1. 1. DIESEL LOCOMODERNISATION WORKS, PATIALA
2. 2. Company Profile Diesel Loco modernization Works was conceived with a view to providemaintenance supports to zonal railways for the maintenance of over 4500diesels locomotive, which are in services. DMW believes that product quality has to be built in during manufacturing.In accordance with the belief, the quality assurance system forms integralpart of workshop activities. With quality as its strength factor, DMW is surely and steadily notching upits market share.
3. 3. Salient Features: Workshop area (Sq m)837936 Covered area in shops (Sq m)87578 Township area (Sq m)1416800 Electrical Energy Consumption 161.01(Lakhs of units/year)
4. 4. Strategy Followed In Planning Of DCW Each workshop has a major area functioning under middle management levelofficers, who are totally answerable for their performance. Layout of workshops is such that there is a smooth flow of jobs from oneworkshop to another. Fully integrated with CNC, NC and NON-CNC machines to overcome thedemand. Machines are placed according to group technology so that final job comes outas single. Inspection and testing is done 100% with very accurate instruments for goodquality.
5. 5. Project ObjectiveDiesel-Loco Modernisation Works was setup in the year 1981 to extend theservice life of Diesel Locomotives of the Indian Railways and significantly raisethe level of their availability. Manufacture and supply of high quality components and sub-assemblies asspares. Manufacture of Components hitherto imported achieving importsubstitution and timely availability Rebuilding Locomotives and power packs and turning them out in state- of-the-art condition. Retrofitting the locomotives with systems
6. 6. Diesel Locomodernisation Works Layout
7. 7. DMW Is Divided In Two Parts- Phase 1- Phase 1 was sanctioned in May 1982 and that of Phase 2 in June 1986.For phase 1 group of shops covering an area of 47,000sq.m has been providedin which 734 items of different machinery & plant have been installed. Phase 2- Construction of Phase 2 group of shops, where rebuilding of dieselloco per annual is to be undertaken was taken up in 1986-87 at an estimated costof 46.63 crores. For this purpose covered area of 25,000sq.m and 298 differentitems of machinery and seven plants have been provided. Facilities forrebuilding of power packs & diesel locomotives are provided in various shops
8. 8. Various Shops in DMW Are: - P.M.SPlant Maintenance Shop T.RTool Room L.M.SLight Machine Shop C.B.SCarbon Brush Shop H.T.SHeat Treatment Shop V.M.SVehicle Maintenance Shop T.M.STraction Machine Shop M.R.SMain Receiving Shop
9. 9. H.M.S Heavy Machine Shop C.L.S Cylinder Linear Shop P.P.S Power Pack Shop B.S Bogie Shop S.S.S Super Structure Shop L.R.S Locomotive Rebuilding Shop
10. 10. Manufacturing Shops-Phase 1 shops are also known as Manufacturing shops. There are totalseven shops which come under manufacturing . These shops manufacturesmall and heavy parts of loco. The various shops are described as follows:- Light Machine ShopAbout 300 spare parts required by DMW and Zonal Railways forlocomotive maintenanceincluding Camshafts,Gears, Valve gearcomponents, Equaliser beams, Axles, Armature shafts, Axle box housings,Gas inlet casings, etc. are manufactured in the Light Machine Shop.
11. 11. This shop is also known as for Manufacture of Rail-cum-Road Vehicle. Herevarious tools and components of locomotives are produced with variousmachines. Most of the machines are controlled by CNCs.
12. 12. Heat Treatment ShopRequisite heat treatment that is induction hardening, case carburizing etc. iscarried out in the Heat Treatment Shop to develop optimum properties in thefinished components.
13. 13. Carbon Brush Shop The Carbon Brush Shop manufactures 14 types of carbon brushes requiredfor Traction Generators, Traction Motors and Auxiliary Electrical Machines.Recently carbon brush CB-48 has been developed for fans of ICF coaches.
14. 14. Heavy Machine Shop Engine Blocks of diesel locomotives and Traction Motor Magnet Frames aremachined in this shop. Precision machining of the Blocks is carried out onCNC Horizontal Boring & Milling Machine of PAMA, Italy make CNCmachine.
15. 15. Traction Machine ShopA wide variety of Traction Motors, Traction Generators and Alternators arerewound / remanufactured in this shop. Facilities include 500 T HydraulicPress for shafting/deshafting, Glass Bead Blasting Machine, VacuumImpregnation Plant, HYT Lathe, Dynamic Balancing Machine, etc.
16. 16. Locomotive rebuilding shopsPhase 2 comprises of Loco-rebuilding Shops. There are total five shops.During Locomotive Rebuilding, besides upgrading output to 3100 HP, thelocomotive is also modernized to incorporate numerous improvements inlocomotive technology. Power Pack ShopAll the Power Packs from incoming locomotives are sent to the Power PackShop for remanufacturing. In this shop the power pack is wholly dismantledand rebuilt, tested and then sent to LRS for fitment on the LOCO.
17. 17. The main functions of this shop are- Dismantling, Reconditioning and assembly of power pack. Load testing, specific fuel consumption testing and other types.
18. 18. Engine view
19. 19. Locomotive Rebuilding Shopa) Locomotive rebuilding facilities include dismantling, repairs and reassembly of the complete Locomotive including under frame.b) A manipulator has been developed for ensuring downhand welding during the repair of under frame and chasis.c) Remanufacturing facilities for auxiliary machines and electronic control harness are also available.d) Air Brake and Paint Shops constitute the supporting activity areas for locomotive rebuilding.e) Power and control cables are renewed and control equipment is remanufactured.
20. 20. Loco Assembly
21. 21. Bogie ShopThe locomotive bogies are rebuilt with new wheel sets, suspension bearingsand remanufactured traction motors. Separate shop has been set up formachining of wheel sets and assembly of locomotive bogies.
22. 22. Support shopsAbove activities are adequately supported by competent workforce of staffand supervisors of Plant Maintenance Shop, Tool Room, Main ReceivingStation and other support shops. Electronics Lab
23. 23. There is a full-fledged Electronic Lab which has been set up to cater tomaintenance need of highly sophisticated CNC machines and component /subassembly level trouble shooting of PCBs, Servo Drives, Microprocessorbased controllers and electronic units. A saving of Rs.1.17 Cr. has been achieved in 2005-06 due to repair ofPCBs.
24. 24. Activities and Products Of DMW Mid life rebuilding/ reconditioning of WDM2 ALCO locomotive.Upgrading them from 2600HP to 3100HP and 3300 HP. Incorporating various modifications to enhance the efficiency, reliability,safety of locomotive. Manufacture of various type of carbon brushes used on traction machines ofWDM2, WDM3A, YDM4, WDG4, WDM3C, DMU. Rewinding/ reconditioning of traction motors, traction generator & tractionalternators of locomotives. Reconditioning of engine block of ALCO locomotives, power pack andsupply of New Power packs.
25. 25. WDM3A Diesel locomotive rebuild at DMW
26. 26. Machines and technology used in DMW PAMA Machine This machine is the most important machine of DMW. This machine islocated here only in all over India. This machine is a part of Heavy Machine Shop (H.M.S.). It is used for cutting and boring purposes in a tool. Mainly an engine block is manufactured and repaired in this machine. Oneengine block can be repaired three times in this machine. The main description can be given as PAMA Horizontal Boring and MillingMachine (with speed RAM).
27. 27. View Of PAMA Machine
28. 28. CNC Machines Computer Numeric Control machines is a closed loop machine. As the name depicts these machines use computer for their operation. Computer Numeric Control machines are controlled by a set of differentISO codes that helps in proper controlling of the machine. In modern CNC systems, end-to-end component design is highly automatedusing CAD/CAM programs.
29. 29. Block Diagram Of CNC Machine
30. 30. Vertical Rotary MillThis machine is CNC operated machine. Vertical Rotary mill is located inLMS shop. It is used mainly for boring and milling of the tools. It needs a total power of 35 KW for its operation. It is worth Rs 17.09322 lacs. The main components used are- Main Bearing Cap, Connecting Rods,Casing Lop, Support V/L. The maximum capacity of it per day is around 45. It has three axis : X Rotating, Y - Horizontal. Forward and backwarddirection, Z - Vertical. Up and down direction.
31. 31. View Of Vertical Rotary Mill
32. 32. Electronic Lab EquipmentSome of the sophisticated workstations and testing equipment in the Lab are: X-Y, Y-T, 3-Channel Recorders. Dual Channel 100 MHz Oscilloscope with DMM. 5 Digit Bench Programmable Digital Multimeter. Function Generator with Arbitrary waveform generation. PCB Test Station Automatic Test Equipment (ICT). Universal PROM / EPROM Programmer. Digital / Analog IC Tester. Surface Mount Component Repair Station.
33. 33. PCB Test Station and Universal PROM / EPROM Programmer
34. 34. Result And Conclusion The Indian Railway is the most widely used transport system in India. Theproduction of the parts and units of rails forms an important and integralpart of the proper functioning of the railway system in India. Its Worlds largest manufacturer of ALCO diesel loco spares such as Gears,Cams, Con rods, Pins, Carbon Brushes etc. DCW manufactures large components such as traction motors andlocomotive power packs, rebuilds engine blocks, traction generators, etc. They have more recently been upgrading WDM-2 locos to WDM-2C class.
35. 35. View of New Diesel Electric Locomotive
36. 36. View of Rebuilt Diesel Electric Locomotive