Diesel loco modernization


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Diesel loco modernization

  2. 2. Company Profile Diesel Loco modernization Works was conceived with a view to provide maintenance supports to zonal railways for the maintenance of over 4500 diesels locomotive, which are in services. DMW believes that product quality has to be built in during manufacturing. In accordance with the belief, the quality assurance system forms integral part of workshop activities. With quality as its strength factor, DMW is surely and steadily notching up its market share.
  3. 3. Salient Features: Workshop area (Sq m) 837936 Covered area in shops (Sq m) 87578 Township area (Sq m) 1416800 Electrical Energy Consumption 161.01 (Lakhs of units/year)
  4. 4. Strategy Followed In Planning Of DCW Each workshop has a major area functioning under middle management level officers, who are totally answerable for their performance. Layout of workshops is such that there is a smooth flow of jobs from one workshop to another. Fully integrated with CNC, NC and NON-CNC machines to overcome the demand. Machines are placed according to group technology so that final job comes out as single. Inspection and testing is done 100% with very accurate instruments for good quality.
  5. 5. Project Objective Diesel-Loco Modernisation Works was setup in the year 1981 to extend the service life of Diesel Locomotives of the Indian Railways and significantly raise the level of their availability. Manufacture and supply of high quality components and sub-assemblies as spares. Manufacture of Components hitherto imported achieving import substitution and timely availability Rebuilding Locomotives and power packs and turning them out in state- of-the- art condition. Retrofitting the locomotives with systems
  6. 6. Diesel Locomodernisation Works Layout
  7. 7. DMW Is Divided In Two Parts- Phase 1- Phase 1 was sanctioned in May 1982 and that of Phase 2 in June 1986. For phase 1 group of shops covering an area of 47,000sq.m has been provided in which 734 items of different machinery & plant have been installed. Phase 2- Construction of Phase 2 group of shops, where rebuilding of diesel loco per annual is to be undertaken was taken up in 1986-87 at an estimated cost of 46.63 crores. For this purpose covered area of 25,000sq.m and 298 different items of machinery and seven plants have been provided. Facilities for rebuilding of power packs & diesel locomotives are provided in various shops
  8. 8. Various Shops in DMW Are: - P.M.S Plant Maintenance Shop T.R Tool Room L.M.S Light Machine Shop C.B.S Carbon Brush Shop H.T.S Heat Treatment Shop V.M.S Vehicle Maintenance Shop T.M.S Traction Machine Shop M.R.S Main Receiving Shop
  9. 9.  H.M.S Heavy Machine Shop C.L.S Cylinder Linear Shop P.P.S Power Pack Shop B.S Bogie Shop S.S.S Super Structure Shop L.R.S Locomotive Rebuilding Shop
  10. 10. Manufacturing Shops- Phase 1 shops are also known as Manufacturing shops. There are total seven shops which come under manufacturing . These shops manufacture small and heavy parts of loco. The various shops are described as follows:- Light Machine Shop About 300 spare parts required by DMW and Zonal Railways for locomotive maintenance including Camshafts, Gears, Valve gear components, Equaliser beams, Axles, Armature shafts, Axle box housings, Gas inlet casings, etc. are manufactured in the Light Machine Shop.
  11. 11. This shop is also known as for Manufacture of Rail-cum-Road Vehicle. Herevarious tools and components of locomotives are produced with variousmachines. Most of the machines are controlled by CNC’s.
  12. 12.  Heat Treatment Shop Requisite heat treatment that is induction hardening, case carburizing etc. is carried out in the Heat Treatment Shop to develop optimum properties in the finished components.
  13. 13.  Carbon Brush Shop The Carbon Brush Shop manufactures 14 types of carbon brushes required for Traction Generators, Traction Motors and Auxiliary Electrical Machines. Recently carbon brush CB-48 has been developed for fans of ICF coaches.
  14. 14.  Heavy Machine Shop Engine Blocks of diesel locomotives and Traction Motor Magnet Frames are machined in this shop. Precision machining of the Blocks is carried out on CNC Horizontal Boring & Milling Machine of PAMA, Italy make CNC machine.
  15. 15.  Traction Machine Shop A wide variety of Traction Motors, Traction Generators and Alternators are rewound / remanufactured in this shop. Facilities include 500 T Hydraulic Press for shafting/deshafting, Glass Bead Blasting Machine, Vacuum Impregnation Plant, HYT Lathe, Dynamic Balancing Machine, etc.
  16. 16. Locomotive rebuilding shops Phase 2 comprises of Loco-rebuilding Shops. There are total five shops. During Locomotive Rebuilding, besides upgrading output to 3100 HP, the locomotive is also modernized to incorporate numerous improvements in locomotive technology. Power Pack Shop All the Power Packs from incoming locomotives are sent to the Power Pack Shop for remanufacturing. In this shop the power pack is wholly dismantled and rebuilt, tested and then sent to LRS for fitment on the LOCO.
  17. 17. The main functions of this shop are- Dismantling, Reconditioning and assembly of power pack. Load testing, specific fuel consumption testing and other types.
  18. 18. Engine view
  19. 19.  Locomotive Rebuilding Shopa) Locomotive rebuilding facilities include dismantling, repairs and reassembly of the complete Locomotive including under frame.b) A manipulator has been developed for ensuring downhand welding during the repair of under frame and chasis.c) Remanufacturing facilities for auxiliary machines and electronic control harness are also available.d) Air Brake and Paint Shops constitute the supporting activity areas for locomotive rebuilding.e) Power and control cables are renewed and control equipment is remanufactured.
  20. 20. Loco Assembly
  21. 21.  Bogie Shop The locomotive bogies are rebuilt with new wheel sets, suspension bearings and remanufactured traction motors. Separate shop has been set up for machining of wheel sets and assembly of locomotive bogies.
  22. 22. Support shops Above activities are adequately supported by competent workforce of staff and supervisors of Plant Maintenance Shop, Tool Room, Main Receiving Station and other support shops. Electronics Lab
  23. 23. • There is a full-fledged Electronic Lab which has been set up to cater to maintenance need of highly sophisticated CNC machines and component / subassembly level trouble shooting of PCBs, Servo Drives, Microprocessor based controllers and electronic units.• A saving of Rs.1.17 Cr. has been achieved in 2005-06 due to repair of PCBs.
  24. 24. Activities and Products Of DMW Mid life rebuilding/ reconditioning of WDM2 ALCO locomotive. Upgrading them from 2600HP to 3100HP and 3300 HP. Incorporating various modifications to enhance the efficiency, reliability, safety of locomotive. Manufacture of various type of carbon brushes used on traction machines of WDM2, WDM3A, YDM4, WDG4, WDM3C, DMU. Rewinding/ reconditioning of traction motors, traction generator & traction alternators of locomotives. Reconditioning of engine block of ALCO locomotives, power pack and supply of New Power packs.
  25. 25.  WDM3A Diesel locomotive rebuild at DMW
  26. 26. Machines and technology used in DMW PAMA Machine This machine is the most important machine of DMW. This machine is located here only in all over India. This machine is a part of Heavy Machine Shop (H.M.S.). It is used for cutting and boring purposes in a tool. Mainly an engine block is manufactured and repaired in this machine. One engine block can be repaired three times in this machine. The main description can be given as PAMA Horizontal Boring and Milling Machine (with speed RAM).
  27. 27.  View Of PAMA Machine
  28. 28.  CNC Machines Computer Numeric Control machines is a closed loop machine. As the name depicts these machines use computer for their operation. Computer Numeric Control machines are controlled by a set of different ISO codes that helps in proper controlling of the machine. In modern CNC systems, end-to-end component design is highly automated using CAD/CAM programs.
  29. 29.  Block Diagram Of CNC Machine
  30. 30.  Vertical Rotary Mill This machine is CNC operated machine. Vertical Rotary mill is located in LMS shop. It is used mainly for boring and milling of the tools. It needs a total power of 35 KW for its operation. It is worth Rs 17.09322 lacs. The main components used are- Main Bearing Cap, Connecting Rods, Casing Lop, Support V/L. The maximum capacity of it per day is around 45. It has three axis :– X – Rotating, Y - Horizontal. Forward and backward direction, Z - Vertical. Up and down direction.
  31. 31.  View Of Vertical Rotary Mill
  32. 32.  Electronic Lab EquipmentSome of the sophisticated workstations and testing equipment in the Lab are: X-Y, Y-T, 3-Channel Recorders. Dual Channel 100 MHz Oscilloscope with DMM. 5½ Digit Bench Programmable Digital Multimeter. Function Generator with Arbitrary waveform generation. PCB Test Station Automatic Test Equipment (ICT). Universal PROM / EPROM Programmer. Digital / Analog IC Tester. Surface Mount Component Repair Station.
  33. 33.  PCB Test Station and Universal PROM / EPROM Programmer
  34. 34. Result And Conclusion The Indian Railway is the most widely used transport system in India. The production of the parts and units of rails forms an important and integral part of the proper functioning of the railway system in India. Its Worlds largest manufacturer of ALCO diesel loco spares such as Gears, Cams, Con rods, Pins, Carbon Brushes etc. DCW manufactures large components such as traction motors and locomotive power packs, rebuilds engine blocks, traction generators, etc. They have more recently been upgrading WDM-2 locos to WDM-2C class.
  35. 35. View of New Diesel Electric Locomotive
  36. 36. View of Rebuilt Diesel Electric Locomotive