INNOVATIONS DONE ON ZONAL RAILWAYS – JUNE, 2015

Central Railway

Vehicle Control Unit (VCU) Test bench- Vehicle Control Unit (VCU) test bench was fabricated in Electric Loco Shed, Kalyan in-house for testing of digital I/O card of WAG-9 locomotives. It is also useful for downloading software in cards. (Picture-1)

Picture - 1Eastern Railway

After cooler tube de-scaling plant for ALCO locomotives- Diesel Shed, Andal has designed and fabricated in house an ‘After cooler tube de-scaling plant’ for ALCO locomotives for removal of scale formed inside the After cooler tubes. In this process, the solution of de-scaling compound and water in ratio 1:10, circulated at a temperature of 60°-70°C through internal tubes of after cooler in a pressure of 4 Kg/cm2, which removes scale formation inside the tube. This plant will also be helpful for de-scaling the heat exchangers of HHP locomotives also.

East Coast Railway

Reconditioning of CMS crossing by robotic process- Due to high density of traffic, points and crossings wear out within a short period. Earlier, the repair and reconditioning was done in track depot after taking out the worn-out crossing, which involves huge manpower and time along with traffic block. To avoid loss of time for removal of CMS crossings and put them back after reconditioning along with transportation, it was considered to use the new Translamatic Robotic Welding Technology. It is a handy machine and can be lifted by two persons. It works through software for which data is fed in the logger. The welding is done by core flaxed fire called Translamagna wire of 1.6 mm diameter.It is ideal for repairing CMS crossings and provides consistent high quality of welds and also improves the service life of CMS crossing and eliminates requirement of traffic block for removal and insertion of CMS crossing.

1

3 nos. of CMS crossings at Jagadalpur yard on run through line were reconditioned by adopting the above welding process. Now, the process is being continued at Amagura (AGZ) and Nakti Semra (NKX) yards. (Picture-2)

Picture - 2

North Central Railway

2

Development of Pivot lifter:- In Wagon Repair Depot, Jhansi previously damaged pivot tops were changed manually by lifting the centre pivot top and then holding it in correct position. In this process, more man power was required and it could cause accident. Now, Wagon Repair Depot, Jhansi has developed a pivot lifter in which centre pivot top is lifted by rotation of screw. In this technique, less man power is required and the pivot is continuously supported.(Picture-3&4)

Picture – 3 Picture - 4

Picture - 3 Picture - 4

Western Railway

Power assembly (Mandrel for checking blade connecting rod)- A Mandrel has been designed & fabricated by Diesel Shed, Sabarmati to check slipper surface of blade connecting rod of power assembly for open & closed end in WDG4 locos so as to re-qualify blade connecting rod before re-using to improve maintenance quality of power assembly. This will help in recording dimensions accurately to avoid the failure of Con-rod bearing that ultimately results in damage to engine block. (Picture-5&6)

3

Picture - 5 Picture - 6 Parel workshop has modified CTRB (Cartridge Tapered Roller Bearings)

extractors used for mounting/dismounting of CTRB bearing used in FIAT bogies by providing pressure sensors and Digital Read Out System to monitor the actual force applied during the mounting and dismounting activities.

Electric Loco Shed, Vadodara has successfully formed the first multiple unit WAP5 loco (No. 30071 + 30072) in Indian Railway. Trial of multiple unit loco has been done successfully.

Test bench for “ON LOAD” testing of digital Input/Output card of 3- phase loco- During the month, Electric Loco Shed, Vadodara has in house developed test bench set up for ON LOAD testing of digital I/O card (URB-512 & URB177D15) used in VCU & SR of 3-phase locomotives to find defective reed relay with intermittent problem as per RDSO SMI 277. (Picture-7&8)

4

Picture - 7 Picture - 8 Flexible spanner for transformer bolts tightening- During the

maintenance work of transformer, difficulty is faced to tighten the foundation bolts of transformer which are just below the radiator. This work was very inconvenient & risky. Normal spanner & palm are not convenient to tight the foundation bolts. To overcome this problem, Electric Loco Shed, Valsad has developed a flexible special tool (spanner), so that transformer foundation bolt can be tightened in position because of movement of the spanner through handle in oblong position. With this spanner the proper tightness of foundation bolt can be ensured safely & conveniently. The work has been executed with the existing material available in the shed. (Picture-9)

Foundation bolt of Transformer

32 mm Hexagonal socket type

spannerMovable coupling

Handle for operating the

spanner

Picture - 9

West Central Railway

5

Bio-diesel filling by Diesel Loco Shed, Itarsi- On World Environment day 5th June, 2015 Diesel Loco Shed, Itarsi became the first Diesel Loco Shed in Indian Railways to fuel its locomotive with 5% bio-diesel blended HSD. Loco no. 40107 became the first loco filled with 5% blended bio-diesel which worked train no. 15017 of the day. (Picture-10)

Picture – 10

Manufacturing of rack for keeping air brake pipes by Carriage Repair Workshop, Bhopal- A rack has been erected to store pipes of diameter 10 mm, 15 mm & 25 mm in segregated lots. By this method pipes are now stored above the ground preventing them from dust and moisture. Their segregation makes them convenient for use by staff also. (Picture-11)

Picture - 11

6