How best quality commutators are manufactured?

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

Dynamic Balancing of Hitachi Commutataor pressing ( W 23.031)

Points noticed:- 

• Commutator dymanic seasoning was being done at 1450 rpm against 3050 rpm prescribed in WI para 3.2 this is well known limitation and being solved.
• Seasoning temperature should not be 190 degrees against 220 degrees mentioned in WI.
• Guage for seasoning presuure measurement (80T) was being sent for calibration.

Assembly of Hitachi Commutator on Armature Stack ( W 23.032):-

Points noticed:-

• 
  Centering gauge ING-201 was being sent for calibration.

• Pressing machine guage was being sent for calibration.

How best quality traction motor armature is manufact

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

Manufacture of Armature Core ( W 21.101):-

Points noticed:-

• Pressing machine was being sent for calibration.

• Armature main punchings supplied by M/S Kapsons –Jalandhar were checked for  Inspection stmp on the packing note/box.

• Post pressing stack length was checked. Mentioned in the WI was 480.5 mm max.

• Slot regularization jig ING-110 was being sent for calibration.

• Pressing jig INJ-114 was being sent for calibration.
• Stack Varnish WSY101 being used was of expiry date.

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DyCME ELA  reported the problem of oversized centre pivot liner in Loco no. HH1437.

This material was supplied by M/S PKE and inspected by HWH office.

Actual dimension was 231 mm as against 230-0.920 as mentioned in in drawing No.06/2/31/106.

Checking of CP liner dia, as in case of all trade items is not in standard in-house inspection checklist. Same recomended for inclusion

Manufacturing Poles of Traction Motor

How Poles are manufactured in the TM shop?

Manufacture of Main Pole and Compole Core ( W 21.102):-

Points noticed:-

• Jigs used while hydraulic pressing INJ-116 and INJ-118 is sent for calibration.

• Gauge for pressure in the machine is sent for calibration.
• Tack welding of rivets is not done with mild steel electrode but done with low hydrogen electrode as mentioned in para 3.3 of the WI.

• Straight bead welding jig INJ-119 is sent for calibration.

• SS support welding jig INJ-052 is sent for calibration.

• Overall quality of the bead welding is inspected.

Traction Motors in CLW how best quality is maintained.

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

Static Balancing of Armature Stacki ( Before Mounting with Commutator) ( W 23.033):-
Points noticed:-

• Gauges used for checking balance are sent for calibration.

• Static balancing is being done as sacrosanct process.

Welding of Mainpole and Compole ( W 21.103):-

Points noticed:-

• Pin Hole checking  being done as per para 3.3 of this WI.
• Bead slump measurement is being done as per para 3.4 of this WI.

• Mild Steel welding is being done in place of Low Hydrogen welding as prescribed in the para 3.1 of WI.

Another problem in brake hanger bracket failure was reported by CEE(Loco) during shop inspection, same will be studied in detail later.