Thursday, January 31, 2013

Traction Motor Assembly

Audit of following 2 Work Instructions was done today in TM Shop. Report is as follows:-
Motor Assembly ( W 21.301):-
Points noticed:-
  • While doing CE end bearing bracket preparation, air blowing/cleaning as per para 3.1.1 and 3.1.2 should be done.
  • WI prescribes for various quantities of grease to be filled ( 195 gms, 89 gms, 505 gms etc). There is no method of measuring that quantity exactly.

  • Special tool mentioned in para 3.1.4 should be available.
  • Molybdenum disulphide being used ( trade name Molygraf) should be checked for expiry date.
  • While preparing for PE side bearing bracket same points as mentioned above stand good.
  • While doing armature assembly, guide collar (INJ-067) should be  used on CE side.
  • Fasteners(M20, M24) being used are of UNK and AEL make. They should be checked for approved source.

  • Machine oil as mentioned in para 3.4.4 should be used.
  • Method of armature assembly as mentioned in para 3.4.2 of this WI should be followed.

Motor Assembly ( W 21.302 )
Points noticed:-
  • Guide collar as mentioned in para 3.1.2 of this WI for inserting armature  should be used.
  • Tightening torque 3500 Kg Cm should be given with torque wrenche, but same should be used.
  • Para 3.1.7 of this WI should be followed.
  • Press board as mentioned in this WI para 3.1.11 should be used.
  • 5mm gap as mentioned in para 3.1.12, should be recorded.

  • Dial indicator as mentioned in para 3.1.14 should be used. Dial gauge when taken out was found due for calibration. 
  • Croocdness of brush holder as mentioned in para 3.1.18 should be measured/recorded.

  • Rocker assembly should be tightened with torque wrench.
  • Fasteners(M16, M20, M24) being used are of UNK and AEL make. They should be checked for approved source.

Traction motor manufacturing

Audit of following 3 Work Instructions was done in TM Shop. Report is as follows:-

Brush Holder Rocker Assembly ( W 21.303):-
Points noticed:-
  • Device for checking spring tension due for calibration planned.
  • HEW compound availability in the shop should be checked. Same should be checked for expiry date .
  • Varnish TVA1410 should be expiry date.
  • Production was held up because of non-availability of rocker ring insulator.
Motor Assembly ( W 21.304):-
Points noticed:-

  • Load test record maintained by supervisors should not have over-writings.
  • Load test mentioned in next WI should be mentioned in this WI.

Despatch work during Assembly of Hitachi Traction Motor ( W 21.305):-
Points noticed:-
  • TM name plate stands dwarf besides stator nameplate. This anomaly needs to be addressed.
  • This WI needs modification. Para 3.4.0 and para 3.5.0 ( Load test- which is already conducted) is not part of dispatch practically.
  • Para 3.6.5 and 3.6.6 of this WI should be followed.

  • TM Painting as mentioned in para 3.7.2 should be followed , instead Black-Grey PU paint application should be avoided.
  • 24 Hour Natural drying as mentioned in para 3.7.3 should be followed.

Stator manufacturing

Audit of following Work Instructions was done in TM Shop. Report is as follows:-

Manufacturing of Stator Stack ( W 21.401):-
Points noticed:-

  • Positioning plate as mentioned in para 3.2 of this WI should be available.
  • Measurement of 477 and 478 mm as mentioned in para 3.10 and 3.11 of this WI should be recorded.
  • Hydraulic pressure reduction of 71 T after initial application of 81 T as mentioned in para 3.22 of WI should be done.
  • Punch marking on the dege of tension bars is not being done.
Other inspection:-
Crimping of cables were inspected alongwith CEE(P&I), and CEE (Loco) and were found to be satisfactory.
5 months ago, crimping quality compliant was raised to production.

Reports from sheds:-
Gomoh Shed:- reported that they have sent the recent commissioning defects report to CLW. Same will be traced in coming days.
Itarsi Shed:- reported that glasses on the WAP-4 windows are not marked about dimensions and suppliers don’t supply same sizes. This problem will be discussed with DyCEE design .
Vadodara Shed:- Harmonic Resistor in recently sent 3 phase loco has failed. They will email the details.