How Hitachi Armature Coils are formed

Audit of 2  WIs was done today in TM Shop. Report is as follows:-

Hitachi Armature Coil Forming ( W 23.007):-

Points noticed:-

• WI needs modification since....
• Conductor being cut was of lesser length than mentioned in WI.

Conductor	Length in WI	Actual Length found during inspection
a-b	1691 mm	1689 mm
c-d	1682 mm	1680 mm
e-f	1666 mm	1664 mm
g-h	1654 mm	1652 mm
i-j	1642 mm	1640 mm

• Actual length being cut in shop is less than permitted tolerance in WI.
• Bending Jig INJ-017 was being sent for calibration.
• Clearance between jig and roller not as per para 3.2.3 of WI.
• Stopper location 810 mm instead of 812 mm mentioned in WI para 3.2.5

• Spacers used were not as per para 3.2.8 of WI.

• No GO guage for measuring dia of head also “goes” through.

Hitachi Armature Coil Forming ( W 23.008):-

Points noticed:-

• Tube KCTUN-1 was being used in place of KCTUN-CI -6 mentioned in WI.
• KCTUN was of 3 A make. This could not be located in the CLW approved list.
• KCTUN tube was being cut for 30 mm whereas mentioned 30mm in the WI. para 3.2.1

• 30 T press machine for doing Step Down was being sent for calibration.

• Jig for Step Down INJ-016 was being sent
  
  
  for calibration.

How Coils of Hitachi Traction Motor are formed?

Hitachi Armature Coil Forming ( W 23.009):-

Points noticed:-

• Flattening Jig INJ-016 was being sent for calibration.

Hitachi Armature Coil Forming ( W 23.010):-

Points noticed:-

• Lead bending Jig INJ-018 was being sent for calibration.

Hitachi Armature Coil Forming ( W 23.011):-

points noticed:-

• Coil forming fixture CINJ 300 was being sent for calibration.

Hitachi Armature Equaliser Coil Forming ( W 23.012):-

points noticed:-

• Fixture No.23.9300.04 for forming loop was being sent for calibration.

• Machines needed general cleaning. Cobwebs surrounding the machine panels were cleared.
• A and B Conductor mentioned in para 3.3.3 are 164.5mm and 174.5 mm respectively. Actual size being manufactured is slightly more than that. ( 165 mm and 175mm). WI needs change
  
  
  

• Jig No. C INJ 301 was being sent for calibration.

Hitachi Powe Coil Winding ( W 23.013):-

points noticed:-

• High Quality Manufacturing.

Power Coil Winding ( W 23.014):-

points noticed:-

• Device for giving 100 kg tension to the tape was being sent for calibration.

Hitachi Armature Power Coil Winding ( W 23.015):-

Points noticed:-

• In fact this was the shop where one found jigs  ING 203,204 duely calibrated.

Hitachi Traction Motor Armature Manufacturing

Power Coil Winding of Hitachi Armature  ( W 23.017):-

Points noticed:-

• Source of supply of distance pieces ( high conductivity electrolytic copper) should be established in the shop floor.

Power Coil Winding of Hitachi Armature  ( W 23.017):-

Points noticed:-

• ING 204 was being sent for calibration.

Insualtion cutting to sizer  ( W 23.018):-

Points noticed:-

• Source of supply P-200 powder should be established in the shop.

Equaliser Coil Winding of Hitachi , Deck Insulation-CE Side  ( W 23.019):-

Points noticed:-

• Staff working on equalizer coil were sure of doing 500 V insulation test before the winding.
• Insulation GUFZ 0.13 as mentioned in the para 3.8 of this WI should be located by staff.

Hitachi Traction Motor Manufacturing

PE Side Deck Insulation of Equaliser Winding of Hitachi  ( W 23.020):-

Points noticed:-

• Grease KS707 for mould release treatment should not be of expiry date.

Equaliser  Coil Winding of Hitachi Armature  ( W 23.021):-

Points noticed:-

• Date of expiry of GUFZ 0.13 sheet should be established.

Equaliser Coil Earth Insualtion of Hitachi  ( W 23.022):

Points noticed:-

• P-200 powder and all M-60 mica sheets should be of expiry date.

Hitachi Armature Coil Earth Insulation  ( W 23.023):-

Points noticed:-

• Inter-Turn test machines were told to be calibrated but date of calibration was not marked.