in more than 25 countries spread
worldwide including Syria, Tunisia, UAE, Jordan, Suriname, South Africa, UK, Sri Lanka,
Bangladesh, Philippines, Indonesia, Oman, Nepal etc. An export house with ‘Star Exporter’ status,
BEML has proven strengths in handling large-scale trading and counter-trade and has pushed the
export of engineering goods as well as other equipment. In recognition of its outstanding
performance, BEML has received Institutional Award for Best Performance in Exports in the year
2007-08.
1.5 Technology Division.
BEML Technology Division (www.bemltech.com) offers end-to end services and solutions in
areas of CAD, CAE, Testing and Technical Documentation. Design and Development experience
in CEMILAC (Centre for Military Airworthiness and Certification) and ISO 9001:2008 certified
environment, NABL certified test facility and strategic alliances with global partners have ensured
a competence comparable with the best in the world. The company has a reputation for innovative
products, Robust Designs and excellent customer satisfaction.
1.6 Trading Division.
Trade Division deals with non-company products and commodities for captive requirements
and also for customers within the country and abroad. Trading Division of BEML has been awarded
the status of Two Star Export House.
This Division currently deals in mineral oils, etc. and also plans to handle all India distribution
of industrial products and intermediaries from global suppliers. Exports/Imports of high value
projects /products may find BEML’s trading services convenient and valuable. Trading Division is
one window wherein all the import and export needs of customers are catered to.
1.7 Vision and Mission:
To become a market leader, as a diversified company supplying products and services to
Mining and Construction, Railway and Metro and Defence Services and emerge as an international
player.
1. Improve competitiveness through organizational transformation and collaboration/
strategic alliances / joint ventures in technology.

2. Grow profitably by aggressively pursuing opportunities in national and international
markets.
3. Attract and build people in a rewarding and inspiring environment by fostering creativity
and innovation.
1.8 Objectives:
The objectives of BEML limited are:
1. To maintain a dominant position in design, development, manufacture and marketing of
Defence, Earth moving and Construction and Rail and Metro equipment.
2. To diversify and grow.
3. To provide total engineering solutions to its customers.
4. To internationalize operations by enhancing exports.
5. To improve profitability.
6. To maintain State-of-the-Art technology for all products.
7. Re-orientation of the business operations to match present scenario.
1.9 Commitment to Quality.
BEML Limited views Quality improvement as a business strategy and hence remains
proactive in the areas of product and service quality. At BEML, a Corporate Quality Policy
emphasizing Total Quality Management ensures that quality system adopted results in products,
services and processes that meet stringent standards and requisite performance criteria. A separate
Quality Department under a General Manager spearheads the thrust towards Total Quality
Management.
All the manufacturing units of the company have been certified for ISO 90012008 Quality
Management System (QMS). The KGF complex, Bangalore complex and Mysore complex are
certified for ISO 14001-2004 Environmental Management System(EMS).Also, the Bangalore

complex is certified for BS OHSAS 18001-2007 OHSAS Integrated Management System and
Engine Division, Mysore complex is certified for AS9100B Aerospace certification.

Chapter 2
ABOUT THE COMPANY
BEML Limited (formerly Bharat Earth Movers Limited) was established in May 1964 as a
Public Sector Undertaking for manufacture of Rail Coaches & Spare Parts and Mining Equipment
at its Bangalore Complex. The Company has partially disinvested and presently Government of
India owns 54 percent of total equity and rest 46 percent is held by Public, Financial Institutions,
Foreign Institutional Investors, Banks and Employees.
The company has 9 manufacturing units spread over the following locations:
1.Kolar Gold Fields (KGF) Complex (around 100 Km from Bangalore) Earth Moving
Division, Rail Coach Unit II, Heavy Fabrication Unit and Hydraulic & Powerline Division.
2. Mysore Complex (around 130 Km from Bangalore) Truck Division and Engine Division.
3. Bangalore Complex - Rail & Metro Division, Palakkad Complex and Vignyan Industries,
a subsidiary located at Tarikere (around 300 km from Bangalore) - Steel Castings.
BEML's nationwide network of sales offices enables buyers with ready access to its wide
range of products. Also, the full-fledged service centers and parts depots offer total equipment care,
maintenance contracts and rehabilitation services.
The Company has drawn up VISION – 2013 with an ambitious growth rate of 12% CAGR
for crossing Rs.5,000 Cr turnovers by 2013-14 coinciding with BEML’s Golden Jubilee year. With
this emerging prospects, BEML has plans to cross Rs.5,000 Cr in the next 2 years and is poised to
achieve Rs.10,000 Cr mark by 2016-17 and the company is gearing up with necessary infrastructure
for achieving the same
2.1 Quality Department.
The work of this department runs parallel to production. The engineers in this department form
a part of the inspection team that perform the stage wise inspection in order to clear the product to
the next stage of production.
For every stage of manufacturing this department has an ITP (inspection test plan).According
to this the inspection process is carried out. The general contents of the ITP include the following:

1. Scope-To check/inspect that the products conform to the technical specifications and the
relevant procedures.
2. Abbreviations and definitions that are used in the ITP are explained.
3. Control of applicable documents and drawings-documents and drawings which are
applicable to each inspection test are designated in the table of ITP.BEML will also maintain the
latest drawings and documents for the customer’s requirement.
4. Requirements, standards and specifications-the ITP is prepared based on technical
specifications, test methods etc.
2.2 Product Design (pd) Department.
Once the contract is obtained by the marketing division it is reviewed in the precontract review
meeting in which all the managers of different departments discuss the following:
1. Delivery schedule.
2. Manufacturing capabilities and parameters.
3. Constraints should be added (if needed).
The PD department then studies the general specifications required by the customer(a general
outline of the product is given by the customer).The engineers then come out with the required
manufacturing drawings specifying the dimensions, size, shape and the materials(BOM) to be used.
These have to be approved by the customer or his agency (RDSO in case of Indian railways).
Then a prototype of the product is made and is inspected by the customer’s agency (RDSO)
.If any changes are required it is made accordingly. Once satisfied the customer’s agency (RDSO)
gives the approval for bulk production.
The drawings are then printed in a non tearable sheet by the draftsmen, after which nine blue
prints are made of which two are retained by the department; one each is sent to the methods
planning and industrial engineering departments. The other five are sent to the PD control rooms
present in the shop floors. The department uses an enterprise resource system (ERP) for all its
activities.

2.3 Stores.
2.3.1 Receiving Stores:
These receive materials through the gate pass, and are sent to the concerned departments.
2.3.2 Project Stores:
These receive materials concerned to the production work.
2.3.3 Non Project Stores:
These receive materials which indirectly help in the production work like weld rods etc,.
2.3.4 Stock Control Department:
This department will look after non production materials such as issuing of clothes,
medicines, books etc,.
2.3.5 Salvage Stores:
These collect waste materials from shop side on corner of factory premises and are stored for
the further processing.
2.3.6 Rejected Stores:
These collect rejected items from the various departments and send it for further action.
The other stores are:
• Painting Store
• Cylinder Store
• Oil and Diesel Store
For identification each product in the stores has a BIN card. The BIN card indicates the date
of arrival and withdrawal of the product from the stores, net quantity and location in the stores.
Every product has a reference number. This system is common for all the factories of BEML.

2.4 Marketing Department.
BEML manufactures capital goods. These goods need not be endorsed as durable goods are.
The goods generally are concerned with the economic interests of the country.
BEML has an all India based effective marketing network that provides customer with
immediate access to BEML’s wide range of products and services. The company’s marketing
strength and reach has enabled it to achieve a share of even 70% in the Indian market. The corporate
head quarter is in Bangalore but the central marketing unit has been shifted to KGF where most of
the equipment for commercial purpose is manufactured. It has regional offices, large number of
district offices, spare parts depots and service centers located within the country and also abroad.
2.5 R and D Department.
This department is involved in the designing of the product components. The EMU division
is generally handled by this department. The engineers are divided among themselves into four
groups:
1. EMU body.
2. Boogie.
3. Electrical.
4. Outfitting.
They also set the inspection standards and passing criteria for various test procedures. It is
also required to check that purchases satisfy the technical requirements.
2.6 Material Testing and Chemical Laborotary.
The laboratories mainly conduct production oriented tests and to some extent tests on the
incoming materials to the factory as and when required by different departments. Usually the vendor
along with the products shows the test reports conducted by him. It is generally accepted, but incase
certain departments want it tested again it is the function of these labs to conduct the specific tests
and give the result accordingly. Some of the tests conducted are mentioned below.
1. Shear tensile test of spot weld-this test is carried out on a universal testing machine. The
specimen is placed between the grips as shown in the picture below. The load is then applied

gradually. The deflection is indicated by the dial gages. The ultimate load taken by the specimen is
noted.
2. To check spot penetration of the weld-this test is conducted to check whether the spot
weld is penetrated deep enough through all the layers of the metal sheets.
Fig . 2.6 Universal testing machine

2.7 Achievements and Awards.
 BEML CEO received Public Relations Council of India’s ‘CHANAKYA AWARD’ for
the year 2009-10.
 Received ‘Wealth Builder-Miniratna-Manufacturing Award’ in the second DSIJ PSU
Award-2010 held at New Delhi on 6th April 2010.
 Received ‘Golden peacock award’ for innovation Management from Institute of Directors
on 26th of January 2010.
 BEML CEO received the ‘BEST PSU AWARD’ instituted by India’s leading B School,
Indian Institute of Planning & Management held at Bangalore on 25th March 2009.
 Southern Region of EEPC India Award for excellence for ‘Best Performance In Exports’
held at New Delhi on 7’th November 2008.
 BEML CEO received the ‘ROTARIAN AWARD’ of Vocational Excellence in their
District Conference held at Bangalore on 9’th February 2008.
 BEML CEO received the ‘BEST CEO AWARD’ from Mr. SK Sharma, National President,
Indian Institute of Materials Managements (IIMM) on 30’th November 2007 at
Chandigarh.
 Conferred ‘Star Performer Award’ by Engineering Export Promotion Council, Southern
Region on 24’th November 2007.
 BEML CEO received the ‘SCOPE Award for Excellence and outstanding Contribution to
the Public Sector Management-Medium PSE Category D’ for the year 2006-07.
 BEML CEO received Raksha Mantri’s Award for ‘BEST DEFENCE PSU’ for the year
2007.
 Award for ‘Excellence in Technology and Innovation’ from Confederation of Indian
Industries (CII).
 Rated ‘AAA’ by ICRA in January 2007.
 Received ‘Golden Peacock Award for Innovation Management’ from Institute of Directors
on 14th January 2007.

Chapter 3
Tasks performed
BEML Bangalore complex is involved in the manufacture of rail products.
1. URBAN TRANSPORT
Fig. 3.1 Broad gauge metro car(25 KV AC)

Fig. 3.1.2 Standard gauge metro car(25 KV AC)
Fig. 3.1.3 Standard gauge metro car(750 V DC Rail)

The following are the broad specifications of the cars:
 Gauge Standard/Broad gauge (1435/1676 mm).
 Car formation 3/6 cars (DMC-TC-DMC)/(DT-M-TC-M-M-DT).
 Passenger capacity 1000/2000 persons in full load condition.
 Axle load 15/16 tons per axle.
 Speed control By Variable Voltage Variable Frequency (VVVF).
 Max design speed 90 kmph.
 Max operating speed 75 kmph.
 Input power 750V DC through 3rd rail bottom collector system.
 Traction motor type AC 3- phase induction motor (squirrel cage).
 Other specifications All stainless steel body, fully AC to run under.
Other Railway Products:
BEML since its inception has been supporting Indian Railways by manufacturing and supplying
equipment’s such as:
 Second Class Passenger Coaches (Sleeper).
 DC EMU’s.
 AC EMU’s.
 Stainless Steel EMU’s.
 Rail Busses.
 8-Wheel & 4-Wheel Overhead Electric Inspection Cars (Catenary eqpt.).
 Treasury vans.
 Spoil Disposal Units.
 Track Laying Equipment.
 Military Rail Coaches and Wagons for Defence Requirements.
 Utility Track Vehicles (UTV).

Fig. 3.1.4 SS EMU
Fig. 3.1.5 DEMU
Fig. 3.1.6 MEMU

3.1 Work Flow Model
Order from customer
Marketing
Research and Development
Product design
Planning
Purchase
Progress
Inspection
Manufacturing
Finished goods
Inspection
Delivery

3.2 Production Department.
BODY SHOP- Each metro car consist of six modules.
 Under frame.
 Side wall RH.
 End wall.
 Cab.
 Roof.
Each of the above mentioned components start their journey from stainless steel parts that
are sub-contracted to other companies. The side wall and the roof are fabricated in the car body
shop.
Each of the above mentioned components start their journey from stainless steel parts that
are sub-contracted to other companies. The side wall and the roof are fabricated in the car body
shop.
Fig. 3.2 Top view of the side wall
According to the drawings both the side wall and roof are fabricated using robotic spot
welding machines. The weld points are also specified in the drawing. The fixtures are welded
using TIG (tungsten inert gas welding).

3.2.1 Under Frame Section.
This section forms an integral part of the overall assembly as it has to support the weight of
the car. This section manufactures underframes for Indian railways, suburban trains and metro. For
the metro stainless steel is used which is in contrary to the mild steel used for Indian railways and
the sub urban trains. Basic process that are involved are MIG, spot and seam welding.
3.2.2 Seam Welding.
The three sheets are placed on a jig with the seam welding machine running along the side
of the jig. The X in the figure indicate the initial tact weld. Once this is done a complete weld as
indicated by the line is done.
Fig. 3.2.2 Showing the welded parts.

3.3 Layout of Metal Fabrication Shop.

3.4 Layout of EMU Body Shop.

3.5 End Under Frame.
The end under frame consists of the following components.
 Body bolster.
 Center sill.
 Rear assembly of center sill.
 Support beams.
 Anti-climbers.
Shown below is under frame with the end under section visible. The EMU trains use a
similar end frame.
Fig. 3.5 Under frame of EMU body.

3.6 Layout of End Under Frame Section.

3. 7 Furnishing Section (Outfitting Department).
Once the car rolls out from the car body shop its outer is complete .This serves as the input to
this section. The car body then spends the next thirty days in this section. The following are added
to the car body shell in this section.
 Floor boards over which linoleum covers are put.
 Glass wool insulation is done. Since the metro car is an air-conditioned car it is imperative
to carry out the insulation properly.Infact only after the customer is satisfied with this does
he clear the car to move further.
 Window glasses are installed using seals.
 Roof and under frame cable ducts are added.
 Doors and their opening and closing systems are installed.
 Interior panels are installed throughout the car.
 Plastic seats are also installed.
 Piping for the braking is installed as per drawings.
 Electrical units are installed.
Fig. 3.7.1 Cable ducts.

Fig. 3.7.2 Interior panels.
Fig. 3.7.3 Completed interiors.

3.8 Components and Working of Braking System.
The air braking system is used in the metro car.it is an electro-pneumatic controlled system.
The main compressor unit is located in the trailer car. Power required to run the main compressor is
taped from the electrical grid using the pantograph. There is also an auxiliary compressor unit for
lifting and dropping of the pantograph. The voltage required for the compressor is stepped down
using a step down transformer.
The EMU train system comes equipped with three brakes.
1. Service brake.
2. Emergency brake.
3. Parking brake.
Fig. 3.8 Block diagram of two pipe air brake system.

The main parts of the braking system are:
3.8.1 Compressor.
The pump which draws air from atmosphere and compresses it for use on the train. Its
principal use is for the air brake system, although compressed air has a number of other uses on
trains.
3.8.2 Main Resevoir.
Storage tank for compressed air for braking and other pneumatic systems.
3.8.3 Drivers Brake Valve.
The means by which the driver controls the brake. The brake valve will have (at least) the
following positions: "Release", "Running", "Lap" and "Application" and "Emergency". There may
also be a "Shut Down" position, which locks the valve out of use.
The "Release" position connects the main reservoir to the brake pipe. This raises the air
pressure in the brake pipe as quickly as possible to get a rapid release after the driver gets the signal
to start the train.
In the "Running" position, the feed valve is selected. This allows a slow feed to be
maintained into the brake pipe to counteract any small leaks or losses in the brake pipe, connections
and hoses.
"Lap" is used to shut off the connection between the main reservoir and the brake pipe and
to close off the connection to atmosphere after a brake application has been made. It can only be
used to provide a partial application. A partial release is not possible with the common forms of air
brake.
"Application" closes off the connection from the main reservoir and opens the brake pipe
to atmosphere. The brake pipe pressure is reduced as air escapes. The driver (and any observer in
the know) can often hear the air escaping.
Most driver's brake valves were fitted with an "Emergency" position. Its operation is the
same as the "Application" position, except that the opening to atmosphere is larger to give a quicker
application.

3.8.4 Feed Valve.
To ensure that brake pipe pressure remains at the required level, a feed valve is connected
between the main reservoir and the brake pipe when the "Running" position is selected. This valve
is set to a specific operating pressure.
3.8.5 Equalising Reservoir.
This is a small pilot reservoir used to help the driver select the right pressure in the brake
pipe when making an application. When an application is made, moving the brake valve handle to
the application position does not discharge the brake pipe directly, it lets air out of the equalising
reservoir. The equalising reservoir is connected to a relay valve which detects the drop in pressure
and automatically let’s air escape from the brake pipe until the pressure in the pipe is the same as
that in the equalising reservoir.
The equalising reservoir overcomes the difficulties which can result from a long brake pipe.
A long pipe will mean that small changes in pressure selected by the driver to get a low rate of
braking will not be seen on his gauge until the change in pressure has stabilized along the whole
train. The equalizing reservoir and associated relay valve allows the driver to select a brake pipe
pressure without having to wait for the actual pressure to settle down along a long brake pipe before
he gets an accurate reading.
Brake Pipe The pipe running the length of the train, which transmits the variations flexible
hoses, which can be uncoupled to allow vehicles to be separated. The use of the air system makes
the brake "fail safe", i.e. loss of air in the brake pipe will cause the brake to apply. Brake pipe
pressure loss can be through a number of causes as follows:
A controlled reduction of pressure by the driver.
A rapid reduction by the driver using the emergency position on his brake valve.
3.8.6 Angle Cock.
At the ends of each vehicle, "angle cocks" are provided to allow the ends of the brake pipe
hoses to be sealed when the vehicle is uncoupled. The cocks prevent the air being lost from the
brake pipe.

3.8.7 Coupled Hoses.
The brake pipe is carried between adjacent vehicles through flexible hoses. The hoses can
be sealed at the outer ends of the train by closing the angle cocks.
3.8.8 Brake Cylinder.
Each vehicle has at least one brake cylinder. Sometimes two or more are provided. The
movement of the piston contained inside the cylinder operates the brakes through links called
"rigging". The rigging applies the blocks to the wheels. Some modern systems use disc brakes.
The piston inside the brake cylinder moves in accordance with the change in air pressure in the
cylinder.
3.8.9 Auxiliary Reservoir.
The operation of the air brake on each vehicle relies on the difference in pressure between
one side of the triple valve piston and the other. In order to ensure there is always a source of air
available to operate the brake, an "auxiliary reservoir" is connected to one side of the piston by way
of the triple valve. The flow of air into and out of the auxiliary reservoir is controlled by the triple
valve.
3.8.10 Brake Block.
This is the friction material which is pressed against the surface of the wheel tread by the
upward movement of the brake cylinder piston. Often made of cast iron or some composition
material, brake blocks are the main source of wear in the brake system and require regular inspection
to see that they are changed when required.
Many modern braking systems use air operated disc brakes. These operate to the same
principles as those used on road vehicles.
3.8.11 Brake Rigging.
This is the system by which the movement of the brake cylinder piston transmits pressure
to the brake blocks on each wheel. Rigging can often be complex, especially under a passenger car
with two blocks to each wheel, making a total of sixteen. Rigging requires careful adjustment to
ensure all the blocks operated from one cylinder provide an even rate of application to each wheel.
If you change one block, you have to check and adjust all the blocks on that axle.

Chapter 4
REFLONECTIAL NOTES
In this chapter we reflect on the internship. Regarding our learning goals we shortly discuss
our experiences; if we have achieved our goal, and the technical as well as the non technical
outcomes of the internship programme.
4.1 Working Conditions of Manufacturing Industry.
At the beginning we did not have any experience. Although we had seen one, we now
understand better the functioning like the organization structure and setting up the industry. Trying
to operate as a industry we saw the importance of financial support and personal capacity. The
dependence on external suppliers for various items used in the transformer is a very important part
of the industry.
4.2 Enhancing technical skills.
The academic knowledge of transformers which we had studied as a part of our academic
programme was found to be woefully short of the practical experience. The various testing
procedures was new to us and we found them to be extremely useful in understanding their
importance in determining if a transformer is ready to be used in real life.
4.3 The use of Skills and Knowledge gained in the University.
The skills and knowledge gained in my study could be put to use to practise in our internship.
Calculations of phase resistances using data from the tests performed was done based on the
academic studies we had made over the past year.

4.4 Industrial Saftey.
 Training conducted for employee’s and associates regarding safety, operating procedure,
maintenance practices to enhance the knowledge.
 Display of sign boards, standard operating procedures, standard maintenance practices,
equipment name display boards.
 The most important factor or the context to be understood is safety and should have
brief knowledge of industrial safety before entering into any industry.
 It is mandatory to wear all the Personal Protective Equipments (PPE’s) which include
Safety helmet, Safety Shoes, Ear Plug, Goggles, Dust mask and Safety jacket.
 All the persons are trained for any new safety standards implemented.
 Display of boards which create awareness regarding safety at work location.
 Display of emergency contact numbers for Ambulance, Fire Safety,etc.
 Visitors are not allowed at worksite for safety reasons.
4.5 Wide Applications of Hydraulics and Pneumatics.
 During the Internship, came across wide range of applications on Hydraulics &
pneumatics.
 Almost in all major equipments we can find the hydraulic and pneumatic actuators
out of which most are cylinders.
 Various components which make up a hydraulic system are Oil tank, Pump, Filter,
Pipeline, Valve Stand, and Cylinders in general.

4.6 Maintenance Practices.
 Maintenance is the regular activity which is carried out to have good healthiness of
equipments and higher equipment availability.
 Monthly two or three shutdowns are planned to carry out the maintenance activities.
 Exposure to different type of maintenance practices like Preventive maintenance.
 Corrective maintenance, breakdown maintenance, opportunity based maintenance,
condition based maintenance.

4.7 Brake Applications.
 The driver has placed the brake valve in the "Application" position. This causes air
pressure in the brake pipe to escape.
 The loss of pressure is detected by the slide valve in the triple valve. Because the
pressure on one side (the brake pipe side) of the valve has fallen, the auxiliary
reservoir pressure on the other side has pushed the valve (towards the right) so that
the feed groove over the valve is closed.
 The connection between the brake cylinder and the exhaust underneath the slide valve
has also been closed. At the same time a connection between the auxiliary reservoir
and the brake cylinder has been opened.
 Auxiliary reservoir air now feeds through into the brake cylinder. The air pressure
forces the piston to move against the spring pressure and causes the brake blocks to
be applied to the wheels.
 Air will continue to pass from the auxiliary reservoir to the brake cylinder until the
pressure in both is equal. This is the maximum pressure the brake cylinder will obtain
and is equivalent to a full application.
 To get a full application with a reasonable volume of air, the volume of the brake
cylinder is usually about 40% of that of the auxiliary reservoir.
4.8 Improvement in Time Management Skills.
 Clear understanding between important and urgent tasks and executing accordingly.
 Understanding clearly the problems importance and its effect on production,
prioritizing the time and problem to solve the problem.
 Proper scheduling of activities required to complete the task at the earliest.

Chapter 5
CONCLUSIONS
On the whole, this internship was a useful experience. We have gained new knowledge,
skills and met many new people. We achieved several of our learning goals. We got insight into
professional practices currently advocated in the industry. We learned the different facets of working
within a well established industry.
INTERNSHIP AT BEML Limited - a learning Experience.
As envisioned by our first PM, Pt. Jawaharlal Nehru, BEML Limited has proved to be true
one among the modern temples of engineering of India and BEML has proved beyond doubt that
they are no less than their competitors in the private sector. As I have seen and experienced, there
is no dearth of expertise, talent, professionalism and dedication of the workforce towards
accomplishing the tasks and targets in meeting delivery of products to its various customer
segments.
Today, I am proud to be associated with this esteemed organization as an intern and I am
fortunate to have the exposure across most of the departments and its industrial functioning. Overall
it was a good learning and rewarding experience.
Logistics.
Design.
Production.
Plannig.
Department.
This interaction gave me an insight and first-hand experience of industrial scenario outside
the institute curriculum. In addition, the exposure gave me the practical knowledge into the overall
functioning of the organization, human behavior in industry and also helped us co-relate theoretical
concepts of classroom and practical approach to industrial production.
The entire duration of four weeks in BEML was professionally managed by all the
responsible persons I came across, very informative and I have no doubt, it will retain its
significance when I embrace my professional careers as an engineer.
In doing so, I gratefully acknowledge the large heartedness of this institution for giving me
an opportunity to complete this internship.

DESIGN AND MANUFATURE OF METRO CAR BODY

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