Summer training report

on

diesel locomotive works Varanasi submitted to- submitted by- MECHANICAL ISHANT GAUTAMDEPARTMENT B.TECH (M.E) 4th Year.TITM, MEERUT ROLLNO- 1232140025 TITM, MEERUT

DLW, was founded by Late Railway Minister Mr. Lal Bahadur Shastri on 23 April 1956. It is spread in 300 acres area at Varanasi.

It is a production unit owned by Indian railways , for which it manufactures diesel–electric locomotives and its spares parts.

To meet the increased transportation needs of the Indian railways it was established in collaboration with ALCO( American Locomotive Company), USA in 1961.

DLW rolled out its first locomotive three years later, on January 3, 1964. It manufactures locomotives.

Introduction

DLW’s annual production - 250 Loco Cost of one loco - 12 to 14 crore (EMD) 8 crore (Alco) Weight of one Loco - 121 Ton Fuel Consumption; At Full Load - 540 lt/hr. Idle Load - 40 lt/hr. Max. Speed - 160 Km/hr. Dia of Wheel - 1092 mm Wheel to Wheel Distance - 1596.5 mm Length of Under Frame - 19962 mm

some facts about diesel electric locomotive

In a diesel-electric locomotive, 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.

Diesel electric locomotive

WELDING shopWelding is a process which produces joining of materials

by heating them to suitable temperatures with or without the application of pressure and with or without the use of filler material.

Welding is used for making permanent joints.

It is used in the manufacturing of automobile bodies, aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers, general repair work and ship building.

Shielded Metal Arc Welding [SMAW]Submerged Arc Welding [SAW]Gas Shielded Metal Arc Welding [MIG]Flux Cored Arc Welding [FCAW]

Types Of Welding Used In DLW

bogie assembly shop

A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle.

Usually the train floor is at a level above the bogies, but the floor of the car may be lower between bogies.

Bogie Assembly (EMD)

Wheel and Axle assembly. Brake rigging assembly. Traction motor & gear case assembly. Bearing adopter assembly. Final assembly.

Axle, Wheel & Axle Box assembly

These wheels are having wear adapted profile to RDSO drawing.

Axle, wheel & Gear assembly with Traction Motor

PRESS BULL GEAR ON AXLE.

SHIFT ABOVE ASSEMBLY AT BEARING HOUSING FITTING STAND.

FIT THE BEARING HOUSING AND BOLTING .

ASSEMBLE SEAL , CAP AND TAPER ROLLER BEARING

BOLTING .

NOW, SHIFT THIS ASSEMBLY ON WHEEL & AXLE PRESS MACHINE.

ASSEMBLY PROCESS:

Break down of machine can occur due to the following two reasons: Due to unpredictable failure of component which cannot be prevented.

Due to gradual wear and tear of the parts of the machine which can be prevented by regular inspection known as preventive maintenance.

Preventive maintenance Also termed as “planned maintenance” or “systematic maintenance” .

An extremely important function for the reduction of the maintenance cost and to keep the good operational condition of equipment.

Breakdown maintenance

MAINTAINANCE AREA

To obtain maximum availability of the plant by avoiding break down and

by reducing shut down period to a maximum.

To keep the machine in proper condition so as to maintain the quality of the product.

To ensure the safety of the workers.

To keep the plant at the maximum production efficiency.

To achieve the above objectives with most economical combination.

objective of preventive maintenance

1. Heavy Machine Shop2. Light Machine Shop

MACHINE SHOP

1. Conventional machine2. NC machine3. CNC machine

1. Conventional machine: It is a simple machine which is now an old technique.

2. Numerical control machine: Numerical control is defined as a system in which the actions of the machines

are controlled by the insertion of the numerical data. In other words number controls the action.

Types of machines

CNC milling machines

CNC mills can perform the functions of drilling and often turning. CNC Mills are classified according to the number of axes that they possess. A standard manual light-duty mill is typically assumed to have four axes:Table x.Table y.Table z.Milling Head z.

LOCO & ENGINE TEST SHOP

Lubricating oil testing

Lubrication is done for better performance of the engine parts. testing is done by checking the circulation of lubricant oil. For rotating parts checking is done by seeing the returning path of the oil

i.e. checking not only the forward path but also the returning path. RR40 is used as lubricating oil.

types of testing

Water acts as a coolant for moving part of the engine because constant

movement or rotation causes various parts to heat up and water working as coolant cooled down the concerned part.

Load testing For load testing electrical load is provided to the engine. If there is

any abnormal sound then the engine is again tested for lubrication so that any flaw which is there can be removed.

water testing

Fork lift truck

Forklift  is a powered industrial truck used to lift and transport materials.

HYDRAULIC LADDER

cranesA crane is a lifting machine, generally equipped with a winder, wire ropes or chains and sheaves, that can be used both to lift and lower materials and to move them horizontally.