Rail Coach Factory Kapurthala
TRAINING REPORT (6 WEEKS)
SUBMITTED TO: Dr. H.K.Kansal
SUBMITTED BY: Sukhjit Singh Roll No.- UE109073 Mechanical/5th Sem.
OBJECTIVES OF TWO MONTH INDUSTRIAL TRAINING The main objective of the Training was to get first hand technical and
practical knowledge about the industry. The main purpose was that the students would become familiar with
industrial environment so that they can take up future challenges when they turn up in an industry with good confidence. The students will thus understand the flow of control and information in
an industry. This two-month Industrial Training has been introduced in Degree
Engineering Courses for the enhancement of student’s administrative and professional knowledge about their respective fields.
After completion of their Degree Courses, this training experience will
help them to make their workplace stronger in the ever-competitive job fields.
INTRODUCTION RCF’s Origin: •
Taking into account country’s large population, a proper system of transportation is inevitable.
•
The demand of more and more passenger trains is the result of the country’s ever increasing prosperity and population.
•
The decision to set up a Rail Coach Factory at Kapurthala, Punjab in August’85 was a timely step towards making good shortfall and complementing the coach manufacturing capacity of Railway’s other manufacturing units.
Location: •
The foundation stone of this factory was laid by the honorable Prime Minister (Late Shri Rajiv Gandhi) of India on 17th August 1985.
•
It is located 9 kms. From Kapurthala, near the Jalandhar–Ferozepur railway line and state highway, near the Hussainpur village.
Growth of RCF: •
During year 2001-02, RCF has manufactured 1250 coaches having 974 non-AC and 276 AC.
•
During recent development RCF is now started manufacturing the new series of L.H.B coaches with the help of agreement of German Technology in design and manufacturing.
OBJECTIVES OF RCF DESIGN IMPROVEMENT: The emphasis is on light-weight Passenger
Coaches with higher passenger capacity, improved safety and comfort and high speed. TECHNOLOGY: Keeping pace with latest technological developments. PRODUCTIVITY: Improvement in productivity vis-à-vis the existing coach
unit. QUALITY: Maintaining workmanship of higher International standards. MANPOWER DEVELOPMENTS: Development of an effective organization
with pride in their work and faith in the organization. NATIONAL OBJECTIVES:
Self sufficiency Energy conservation Increased employment Pollution free environment
VARIOUS SHOPS IN RCF Sheet Metal Shop
Fabrication Shop Shell Assembly Shop Paint Shop
Bogie Shop Furnishing Shop Finishing Shop
SHEET METAL SHOP In sheet metal shop, all the raw material is transported which is
1.
2.
3. 4.
required for the coach manufacturing of components. This material is either brought from steel authority of India or is imported from Japan. Commonly used sheet for the part is carbon steel and the SAIL supplies mild steel. The carbon steel can be divided in to four groups or categories: Low Carbon Steel: It has the composition of carbon ranging from 0.05to0.25%. These are use only when moderate strength is required together with considerable plasticity. These are generally used for sheets, strips, tubing, wire nails, rivets, screws and parts to be case hardened. Structure Steel: This type of carbon steel has carbon contents between0.2 to 0.35%. They have high yield point (3300 kg/sq.cm.) and are best suited for both welding and riveted operation. Forging Steel: These contain carbon between 0.30 to 0.40% and are used for axles, bolts, pins, connecting rods, crank shaft etc. Tool Steel: Steel containing 0.6 to 1.30% carbon is called tool steel and is used for the manufacture of tools due to its property of hardness and roughness.
FABRICATION SHOP
It consists of sections including under frame, side wall, roof & end
wall. 1.
Under Frame:
Under-frame constitutes the chassis of the coach.
Four jigs are used to make the assembly of under-frame.
The assemblies are placed in the jigs and then welded together.
After this, it is lifted with the help of overhead cranes and placed on the tracks for the 2nd stage on the other side of the frame.
The components, which are located on this side, are welded and after final welding, the frame is painted in black paint and transferred to the transfer bay for main assembly of the shell.
2.
Side Wall:
The sidewall is assembled in the pneumatic operated jigs.
The major parts of the sidewall are body side pillar, sidewall sheet, light rail, waist rail and stiffeners.
All these components are placed in the jig and welded together.
The sidewalls are of eight window sheets and lavatory sidewall sheet.
A number of other components like window ceiling angel etc. are welded after the wall is taken out of the jig.
3.
Roof:
The main roof is assembled on a rotary jig on which the basic components i.e. car line is located and after location, Ustiffener is welded to hold them.
After welding of these components, the roof sheets that are eight in no. are located together and tied properly with the help of stainless steel fasteners.
The Jig is then turned round to position and the roof sheet is welded together.
The roof is then removed from the jig & put on trestles for providing other components like fan brackets, lamp, brackets etc.
4.
End Wall:
This is the end portion of the coach.
The main component of end wall is end sheet, side sheet, end stanchions and center stiffeners.
All these components are positioned in the jig located and weld together.
When welded, these are taken out and placed on trestles for fixing pipes and other fittings.
All the components are welded with MIG welding.
SHELL ASSEMBLY SHOP In the shell assembly shop, sidewall, end wall, roof, under-frame is
assembled and other necessary operation for making shell is done. Shell assembly operations are done in five stages: Stage 1: In first stage, under-frame is placed on the jig. Then setting of camber is done to avoid bending of under-frame downward. Then sidewalls and end walls are placed on shell jig along with under-frame and are
fully welded. Afterwards roof is placed and full welding is done, the sidewalls and roof are made
tight for welding by using tie rods. After welding all clamps and tie rods are removed and checking for final camber is
done. Cables pipes are also attached.
Stage 2: In this stage End walls and Sidewalls are welded to each other. Residual welding for shell integral from first stage is also done. Door corner fitting, Conditioning of under-frame, junction box and cable box are fitted,
flooring work is also done in this stage.
Stage 3: In this stage, vestibule doorsill, alarm tube bends; ceiling support angle and window bar
fitting is done. Skin tensioning is also done in this stage. In Skin tensioning heating on spots at some distances is done and then hammering is done to remove any deformations.
Stage 4: In this stage partition framing of lavatory and seating is done. Besides this, door fitment operations are also performed.
Stage 5: Buffer and draw Gear assembly is done at this stage. Components of Buffer are:
CASING
STEEL ROD
PLUNGER
RUBBER PAD
SPRINGS
PLATE
PAINT SHOP In this shop, the shell is painted manually or with automatic
painting plants with different coats of chemical and paint etc. Various operations done in paint shop are:1. Shot Blasting:
Small steal balls are made to strike against the external surfaces of the shell with great speed.
Firstly marking is done to render steel balls to enter inside the shell.
It is done with wooden boards size of shots are 170mm,230mm,280mm.
Centrifugal machines are used in plants.
2.
Primer Application:
After that shot blasting primer is applied with automatic machines with nozzles which moves up down and side ways are used for this purpose in primer plant.
There are mainly two type of primer: 1.Internal Primer 2.External Primer
3.
Putty Application:
To obtain uniform thickness, putty cutting is done.
It is done with silicon water Emory paper.
Putty cutting is done by applying water at the required place.
This cutting is called wet cutting.
4.
Surface Application:
After putty, surface is applied to the external.
The surface are applied with the help of air less spraying machines.
When it become dry than cutting of surface is done with Emory papers.
5.
Top Coat Application:
After drying surfaces top coat is applied on the external surface with the help of automatic and air less spraying machines as used while primer application.
The thickness of paint on coaches is 200-250mm.
In paint shop, air film transversal is used for shifting of coaches.
BOGIE SHOP Bogie is the part on which the coach
rests and due to which the coach runs on the rail line That’s why it is manufacture under strict precision so that the dimensions do not vary too much from drawing. In the bogie shop the bogies of different
coaches are manufacture in the various stages. The various parts of the bogie are not
manufactured in that shop, only bogie frame is manufactured in this shop and the rest of the parts are imported from out side sources. These parts are only assembled here. The coach consists of eight wheels and
these eight wheels are divided into two sets of two wheels with suspension frame, springs and dampers when assembled properly then these two sets are known as BOGIE.
The main parts of the bogie are: 1.
Frame:
In this part of the bogie, shell is placed.
It is made of Leo Fein steel sheet.
The thickness for general coaches and high-speed coaches is 8 mm and 12 mm respectively.
Its parts are Head stock, transverse, Longitudinal and side frames
These parts are machined in this shop and at last are assembled in this shop with the help of jigs.
2.
Wheels:
These are the casting of Mild Steel and are flanged from inner side.
The diameter of the wheel is 890 mm and its thickness is 120 mm.
Two wheels are joined with frame by AXLE.
Each Bogie contains two wheels and a coach contains four wheels.
3.
Bearing:
In this section Bearing are fixed on journal.
The types of bearing used are roller bearings.
The diameter of wheels, journals & axles are 915mm, 130mm, and 155mm.
The distance between wheels is 1600mm.
4.
Brake System:
Air Brake system is used for braking action. For high speed coaches such as L.H.B and IRY coaches the disc brakes are used and for other coaches block brake are used. The band blocks are used for breaking and the braking is system is basically of liver pulley system. The pressure is applied on the pipes from the cylinder to the liver and then the brakes are applied.
5.
Alternator:
It is a source of electricity when the train is moving. For AC coaches two alternators of 25KW power each are used in a single coach. For general coaches an alternator of 4.5 KW power per coach is used. V – Belts and Pulleys, connects the shaft of the alternator to axle.
6.
Suspension System:
a) b)
It is used for absorbing shocks. It consists of springs and shockers. Springs are made of steel. Suspension system has two parts: Primary parts: It takes the load of shell only and restricted its vibrations. Secondary parts: It takes the load of shell as well as the thrust from wheels.
Testing of Final Bogie:
STATIC TESTING MACHINE:
Static testing machine is used to test the bogie frame by applying same amount of load as in actual service condition.
Purpose of this testing is to check the strength and correctness of different Bogie parts under the application of load on it.
Load is applied by hydraulic system at the center of bogie.
Under this load the deflection in spring is noted down and the deflection is compared with specified deflection for particular spring.
If the deflection is with in the safe limit or with in the specified limit and the other parts also behaved in specified way then the Bogie gets the OK signal. Otherwise, the defective part is replaced and then again the testing is done, until it gets OK.
FURNISHING SHOP The furnishing shop is working for decoration of coaches. So all the decorative
work is done here in this shop. In this shop seats, birth, electrical applications, portions, flooring, bogie
installation and many more other goods are fitted here. The shop consists of no. of sections and these sections are:-
1.
Flooring & PVC Section:
In this section flooring is done on the metal under frame.
First of all, the plywood flooring is done on the under frame.
The plywood is screwed to the metal floor of the coach, then after this the water sealing compound ISOPATHIC PUTTY is applied on plywood joints and is rub by emery paper later on for the uniformity of the flooring.
2.
Electrical Stage:
In this stage, all the electrical wiring is done for the electrical equipment.
D.C batteries are also loaded on the coaches.
For A.C, S.G and general coach, wires used are 1.5mm.
Equipment for which these batteries and invertors are provided is Fans, Lights, Air Conditioner, etc.
3.
Window and Ceiling Section:
After electrical wiring, windows and ceiling covers are mounted on the coach in window and ceiling stage.
These windows are not manufactured in this factory. These are manufactured by vendors as the design recommended by R.C.F.
These windows consist of a
4.
Panel Section:
After providing the windows and ceiling covers the work of paneling is done.
In this stage all the inner walls of coach are covered with thin-mica sheets, this is known as paneling.
These mica sheets are fastened with help of screws.
5.
Moulding Section:
After paneling the work of molding is done.
In this stage aluminum strips cover all the joints of paneling.
The molding is done for better out look of inner walls of coach.
Screws fasten these strips.
6.
Lavatories Section:
In this stage, all the accessories of lavatories are mounted such as flushes, washbasins, water tanks.
7.
Plumbing Section:
In this section, the fitting of pipes from water tank to lavatory and to wash basins is done.
8.
Seat and Berth Section:
In this section, following work is done:
Fixing of chairs angels and sleeve for
single seats. Fitting of luggage racks and back rests
arrangements. Fitting of guard compartment. Fitting of designation board. Fitting on no. plates of seats and
berths. Stench works indicating type of zones
and type of coach.
9.
Lowering Section:
Fixing of bogies to the coaches is the main function in this shop.
The procedure followed in this section is given below:
Fixing of center pivot pin.
Adjustment of buffer height. Fitting of bearing plates in Bogie. Taking bearing frame to the center. Lowering of coach on bogie. After lowering, the fitting of cotter and
split pin. Buffer point adjustment.
10. Electrical Stage-1:
In this stage all the electrical equipment are mounted on coaches.
This electrical equipments are fans, lights, electrical switches and air conditioner units.
The wiring is attached to these equipments.
11. Air Brake Section:
After lowering of coach all the connections of air brake are completed.
In early days Vacuum Brakes were used but now-a days air pressure brakes are used.
There are two types of pipes Feed pipe and Brake pipe. Feed pipe is of white color and Brake pipe is of green color.
Pressure in Feed pipe and Brake pipe is 6Kg/cm and 5Kg/cm.
These two pipes are connected to a diaphragm. With the help of this diaphragm air pressure is released to piston cylinder arrangement, with the help of which brake is applied.
12. Finishing Stage:
In this stage, all the work that is completed in furnishing, is checked i.e. all equipments are switched on by connecting to electric supply to the coach.
FINISHING SHOP
Following operations take place in this shop:
1.
Installation of Air Brake System and Testing:
Air brake system is installed in the coach and is being tested by passing the compress air in pipelines.
Generally two-pipe line exists in which one is white and another is green.
2.
Shower Testing:
In this the coach is placed below water shower and then the shower is started.
This inspection is done to check whether the leakage is there in roof or not.
This testing is mainly done to check
3.
AC Generation Test:
This can be tested with the help of motor and belt.
After checking the electricity generation, the performance of the AC unit is also checked by glowing number of high wattage bulbs and with AC unit ON.
So after all this a final inspection is done and after getting OK signal from inspectors, the coach is sent to Delhi headquarters, from there they will sends to the various railway zones according to their demand.
