HITACHI commutator manufacturing

Audit of 3  WIs was done in TM Shop. Report is as follows:-

TIG Welding , Deburring, Fillling of Compound & Joggling Cutting ( W 23.002):-

Points noticed:-

• Pressure, Flow rate and Current measuring gauges while TIG welding were being sent for calibration.

• Jigs used in deburring  INJ-026,028 were being sent for for calibration.
• Standard Spatula for mixing compound was being made available.

• Compound HEW 823A was of expiry date. Dial guage used while Joggling Cutting was being sent for calibration.
• Surge/Impulse testing record should be entered in the formats with mentioning time of baking.

Turning of Sliding Surface of Commutator i.e. ‘Diamand Turning’ ( W23.004):-

 Points noticed:-

• Commutator diameter measuring gauge was being sent for calibration.

• Ovality Checking dial gauge was being sent for calibration.
• Job no 21518 was checked for testing records. It was the latest job for which complete records were available; however, jobs have been dispatched further after this also.

Pitch Measurement & Correction of Hitachi Commutator ( W23.029):-

Points noticed:-

• This WI is needs to be withdrawn.
  
  

More on Hitachi TM Manufacturing

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

Polyglass Binding ( W 23.003):-

Points noticed:-

• Varnish/Solvents KS707, WSY 285  and S30 being used in the shop mentioned in the WI are being checked of expiry date.
• EGY Glass Twine Chord 2mm dia mentioned in WI point no 3.9 is being followed at all.
• PG banding sequence mentioned in WI point # 3.6 is being followed. PE side was being done before CE side

• In place of EGT , ETT of size ( 0.18 x 25 ) was being used , this size is not mentioned in the WI.
• Jig INJ-030 was being for calibration
• Tape Tension measuring machine was being sent for calibration.
• Record for baking done for 12 hours was being found.

Balancing of HITACHI Armature  ( W23.005):-

Points noticed:-

• Balancing machine was being sent for calibration.

Other Shop Inspection:-

Loco no WAG-7 48427 due for dispatch today was inspected. NC of pipe passing holes, which was pointed out in earlier locos too (reported in my inspection report dated 11.2.2012 ), was not attended.

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.