Mechanical Department - Matunga Workshop INNOVATIONS BY MATUNGA WORKSHOP HEADSTOCK MANIPULATOR AND FIXTURE

Earlier repair to the head stock was being carried out by replacing/repairing individual items of the headstock assembly viz. HS, Aux. HS, centre stiffner, yoke bracket, stiffner etc. during the corrosion repair of the coaches. Fixture for assembly of complete headstock has been commissioned which facilitates precise and expeditious assembly of headstock. The manipulator facilitates down hand welding which enhance welding quality and thereby safety.

GRAVITY CONVEYER SYSTEM

A gravity conveyer system was commissioned to eliminate manual handling for painting of coil springs. The springs are now being painted in two stages – primer and black painting. The gravity conveyer system minimizes handling of springs, saves time and also improves quality of spring painting.

MOTORIZED BEARING AND AXLE BOX EXTRACTION SYSTEM

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Motorized bearing and axle extraction system has been commissioned which saves man hour and thereby additional outturn per shift is achieved. By using this extractor bearings are pulled out easily, safely and without any defects. In manual extraction some bearing could not be pulled out due to over pressure and other defects. In such cases wheel discs were pressed off along with bearing in wheel press machine.

ROOF LEAKAGE TESTING BY SPRINKLING WATER ON THE ROOF

During the monsoon season, divisions had complained for leakage through the coach roof. To overcome this problem, Matunga workshop has developed in-house roof leakage testing facility by sprinkling the water on the roof top. This innovation may help to examine the roof leakage on the coach and attending the same.

BSS/BRAKE BLOCK HANGER TESTING AND PAINTING INTEGRATED WORK STATION

BSS and Break Block Hangers were tested in C&M Lab at BB end Trolley Shop and transported to Smithy Shop for Stress reliving &Painting. An Integrated Work Station is developed in Smithy Shop for BSS and Break Block Hangers in Smithy Shop for Testing, Stress reliving &Painting. This has helped to reduce transportation manpower and also has improved the quality. PROVISION OF VENTURY TYPE VENTILATORS AND RELOCATING BODY SIDE WINDOWS OF KITCHEN AREA.

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Four windows out of the five existing windows were closed; this will help in reducing gas consumption as the direct air from the window will not strike the gas flames. Also as the windows are closed possibility of throwing of garbage and water from windows is eliminated which will prevent corrosion of body side panel.

Ventury type ventilators are provided on the top of the body side panel which improves the ventilation in the pantry car. PROVISION OF MODEL ROOM FOR ERRU TRAINING In the Year 2006 RDSO introduced electronic rectifier regulator unit to be used in place of conventional rectifier regulator unit. The regulation achieved in the ERRU as well as ripple content in the E.R.R.U. are better than R.R.U. Further biggest advantage in ERRU is to get the data downloaded from the E.R.R.U. and analysis of data for further corrective action.

• FACILITY OF DATA DOWN LOADING.

• FACILITY OF DATA ANALYSIS.

• FACILITY OF SIMULATION STUDY OF VARIOUS FAULTS SUCH AS

FUSE FAILS, OVER VOLTAGE ETC...

• FACILITY FOR DATA DOWN LOADING FROM CIP.

• FACILITY FOR WAVE FORM ANALYSIS FROM STORAGE TYPES C.R.O.

.

• FACILITY FOR CHECKING HEALTHYNESS OF E.E.R.U. CAPACITORS,

RESISTANCE & INDUCTORS.

Data downloading and data analysis from the ERRU was a challenge faced by field staff. To overcome such difficulties original manufacture of ERRU such as STASLIT, KEL, HMTD, ICE were called at MTN Workshop and detail training programme of field supervisor of all Division of Central Railway was organized. During the training it was felt necessary to provide Model Room for ERRU where all training related to ERRU such as data downloading from various makes of ERRU, data analysis from the downloaded data, simulation Study of various faults and identification of ERRU components etc to be given. Matunga Workshop has taken lead towards provision of model room having flowing features. Commissioning of Variable Voltage Variable Frequency drive on Alternator Testing Beds

This workshop has been taking various measures for energy conservation to achieve considerable reduction in Electricity consumption. Variable Voltage Variable Frequency drive with regenerative control panel is energy saving system provided in Alternator testing bed in ER Shop. 03 Nos. of 25KW Alternator testing beds have been provided with VVVF drive.

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REGULAR TRAINING OF MATUNGA STAFF AT BASIC TRAINING CENTER

At Matunga workshop BTC is having 5 class rooms and a seminar hall, having capacity to train 175 trainees. BTC Matunga is equipped with all multimedia audio-visual teaching aids. Various training courses are being conducted at BTC MTN like Training of Apprentice Mechanics, Graduate Apprentice, Trade Apprentice, Competency training, refresher training, In-plant training, pre-promotional courses, training on safety etc.

Recently Interactive touch screen board has been commissioned which is having various teaching application like demonstration of photograph, video clips, creating new sheets from the power point presentation, taking a print out of created work sheet etc. This modern teaching aid has improved teaching quality in BTC.

BTC Matunga is having model room which is provided with cut section models for better understanding of important assemblies. BTC Matunga is also having CDTS test bench, CDTS is a new technology introduced in Railway, provision of CDTS test bench gives opportunity of better understanding of the system to the trainees of BTC. SAFETY

Safety cell Matunga was formed in November 2003 dedicated exclusively for industrial safety. Safety cell Matunga is manned with 3 safety officers belonging to Mechanical, electrical and EMU branches. Safety cell Matunga is involved in carrying out safety audit/inspection of various shops/sections of Matunga workshop and time to time issue of safety circulars and instructions. Safety counselling centre is set up at Main gate Matunga. Safety cell is taking persistent effort for provision of personal protective equipments like safety shoes, hand gloves, masks, safety goggles etc.

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