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![Locos, except the older steam ones, have
classification codes that identify them. This code
is of the form:
“[ gauge ][ power ][load ][ series ][ sub type ]”
e.g. WDG5A](https://image.slidesharecdn.com/a9c07ef2-970f-4162-b5f0-667c6ac82611-161224125227/85/Presentation-on-Industrial-Training-6-320.jpg)
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Presentation on Industrial Training
- 1. Presentation on Industrial Training at MangleshSingh Mechanical Engineering Final Year 1350840049
- 2. o Production Unitunder ministry of railways set up in Ancient city of temples, Varanasi to Undertake indigenous manufacture of Diesel Locomotives. o Set Up in Collaboration with American Locomotive Company (ALCO) in 1961. o First Locomotive was rolled out in 1964. o DLW got its first ISO certification in 1997. Recently DLW has obtained “Integrated Quality and Environment Management system” certification based on ISO-9001 and ISO-14001. o Produces two types of locomotives o ALCO loco o GM loco o DLW exports locomotives to Sri Lanka, Malaysia, Vietnam, Tanzania, Bangladesh.
- 3. GM (General Manager) CME(G) Chief Mechanical Engineer CME (P) Chief Mechanical Engineer (Production) Dy. CME (Engine) Dy. CME (Block) Dy. CME (Loco) Dy. CME (Tooling) Dy. CME (Planning) Dy. CME (M&P)
- 4. Continued… WM (Works Manager) (AWM)Assistant Works Manager SSE (Senior Section Engineer) SE (Section Engineer) JE (Junior Engineer) MCM (Master Crafts Man) FTR-I (Fitter-I) FTR-II (Fitter-II) FTR-III (Fitter-III) Helper (Khalasi)
- 5. DLW’s annual production:250 locos Cost of one loco :12 to 14 crore (GM loco) 8 crore (Alco) Weight of one Loco :121 Ton Fuel Consumption :At Full Load - 540 lit/hr. :Idling- 40 lit/hr. Max. Speed :160 Km/hr. Dia of Wheel :1092 mm Wheel to Wheel Distance :1596.5 mm Length of Under Frame :1962 mm
- 6. Locos, except theolder steam ones, have classification codes that identify them. This code is of the form: “[ gauge ][ power ][load ][ series ][ sub type ]” e.g. WDG5A
- 7. In a diesel-electriclocomotive, the diesel engine drives an electrical generator or alternator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels.
- 10. • The ALCOis a passenger/freight-hauling diesel-electric locomotive with AC electric transmission designed by the American Locomotive Company and produced under license by Diesel Locomotive Works (DLW) of Varanasi, India for Indian Railways as their classes WDM-2, WDM-3A/2C, WDM-3D and WDG-3A for operation in India. • Power output •2,600 hp (1,940 kW) (WDM-2) •3,000 hp (2,240 kW) (WDM-3A/2C) •3,100 hp (2,310 kW) (WDG-3A) •3,300 hp (2,460 kW) (WDM-3D)
- 11. • The WDG4& WDP4 series of DLW make locomotives are GM (General Motor) locomotives. • The GM locomotive is equipped with a microprocessor based computer control system- referred to as EM- 2000 locomotive. • The GM locomotives are also fitted with equipments like Engine, Turbo super charger, Compressor, Alternator, Traction motors etc. like those in ALCO locomotive but their designs are different. • GM locos can produce power output up to 4500 hp.
- 14. Machining and Fabricationof Cylinder Block. Machining : HMS Fabrication: HWS
- 15. • Precision flamecutting by CNC machines • Thickness of plates: 80 mm • 5 axis CNC machine • This machine performs milling, drilling, tapping and boring operations in single setting.
- 16.
- 17. The shop dealswith manufacturing of various components required for the power pack unit such as cam shaft, connecting rod, gear levers, piston pins etc.
- 18. This section dealswith testing of functioning of engine at various parameters.
- 19. This section involveshardening, tempering and stress removal of various components including camshaft, rocker arm, cam lobe etc.
- 20. This section involvesassembly of turbo-supercharger to the engine.
- 22. Fabrication of frameson which locomotives are mounted.
- 23. Bending of variouspipes used in the locomotive frame.
- 24. • Machining andAssembly of Axle-Wheel. • Mounting of traction motor on axle.
- 25. • Assembly oflocomotive and loco-frame. • Assembly of driver cabin with locomotives.
- 26.
- 27.
- 28. Starter Motor Arrangement of startermotor pinion and Flywheel: As motor starts and solenoid actuates, pinion shifts to mesh with tooth on outer periphery of flywheel.
Editor's Notes
- #3 Tell what you have done in four weeks
- #7 The first letter (gauge) W- Indian broad gauge(1.67 m) Y- meter gauge Z- narrow gauge(2.5 ft) ( 0.762 m) N- narrow gauge (2 ft) ( 0.610 m) The second letter (motive power) D- Diesel C- DC electric (can run under DC traction only) A- AC electric (can run under AC traction only) CA- Both DC and AC (can run under both AC and DC tractions) B- Battery electric locomotive (rare) The third letter (load type) G-goods P-passenger M-mixed traffic ; both goods and passenger S-Used for shunting U-Electric multiple units (E.M.U.) R-Railcars THE fourth letter (series) The series digit identifies the horsepower range of the locomotive. Example for the series letter ‘3’ means that the locomotive has power over 3000 hp but less than 4000 hp. The fifth letter (subtype) an optional letter or number that indicates some smaller variations in the basic model.
- #12 The computer controlled system is equipped with a diagnostic display system (DDS) in the cab to provide an interface between the locomotive driver and the computer. The EM- 2000 computer is programmed to monitor and control locomotive traction power, record and indicate faults, and allow diagnostic testing.
- #16 Flame Cutting Steel plates of sizes up to 80 mm thickness are ultrasonically tested before being precision cut by numerically controlled flame cutting machines, Plasma Cutting Machine. Components are straightened and machined prior to fitting & tacking on fixture designed specially for engine block fabrication to ensure close tolerance on engine block. Portal Milling Machine Engine block machining is done on Portal Milling Machine which is a 5 axis CNC machine with SIEMENs 840-D state of art system control with dedicated tool management system. The machine accuracy of 10µ enables adhering to the tolerance required on engine block.
- #20 450deg celciuus -> camshaft stess removal Tempering 200deg c, heat for 2 hours.
- #21 Tell the working principle of turbocharger and supercharger.
- #23 Plasma Cutting machine Shot blasting machine