Presented by: Abhishek Raj 091603 mechanical

INTRODUCTION TO DLW
Diesel locomotive Works ,Varanasi is a Production Unit of

Locomotives under government of india ,Ministry of Railway with ISO-9001, ISO-14001 & OHSAS-18001 certification. It is spread over 300 hectares in the midst of city Temples , Varanasi. DLW has been manufacturing High quality Locomotives ( both ALCO& EMD type) & Diesel Generating Sets for Indian & Global market. It annualy manufactures 200 locomotives & Annual turnover is 1151 crores.

Loco Manufacturing Procedure

The Manufacturing Activity at DLW is broadly divided

into three major divisions.

Block Division
Heavy Weld Shop

Engine Division
. Engine Erection Shop

Loco Division
Loco Frame Shop

Heavy Machine Shop

Engine Testing Shop Light Machine Shop Sub Assembly Shop

Pipe Shop

Truck Machine Shop

Traction Assly. Shop Sheat Metal Shop Loco Assly. Shop Loco Paint Shop Loco Test Shop

Rotar Shop

Heat Treatment Shop

Flowchart
Heavy Weld Shop Heat Treatment Shop Heavy Machine Shop Engine Erection Shop

Engine Testing Shop

Engine

Truck Machine Shop

Traction Assly. Shop

Truck

Loco Assly. Shop

Loco Paint Shop

Loco Test Shop

COMPLETE LOCOMOTIVE READY FOR SERVICE.

Loco Frame Shop

Underframe
Sheat Metal Shop

Superstructure

TRUCK MACHINE SHOP

Bogies works as a leg of locomotive. It bears load of loco U/F, power pack , super structure and other accessories of locomotive. Two bogies are used in one locomotive.

TYPES OF TRUCK FRAME A. According to wheel arrangement bogie are to two type mainly. * Bo-Bo Bogie ( Bi axle bogie, axle independently driven ) it contain 2 axle 4 wheels, 2 TM. * Co-Co Bogie ( Tri axle bogie, axle independently driven ) it contain 3 axle 6 wheels, 3 TM. B. According to truck frame manufacturing method. * Cast steel type truck frame such as YDM4, WDM2, WDS6, WDG4, WDP4. * Fabricated truck frame such as WDG3A, WDM3D, WDP2, WDP1

Main Items of Boggie

Axle

Axle wheel assly.

Mounting pressure for Gear 50-115 Tones Mounting pressure for Wheel. 80- 130 Tones Mounting Pressure for journal bearing 50 Tones Uniform rise in pressure to be maintained

Axle, wheel & Gear assembly with Traction Motor.

ASSEMBLED WHELL & AXLE

Back lash clearance between Pinion and Bull Gear should be in the range of 0.016" to 0.024"

Assly. Of axle wheel with truck frame

Primary suspension system

Top view of EMD Bogie After axle-wheel is assembled with truck frame , suspension systems are installed .

Heavy Machine Shop

Engine crankcase is manufactured firstly by cutting the steel plates using plasma & laser cutting , and then it is welded in heavy weld shop to manufacture engine

crankcase . After welding , weld joints are Radiographically & hydrolically tested. Now it is Heat treated in Heat Treatment shop to normalise the crankcase . After Normalising , it is send to Heavy Machine shop , where it is given close tolerances upto 1 thou, on portal milling machine, Planar machines & Angular boring Machine.

Plasma arc cutting

Engine crankcase After Normalising

Machining of crankcase on Portal Milling Machine

Machining of crankcase on Angular boring Machine.

Tool Magazine for portal milling

ENGINE SHOP
Main Parts of EMD Engine

Oil Pan Crankcase

Crankshaft Power Assl.

Cylinder Head

Piston Assly.

Alternator

Complete Assly Of Power pack

LOCO ASSEMBLY SHOP

All the piping systems for

brake & coolling of traction motor , fuel tank , Main Reserviors etc are installed in the loco Frame at the Loco Frame shop, and then Loco frame is transferred to LAS. Complete Superstructure , which possess driver cab , longhood , shorthood etc is taken from sheet metal shop to LAS . Once engine , compressor, ECC, etc are installed on the underframe , superstructure is joined at it.

 Once a Locomotive is assemled

comletely Except mounting on boggies, it is shifted for Painting to Loco Paint Shop. From Loco Paint shop , It Is again taken to Loco assembly shop, where it is mounted on boggies. Now loco is completely assembled. So it is proceded for testing to Loco Test Shop. If at LTS , any part is found faulty , it is sent back to the corresponding shop. After loco is tested , it is ready for the service.

Mounting of Underframe +engine + othr accessories on boggies.

THANK YOU