BEML Bharth Earth Movers Limited , Bangalore . Metro Train manufacturing plant.

1. BEML
Bharth Earth Movers Limited
INTERNSHIP REPORT
Davalsab.M.L
R15MDD10
M.Tech – Machine Design & Dynamics
Daval.techno@gmail.com
Cell -8904567449

2. Content
 Company profile
 Plant layout
 Plant Layout In-Detail
 Product
 Manufacturing facilities.
 Metro Train Configuration
 Design innovation
 Design & Product Development
 Design Modeling of car body
 Structural Analysis of Car body
 Design of Interior
 Car body Validation
 Manufacturing infrastructure
 Car body Manufacture
 Car Furnishing Assembly
 Customer feedback
 Contribution towards Self Reliance

4. DC Electric Multiple UnitPassenger Coach
UnitEMU Electric Multiple Unit Trains Rail BusStainless Steel Metro
Stainless Steel EMU Trains
Products

5. The products manufactured at Bangalore
 Stainless Steel Metro Cars for DMRC
 Passenger Coaches
 DC Electric Multiple Units
 AC Electric Multiple Units
 Overhead Equipment Inspection Cars
 Rail Bus
 Treasury Vans
 Spoil Disposal Units
 Track Laying Equipment
 Sky Bus
 MIL Rail Coaches
 Utility Track Vehicle (UTV)
 Variants on BEML-Tatra Trucks
 Prithvi Missile Launcher
 Field Artillery Tractor
 Crash Fire Tender
 30m Mobile Mast
 Ammunition Loader
 15m Bridge - Sarvatra
 Pontoon Bridge System
 Trailers- 50T, 20T
 Railway Products for Defence
 Wagons
 Military Rail Coach
Rail & Metro Defense

6. Manufacturing Facilities
 Boring machines for Axle box
 AF / Axle Box spring seat machining
 Wotan internal grinding machine
for Axle box
 Vertical turret lathe for Axle box
machining
 Honing machine
 Flash butt welding machine for
Brake Tension rod
 Hydraulic press 100 T for Bush
pressing
 Laser cutting machine
 NC shearing machine
 Punch press: 40 - 1000 T
 Press Brake: 40 - 500T
 Optical tracer flame
cutting machines
 CNC Flame cutting
machine
 Shot blasting machine
for (Rolled section &
Plates)
 Shearing M/C to 30
mm capacity with
inbuilt Beveling for weld
joints
 Foil Roll welding
machine for welding of
corrugated sheets used
for Floor
 Corrugated rolling
machine
 Plasma Cutting machine
Machine Shop Sheet Metal Material Preparation Under Frame

7. Manufacturing Facilities
Bogie
• Submerged Arc welding sets
• Check & straightening machine
for Bogie components
Major Assembly & Erection Shop
• Robot Spot Welding Machine
• Roller bending machine for roof
skins
• Foil Roll-Welding M/C for Roof,
Side wall & End wall of Rail
coaches
• Roof leak test facility
Pre-treatment & Painting Shop
• Conveyorised painting booth
• Shot Blasting facilities for Rolled
Sections and plates
Coach Delivery Shop
• Lifting jacks of 16 T capacity
• Air brake testing equipments (4 numbers)
• Traversors of 75 T capacity (2 numbers)
• Water leak test facility for Metro cars
Dedicated Facilities
• 248 M Test track (2 Numbers) for Metro
and AC-EMU testing
• Bogie testing machine (3 Numbers) up to
60 Ton capacity
• Well-established metrological laboratory
for Quality products
• Well-laid Railway lines inside the
production shops for smooth stage
production
• Railway sidings for delivery of coaches
and receipt of raw materials
Welding Fabrication and Associated
Facilities
• Electrical resistance Foil Roll butt
machines
• Electrical resistance spot welding
machine
• Flash butt welding equipment
• Pulse tig-welding machine
• Auto and semi auto submerged Arc
welding
• CO2 welding sets of capacity of 400
AMPS
• Thermal stress relieving furnaces
• Radiographic and Ultrasonic tests on
welded structures

8. Train Configuration
Configuration 1 – Used in Bangalore metro (Standard Gauge)
There are three different types of cars that are used in metro, they
are- DM car, M car and T car connected together with the help of
semi-couplers and an auto-coupler in the DM cars.
 DM - Driving Motor car
 M- Motor car
 T -Trailing Car
Bangalore and Delhi metro has different configurations and these
configurations are shown below in the form of block diagrams.

9.  Configuration 2 - Used in Delhi Metro
The Delhi Metro has different configuration compare to the one that is being
used in Bengaluru. The Delhi metro has two units. Each of these units has
three cars namely- Driver motor car (DM car), Trailing car (T car) and Motor
car (M car) and these two units are connected together with the help of an
Auto-coupler. The Trailing car will have a pantograph on the roof of the car
and electricity will be supplied to the transformer with the help of
pantograph. Furthermore, the bogie of the trailing car (T car) lacks the
Motor housing as well as the Driver Gear housing which is otherwise present
in the Driver Motor car (DM car) as well as in the Motor car (M car).
 DM - Driver Motor Car
 T - Trailing Car
 M - Motor Car
 AC - Auto-Coupler
 SC- Semi-Coupler

10.  Design of wide bodied SS carbody structure with 16 passengers /
sqm loading (double of International & Indian metro standards)
was a challenging task
 Interior design was made with aesthetics & cost effectiveness in
mind, FRP panels used
 New design of window with wider opening. Design is having
provision for converting to Air-conditioned type with minimal
changes
 Passenger seats with polycarbonate material & dual tone shade to
match the interiors.
 FRP cab mask incorporated in the front to give a better look. FRP
driver’s desk ergonomically designed.
DESIGN INNOVATIONS

11. DESIGN & DEVELOPMENT EFFORTS
 Design effort involved:  Development effort involved:
 Analysis of customers requirements,  Manufacturing drawings
 Conceptual Design,  Procurement technical specifications
 Detail design calculations  Quality Documents.
 3D modeling  Manufacturing of Prototype carbody
 Structural Integrity & Strength Analysis  Design validation by squeeze testing
 Manufacturing, Furnishing & In-house
testing
 Testing and commissioning at
customers location.

12.  Complete carbody modeled using CATIA V5 software.
 Carbody section to be within the allowable maximum moving dimensions.
 Weight reduction by 2 Tonnes
DESIGN MODELING OF CARBODY

13.  Structural Integrity & Strength Analysis of the carbody checked
 To meet UIC 566 standard,
 Analyzed using MSC Nastran software,
 Super dense passenger loading of 16 passengers / sqm
 Stress levels within acceptable limits.
STRUCTURAL STRENGTH VERIFICATION

14.  CAD model of interiors, driver’s desk & cab mask prepared
 Interferences checked
DESIGN OF INTERIORS

15. CARBODY MANUFACTURE
TRAILER COACH CARBODY
MOTOR COACH CARBODY
 Manufacturing of Stainless steel
EMU carbody in production line.

16.  Furnishing of Stainless Steel EMU in
production line.
CAR FURNISHING & ASSEMBLY
INTERIOR VIEW
DRIVER DESK
EXTERIOR VIEW

17. • In BEML 70 per cent of a Metro coach was indigenous, with BEML pushing for local sourcing
“except for a few critical aggregates like doors, air conditioners and most of the components are
manufactured or sourced locally through vendors.
• It is BEML’s endeavour to achieve enhanced self reliance by whole heartedly participating in
‘Make in India’ drive with increased sourcing from Indian industries.”
• In obstruction detection devices, door sensitivity, enhanced dedicated bandwidth for streaming
a situation in a train to the will be other safety features of the driverless trains. Until the
driverless trains become fully operational, one attendant will be present in each train to ensure
smooth transition from previous models.
• BEML, which is catering to nearly 46 per cent of the demand for Metro trains in the country, is
executing orders for 96 coaches for DMRC. These will be used to convert six-coach Metro
trains to eight-coach ones by the end of next year. The RS 13 coaches will be supplied to
DMRC by next August 2017
DMRC Metro Plan

18. • The indigenously designed & developed SS EMU has successfully undergone
all the stringent tests & trials of the customer, IR
• User satisfactory performance certificate received.
• Based on the successful user trials, further order of 4 rakes (36 cars) has been
received from IR
• MD, MRVC (Mumbai Rail Vikas Corporation) after his visit to BEML had made
the following observations
• “ We were extremely happy to observe the international standard achieved
by
• BEML in the design & manufacture of stainless steel coaches for Metro &
Suburban railway system in India. “
Customer Feedback

19.  SS EMU designed & developed for Indian Railways for the first time through in-
house R&D efforts without any foreign collaboration.
 Stainless steel carbody joining / manufacturing process established which will
be helpful for other projects.
 Stainless steel raw material of desired specification developed by indigenous
sources.
 Interior furnishing items developed through indigenous sources.
 Future requirements of rolling stock variants with stainless steel carbody can
be developed within the country.
CONTRIBUTION TOWARDS SELF RELIANCE

20. The internship opportunity I had with BEML was a great chance for learning and professional
development. Therefore, I consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I also grateful for having a chance to meet so many wonderful
people and professionals who led me though this internship period.
In the first part of the project report, the general information of the company has been
collected information is gathered through the primary and secondary source as well.
In the second part of the report, contains the specialized subject study. Objective of the
project is to work on the various Engineering methodologies used in the BEML Company.
And in details of metro Rolling Stocks and Assembly and testing Rolling stocks.
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.
Conclusion

21. Thank you