traction machine shed knapur

HISTORICAL BACKGROUND OF INDIAN RAILWAYS
Railways made their first appearance in India in April 1953, when a section from Bombay to Kalyan
(32 miles) was opened to traffic. This was followed by Calcutta-Raniganj (120 miles) and Madras-
Arkonam line (39 miles). The management of Railways was left to private companies who used to run
this system in different territories on 99 years lease bases. There was however a clause in the lease
deed, which could enable government to purchase the line after every 25 years.
As railway system consisting of broad, meter and narrow gauges, grew in size haphazardly owing to
historical reasons, so also grew the public demand for its nationalization of the whole railway system.
On the favorable recommendations of this committee railways were gradually taken up by central
government.
pg. 1 INDIAN RAILWAYS

This process started in 1925 took full 25 years to complete when railways were reorganized and
renamed on zonal basis up to mid. 30’s electric traction existed in India at two places namely Bombay
and Madras with total of 398 route kilometers and employing 500 V D. C. overhead supply system.
After the partition of India and with the launching of 5 years plan, it became necessary to electrify
more and more routes.
It was also in the beginning of 50’s that French National Railways published a report on the
potentialities of A.C. traction system employing 25 kv, 50HZ A.C. supply the railway board rightly
took a decision in 1957 to adopt 25 kv, 50 HZ A.C. supply for all future railways electrification. As a
result of this momentous decision, not only all the subsequent and Howrah regions was subsequently
converted to 25 kv, 50 HZ A.C. systems.
Now the electrification has become a regular program of Indian Railways and it is contemplated to
electrify trunk routes interlinking metropolitan cities of Calcutta, Delhi, Mumbai & Chennai.

INTRODUCTION
GENERAL:-
NAME: TRACTION MACHINE SHED
ADDRESS: TRACTION MACHINE SHED, KANPUR
RAILWAY STATION: KANPUR
BACKGROUND:-
1. The traction machine shed was established in year 1973 as a unit of Electric Loco Shed, Kanpur and
later
on 18/01/74, it was made independent unit.
2. This shed was commissioned primarily to meet the imperative maintenance needs of electric loco
motors.
At present the scope of work includes following:-
a. Reclamation/rewinding of armature and stator of traction motor and other auxiliary machines
of electric locos & EMU for various sheds of Indian Railways, rewinding of loco auxiliar y
machines and other general power electrical machines of Northern Railways, India.
b. Reclamation and repair of SL’S of Northern Railways.
c. Reshafting of armatures and associated activities.
d. Stator coil manufacturing for TAO and HITACHI traction motors.

BRIEF DESCRIPTION OF ACTIVITIES OF DIFFERENT SECTIONS
1. AUXILIARY SECTION:
 The unloading of machines as per instruction of PPO in the presence of testing section.
The record of auxiliary is done in the unloading register.
 The decision by testing section along with the details and the work required to be done
by testing section.
 The auxiliary those involve the auxiliary reported can be of two types, i.e. rewinding
and other mechanical repair.
2. TESTING:
 Investigation of T.M. Armatures, Auxiliary Machines and other machines.
 Testing of T.M. Armatures, Stators, Auxiliary machines and other products.
 Recording of details of investigation and testing.
 Issue of job cards for all machines going for under repair.
3. GENERAL-3 SECTION:
 Maintaining the shed and providing several services like carpentry and preparation of
display boards etc.
4. MILL WRIGHT SECTION:
 Mechanical repair ( head changing and reshafting ) of Armatures.
 Shaft machining of Armatures and commutator turning.
 Crane operation, welding work and wagon movement.
5. ARMATURE SECTION:
 Rewinding of TAO-659. Hitachi & EMU TM armature.
 Minor of TAO-659. Hitachi & EMU TM armature.

6. STATOR SECTION:
 To undertake major / minor repairs of Traction Motor stators as per the job card issued by
testing section.
 To dispatch the repaired stator duly tested and passed by testing section.
 To undertake work of manufacturing of field coils of TM stators.
7. COIL SECTION:
 To arrange and ensure manufacturing of coils for TAO- 659, EMU & Hitachi armatures.

TIG (TUNGSTON INERT GAS) WELDING MACHINE
INTRODUCTION:
Tungsten Inert Gas Welding process; commonly termed as Argon Arc Welding process; is ideally
suitable for Arc Welding of most grades of Carbon and Alloy Steel, Stainless Steel, Aluminium
and it’s Alloys, Copper, Brass, Bronze and also high temperature and hard surfacing Alloys.
PRINCIPLE:
An arc is generated b/ w two conductors of electricity, cathode and anode (considering direct current,
DC ), when they are touched to establish the flow of current and then separated by a small distance.
An arc is a sustained electric discharge through the ionized gas column called plasma b/ w the two
electrodes.
Similarly welding can be done with an arc of the alternating current (AC ), with the main difference
that the cathode and anode would change continuously and as a result, the temperature across the arc
would be more uniform compared to a DC arc.
NEED OF INERT GAS:
The Endeavour of the welder is always to obtain a joint which is as strong as the base metal and at
the same time, the joint is as homogeneous as possible. To this end, the complete exclusion of oxygen
and other gases which interfere with the weld pool to the detriment of the weld quality is very
essential. In manual metal arc welding, the use of stick electrodes does this job to some extent but
not fully. In inert gas shielded arc weldind processes, a high pressure inert gas flowing around the
electrode while welding would physically displace all the atmospheric gases around the weld metal
to fully protect it.

ELECTRODE USED IN TIG WELDING:
TIG Welding or gas tungsten arc welding ( GTAW ) is an inert gas shielded arc welding process
using non – consumable electrode. The electrode may also contain 1 to 2% thoria (thorium oxide
) mixed along with the core tungsten or tungsten with 0.15 to 0.40% Zirconia ( Zirconium oxide
). The pure tungsten electrodes are less expensive but will carry less current. The thoriated tungsten
electrodes carry high currents and are more desirable because they can strike and maintain a stable
arc with relative ease.
DESCRIPTION OF THE EQUIPMENTS:
The TIG Welding system consist of followings:
 High Frequency Unit,
 Welding Torch,
 Gas Regulator cum Flow Meter,
 Power Source A.C. or D.C.,
 D.C. Suppressor,
 Resistance Box and Water Circulating Unit

V.P.I. (VACUUM PRESSURE IMPREGNATION) PLANT
 In TMS V.P.I. plant is a plant used for varnishing various components i.e. armature and stator
and 3 phase auxiliary machines.
 Under vacuum pressure impregnation the component is varnished by infecting the suitable
varnish under pressure in an evacuated space.
 Varnish is used to avoid air gaps and bubbles inside the component body and also due to varnish
armature’s and stator’s surface get unaffected by the moisture.
 The armature or stator which is to be varnished is placed inside the plant where vacuum is
created by an exhausted and from varnish tank varnish enters with pressure with the help of a
compressor.
PROCEDURE:
 First the component is preheated at an average temperature of 120 degree Celsius for at least
6 hours in an oven and then it is cooled to 50 to 60 degree Celsius.
 Then the component is placed in V.P.I. plant and a vacuum of at least 755 mm Hg is created
which is maintained for at least 20 minutes.
 Now the impregnation varnish is admitted from the bottom with motor kept in vertical position
for 30 minutes.
 After this the vacuum is destroyed and the motor is kept under a pressure of 3 kg/cm sq. for
½ hour and then the component is cooled down to ambient temperature.
Different varnishes are used for different components as will as different type of armatures as
following:
Component Varnish used
Hitachi armature HEW-290
EMU Armature FT-2005
TAO-659 Armature FT-2005
3 phase auxiliary machines H-71
Stators H-71
Varnish is kept in an A.C. tank (such as H-71 at 25 degree cel) so that it may not freeze.

DYNAMIC BALANCING
 Dynamic balancing is a process of balancing of machine’s rotating parts. In TMS the armatures
which are the rotating part in a motor, are balanced otherwise it may create noise as well as
armature shaft and motor may also damage.
 The armature (with shaft) is rotated through spindles on lathe m/c and the imbalance is checked
by the display m/c providing data as the angle and weighty which is to be balanced. The speed
of m/c is increased gradually.
 The radii of A, B, C parts (as shown in figure as Ra, Rb, Rc,) are fed on display m/c by the
operator and the lathe m,/c is started to rotate the armature. The reading is taken through the
display m/c.
 The weight which is to be balanced is added or removed as per the requirement at the angle
shown on display m/c.
 The armature is again rotated and checked for imbalance. If not balanced again weights are
inserted to be balanced the armature. This process is continued until the armature is completely
balanced. After the balancing of armature the display machine shows the balanced condition.
 The weight range of the balancing m/c in TMS is 25 to 100 and 100 to 3000 Kgs. The data
recorded during the balancing of an armature, as an example, are as follows.
WT OF ARMATURE (KG) BALANCING SPEED
(RPM)
MIN MAX
100 300 1000
300 1000 700 or 500
1000 3000 350
After balancing the weights are added are further welded so that weights may not be thrown by
centrifugal force while rotating and may fixed on armature.

AN OVERVIEW OF MACHINES AND PLANTS USED IN TMS/CNB
SL
NO
TYPE OF MACHINES PURPOSE
1 Over head crane
Capacity:-20,10,5 Tons
To shift the armature and other heavy
jobs to different places in sections.
2 Lathe:
(1) Turning lathe
(2) Grinding lathe
(a) Commutator turning
(b) Shaft turning
(c) Other job’s turning
Shaft grinding
3 Shaper machine Shaping the shafts at a specific angle.
4 Milling m/c To cut the groove in teeth in gears.
5 Boring & Drilling machines Bore and drill making in shafts of
Armatures and other jobs.
6 Hydraulic press
Capacity: (1) 300 tons
(2) 300 tons
(3) 70 tons and 60 tons
For de shafting and re shafting in
general section
For pressing the stator coils to shape
them in stator section
For shaping coils with the help of dies in
manufacturing of armature coils in
coil section
7 Brazing To connect the terminals in stator coils
in stator section.
8 Edge winding m/c For the forming of coils in stator
section using suitable fixtures.

LATHE
Lathe is the oldest tool invented ,starting with the Egyptian tree lathes. In the Egyptian tree lathe, one
end of the rope wound round the work piece is attached to a flexible branch of a tree while the other
end is pulled by the operator, thus giving the rotary motion to the work piece.
The principal form of surface produced in a lathe is the cylindrical surface. This is achieved by rotating
the work piece while the single point cutting tool removes the material by traversing in a direction
parallel to the axis of rotation and termed as “ Turning “.The popularity of the lathe due to the fact that
a large variety of surfaces can be produced.
 Different types of lathes are used in manufacturing shops. Some of them are:
 Centre lathe
 Tool room lathe
 Special purpose lathes
 Copying lathe
 Gap bed lathe
 Capstan and turret lathes
 Automatic lathes.
The centre lathe is the most common lathe which derives its name from the way a work piece is
clamped by centers in a lathe, through this is not the only way in which the job is mounted. This is
sometimes also called as engine lathe in view of the fact that early lathes were driven by steam engines.
The tool room lathe is generally meant for applications of tool making, where the accuracy desired is
much higher than that is normally required for general production work.
Special purpose lathes are developed from the centre lathe to cater to special forms of application
which cannot be handled by the conventional centre lathe.

Capstan and turret lathes and automatic lathes cater to high rate production and thus are used for special
application purposes.
MILLING
 After lathes, Milling machines are the most widely used for manufacturing applications. In
milling the work piece is fed into a rotating milling cutter, which is a multi point tool, unlike a
lathe, which uses single point cutting tool. The tool used in milling is called the ‘Milling
Cutter’.
 In the milling process, each of the cutting edges removes material for only a part of the rotation
of the milling cutter. As a result, the cutting edge has time to cool before it again removes
material. Thus the milling operation is much cooler compared to the turning operation. This
allows for much larger material rates.
 In TMS, Milling m/c is mainly used for cutting key grooves on shafts and cutting the groove
on gear teeth.
SHAPER
 The shaper is a m/c which uses only reciprocating action.
 The shaper is a relatively slow m/c tool with very slow metal removal capability.
 The shaper uses a single point cutting tool similar to a clapper box which in turn is mounted to
a reciprocating ram. The ram while undertaking the cutting stroke (forward stroke) pushes the
cutting tool through the work piece to remove the material. When the ram returns (Return or
Idle stroke) cutting takes place.
 The single point cutting tool is clamped in the tool head. The tool head has the ability to swivel
the cutting tool in any angle while clamping the tool with any overhang, depending upon the
requirement. The swiveling ability is important for the tool to machine surfaces that are not in
a horizontal plane.
 The shaper is generally used for machining flat surfaces in horizontal, vertical and angular
directions. It can also be used for machining convex and concave curved surfaces. The actual
surface generated is by means of the linear motions of the cutting tool.

PLANER
 The Planer is very similar to the shaper in terms of the surfaces that can be generated.
 A planer is generally used for machining large work pieces which cannot be held in a shaper.
 In a shaper, the cutting tool reciprocates during the cutting motion, while in case of planer the
work table reciprocates.
 The feeding motion in a planer is given to the cutting tool, which remains stationary during the
cutting motion.
 The tool head can be moved along the cross rail for the feeding action while the depth of the
cut can be controlled by moving the tool downwards.
 It is possible to mount more than one tool head on the cross rail as well as on the columns on
the both sides, so that multiple can be completed simultaneous ly. This helps min total
machining time since planning is a relatively slow operation like shaping.
DRILLING
Machining round holes in metal stock is one of the most common operations in the manufactur ing
industry. It is estimated that of all the machining operations carried out, there are about 20% hole
making operations. Drilling in the operation used for hole making in solid materials. The cutting tool
used for making holes in solid material is called the “Twist Drill “. It basically consists of two parts;
the body consisting of the cutting edges and the shank which is used for holding purpose. This has two
cutting edges and two opposite spiral flutes cut into its surface. These flutes serve to provide clearance
to the chips produced at the cutting edges. They also allow the cutting fluid to reach the cutting edges.

HEAT TREATMENT
Heat treatment of metals may be defined as an operation or a combination of operations involving the
heating and cooling of metals or alloys in the solid state to produce certain desired properties. Only by
heat treatment it is possible to alter the structure and consequently the mechanical properties of metals
required for normal operation of modern machinery and tools. As well, many shaping, forming and
joining processes involve heating and cooling the metal and thus “accidental” heat treatment may
result. All heat treatment processes may be considered to consist of three main parts:
 The heating of the metal to the pre-determined temperature.
 The soaking of the metal at that temperature until the structure becomes uniform throughout
the section.
 The cooling of the metal at some pre-determined rate to cause the formation of desirable
structures within the metal for the desired properties.
METHODS OF HEAT TREATMENT:
Following are same methods of heat treatment:-
(1) Annealing
(2) Normalizing
(3) Hardening
(4) Tempering
(5) Case hardening

BRIEF DESCRIPTION OF WORKS HELD IN GENRAL SECTION
In general section repairing and maintenance of machines are being done. Following are some works
which are done in this section with their procedure.
 ARMATURE MECHANICAL REPAIR:
 Armature is received from armature section with job card.
 Racers are removed from the CE (commutator end) & PE (pinion end) if intact by
heating it with gas welding plant.
 Gullet ring is cut and removed by gas welding.
 HEAD CHANGING:
 Armature is baked at 180 degree Celsius for 16 hours.
 The shaft is pressed out with the help of 300 ton press by applying pressure 150 to 250 ton.
 Head is removed from armature with the help of crane. If requires , hammering is done and
head is removed.
 The shaft is cooled down to the atmosphere temperature.
 The shaft is pressed in head applying 75 ton pressure on the 300 ton press (in case of TAO-
659 armature).
 The head is checked for ovality and grooves are cut on lathe machine.
 Armature is baked in oven for 16 hours at 180 degree Celsius.
 The shaft with head is pressed in armature applying 75 to 150 ton pressure on 300 ton press.
 The armature is cooled down to atmospheric temperature.
 The additional sleeve is preheated with oxyacetylene flame and is shrunk fitted in the shaft.
 Commtator risers are turned on the lathe machine.
 The armature with job card is returned to armature section.

RESHAFTING:
 Armature is baked at 180 degree Celsius for 16 hours.
 The shaft is pressed out by 150 to 250 ton pressure on hydraulic press.
 The new machined shaft is pressed in by applying 75 to 150 ton pressure on 300 ton press.
 The armature is cooled down to atmospheric temperature.
 The additional sleeve is pre-heated with oxyacetylene flame and is shrunk fitted in the shaft.
 The riser is turned for coil stripping.
 Armature is returned to armature section for rewinding with job card.
 HEAD CHANGING + RESHAFTING:
Procedure is the same as in head changing only difference is that new shaft and new head are used in
this case.
 MACHINING WORK:
 Drilling and taping on both end of the shaft is done as per drawing on radial drilling
machine.
 Final machining and grinding of the shaft is done on the kirloskar lathe/HMT lathe as per
the drawing.
 Key groove is cut on milling machine.
 Key is fitted in key groove.
 Shaft is ready for use.
 Turning of riser of commutators of all rewound armatures is done.
 Stator coil machining.

 WAGON MOVEMENT:
Wagon which comes from different railways following actions are taken for unloading and loading.
 To pull wagon in TM shed with the help of fork lifter/man power.
 To open and closed the root of departmental wagons for unloading and loading.
 To seal and tag the wagon for its dispatch.
 To push out the wagon out of TMS with the help of fork lifter.
CRANE OPERATION:
 To provide crane drivers to operate the EOT cranes.

MEANING OF SOME TERMS:
 WINDING OF COIL:
As the coils are in the form of strips which is bended in the u- shapes through edges on Edge Winding
m c.
 CRUSHING:
As due of winding of coil, it swells out on bends. To remove this and maintain an overall same
thickness of coil crushing is done with the help of hydraulic press m / c.
 MILLING & BUFFING:
In this process, cleaning, removing of dirt, dust and equalizing and scraping the surface of coil are
held.
 PICKLING:
Pickling is held in a steel tank in which there is a mixture of H2SO4, Sodium di Cromate and water in
the ratio of 20: 20: 60. In this mixture coil is dipped so as to remove ashes of annealing, dirt, CuS,
Oxide layer etc. to get bright and clean copper surface.
 POTTING:
It is the process of applying a mixture of HEW- 823 A&B on the surface of coil to seal it up so that it
may fix and may not move.
 POURING:
Pouring is a process of filling the gap b/w shoe and coil.
 H. F. TEST:
High Voltage (H.V.) test is for checking the coil not to be earthed or shorted.

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