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diesel locomotive works Varanasi
Introduction
It is a production unit owned by Indian railways , for which it manufactures
December 2002.
With technology transfer agreement from manufacturers such as GM-EMD,
DLW today produces advance locomotives having output range from 2600 to
4000 hp.
It has supplied locomotives to other countries such as Sri Lanka, Bangladesh,
weatherproof and without the dirt and heat that is an inevitable part of operating
a steam locomotive.
Steam locomotives require intensive maintenance, lubrication and cleaning
engines.
Diesel-electric locomotive
In a diesel-electric locomotive, the diesel engine drives an electrical
basic concepts
Diesel
engine
Alternator
rectifier
Traction
control
governor
Front
traction
motor
bogie
Rear
traction
motor
bogie
alternator
Alternators generate
electricity by the same
principle as DC generators,
namely, when the magnetic
field around a conductor
changes, a current is induced
in the conductor according
to faradays law of
electromagnetic induction.
Typically, a rotating magnet called the rotor turns within a stationary set of
conductors wound in coils on an iron core, called the stator. The field cuts
across the conductors, generating an electrical current, as the mechanical
input causes the rotor to turn.
Alternating voltage may be generated by rotating a coil in the magnetic
field or by rotating a magnetic field within a stationary coil. The value of
the voltage generated depends on the number of turns in the coil.
strength of the field.
the speed at which the coil or magnetic field rotates.
Synchronous speed
The output frequency of an alternator depends on the number of poles and
Rpm at 50 Hz
Rpm at 60 Hz
3000
3600
1500
1800
1000
1200
750
900
10
600
720
12
500
600
14
428.6
514.3
N = 120f / P
where f is the frequency in Hz (cycles per second)
P is the number of poles (2,4,6...) and
N is the rotational speed in revolutions per minute (RPM)
Governor
A device used to measure and regulate the speed of an engine.
The microcontroller based governor consists of a control unit mounted in
based on the selected notch on throttle handle and measure engine RPM . A
steeper motor drive is used to control the fuel rack of diesel engine .
the lube oil pressure is less than the specified pressure so as to protect
the engine from damage due to malfunctioning of lube oil pump etc.
THROTTLE
It is the mechanism by which the flow of a fluid is managed by constriction or
obstruction.
An engine's power can be increased or decreased by the restriction of inlet gases.
control system. The ignition timing and fuel injection timing are altered
depending upon the position of the throttle, and also depending on the rate of
change of that position.
Engine control units control engines by determining the amount of fuel, ignition
1. The prime mover will be receiving minimal fuel, causing it to idle at low
RPM.
2. The traction motors will not be connected to the main generator and the
generator's field windings will not be excited . the generator will not
produce electricity with no excitation. Therefore, the locomotive will be in
"neutral".
To set the locomotive in motion, the reverser control handle is placed into
the correct position (forward or reverse), the brake is released and the
throttle is moved to the run 1 position (the first power notch).
1. this cause the traction motors to be connected to the main generator and the
latter's field coils to be excited.
2. It will not, however, increase engine RPM.
3.With excitation applied, the main generator will deliver electricity to the
traction motors, resulting in motion. Thus the locomotive will easily
accelerate.
As the throttle is moved to higher power notches, the fuel rate to the prime
Traction
Traction refers to the maximum frictional force that can be produced
usable force for traction divided by the weight on the running gear (wheels,
tracks etc) i.e.
Usable Traction = coefficient of Traction x Weight
As the coefficient of traction refers to two surfaces which are not slipping
relative to one another it is the same as Coefficient of static friction.
and ground is more desirable than low traction, as it allows for more
energetic acceleration (including cornering and braking) without wheel
slippage.
is designed to prevent loss of traction of the driven road wheels, and therefore
the control of the vehicle, when excessive throttle is applied by the driver.
The intervention can consist of one or more of the following:
Traction motor
Electric motor providing the primary rotational
Usually, the traction motor is simply suspended between the truck (bogie) frame
rather than to the truck (bogie), better dynamics are obtained allowing muchimproved high-speed operation.
Types of traction
1. DC Traction: employed until the late 20th century in diesel-electric
traction units.
With DC, the most popular line voltages for overhead wire supply systems
frequent intervals.
The low-voltage, series-wound, DC motor is well suited to railroad traction,
2. AC Traction:
Three-phase AC motor traction became practicable in the 1980s.
With AC, especially with relatively high overhead-wire voltages (10,000 volts
or above), fewer substations are required.
With commercial-frequency, AC systems, there are two practical ways of taking
bogie
A bogie is a wheeled wagon or trolley. In
Usually two bogies are fitted to each carriage, wagon or locomotive, one at
each end. Most bogies have two axles as it is the simplest design, but some
cars designed for extremely heavy loads have been built with up to five
axles per bogie.
3. At least one wheel set, composed of an axle with a bearings and wheel at
each end.
4. Axle box suspension to absorb shocks between the axle bearings and the
bogie frame.
5. Brake equipment. Two main types are used: brake shoes that are pressed
against the tread of the wheel, and disc brakes and pads.
rectifiers
A rectifier is an electrical device that converts AC to DC, a process known
known as an inverter.
Rectifiers are of two types:
Half-wave rectification
Either the positive or negative half of the AC wave is passed, while the
other half is blocked. Because only one half of the input waveform reaches
the output, it is very inefficient if used for power transfer. Half-wave
rectification can be achieved with a single diode in a one-phase supply, or
with three diodes in a three-phase supply.
Full-wave rectification
A full-wave rectifier converts the whole of the input waveform to one of
Classification of locomotives
The classification syntaxes:
Locos, except the older steam ones, have classification codes that
identify them. This code is of the form
[ gauge ][ power ][load ][ series ][ sub type ][ suffix ]
The first letter (gauge)
D- Diesel
C- DC electric (can run under DC traction only)
A- AC electric (can run under AC traction only)
CA- Both DC and AC (can run under both AC and DC tractions), 'CA' is
considered a single letter
B- Battery electric locomotive (rare)
The third letter (load type)
G-goods
P-passenger
M-mixed traffic ; both goods and passenger
S-Used for shunting
U-Electric multiple units (E.M.U.)
R-Railcars
Telephone exchange
Provides telephone connections to the D.L.W. administrative blocks and D.L.W.
colony area.
The exchange is also provided with rack type Main Distribution Frame (M.D.F.).
This has capacity to mount fuse mounting with fuses and test jacks.
The exchange is designed to perform satisfactorily for a line loop resistance of
H2SO4 burst and by this action H+ ions goes to the positive plate (PbO2) and
SO4- - ions goes to the negative plate (Pb). Then the equation formed at
Positive plate:
(a) cross-connects the user cable media to individual user line circuits and
(b) may serve as a distribution point for multi pair cables from the main
distribution frame (MDF) to individual cables connected to equipment in
areas remote from these frames.
The cables that come out of the exchange line cards are installed in the
thundering or vibrations occurs the fuse gets blow off making the circuit
break and thus we can prevent further damage.
Jumper wire
Each jumper is a twisted pair.
Twisted pair cabling is a form of wiring in
Electromagnetic interference :
It is a disturbance that affects an electrical circuit due to either
electromagnetic radiation emitted from an external source.
The disturbance may interrupt, obstruct, or otherwise degrade or limit the
effective performance of the circuit.
In balanced pair operation, the two wires carry equal and opposite signals and
Distribution pole
DP is much nearer to the consumer where it is easier to take cable from the
consumer.
Distribution board
In telecommunications, a distribution
faults
Line contact: It means that the drop wire has connected either with pole
processor.
The control unit stores the programmed information of the work piece, the
travel limits, collisions zones and the diagnostic information etc. it also
gives a feedback to the operator about the current position and distance to
be travelled etc.
CNC machines have the ability to edit or alter the existing program in no
time.
CONVENTIONAL
NUMERICAL
CONTROLLED
CNC
1.
Occupies less
space
2.
Run by operator
3.
4.
Partially automatic
clamping
Fully automatic
tool changing,
indexing
NO.
CONVENTIONAL
NC
CNC
6.
High degree of
flexibility in design,
modification and
editing
7.
No facility of program
storage and diagnostics
Program storage,
editing and fault
diagnostic are possible
8.
Repeatability depends
upon operator
Partially depends on
operator
High repeatability
9.
Limitations in selecting
specific cutting
parameters
machines in area B
Flame cutting
Breakdown maintenance
Break down of machine can occur due to the following two reasons:
Due to unpredictable failure of component which cannot be prevented.
Due to gradual wear and tear of the parts of the machine which can be prevented
Preventive maintenance
Also termed as planned maintenance or systematic maintenance .
product.
To ensure the safety of the workers.
To keep the plant at the maximum production efficiency.
To achieve the above objectives with most economical combination.
Meter section
Calibration of meter is done and the fault in the meter is detected.
Calibration
Calibration is a comparison between measurements-one of known
magnitude or correctness made or set with one device and another
measurement made in as similar a way as possible with a second device.
The device with the known or assigned correctness is called the standard.
The second device is the unit under test (UUT), test instrument (TI).
Overhauling section
Induction motor
The most common motors used in industrial motion control systems, as
rotor that spins inside with a carefully engineered air gap between the
two.
The rotating magnetic field is created naturally in the stator because of the
nature of the supply.
stator
Made up of several thin laminations of aluminium.
Punched and clamped together to form a hollow
cylinder with slots .
Coils of insulated wires are inserted into these slots.
rotor
Made up of several thin steel laminations with evenly
spaced bars, of aluminium or copper.
In the squirrel cage rotor, these bars are connected at
ends mechanically and electrically by the use of rings.
Squirrel cage rotor has a simple and rugged
construction.
The rotor consists of a cylindrical laminated core with
axially placed parallel slots for carrying the conductors.
Each slot carries a copper, aluminium, or alloy bar.
These rotor bars are permanently short-circuited at both
ends by means of the end rings.
motor rotation is not generated and s will cause the rotor to vibrate, but not
to rotate.
own.
Starting of motor
Variable-frequency drives
A VFD can easily start a motor at a lower frequency than the AC line, as
well as a lower voltage, so that the motor starts with full rated torque and
with no inrush of current. The rotor circuit's impedance increases with slip
frequency, which is equal to supply frequency for a stationary rotor, so
running at a lower frequency actually increases torque.
Transport section
In transport section there are basically two types of machine are used for
forklift is a powered
industrial truck used to lift
and transport materials.
cab that helps protect the operator from any falling objects.
Power Source - may consist of an internal combustion engine or battery.
cranes
A crane is a lifting
machine, generally
equipped with
a winder (also called a
wire rope drum), wire
ropes or chains and sheav
es, that can be used both
to lift and lower materials
and to move them
horizontally.
General characteristics
Used to move loads over variable (horizontal and vertical) paths within a
restricted area
Used when there is insufficient (or intermittent) flow volume such that the
Engine testing
types of testing
For rotating parts checking is done by seeing the returning path of the oil
i.e. checking not only the forward path but also the returning path.
water testing
Water acts as a coolant for moving part of the engine because constant
Load testing
For load testing electrical load is provided to the engine. If there is any
abnormal sound then the engine is again tested for lubrication so that any
flaw which is there can be removed.
DWG2
DWG2 class 3100 hp diesel electric locomotive AC-DC transmission,
General characteristics
Installed
Power input to traction under site condition
Gauge
3100 hp
2750 hp
1676 mm
Principle dimension
Locomotive weight
Nominal axel load
Wheel diameter
123000 kg
20500 kg
1092 mm
37884 kg
6000 liters
100 km/hr
Basic features
Diesel engine
Model 16 cylinder ALCO251C , DLW built
Medium speed, 4 strokes
Fuel efficient
Transmission system
Electrical AC-DC
Electronic excitation control
Traction alternator BHEL TA10102DW
Traction motor BHEL TM4907 AZ roller suspension bearings
Thank you