Presentation on Industrial Training

at

Presented by:Manglesh Singh

Mechanical EngineeringFinal Year

1350840049

o Production Unit under ministry of railways set up in Ancient city of temples, Varanasi to Undertake indigenous manufacture of Diesel Locomotives.

o Set Up in Collaboration with American Locomotive Company (ALCO) in 1961.

o First Locomotive was rolled out in 1964.o DLW got its first ISO certification in 1997. Recently DLW has obtained

“Integrated Quality and Environment Management system” certification based on ISO-9001 and ISO-14001.

o Produces two types of locomotiveso ALCO locoo GM loco

o DLW exports locomotives to Sri Lanka, Malaysia, Vietnam, Tanzania, Bangladesh.

About DLW

GM (General Manager)

CME (G)Chief Mechanical

Engineer

CME (P)Chief Mechanical

Engineer (Production)

Dy. CME(Engine)

Dy. CME(Block)

Dy. CME(Loco)

Dy. CME (Tooling)

Dy. CME(Planning)

Dy. CME(M&P)

Organisation Structure:

Continued…WM (Works Manager)

(AWM) Assistant Works Manager

SSE (Senior Section Engineer)

SE (Section Engineer)

JE (Junior Engineer)

MCM (Master Crafts Man)

FTR-I (Fitter-I)

FTR-II (Fitter-II)

FTR-III (Fitter-III)

Helper (Khalasi)

Organisation Structure:

Salient Features:DLW’s annual production :250 locosCost of one loco :12 to 14 crore (GM loco) 8 crore (Alco)Weight of one Loco :121 TonFuel Consumption :At Full Load - 540 lit/hr. :Idling- 40 lit/hr.Max. Speed :160 Km/hr.Dia of Wheel :1092 mmWheel to Wheel Distance :1596.5 mm Length of Under Frame :1962 mm

Locos, except the older steam ones, have classification codes that identify them. This code

is of the form:

“[ gauge ][ power ][load ][ series ][ sub type ]” e.g. WDG5A

Nomenclature of locos

In a diesel-electric locomotive, the diesel engine drives an electrical generator or alternator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels.

Diesel Locomotive: Overview

Engine Alternator Assembly

Axle- traction motor Assembly

ALCO LOCOMOTIVES• The ALCO is a passenger/freight-hauling diesel-electric locomotive with

AC electric transmission designed by the American Locomotive Company and produced under license by Diesel Locomotive Works (DLW) of Varanasi, India for Indian Railways as their classes WDM-2, WDM-3A/2C, WDM-3D and WDG-3A for operation in India.

• Power output• 2,600 hp (1,940 kW) (WDM-2)• 3,000 hp (2,240 kW) (WDM-3A/2C)• 3,100 hp (2,310 kW) (WDG-3A)• 3,300 hp (2,460 kW) (WDM-3D)

GM Locomotives• The WDG4 & WDP4 series of DLW make locomotives are GM

(General Motor) locomotives.

• The GM locomotive is equipped with a microprocessor based computer control system- referred to as EM- 2000 locomotive.

• The GM locomotives are also fitted with equipments like Engine, Turbo super charger, Compressor, Alternator, Traction motors etc. like those in ALCO locomotive but their designs are different.

• GM locos can produce power output up to 4500 hp.

Loco Division

Block Divisio

n

ProductionShops

Heavy Machine Shop

Heavy Welding Shop

Block Divisio

n

Block DivisionMachining and Fabrication of Cylinder Block.Machining : HMSFabrication: HWS

Flame Cutting of Components• Precision flame cutting by

CNC machines • Thickness of plates: 80

mm

Portal Milling Machine• 5 axis CNC machine • This machine performs

milling, drilling, tapping and boring operations in single setting.

Engine Divisio

nEngine

Erection Shop

Heat Treatment Shop

Engine Test Shop

Rotor Shop Sub

Assembly Shop

Light Machine

Shop

Turbo Section

Light Machine ShopThe shop deals with manufacturing of various components required for the power pack unit such as cam shaft, connecting rod, gear levers, piston pins etc.

Engine Test ShopThis section deals with testing of functioning of engine at various parameters.

Heat treatment shopThis section involves hardening, tempering and stress removal of various components including camshaft, rocker arm, cam lobe etc.

Turbo SectionThis section involves assembly of turbo-supercharger to the engine.

Loco Divisio

n

Traction Assembly Shop

Loco Frame Shop

Pipe Shop

Truck Machine

ShopSheet Metal Shop

Loco Assembly Shop

Paint Shop

Loco Test Shop

Loco frame shopFabrication of frames on which locomotives are mounted.

Pipe ShopBending of various pipes used in the locomotive frame.

Truck Machine Shop• Machining and Assembly of Axle-

Wheel.• Mounting of traction motor on axle.

Loco Assembly Shop• Assembly of locomotive and loco-frame.• Assembly of driver cabin with

locomotives.

Pictures of some components of locomotives

Flywheel

Valve

Water Pump

Pictures of some components of

locomotives

Rocker ArmHead

Pictures of some components of

locomotives

Starter Motor

Arrangement of starter motor

pinion and Flywheel: As

motor starts and solenoid

actuates, pinion shifts to mesh with tooth on

outer periphery of flywheel.

Thanks!