Insulation sheet on PCB

fixation

ZBV Box

PCB

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)

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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.

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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

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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)

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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)

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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)

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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)

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Modified SLR sliding door with MS Plate

MS Rollers welded on MS plate

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)

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