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. 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. 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. 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. Diesel Locomodernisation Works Layout
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
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. 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. 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. 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. 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. 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. 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. 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. The main functions of this shop are- Dismantling,
Reconditioning and assembly of power pack. Load testing, specific
fuel consumption testing and other types.
18. Engine view
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. Loco Assembly
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. 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. 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. 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. WDM3A Diesel locomotive rebuild at DMW
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. View Of PAMA Machine
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. Block Diagram Of CNC Machine
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. View Of Vertical Rotary Mill
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. PCB Test Station and Universal PROM / EPROM Programmer
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.