BHARAT HEAVY ELECTRICALS LIMITED,

BHOPAL
(HUMAN RESOURCE MANAGEMENT DIVISION)

VOCATIONAL TRAINING REPORT

ON
traction motOr
TRAINING PERIOD 01/02/18 TO 14/02/2018
Submitted For
Bachelor Of Engineering
From

IPS ACADEMY INDORE

Department Of
ELECTRICAL & ELECTRONICS Engineering
Session (2015-2019)

Guided By Submitted By
Mr. RAJU PRASAD GUPTA UPENDRA VISHWAKARMA
Dy. MANAGER (B.E. 3rd Year)
BHEL BHOPAL EX Branch
VT NO. 3473/2017
 REPORT ON
VOCATIONAL TRAINING IN BHEL,BHOPAL ON
TRACTION MACHINES

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 ACKNOWLEDGMENT
I deem it my privilege to extend my profound gratitude & appreciation
towards all those who have directly or indirectly involved themselves in making this
project (training) a great success.

I would like to heartily thank to my guide Mr. RAJU PRASAD GUPTA for his
continuous guidance and suggestions for improvement of my project.

I am also indebted to our parents and friends for their cooperation &
encouragement.

With gratitude

UPENDRA VISHWAKARMA
E.No.- 0808EX151078
th
6 Sem, ELECTRICAL & ELECTRONICS
Engineering
IPS ACADEMY INDORE

3
 CERTIFICATE

This is to certify that UPENDRA VISHWAKARMA

studying in 3rd year in ELECTRICAL & ELECTRONICS
Engineering Branch of IPS ACADEMY INDORE has
done his two weeks of training in M.N.X department of
BHEL ,Bhopal.

MR. RAJU PRASAD GUPTA

Dy. MANAGER

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ABOUT BHEL
BHEL is the largest engineering and manufacturing enterprise in India in the energy-
related/infrastructure sector, today. BHEL was established more than 40 years ago, ushering in the
indigenous Heavy Electrical Equipment industry in India - a dream that has been more than realized
with a well-recognized track record of performance. The company has been earning profits
continuously since 1971-72 and paying dividends since 1976-77.

BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of
the Indian Economy viz., Power Generation & Transmission, Industry, Transportation, Renewable
Energy, etc. The wide network of BHEL's 14 manufacturing divisions, four Power Sector regional
centres, over 100 project sites, eight service centres, 18 regional offices and one subsidiary enables
the Company to promptly serve its customers and provide them with suitable products, systems and
services -- efficiently and at competitive prices. The high level of quality & reliability of its products is
due to the emphasis on design, engineering and manufacturing to international standards by
acquiring and adapting some of the best technologies from leading companies in the world,
together with technologies developed in its own R&D centres.

BHEL has acquired certifications to Quality Management Systems (ISO 9001), Environmental
Management Systems (ISO 14001) and Occupational Health & Safety Management Systems (OHSAS
18001) and is also well on its journey towards Total Quality Management.

BHEL has

Installed equipment for over 90,000 MW of power generation -- for Utilities, Captive and Industrial
users.

Supplied over 2,25,000 MVA transformer capacity and other equipment operating in Transmission
& Distribution network up to 400 kV (AC & DC).

Supplied over 25,000 Motors with Drive Control System to Power projects, Petrochemicals,
Refineries, Steel, Aluminum, Fertilizer, Cement plants, etc.

Supplied Traction electrics and AC/DC locos to power over 12,000 kms Railway network.

Supplied over one million Valves to Power Plants and other Industries.

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BHEL's operations are organized around three business sectors, namely Power, Industry - including
Transmission, Transportation and Renewable Energy - and Overseas Business. This enables BHEL to
have a strong customer orientation, to be sensitive to his needs and respond quickly to the changes
in the market.

BHEL's vision is to become a world-class engineering enterprise, committed to enhancing

stakeholder value. The company is striving to give shape to its aspirations and fulfill the expectations
of the country to become a global player.

The greatest strength of BHEL is its highly skilled and committed 42,600 employees. Every employee
is given an equal opportunity to develop himself and grow in his career. Continuous training and
retraining, career planning, a positive work culture and participative style of management all these
have engendered development of a committed and motivated workforce setting new benchmarks in
terms of productivity, quality and responsiveness.

Thefourteen manufacturing Divisions are located at

• Bhopal(Madhya Pradesh)
• Bharat Heavy Electrical Limited, Ranipur, Haridwar (Uttarakhand) *4+
• Hyderabad (Andhra Pradesh)
• Jhansi (Uttar Pradesh)
• Tiruchirapalli(Tamil Nadu)
• Ranipet (Tamil Nadu)
• Bangalore (Karnataka)
• Jagdishpur (Uttar Pradesh)
• Rudrapur(Uttrakhand)
• Goindwal (Punjab)
• Bharat Heavy Plates and Vessels Limited (Vizag)

Besides these manufacturing units there are four power sectors which undertakeEPC contract from
various customers. The Research and Development arm of BHELis situated in Hyderabad and two
repair shops are at HERP(Heavy EquipmentRepair Plant),Varanasi and EMRP(Electric machines
repair plant) Mumbai.

BHEL has 4 power sectors-

PSNR-Power Sector Northern Region

PSER-Power Sector Eastern Region
PSWR-Power Sector Western Region
PSSR-Power Sector Southern Region
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BHEL BHOPAL

INTRODUCTION-
BHEL is a Navratra company.It supplies all over the world about 70%.It has 14
manufacturing unit all over india except Bhopal.

It has 12 blocks-

Block 1
 PFM – Pre fabrication manufacturing
 HCM – Heated condenser manufacturing(Hydro,Water turbines)

Block 2
 EM – Electrical motors
 IMM – Industrial machines manufacturing division
 LEM – Large electrical motors
 TAM – Traction alternator &auxillary machines
 TXM – Traction motors manufacturing division

Block 3
 TCB – Transformer Capacitor & Bushing
Block 4
 SCR – Switch gear Control gear & Rectifier
Block 5
 FYM – Foundry manufacturing division
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Block 6
 STM – Steel turbine manufacturing
Block 7
 MOD & WEX – Modarisation& work engineering
Block 8
 CIM – Coil insulation manufacturing
Block 9
 TXM – Traction motors(used in railway engines)
Block 10
 PRM – Pressure rectifier manufacturing
Block 11
 TGM – Tool and gauges manufacturing
Block 12
 NTB – 12 KV Transformer manufacturing
 UHV – Ultra high voltage
Only in Bhopal & No.1 in Asia big transformers

BHEL BHOPAL’S PRODUCT PROFILE

Established in the late 50’s, Bharat Heavy Electricals Limited (BHEL) is, today, a name to reckon with
in the industrial world. It is the largest engineering and manufacturing enterprise of its kind in India
and one of the leading international companies in the power field.BHEL offers
A varities of products sectors like Power Generation, Power Utilisation,Power Transmission,
Transportation and other Miscellaneous products ,An ISO 9000 certification has given the
company international recognition for its commitment towards quality.

AC Motors & Alternators

BHEL is a leading AC Machines manufacturer and in the last four decades have supplied more than
20000 HT & LT A.C. Machines for various applications to Indian as well as Export market. The
applications include Power Plants, Nuclear Energy, Petrochemicals, Fertilizers, Refineries, Cement &
Steel Industries, Irrigation Projects, Pipelines, etc.

The manufacturing plant in Bhopal was established in technical collaboration with AEI UK.
Commercial production of A.C. Machines commenced in the year 1963. Technology was upgraded
by collaborating with Siemens AG, Germany from 1980-1990 and subsequently from 1996-2006.
Motors are offered both in standard as well as tailor made designs to meet customer's specific
needs. High performance is achieved through optimum utilization of the active materials and
components.

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BHEL A.C. Machines offer high efficiency, exceptional reliability, quick installation and minimal
maintenance costs.

Our engineers combine their extensive experience with state-of-the-art analytical design tools,
latest machine tools, Six Sigma methodology and advanced material development to deliver the
best product.

Installed Capacity: 1500 machines per annum

Capacity being augmented to manufacture 2500 machines per annum by the year 2012

Annual Sales Turnover : US$ 100 Million

Hydro Turbines

Aleading engineering enterprise which supplies all types of equipment for hydro power generation.

A leading turbine manufacturer offering a wide range of Hydro Turbine, Valves, Governors, Turbine
and Station Auxiliary systems, Balance of plants for Hydro Power Station and related Services.

Installed manufacturing capacity:2500 MW/annum.

Two units manufacturing hydro turbines.

In the market for more than three decades.

Dedicated shop area of over 100000 sq. meters.

Ultramodern model development and testing facilities.

Sophisticated CAD/CAM facilities.

ISO 9001 Certification.

ASME "Q" stamp for fabrication facilities.

Hydro Generator

Hydro generator is a synchronous alternator driven by a hydraulic turbine.

Motor is synchronous motor to drive pump.

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BHEL Bhopal is a leading supplier of large,medium& small hydro generators,motors,bulb generators
and related services.

Installed manufacturing capacity : 2500 MW

Sophisticated CAD facilities

ISO-9001 certification

Excitation Control Equipment

Excitation Control equipment for Hydro,ThermalNeuclear,Naval and Industrial applications.

Excitation control equipment (automatic voltage regulator (AVR) and static excitation equipment-
(SEE) for semi-static, static and brushless type of excitation system.

Complete range of Digital AVR and SEE available to suit all types of systems and generators added to
product profile in the year 2003.

More than 35 years of field experience.

More than 600 AVRs operating satisfactorily at various Hydro, Thermal and Industrial Power Plants.
A number of captive power plant installed in Sugar, Cemical, Paper and other industries are also
equipped with BHEL make AVRs

Total system solutions on offer.

Retrofitting of old excitation control system with latest state of art digital systems.

Dedicated shop area with modern manufacturing and testing facilities.

Steam Turbines

BHEL has taken its lead role in following fields :

Turbines

1) Design, Manufacturing, Erection, Commissioning and Services of :

 30 MW, 120 MW Steam Turbines

 236 MW Nuclear Turbines.
 15000 SHP Marine Turbines

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  210 MW Steam Turbines.

2) Supply of Spares and Repairs of above Steam Turbines.

3) R & M and Life assessment studies of BHEL & Non BHEL TG sets.

4) Repair and Supply of Spares of 210 MW and 500 MW KWU Turbines.

5) Repair and supply of Spares for Non BHEL TG Sets.

Diversified Projects

For IPR and ISRO : Manufacturing of various components.

Transformers

A Leading Engineering Enterprise which Supplies wide Spectrum of Power Transmission Systems/
Solutions from a single entity

A Leading Transformer Manufacturer Offering wide range of Transformers

Installed manufacturing capacity:18000 MVA/Annum with dustproof facility in critical areas. The
capacity is being augmented by another 12000 MVA/Annum with totally dust proof facility

Annual Sales Turnover Range: US$ 100 Million

Having nearly 4 decades or over 30,000 man-years of experience

Facilities updated with investments of over US$ 40 Millions.

Dedicated shop area of over 80000 sq. meters and unique Ultra High Voltage testing facility

Switchgear

A leading Switchgear Group involved in Design, manufacturing, installation, commissioning and

services of Switchgear.

A wide spectrum of switchgear catering to various applications like power station auxiliaries, power
distribution, process industries, rural electrification, open cast mines, electric traction and other
special applications.

Market leaders in India.

Experience of 5 decades

Thousands of various types of breakers working satisfactorily in India and abroad.

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Unique distinction of widest range of medium voltage Switchgear meeting every requirement of
the customer in stringent Indian conditions.

Strong R & D infrastructure.

Dedicated shop and design area of over 50,000 sq meters.

Regular facilities updation with new capital investment.

Clear room facility for GIS

Strengths:
- Reliable and problem free product
- Proven product in service
- Repeated successful type testing and special testing
- Largest range to suit various application requirements viz Power Stations, Distribution, Industrial
& Railways.
- 100% routine testing as per IS & IEC.

Switchgear design fully type tested as per IEC:62271

On Load Tap Changer

A leading On Load Tap Changer (OLTC) group involved in Design, manufacturing, commissioning and
services of Tap Changers.

Market leaders in India

Latest Technology incorporating high speed resistor switching of OLTC

Capacity to supply 500 nos. OLTC

Experience of more than 4 decades.

Annual sales turnover Rs15 crores or US $2 million

Dedicated shop area of over 10,000 sq meters

Complete system for parallel operation of transformers and remote Tap changer control panel.

Control and Relay Panels

Experience in the field for more then 40 years.

More then 15000 panels supplied to major customers in India and abroad.

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Capability to develop complete control of protection schemes for generation and transmission
systems to suit customer requirements.

Applications of latest state of the art numerical relays with communication facility.

Design of control of relay boards based on latest engineering practices, high degree of reliability
and aesthetic consideration.

Large Current Rectifier

SCR Division of BHEL, Bhopal has been supplying wide range of Large Current Rectifier Equipment
since year 1969.

The large current rectifier equipment provides DC power for electrolytic process of electro-chemical,
aluminum & graphite industries. BHEL have so far supplied more than 60 units of about 16,00,000
Kilowatt rectifiers for caustic soda, aluminum smelter and graphite furnaces.

Some of the special features of the large Current Silicon Power Rectifier Equipment are listed below:

 Compact and Rugged design

 PLC controlled Rectifier (Hot standby option available)
 HMI for control, annunciation, status display
 Interface with customer SCADA possible
 Operates in both current and power control modes
 High Efficiency
 Accuracy of control + 1%
 Uniform current sharing
 Large safety margins in Design
 Easy maintenance and monitoring
 Single rectifier unit up to 60 KA
 Auto/Rectifier Transformer & IPT
 Transductors – housed in single tank
 Externally mounted on-load tap-changer
 Non magneticaluminium rectifier structure
 FRP covers to avoid eddy current losses
 Steel shields
 Suitable for tropical conditions
 Choice of cooling

A rectifier equipment comprises an assembly of semiconductor diodes mounted on heat sinks along
with series connected fuse and surge voltage protection components, all suitably enclosed and a
separately mounted transformer. Additional items, such as interconnections, control cubicles,
switchgear, AC/DC measuring system, AC/DC bus bars are included in scope of supply when
required.

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For large current applications above 25kA, important advantages are gained by mounting the
rectifier assembly in close association with the transformer known as 'Rectiformer' by combining the
two units into an integral equipment (a) The space requirement is considerably reduced (d) Both
preparatory & erection work at site is minimized (c) AC. bus bars connections are reduced to
minimum

Transportation Sector

BHEL's involvement in the transportation sector has been marked with rapid growth.

Today over 85% of Indian Railways, one of the largest railway networks in the world, is equipped
with traction equipment built by BHEL.

The range includes traction motors, traction generators/alternators, transformers, sub-station

equipment, vacuum circuit breakers, locomotive bogies, smoothing reactors, exciters, converters,
inverters, choppers and associated control equipment, viz. master controllers, HSCBs, chopper
controllers brake and door equipment, electronic controls including software based controls
extending to rolling stock and other transport applications.

BHEL has manufactured and supplied large numbers of electric locomotives ( upto 5000 hp) to
Indian Railways and Diesel Electric Locomotives ranging from 350 hp to 2600 hp to cement, steel
and fertilizer plants, thermal power stations, coalfields, ports and other medium and large
industries. This has established BHEL as a leading locomotive manufacturer in the country.

Diesel Multiple Units, underground Metro-rail system at Calcutta, Electric Multiple Unit (EMU)
services at Mumbai, Calcutta, Chennai & Delhi operate on drives and controls supplied by BHEL.

BHEL has also started the supply of equipment for Dual Voltage EMUs with 3 phase technology.

To contain air pollution & to conserve mineral oil resources, battery powered road vehicles are in
operation in various cities, BHEL is also ready to undertake turnkey execution of LRT, MRTS &
electric trolley bus

Oil Rigs

BHEL is the only manufacturer of complete Land Drilling Rig in India.

BHEL has supplied 84 Land Rigs to M/s ONGCL and M/s OIL India Ltd.

BHEL has proven capability of designing, manufacturing and commissioning of different type of land
rig ranging from E 760, E 1400, E 2000, E 3000 , Mobile Rig, Desert Rig and TBA Rig (Transportable by
air). BHEL built E 3000 Type rig has capability of drilling up to 6 Km to 10 Km depth.

BHEL has executed R&U of 20 Nos. BHEL imported Land Rigs, to tailor made customer specification,
to rejuvenate old rigs and meet growing customer requirement. R&U of 16 more rigs is in progress.

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Rig Electrics are manufactured and supplied by BHEL Bhopal Unit.

Fabrication

483 strong workforce of engineers, supervisors and highly skilled artisans; which include about 200
qualified welders and welding operators.

20,000 tons of diversified fabrication capability

More than 40 years experience in fabrication & welding.

Total Engineering solutions & consultancy services for all kinds of fabrication and welding
problems

Accredited with ASME ‘U’ stamp by American National Boiler Board to manufacture Heat
Exchanger and Pressure Vessels since 1989.

All systems qualified and maintained to ISO 9001 and ISO14001 standards

Fully developed ancillary industries within 2kms distance to meet any emergency requirements.

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 TRANSPORTATION GROUP OF BHEL
Preface
BHEL is one of the largest engineering & manufacturing enterprises in india with
presence in major business sectors related to electrical equipment.The Bhopal plant
of BHEL was registered as heavy electrical Ltd on 29th august 1956 & with this the
1stelectricals equipment manufacturing company in the country in collaboration with
M/S AEI,UK.The unit has completed 50 years of successful and glorious operation on
28th august 2006.

The transportation group of BHEL is a key business area for the company & is a
market leader in supply of electrics for rail vehicle system. Today 85% of the Indian
railways rolling stack are powered by BHEL made electrics.

The transportation group of BHEL is engaged in design,development & manufacture

of traction machines of various capacities for all types of applications.BHEL is a
complete solution provider for rolling stack electrics and has the expertise and
facilities to manufacture AC and DC traction motors,AC and DC traction
generators,auxillary machines and their required control system.In tune with the
market scenario ,BHEL has been mostly manufacturing electrics based DC drive
system but with the intro of AC drive systems,BHEL has also successfully geared up to
supply equipment through technology assimilation form repeated international
companies ADB,general motors and traxis for all the areas vizAC locos,Diesel electric
locos & EMUs.

ABOUT THE TRANSPORTATION GROUP

BHEL started its activity in the field of transportation in 1962 in collaboration with
Associated Electrical Industries (AEI), UK.

Traction machines as a product was first established in BHEL in the year 1962,when
16 nos. traction motors were supplied for 1500V DC EMUs for Mumbai.Since then
more than 80000 nos. traction machines of different types have been manufactured
and supplied to the different customers which are working
satisfactorily in our country for Indian Railways and abroad for railways of
Bangladesh, Srilanka, Myanmar, Sudan, Vietnam, Tanzania, Malaysia etc.

More than 70% of locomotives & EMUs working in India are equipped with electrics
supplied by BHEL.

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BHEL’s capability and experience in the transportation field is very wide and electrics
are designed and manufactured for following applications:
 Diesel Electric Freight, passenger and shunting locos with DC & ACdrive.
 25KV AC and 1500 V DC freight and passenger electric locos.
 25KV AC and 1500 V DC Electrical Multiple Units (EMU).
 Diesel Electrical Multiple Units (DEMU).
 Metro systems.
 Tram Cars
 Battery Powered Road Vehicles (BPRV)
 Electric Trolley Bus (ETB).

TRANSPORTATION GROUP OF BHEL SERVES

FOLLOWING SECTORS
Railways-
 DIESEL ELECTRIC LOCOS
 ELECTRIC LOCOS
 DMEU/EMUS

Urban Transportation-
 ETB
 TRAMS
 MOTORS
 MONO RAILS
 SKY BUS

BHEL’s product range consists of large variety of

Traction Machines:
 DC traction motors up to 750 kW.
 3-Phase AC traction motors up to 1150 kW.
 AC traction alternators up to 3000 kW.
 DC traction generators up to 2000 kW.
 DC auxiliary machines up to 50 kW.
 DC blower motors up to 50 kW.
 DC and AC motor generators sets up to 25 kW.
 Motor Generator Sets up to 12 KW
 Motor Alternator Sets up to 20 KVA
 Eddy Current Clutches (ECC)
 Smoothing Chokes and Field Diverter Inductive shunts

All the traction machines manufactured in BHEL conform to international specification IEC
60349.
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CUSTOMER BASE-
Major customers for which the transportation group has developed machines and services
are as under:
National:
 Indian Railway:
 Diesel Locomotive Works, Varanasi
 Diesel Modernization Works, Patiyala
 Rail Coach Factory, Kapurthala
 Integral Coach Factory, Chennai
 All Zonal Railways & Sheds
 RITES
 IRCON
Non Railway Customers:
NTPC, Cement Plants, State Electricity Board, Steel Plants ,Port
trusts, BEML, JESSOP, TEXMACO, TITAGARGH, ONGC (for oil rigs)
International:
 Malaysia
 Vietnam
 Myanmar
 Bangladesh
 Srilanka
 Angola
 Ghana
 Senegal

Fundamentals of traction
Definition

Traction is defined as:

A physical process in which a tangential force is transmitted across an interface between

two bodies through dry friction or an intervening fluid film resulting in motion, stoppage or
the transmission of power.

The units of traction are those of force, or if expressed as a coefficient of traction (as with
coefficient of friction) a ratio.

Specifically, traction refers to the maximum frictional force that can be produced between
surfaces without slipping.

The traction produced by a vehicle if expressed as a force is synonymous with tractive

effort, or tractive force, and closely related to the term drawbar pull.

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Types of Traction Systems:

1. Steam Locomotives
2. Internal Combustion Engines
3. Diesel Locomotives
4. Diesel Electric Locomotives
5. Battery operated Locomotives
6. Electric Traction Systems

Railways traction
Classification of trains

Locomotives
 DIESEL LOCOMOTIVE
Diesel-electric locomotives were introduced in the United States in 1924, and have become the
most widely used type of locomotive. The modern diesel-electric locomotive is a self-contained,
electrically propelled unit. Like the electric locomotive, it has electric drive, in the form of traction
motors driving the axles and controlled with electronic controls. It also has many of the same
auxiliary systems for cooling, lighting, heating, and braking. It differs principally in that it has its own
generating station instead of being connected to a remote generating station through overhead
wires or a third rail. The generating station consists of a large diesel engine coupled to an alternator
or generator that provides the power for the traction motors. These motors drive the driving wheels

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by means of spur gears. The ratio of the gearing regulates the hauling power and maximum speed of
the locomotive. A modern diesel-electric locomotive produces about 35% of the power of a electric
locomotive of similar weight. Diesel-mechanical locomotives have a direct mechanical link
consisting of a clutch and a setries of gears and shafts between the engine and the wheels, similar to
the transmission in an automobile. Because mechanical drives deliver less power to the wheels than
electric and diesel-electric systems, they are only used with the smallest locomotives. In diesel-
hydraulic locomotives the engine drives a torque converter, which uses fluids under pressure to
transmit and regulate power to the wheels. Hydraulic drives are little used in the United States but
are widely used in some countries, such as Germany.

 ELECTRIC LOCOMOTIVE
An electric locomotive is a locomotive powered by electricity from an external source. Sources
include overhead lines, third rail, or an on-board electricity storage device such as a battery,
flywheel system, or fuel cell.

Electric locomotive receives current from overhead line through pentograhp.This high voltage is
step down in case of single phase 25 KV supply and then fed through control and stabilizing circuit to
the motors. In case dc supply it is fed to motor through control equipment.

Multiple units
The term multiple unit or MU is used to describe a self-propelling train unit capable of coupling with
other units of the same or similar type and still being controlled from one cab. The term is
commonly used to denote passenger trainsets that consist of more than one carriage, but single
self-propelling carriages, or railcars, can be referred to as multiple units if capable of operating with
other units.Multiple units are of three main types:

 Electric multiple unit (EMU)

 Diesel multiple unit (DMU)
 Diesel electric multiple units (DEMU)
 Most MUs are powered either by a diesel engine driving the wheels through a gearbox or
hydraulic transmission (DMU), or by traction motors, receiving their power through a live rail
or overhead wire (EMU). Diesel electric multiple units (DEMUs) have a diesel engine that
drives a generator producing electricity to drive traction motors in a similar fashion to a
diesel-electric locomotive.
 A multiple unit trainset has the same power and traction components as a locomotive, but
instead of the components concentrating in one carbody, they are spread out on each car
that makes up the set. Therefore these cars can only propel themselves when they are part
of the set; thus making them semi-permanently coupled. For example, a DMU might have
one car carry the prime mover and traction motors, and another the engine for head end
power generation; an EMU might have one car carry the pantograph and transformer, and
another car carry the traction motors.

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Comparison to locomotive-hauled trains

Advantages

Multiple units have several advantages over locomotive-hauled trains:[citation needed]

 Energy efficiency — MUs are more energy efficient than locomotive-hauled trains. They are more
nimble, especially on grades, as much more of the train's weight (sometimes all of it) is carried on
power-driven wheels, rather than suffer the dead weight of unpowered hauled coaches. In addition,
they have a lower weight-per-seat value than a locomotive-hauled train since they do not have a
bulky locomotive that does not itself carry passengers but contributes to the total weight of the train.
This is particularly important for train services that have frequent stops, since the energy consumed
for accelerating the train increases significantly with an increase in weight.

 Higher acceleration rate — Because of the energy efficiency, higher power-to-weight ratio and higher
adhesive weight to total weight ratio values, MUs generally have higher acceleration ability than
locomotive type trains and are favored in urban trains and subways for frequent start/stop routines.

 No need to turn locomotive — Most MUs have cabs at both ends, resulting in quicker turnaround
times, reduced crewing costs, and enhanced safety. The faster turnaround time and the reduced size
(due to higher frequencies) as compared to large locomotive-hauled trains, has made the MU a major
part of suburban commuter rail services in many countries. MUs are also used by most rapid transit
systems. This is no longer a problem for locomotive hauled trains due to increasingly widespread
usage of push-pull trains.

 Makeup can be changed mid journey — MUs may usually be quickly made up or separated into sets
of varying lengths. Several multiple units may run as a single train, then be broken at a junction point
into smaller trains for different destinations.

 Reliability — Due to having multiple engines, or motors, the failure of one engine does not prevent
the train from continuing its journey. A locomotive-drawn train typically only has one power unit
whose failure will disable the train. Some locomotive hauled trains may contain more than one
power unit and thus be able to continue at reduced speed after the failure of one.

21
  Safety — Multiple units normally have completely independent braking systems on all cars meaning
the failure of the brakes on one car does not prevent the brakes from operating on the other cars.

 Axle load — Multiple units have lighter axle loads, allowing operation on lighter tracks, where
locomotives are banned. Another side effect of this is reduced track wear, as traction forces can be
provided through many axles, rather than just the four or six of a locomotive.

 Easy and quick driving — Multiple units generally have rigid couplers instead of the flexible ones on
locomotive hauled trains. That means that brakes or throttle can be more quickly applied without an
excessive amount of jerk experienced in passenger coaches.

 Allowance for accurate performance calculations for timetabling purposes - In a locomotive-hauled

train, if number of cars is increased in order to meet the demand, acceleration and braking
performance drops. This calls for the necessity that, the performance calculations are to be done
taking the heaviest train composition into account. This may sometimes lead some trains in off-peak
periods to be overpowered with respect to the required performance. When two or more multiple
units are coupled train performance remains almost unchanged. However in locomotive hauled train
compositions using more powerful locomotives when a train is longer can solve this problem.

Commom Equipment used in traction system

Asynchronous Motor
Modern traction motor type using three phase AC electrical supply and now the
favoured design for modern train traction systems. Can be used on DC and AC
electrified railways with suitable control electronics and on diesel-electric
locomotives.
Axle Brush
The means by which the power supply circuit is completed with the substation once
power has been drawn on the locomotive. Current collected from the overhead line
or third rail is returned via the axle brush and one of the running rails. .
Battery
All trains are provided with a battery to provide start up current and for supplying
essential circuits, such as emergency lighting, when the line supply fails. The battery
is usually connected across the DC control supply circuit.

22
Camshaft
Most DC electric traction power circuits use a camshaft to open or close the
contactors controlling the resistances of the traction motor power circuit. The
camshaft is driven by an electric motor or pneumatic cylinder. The cams on the shaft
are arranged to ensure that the contactors open and close in the correct sequence.
It is controlled by commands from the driver's cab and regulated by the fall of current
in the motor circuit as each section of resistance is cut out in steps. The sound of this
camshaft stepping can be heard under many older (pre electronics) trains as they
accelerate. .
Cannon Box
Sleeve used to mount a traction motor on axle in electric power bogies and
sometimes including an axle brush.
Circuit Breaker
An electric train is almost always provided with some sort of circuit breaker to isolate
the power supply when there is a fault, or for maintenance. On AC systems they are
usually on the roof near the pantograph. There are two types - the air blast circuit
breaker and the vacuum circuit breaker or VCB. The air or vacuum part is used to
extinguish the arc which occurs as the two tips of the circuit breaker are opened. The
VCB is popular in the UK and the air blast circuit breaker is more often seen on the
continent of Europe.
Converter
Generic term for any solid state electronic system for converting alternating current
to direct current or vice versa. Where an AC supply has to be converted to DC it is
called a rectifier and where DC is converted to AC it is called an inverter. The word
originated in the US but is now common elsewhere.
Cooling Fans
To keep the thyristors and other electronic power systems cool, the interior of a
modern locomotive is equipped with an air management system, electronically
controlled to keep all systems operating at the correct temperature. The fans are
powered by an auxiliary inverter producing 3-phase AC at about 400 volts.
Creep Control
A form of electronically monitored acceleration control used very effectively on some
modern drive systems which permits a certain degree of wheel slip to develop under
maximum power application. The GM Class 59 diesel-electric locomotive built for the
UK has this system. A locomotive can develop maximum slow speed tractive effort if
its wheels are turning between 5% and 15% faster than actually required by the train
speed.

23
Dynamic Braking
A train braking system using the traction motors of the power vehicle(s) to act as
generators which provide the braking effort. The power generated during braking is
dissipated either as heat through on-board resistors (rheostatic braking) or by return
to the traction supply line (regenerative braking). Most regenerative systems include
on board resistors to allow rheostatic braking if the traction supply system is not
receptive. The choice is automatically selected by the traction control system. See
also the Dynamic Brake section of our Brakes Page.
Grid
Train or locomotive mounted expanded steel resistor used to absorb excess electrical
energy during motor or braking power control. Often seen on the roofs of diesel
electric locomotives where they are used to dissipate heat during dynamic braking.

Ground Relay
An electrical relay provided in diesel and electric traction systems to protect the
equipment against damage from earths and so-called "grounds". The result of such a
relay operating is usually a shut-down of the electrical drive. Also sometimes called
an Earth Fault Relay.
Jerk Limit
A means by which starting is smoothed by adjusting the rate of acceleration of a train
by limiting the initial acceleration rate upon starting. It could be described as limiting
the initial rate of change of acceleration. Also used in dynamic braking.
Line Breaker
Electro-mechanical switch in a traction motor power circuit used to activate or disable
the circuit. It is normally closed to start the train and remains closed all the time
power is required. It is opened by a command from the driving controller, no-
volts detected, overload detected and (were required)wheel spin or slide detected. It
is linked to the overload and no-volt control circuits so that it actually functions as a
protective circuit breaker.
Master Controller
Driver's power control device located in the cab. The driver moves the handle of the
master controller to apply or reduce power to the locomotive or train.

Motor Blowers
Traction motors on electric locomotives get very hot and, to keep their temperature
at a reasonable level for long periods of hard work, they are usually fitted with
electric fans called motor blowers. On a modern locomotive, they are powered by an
auxiliary 3-phase AC supply of around 400 volts supplied by an auxiliary inverter.

24
Resistance Control
Method of traction motor control formerly almost universal on DC electric railways
whereby the power to the motors was gradually increased from start up by removing
resistances from the power circuit in steps.Originally this step control was done
manually but it was later automatic, a relay in the circuit monitoring the rise and fall
of current as the steps were removed. Many examples of this system still exist but
new builds now use solid state control with power electronics.
Synchronous Motor
Traction motor where the field coils are mounted on the drive shaft and the armature
coils in the housing, the inverse of normal practice. Favoured by the French and used
on the high speed TGV Atlantique trains, this is a single-phase machine controlled by
simple inverter. Now superseded by the asynchronous motor.
Transformer
A set of windings with a magnetic core used to step down or step up a voltage from
one level to another. The voltage differences are determined by the proportion of
windings on the input side compared with the proportion on the output side. An
essential requirement for locomotives and trains using AC power, where the line
voltage has to be stepped down before use on the train.

25
 Major traction machines development since inception
Sl Year of Rating Application Unique
No. Product Development Features
1 Traction Motor Type 1962 139KW, 700V,215A, DC EMU ---
TM 133AZ 1160 RPM
2 Traction Motor Type 1967 515KW,700V, AC EMU/ High speed
TM 4939AZ 800A,1100RPM Loco

3 Traction Generators 1969 818KW,505V,1620A, MG DE Single bearing

Type TG 10919 1100RPM Locomotive With spigot
mounting
4 Traction Generators 1969 1688KW,750V,2250A, BG DE With PTU
Type TG 10931AZ 1000RPM Locomotive arrangement

5 Traction Motor Type 1975 48KW,550V, Kolkata ---

TM 2701BY 100A,900RPM Tramways

6 Traction Generators 1977 414KW,460V, DE Shunter ---

Type TG 10901AZ 900A,1000RPM

7 Traction Motor Type 1979 167KW,535V, AC EMU Sealed

TM 4601AZ 340A,1260RPM bearing
arrangement
8 Traction Motor Type 1979 93KW,338V,310A, DE ---
TM 4603BZ 1065RPM Locomotive
9 Traction Motor Type 1981 93KW,338V,310A, Kolkata MTP ---
TM 3603AZ 1065RPM

10 Traction Motor Type 1984 15KW,110V,160A, BPRV Light weight

TM 1701AZ 2500RPM
11 Traction Alternator 1985 1680KW,1000V,1680A, DE Class H
Type TA10102AY 1000RPM Locomotive insulation

12 Traction Motor Type 1986 280KW,325V, DE Class 200

TM 4906AZ 1000A,430RPM Locomotive insulation
13 Traction Generators 1986 210KW,300V, DE Shunter Combine fan &
Type TG 4302AZ 700A,2100RPM coupling

14 Traction Motor Type 1987 167KW,750V, DC EMU Class F

TM 3701AZ 275A,1100RPM insulation
15 Traction Motor Type 1988 34KW,195V, NG BP Round frame
TM 3604AZ 200A,1305RPM Locomotive battery
operated
16 Traction Motor Type 1988 172KW,324V, DE Class H, bush
TM 4501AZ 610A,490RPM Locomotive bearing
17 Traction Alternator 1988 1206 KW, 335V,3600A, DE Class H
Type TA10105 AZ 1000RPM Locomotive insulation

18 Traction Motor Type 1989 82KW,155V DE Shunter Class H, bush

TM 4605AZ 625A,220RPM Bearing
19 Traction Motor Type 1989 82KW,155V,625A, DE Shunter Flood proofing
TM 4606AZ 220RPM

20 Traction Motor Type 1990 630KW,750V, AC High power

HS15250A 900A,895RPM Locomotive

26
21 Traction Motor Type 1991 97KW,592V,182A, AC EMU Sealed
G320AZ 1025RPM bearing
arrangement
22 Traction Alternator 1993 1942KW,525V,3700A, DE Class H
Type TA10102CW 1050RPM Locomotive insulation

23 Traction Alternator 1994 1400KW,750V,3400A, DE Class H

Type TA 10106AY 100RPM Locomotive insulation

24 Traction Alternator 1995 414KW,650V,637A, DEMU Salient rotor

Type TA 7006AZ 1800RPM

25 Traction Alternator 1997 425KW, 650V, DEMU Concentric

Type TA 7005BY 637A,1800RPM type rotor

26 Traction Motor Type 1998 282KW,350V, DE Light weight

TM 5002AZ 925A,444RPM Locomotive

27 Traction Motor Type 1999 192KW,535V, DE High power

TM 4303AZ 400A,1240RPM Locomotive

28 Traction Motor Type 2000 585KW,750V, DE Axle bearing

TAO659BY 840A,1090RPM Locomotive Suspension

29 Traction Motor Type 2001 208KW,557V, DE Class 180

TM4303DY 415A,1160RPM Locomotive insulation

30 Traction Alternator 2001 1500KW,1100V,1227A, DEMU Light weight

Type TA7003BX 1800RPM

31 Traction Motor Type 2002 45KW,300V. MG DEMU Low power

TM3801AZ 170A,800RPM

32 Traction Motor Type 2002 207KW,535V,425A, AC EMU Class 200

TM 4303BY 1170 RPM insulation

33 3-Ph Traction Motor 2002 850KW,2180V, AC High power to

Type 6FRA6068 270A,1283RPM Locomotive weight ratio

34 3-Ph Traction Motor 2002 197KW,1716V, AC EMU Dual voltage

Type DMKT53/42 136A,1259RPM application

35 3-Ph Traction Motor 2003 1150KW,2180V, AC High power to

Type 6FXA7059 370A,1585RPM Locomotive weight ratio

36 3-Ph Traction Motor 2003 425KW,1520V, DE Frame less

Type IM4507AZ 220A,600RPM Locomotive stator

37 Traction Generators 2003 210KW,300V, DE High power to

Type TG 4302BY 700A,2100RPM Locomotive weight ratio

38 Traction Alternator 2003 2083KW,1075V,3700A. DE Rectifier

Type TA10102EV 1050RPM Locomotive mounted

39 Traction Alternator 2003 2757KW,2600V,1060A, DE Silicon rubber

Type TA9901AZ 900RPM Locomotive insulation

40 Traction Alternator 2005 1263KW,730V, DE Rectifier

Type TA10106CY 1730A,1050RPM Locomotive mounted

41 Traction Motor Type 2006 200 Kw Defence Defence

M3001AZ application Application

42 Traction Alternator 2007 2015KW,1380V, DE Hotel load

Type TA10103AZ 1460A,1050RPM Locomotive application

27
43 Traction Alternator 2007 795.79KW,750V,1061A, DE Rectifier
Type TA10106CY 1100RPM Locomotive mounted

44 3-Ph Traction Motor 2008 850KW,2180V, AC High torque

Type IM4801AZ/H 275A,1283RPM Locomotive

45 Traction Motor Type 2008 211KW,3858V, DE Roller

TM4501AV 620A,603RPM Locomotive suspension
arrangement
46 Alternator Type 2008 1430KW,600V, Oil rig Low THF
OA7002AZ 1000RPM

47 Traction Alternator 2008 208KW,557V, Ballast Dual winding

Type TA6303AZ 415A,1800RPM Cleaning

48 Traction Motor Type 2009 282KW,350V, DE DTC machine

TM5003AZ 925A,444RPM Locomotive

49 Traction Motor Type 2009 208KW,557V, DE DTC machine

TM4304AZ 415A,1160RPM Locomotive

50 Traction Motor Type 2009 168KW,675V, Kolkata High power

TM3701BY 275A,1035RPM Metro motor

51 3-Ph Traction motor 2009 297 KW,1070 V, 235 A, AC EMU Double star
type IM3402BZ 75.5 Hz connection

TXM (Traction Motor Manufacturing)

Machine shop:

Introduction: This is fully mechanical machine shop where machining operation is

doing on various critical machines (CNC) and maintained drawing dimension and
tolerance.
INPUT: Our raw material is casted magnet frame of cast steel from our foundry
and also from outside approved vendors.
OUTPUT: We prepare magnet frame after certain operation of machining as per
drawing and inspected by RDSO and dispatch to Assembly area for final assembly.

Machine shop: In this shop, machining at various parts of magnetic frame is

done.The machining process of the frame is serially given below:

 Pinion end boring & facing on vertical boring machine.

 Commutator end boring & facing on vertical boring machine.
 Drilling
 Tapping
 All round machining on CNC(This includes pole hole facing for ducts,milling of
suspension pad, milling of axle tube and pole pad milling).
 Final boring of CE & PE.
 Welding of brush gear pad.
 Joint hole drilling.
After the machining is completed, the frame is sent to assembly section.

28
Horizontal machining center: It is a set of fully automatic machinery, which has some
added features as compared to conventional lathe machine. The additional functions
provided in horizontal machining, center are:
 Automatic pallet changer
 Automatic tool changer
 Chip conveyor system

All round machining center performs various functions mentioned below:

 Pole hole machining

 Facing of duct and other openings (for brush changing etc)
 Milling of suspension pad
 Axle tube milling
 Pole pad milling

Process chart of Magnet Frame Machining:

PE & CE Bore
PE Semi All round Painting and
Final
Dispatch to
finish on V/B drilling Machining on
Assembly
V/B

CE Semi Axle Block Offer to

finish on V/B clearance Welding RDSO

All round CD Checked by

Marking
machining Machining Quality

Pole Pad
All round
PE & CE Drilling (Main Pole & Deburring
welding
Compole)

CE - Commutator end
PE - Pinion end
V/B - Vertical Boring Machine
CD - Centre Distance

29
FIELDING AREA-
Process of fielding

Clean magnetic frame and other component assemble fielding rings on magnetic
frame and keep on stand. Insulate staple and assemble main pole and cum pole
on magnetic frame. Make connection braze and insulate joints complete as per
DRG specification 14393013001; Test as per TM 20063 & check by QC Ref:
QMX/QAP/001

Precaution to be taken while fielding:

 Clean com pole coil arm & main pole coil arm before brazing.
 The point of arm on lead coil which are to be brazed should be cleaned with emery
paper.
 The asbestos tape should be dipped in water before brazing and shouldbe moved
away from the place of brazing so that lead coil doesn’t catchfire.
 Proper temperature should be maintained while brazing.
 Water should not be dropped on coil while brazing with plier.
 Temperature of brazing should be fixed according to the thickness ofupper piece.
 Brazing rod should be inserted between joint so that the joint should beproper.
 Sleafas should used at the joints while brazing, after brazing the sledgeshould be
removed and joints should be checked.
 Frame should be properly cleaned with emery paper before fielding.
 Frame should have rubber pad fixed at corners while fielding.
 Before inserting the solid pole inside the main pole basher should beproperly fitted.
 Basher should be properly inserted b/w main pole & com pole.
 Before tuckering of the joint futti level should be checked so that thereare no sharp
edges.
 After fixing the coil in the frame, the coil should be checked with spare.
 After the completion of all process of fielding clean the machine by air pressure

Commutator & core area-

The commutator core assembly and machining of brush holder is done here.
Fabricated brush holder made up of brass is supplied to TXM by fabrication
shop. Here the finishing of brush holder is done and then sent to assembly
shop of TXM

Brush holder Finishing

Finishing of brush holder involves several operations mentioned below:

 Machining – Top and bottom surfaces are machined tomake them parallel.
 Slotting – Coarse cutting of brush slot is done.
 Broaching – final finishing of brush slot is done.

30
  Drilling – holes in brush holder are drilled and tapped.
 Deburring – all sharp edge are smoothened.

Commutator building
This section of TXM is engaged in manufacturing of commutators and armature
cores of various DC Traction motors. Apart from this 3 phase AC stators are
being fabricated here and also squirrel cage induction rotors for these machine
are manufactured in this section.

A commutator is a rotary electrical switch in certain types of electric motors or

electrical generators that periodically reverses the current direction between the
rotor and the external circuit.The first commutator-type direct current machine was built by
HippolytePixii in 1832, based on a suggestion by André-Marie Ampère.

Sequence of commutator assembly is

 Flattening of commutator segment- manually the commutator surfaces are made

parallel by milleting.
 Slitting- milling operation is done to make slit in the riser of commutator segment for
housing the leads of armature winding. If equalizer coils are also to be placed then
one step is made by milling theslit at different width. This step also enables the
worker to easilyrecognize the placement of equalizer coil and armature coilwhile
assembling the coils
 Deburring- all the sharp edges are cleaned and deburred.
 Commutator building- alternate layers of commutator segment and micasegment
are arranged manually and then set.
 Static seasoning- this involves the heating of commutator in oven in four
cycles. Four cycles include three hot cycles and one last cooling
cycle. Each hot cycle includes continuous heating of
commutator at 150°C for 8 hours and then tightening of screws
in hot condition. After the completion of hot cycles, the
commutator is allowed to cool down at room temperature and
finally tightening is done in cold condition.
 Vee Turning- A V-shape profile is made at both the ends of commutator
so as to match the seating of steel hub at riser end and steel vee ring at
another end. This operation requires very fine finish of the surface and
needs to be done with great precision. CNC machine is used for this.
After this steel Vee-ring and hub are assembled on both sides of
commutator and clamped. Mica Vee ring and mica bush is inserted in
between. If we start from one end then sequence of layers will be: Steel
Vee ring-mica Vee ring-commutator (riser end side)-mica bush- mica
Vee ring- steel hub.
 Static seasoning
 Static balancing
 Dynamic seasoning
 Commuator testing
_ Bar to bar test
_ Flash test

31
  Pressing of punchings& shaft
 Dynamic balancing
 Alignment of commutator w.r.t. slot in armature is checked andstarting
 point(for winding reference) marked.

Commutator Pressing – The build commutator ring is first pressed with the help
of a hydraulic press so as to attain the required building diameter. The
commutator building is kept in the oven at 120°C- 150°C for 6-8 hours. This cycle
is repeated for 3 times with intermittent pressing of commutator rings. Finally cold
pressing is done.

‘V’ Turning of Commutator –

Most critical operation which gives the ‘V’ profile to
commutator and maintains the ID of commutator. This operation is done on aCNC lathe
machine to maintain the accuracy of job. Slightest change in the CNC program can change
the ‘V’ profile.

Ingredients in the Commutator Assembly

 V turned commutator
 Steel V Ring
 Mica ‘V’ Ring
 Mica Bush
 Commutator Hub

Oven tightening of assembled commutators.

Now, the final assembled commutators are again put in oven at 120°C-150°C for
6-8 hours. Here, this cycle is repeated 2 times with intermittent tightening of bolts, followed
by cold tightening and then they are sent for skimming on lathe.

Dynamic Gas Seasoning – one of the most critical operation in the

manufacturing cycle of commutators. Improper seasoning may result in ovality of
commutators. Each cycle consists of heating the jobs, over speed of mandrel @
2900 to 3500 rpm followed by tightening of bolts.

Armature Core Manufacturing-

Armature Punchings are received from Press shop PRM, BHEL Bhopal and
Central Stamping Unit, BHEL Jagdishpur.
These punchings are then stacked in building mandrel as per the designed core
length.
These build cores are then kept in oven @160-180°C for 6-8 hours and then
these cores are shrinked to armature shaft.

32
Process chart for armature-

Core assembly area Milling area Commutator

Punching of cores bar sliting

Srinking @ 150 to 180

degree Commutator V turning area
for 7 to 8 hrs

Core pressing area Commutator assembly area

Insertion of shaft in core

Oven tightening area

Drifting & Filling

Bar to Bar Test & Flash Test

Dynamic balancing

Static Balancing

Dynamic Seasoning

Final Shipment

Equalizer&Main winding

33
Winding section-
Important points of winding-

There are two types of windings

 Lap winding
 Wave winding
Equalizer winding is done only in case of lap winding.

Material required for equalizer winding

 Glass cord
 Finger cut mounded mica
 Glass cloth
 Glass tape
 Shellac varnish

Material required for main winding

 Glass cloth
 Moulded mica
 Flexible glass mica
 U-piece
 Nomex paper
 Glass tape
 Mica separator
 Nomex separator

Temporary banding

Material required for T.B.

1. Tinned steel banding wire 1.6 mm diameter.
2. Press paper
3. Banding strips
4. Cotton tape

A suitable device is required for applying tension.

Preparation prior to T.B.

1. The armature is heated in oven at 140-160 deg for 5 hrs minimum.the hot
armature is placed on the lathe and banding strips are fitted in the core
slots and these are holded with cotton tape.the strips must be long enough
toprogect 12 mm beyond the core at each end.
2. A cotton tape is wrapped around the centre of the core and banding wire
is hooked.

34
Process
1. The tension of 140 kgf is built up over 5-7 turns of wire.
2. The wire is traversed to the CE of the core to formed the end band of 5
turns traversing outwards .this band is finished before the end of fibre
strips.
3. The band is then secured by soldering the 5 turns and the surplus wire is
removed which was used to built up the tension over the core.
4. The rest of the core band is formed and this must also finish before the
end of banding strip.
5. During banding of the core the banding coils strips are tapped down with a
mallet to assist the consolidation of the coils.
6. The band is then secured by soldering.

Permanent banding

Material required

1. Resin impetrated weft less tape 0.3 mm thick and 20 mm width.

2. Glass fiber woven cloth 0.25 mm thick
3. Glass fiber woven tape 0.23 mm thick.
4. Braided glass cord 6 mm dia.
5. CRGO steel sheet
6. Banding driver
7. Suitable device for applying tension.

Vacuum pressure impregnation-

Resin impregnation is a method of sealing porous materials without impacting on

the functional or dimensional characteristics of the material.
Impregnation is not only effective for preventing leaks; it is also an excellent pretreatment
for surface finishes.
It controls the temperature rise and increases the life of armature.

35
The sequence of processes followed in winding section is given in brief as follows

 Bar to bar test (500V) and HV test (at 5.5 KV) to check the soundness
of commutator received from comm. & core area.
 Equalizer winding (in case of lap winding).
 Bar to bar test- to check insulation between adjacent conductors of
equalizer coil.
 Resi-glass tape & glass mica application at CE and PE side
respectively.
 Main winding- Nomex liner is used in straight portion and in over hang
portion glass mica cloth is used.
 HV test- At 5.5KV.
 Baking in oven for 6hrs at 150°C.
 Temporary banding- tinned steel sheet is used at 150 kgf pressure.
 HV Test- at 5KV
 Slot wedge insertion
 H V Test at 5 KV
 First turning- riser facing and commutator dia turning.
 Impulse test at 400V/turn.
 TIG welding
 Baking in oven at 165°C for 6hrs.
 Permanent banding- resin treated glass tape is used at overhang
portion.
 Baking in oven at 165°C for 6hrs- used for curing, also acts as pre
heating of coil before VPI.
 H V Test (at 4.5 KV) & Impulse Test (250 V/turn) in hot condition.
 Vacuum pressure impregnation-the cycle vary machine to machine, in
general steps are as follows:
1. Vacuum of 10-20 mm Hg is created for 15min.
2. Resin is transferred to vessel.
3. Vacuum of 40 mm Hg is created for 10min(to remove the air trapped in
resin.)
4. Insertion of Nitrogen/Dry Air at 5 bar for 30 min.
5. Resin is transferred back to the storage tank.
6. Resin is again transferred to vessel.
7. Step 4 is repeated.
 Cleaning
 Curing of varnish in oven at 195°C for 10-15 hrs.
 Second turning- inner bearing wiper distances are maintained and
ovality of commutator is removed.
 Final turning- final finishing of commutator.
 Mica under cutting.
 Cleaning and PTFE bush fitting
 Final testing- HV Test(at 4.5KV) and Impulse test (at 250V/turn).

36
Assembly section:
Assembly of Brush holder and complete machine takes place in this section.
The machined magnet frame from machine shop and field coils mounted at
poles from CIM are received and assembled here. Then after the pole
mounting, the armature is vertically inserted in the frame with precisely
maintaining the required air gap. Bearings are fitted. Pinion is mounted on
shaft. Then assembled brush holders are fitted at appropriate positions.
Earth return assembly and other cable connections are made. Then end
shields are mounted, after the completion of assembly the machine is sent to
testing area.

Process Chart For Assembly Area

MACHINED MAGNET
FIELDCOILS
FRAME RECEIVED ARMATURE RECEIVED
FROM CIM
FROM MACHINE FROM ARMATURE SHOP
SHOP

BALANCING OF
FIELDING OF MAGNET ARMATURE
FRAME

PAINTING OF COILS IN BEARING ASSEMBLY OF

FIELDED FRAME ARMATURE

FIELDED FRAME FOR ARMATURE READY FOR

ASSEMBLY ASSEMBLY

DROPPING OF ARMATURE IN
FIELDED FRAME

37
 ASSEMBLED MOTOR

LIGHT RUN

TESTING

DESPATCH AREA

TAG AREA

READY FOR FINAL DESPATCH

Bearing Assembly Area

Preparation area

Clean component re-tap holes assemble CE & PE bearings. Shrink paper as perdrawing
(REF C.450008) and check by QC, check run out by RDSO referenceQMX/QAP/001.

HS-15250
PE SIDE CE SIDE
BASE RING ROLLER 4 175 GR. SMEAR
CASE

38
1 BEARING CAPE 320 GR. 1 BEARING ROLLER & 95 GR.
CASE

2 430 GR. 2 INNER BEARING 195 GR.

CAPE

TAG Area
This is the customer inspection area .Here customer inspect the motor as per
QAP and after checking all stages documents give us the tag for final dispatch.

Dispatch Area
 Clean (If required) and assemble suspension tube as per drawing and
check by QC REF: QMX/QAP/001.
 Clean and assembles items as per drawing and check by QC REF:
QMX/QAP/001.
 Clean the shaft, shrink pinion, locks as per DRG and check by QC REF:
QMX/QAP/001.
 Finish the motor and check by QC REF: QMX/QAP/001 and offer the
motor to the customer and attend the points called by the customer.
 Finely finish the motor as per DRG and check by QC REF:
QMX/QAP/001

39