End Brazing and welding in Traction Motors

Brazing of the end rings and MIG welding  was inspected  in the TM shop.

In addition to MIG welding, Induction brazing and Zarconium welding ( stampings) are the other two types of end-ring preparation methods.

Almost 100 three phase Traction Motors are waiting for production for want of RTV622, which is applied in the terminal box as well as inside the winding.

Process of Pole terminal brazing was inspected in the shop.

Some bolts in the TM were found to be just punched of the make, unlike the standard practice of embossing. This was instructed to be recorded as Non-Conformity.



 

Provision of U Nomex paper at the ends of coils in three phase Traction Motor was inspected in the shop.

Fixing up of welding defects in Locomotives

In the light of RDSO’s letter , support lugs of Aluminium gearcase in the WAP 5 loco were inspected in the shop .

Welding defects in the WAG7 loco #28243 were pointed out to production staff in the testing shed. This loco was  due to be dispatched tomorrow and wedling defects were rectified.

Another welding defect in the compressor of WAP 4 loco #31333 was asked to be attended by production staff. This loco has light passing from roof section and was being attended in the test shed as due for dispatch .

Roof fitment in locomotives

Underframe welding defects were observed in the loco# HH 1424 in testing shed inspection .

Inspection staff reported that piping hole defects in this loco pointed out earlier have been attended.

Roof fitment of TP-39 was being done in Assembly shop. Staff of Shop#12 were attending the roof since there were some issues in the fitment.

Status of NCs generated in the month of January-12 was analysed. In that month, total 7557 NCs were generated.

Number of NCs have increased by about 1000 that month.

Regarding problem of OCB equipments fouling with the roof of WAP5 ;TP-39 was inspected .

It was seen that dimensions of the OCB ( 4 parts ) needs to be checked.

It was told  that earlier OCB was imported and now it was being supplied locally, which might have led to dimensional variation leading to light passing through roof.

Locos due for dispatch today were inspected.

In The WAG9, following NCs were found:-

Unfilled holes in the OCB bottom frame will lead to dust ingress.

Baby compressor was mounted on three bolts only instead of four.

Reoprt sent by BZA shed was analysed in the TM shop. 

Satator MP coil over heated in one TM:- For this M/S Saini has been informed .

Armature Polyglass Banding given up in two TMs:- For this, commutators’ firms are being informed.

Stator MP connection open in one TM:- AS reported earlier, brazing workmanship has been found satisfactory. This TM failed after one year of service.

Armature coil damage in one TM:- This was a rewound armature, DyCEE TMM has been informed of the same as rewinding workmanship could not be checked in the shop.

BZA was informed of the above, and shed

asked for assistance regarding motors.

Breaking Effort of Locomotive

Loco brakes should be:-

• Softer than wheel tyres.
• When worn out, should be easily replaceable.
• Should be able to absorb heat ( otherwise thermal cracks )
• Should preserve wheel profile.
• Should do cleaning action in order to have good adhesion coefficient.

HENCE COMPOSITE BRAKE BLOCKS USED  IN PLACE OF METAL BRAKE BLOKES.

Electric Loco Bogies

Co-Co Trimount Bogies:-

• found in WAG 5 and WAM4.
• Cente Pivot shares 60 % load.

Co-Co High Adhesion Bogie:

• found in WAG7.
• Same copied in WDG2.
• CP doesnt carry any load, placed down under.
• TM noses ae in one side.
• Dampers on primary suspenion.
• 4 side bearers.
• 2- piece equalising beam.

Flexi-coil bogies:

• called high speed boges.
• found in WAP 1 and WAP4.
• there is bolster.
• No side bearers.
• Friction damper for vertical and lateral damping.
• use manganese liners.

Loco under inspection in CLW

TPP- 109 was having operating rod deficient in the loco. Upon investigation it was found that after movement of the same, while shunting, operating rod became defective. This NC was recorded by inspection staff under acknowledgement to production staff.

Another problem raised by CEE (Loco) was that of less height of machine room door in TP-39. Same has been instructed to be included in the check sheet now-onwards.

In TP-40, ladder bracket was short in the roof. This was an NC in the roof inspection record. Talking with Shop #12 how they moved the shell without attending the same.

CMM machine was found locked in the TM shop. It has been planned to be seen for working tomorrow.

Request for calibration of roof fixtures is  being attended in Shop #12. Seen in the above picture is the fixture of WAG9 roof in which there is no date of calibration.

Underframe welding defects were observed in the loco# HH 1424 in testing shed inspection 

Inspection staff reported that piping hole defects in this loco pointed out earlier have been attended.

Roof fitment of TP-39 was being done in Assembly shop. Staff of Shop#12 were attending the roof since there were some issues in the fitment.

Status of NCs generated in the month of January was analysed. In a month, total 7557 NCs are generated.