INNOVATIONS DONE ON ZONAL RAILWAYS – JANUARY, 2015
Eastern Railway
· Universal Test Bench with variable D.C. source- Diesel Shed,
Barddhaman has developed a universal test bench with D.C. power
source which will provide variable D.C. voltage as per requirement
for testing & simulation of different small motors at test
room. The unit would primarily be used for testing of small motors
with inverters like FPM, CCEM and DEBM with under-voltage &
over-voltage with smooth testing arrangements. The installation is
also suitable for testing of various control-gear components of
loco e.g. D.C. coils of GP relay/ contactor etc. This test bench is
extendable and can be used as a variable DC voltage source for any
electrical apparatus including DEMU items.
· Fixture for riveting- ROH Depot, Naihati has manufactured a
new fixture for proper riveting. With the help of this fixture
proper riveting can be done at yoke pin support plate, striker
casting & centre pivot top by minimum effort with less
staff.
East Coast Railway
· Insulation sheet for ZBV Box- During trouble shooting of WAG9
loco failures on account of “train bus disturbance – master”, it
was found that ZBV was getting earthed due to direct contact of PCB
with ZBV box. To avoid such failures, provision of nomex insulation
sheet on ZBV box at fixation of PCB was provided in five WAG9
locos. (Picture-1,2)
( Insulation sheet on PCB fixation) (PCB)
( ZBV Box)
Picture-1 Picture-2
· Removal of WAG9 loco Traction Motor(TM) pinion with shaft- The
conventional arrangement for removal & fitment of electric loco
TM pinion is not suitable for WAG9. The TM pinion of WAG9 loco is
combined with hollow shaft of TM. To cut the cost of procurement of
pinion extraction/fitment arrangement, TM pinion fitment &
removing arrangement (costing around Rs 4.0 lacs) in Diesel WDG4
locos was studied, whose traction motor is having similar shaft
arrangement and a modified fixture was developed at Elecrtic Loco
Shed, Visakhapatnam. The trial was successfully completed during
the month for removal & fitment of pinion.
(Picture-3)Picture-3
· Hot Oil Detector (HOD) test stand- Diesel Loco Shed,
Visakhapatnam has rigged up a test stand for Hot Oil Detector,
which is a thermostatic valve, calibrated to open when lube oil
temperature reaches 124°C. (Picture-4)
Picture-4
· SMS alert system for tenderers- SMS based alert system has
been introduced in ECoR to enable the successful tenderers to get
the details of the purchase orders instantly from the system when
the PO is released. Similarly, all the consignees are able to know
their demand case number through SMS alert whenever the
requisitions are registered in MMIS.
North Western Railway
· Retro-reflective yellow colour paint was done on flange of
rail on gauge face side on both rails in 40 m length, at the
location of fog signal 270 m ahead of outer signal of “A” Cabin
Lalgarh Yard, Kanasar side. This innovation was done to alert loco
pilot approaching the outer signal during foggy weather. Its
visibility has been found very well during night and it shall help
in enhancing safety during foggy weather. (Picture-5)
Picture-5
· Development of Over Heat Protector (OHP) test bench- An OHP
test bench has been developed at Jaipur Depot to ensure testing of
OHP at right temperature with less time and to avoid difficulties
while testing OHPs manually.
For OHP testing, “a model of OHP test bench - AC unit” has been
developed. In this, a blower motor and heater bank (as installed in
AC RMPU), supply air system and return air system, vane relay,
auxiliary contactor, return air filter and different contactors are
installed. Temperature sensors are also installed on both the
heater banks, separately, after installing separate OHPs for
measuring temperature. Sensor unit displays temperature separately
for both the OHPs.
One rotary switch is provided on control panel. On turning the
rotary switch to Ist position blower motor gets turned ON and on
turning the rotary switch to IInd position, blower and heater both
are turned ON simultaneously and on turning the rotary switch to
IIIrd position only heater gets turned ON. When only heater is
turned ON, the temperature rises continuously as blower is not
working to evacuate the heat from the area. This temperature rise
is continuously measured by sensors and displayed on the control
panel. When temperature reaches 65ºC both OHP-1 and OHP-2 trip and
turn the heater contactor OFF. Indication and buzzer for tripping
would be turned ON. Thus, tripping at 65ºC temperature can be
ensured. It would result into maintaining temperature between 19ºC
and 21ºC. With this safety and comfort of the passengers can be
ensured in winters.
This test kit will avoid overheating and increase safety of AC
coaches apart from ensuring passenger comfort.
Western Railway
· Fixture for power assembly- In WDG4 locomotive cylinder head
nut is torqued at 240 ft-lbs in two phases. To ensure proper
torqueing of head to liner nut, Loco Care Centre Sabarmati has
developed a fixture to assemble cylinder and liner head of power
assembly. (Picture-6)
This fixture has following advantages over the earlier one:-
· Two power assemblies can be torqued simultaneously, thus the
time taken reducing to half.
· Hydraulic test can also be performed on the same test
stand.
· Dismantling of power assembly can also be done by the same
fixture.
Picture-6
· YES (Yaatri Empowerment through SMS)- Mumbai division has
implemented SMS based onboard complaint redressal system, called
YES (Yaatri Empowerment through SMS). Passenger can complain by
sending SMS for complaint regarding linen, pest/rodent &
cleanliness. The message will immediately go to onboard staff and
TXR control and complaint will be addressed on real time basis.
(Picture-7)
Picture-7
· Gadget for fitment of automatic pulley on coaching axle- A
gadget for fitment of automatic pulley on coaching axle has been
fabricated by Veraval Coaching Depot, Bhavnagar Division. With the
help of this gadget, the pulley can be fitted on axle with more
accuracy avoiding alignment problems. The gadget is user friendly
and reduces pulley fitment time. (Picture-8,9,10,11)
Picture-8Picture-9
Picture-10Picture-11
· Pratapnagar workshop has rigged up a fixture for removal and
fitment of brake gear bushes. The fixture is operated with the help
of double acting airbrake cylinder using a direction control valve.
(Picture-12)
Picture-12
West Central Railway
· Water inlet tube hydraulic testing gadget- Water inlet tube is
a vital component of HHP locomotive. Few instances of water leakage
from water inlet tubes have been experienced by the shed in recent
past. On detailed failure investigation, it has been observed that
water leakage has taken place due to cracking of water tube from
elbow joint due to inadequate sealing between tube and elbow joint.
In order to eliminate the en route failure of water inlet tube, a
test gadget has been designed and fabricated by the shed staff for
testing the water inlet tube of HHP loco. Water inlet tube is
hydraulically tested with the help of this gadget at 10 kg/cm2
pressure. The defective tubes are not allowed to put in service
again on loco. Hence this gadget will be helpful in avoiding the
line failure of water inlet tube of HHP loco. (Picture-13,14)
Picture-13 Picture-14
· Supporting device for sliding doors of SLR- During
loading/unloading of luggage in SLR coaches, generally sliding door
derails due to mishandling by parcel porters and C&W staff has
to be called to put right the same causing unnecessary train
detentions.
To avoid such train detention, M&P wing of Wagon Repair
Shop, Itarsi has developed a supporting device by welding 6 nos.
10x12x8mm size MS rollers at a regular distance of 250mm on a MS
plate of 1660x100x6mm size. This supporting device is welded on
inner wall of coach and SLR, in between sliding door moves. After
providing supporting device in the gap of 38mm, the gap is reduced
to 3mm which eliminates the possibilities of derailing of sliding
door. This supporting device is developed by M&P wing of Wagon
Repair shed, Itarsi with available resources and no extra
expenditure has been incurred thereon. (Picture-15)
(Modified SLR sliding door with MS PlateMS Rollers welded on MS
plate)
Picture-15
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