CGR Final Report Sendable

8/12/2019 CGR Final Report Sendable

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PREFACE

This document has been prepared in order to presents an overview of the Industrial Training Program of the

NDT Electrical Engineering of the Institute of Technology University of Moratuwa, that experienced by me.

It gives extensive details of the training experiences as well as the information about the training organization.

I had my second six months (18.09.2013 18.03.2014) of my first six month training program at Ceylon

Germany railway technical training center (CGR).

This report gives an overview of my training experiences and observations at the training period. It covers the

company background and includes information relevant to construction work to which I was exposed.

To get the full use of this report reader should has to read it in orderly manner. I have presented the report instructured manner Thus for a person, who has an interest on specific area he can easily and understand. The

first chapter presents an overall view of the training organization. Second chapter gives the project details. In

the chapters following I have presented my training experience classified according to area of work covered

in the training. The final chapter is where I have stated my conclusion regarding the In-plant tainting as a

whole.

The most important thing realized during this training period is, the theoretical knowledge is not the only

guidance to be a leading character in industry. Having sound knowledge in both theoretical and practical

aspects of the Electrical Engineering is the best way to develop myself as a professional engineer.

This is my second major report. It may contain any misinterpretation of details. Finally kindly I requested your

responses.

Thank you.

I.M ihsan

10/IT/EEI/119

Institute of Technology

University of Moratuwa.


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ACKNOWLEDGEMENT

I would like to express my sincere gratitude to my internal supervisor, Mr.Ranjan Perera Lecturer Of Industrial

Training, Institute of technology University of Moratuwa for his excellent advice, constructive criticism and

suggestions provided me to complete the training.

I also express my gratitude to the lecture panel of the Division Of Electrical Engineering, ITUM. As well as, it

should be expressed my special thanks to the Chairman, National Apprentice and Industrial Training Authority

(NAITA) for organizing and supervising every aspects of my training.

I wish to acknowledge my deep gratitude to Mr. A.D wickramasinha, training operational manager, for his

valuable advices, suggestions and encouragement, to all foramens and supervisors.

The unreserved support and understanding of my beloved parents, brothers, sisters and my friends ensured

that I had a stable environment in which I can focus on my training.

I.M ihsan

10/IT/EE/119

Institute of Technology

University of Moratuwa.


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Contents

PREFACE .......................................................................................................................................................... 1

ACKNOWLEDGEMENT .................................................................................................................................... 2

1. Chapter 01................................................................................................................................................ 6

1.1 Introduction of CGR ratmalana ............................................................................................................ 6 1.1.1 Locomotive group .................................................................................................................... 6

1.1.2 Carriage and wagon group ...................................................................................................... 6

1.1.3 Production group ..................................................................................................................... 6

1.1.4 Electrical group ........................................................................................................................ 6

1.1.5 Electrical group ........................................................................................................................ 6

1.2 Address ............................................................................................................................................... 7

1.3 Map...................................................................................................................................................... 7

1.4 Vision ................................................................................................................................................... 7

1.5 Mission ................................................................................................................................................ 7

1.6 Organization chart ............................................................................................................................... 8

1.7 CHIEF MECHANICAL ENGINEER (CME) SUB DEPARTMENTS ...................................................... 9

2. Chapter 02.............................................................................................................................................. 10

2.1 Safety of workshop ............................................................................................................................ 10

2.2 fire cylinders and usages ................................................................................................................... 10

2.3 Fire brigade ....................................................................................................................................... 10

2.4 First aid box ....................................................................................................................................... 10

2.5 Medical center ................................................................................................................................... 10 3. Chapter 03 (workshop no 30) ................................................................................................................ 11

3.1 Introduction of workshop no 30.......................................................................................................... 11

3.1.1 Battery group ......................................................................................................................... 11

3.12 Tinkering group .......................................................................................................................... 11

3.13 A/C wiring group ........................................................................................ ................................ 11

3.2 Types and parts of batteries .............................................................................................................. 11

3.2.1 Primary cells or non re chargeable batteries .................................................................................. 11

3.2.2

Secondary cells or re chargeable batteries .................................................................................... 11

3.2.3 Batteries by applications ................................................................................................................ 11

3.2.1 Primary cells ................................................................................................................................... 11

3.2.2 Secondary cells .............................................................................................................................. 11

3.2.3 Batteries by applications ................................................................................................................ 12

3.2.4 Alkaline battery ............................................................................................................................... 12

3.2.5 Lead acid battery ............................................................................................................................ 13

The total chemical reaction can be written as ............................................................................................. 13

3.2.6 Vehicle battery ................................................................................................................................ 14

3.3 Preparing distilled water and battery acid solution ............................................................................ 15


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3.4 Battery tests ....................................................................................................................................... 16

3.5 Battery maintenance .......................................................................................................................... 17

3.5.1 A given battery instruction of operating manual ............................................................................. 17

3.6 Carriage wiring .................................................................................................................................. 18

3.7 Air condition wiring ............................................................................................................................ 18 3.8 Tinkering ............................................................................................................................................ 18

4. Chapter 4 (workshop no 35 electronic control, DC electrical machine and rewinding) ........................ 19

4.1 Introduction of the workshop no 35 .................................................................................................... 19

4.1.1 DC motor repair section ................................................................................................................. 19

4.1.2 Rewinding section .......................................................................................................................... 19

4.1.3 Automatic voltage regulator designing section ............................................................................... 19

4.2 DC motors ......................................................................................................................................... 19

4.3 Repairing and servicies of dc motors ................................................................................................. 20

4.5 Schedule of servicies ......................................................... ................................................................ 21

4.6 A.V.R (auto voltage regulators) ......................................................................................................... 22

4.7 Winding and rewinding ...................................................................................................................... 22

4.6.6 The rewind order ............................................................................................................................ 23

5. Chapter 5 workshop no 39 ..................................................................................................................... 25

5.1 Introduction to the workshop no 39 .................................................................................................... 25

5.2 Rotor repairings ................................................................................................................................. 25

5.3 commutator ............................................................. ........................................................................... 25

5.4 Types of windings .............................................................................................................................. 26 5.5 armature balancing ............................................................................................................................ 27

5.6 Insulating windings ............................................................................................................................ 28

5.7 Define the pols of the stators ............................................................................................................. 29

6. Chapter 6 workshop no 27 ............................................................... ..................................................... 31

6.1 Introductions of workshop 27 ............................................................................................................. 31

6.2 Control cubical work .......................................................................................................................... 31

6.3 Traction motors .................................................................................................................................. 32

6.4 The AV main generator ..................................................................................................................... 33

6.5 Locomotive wirings ............................................................................................................................ 33


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INDEXpicture description page no

Pic 1 map..07Pic 2 fire cylinder.10

Pic 3 alkaline battery...12Pic 4 led acid battery...13Pic 5 car battery... 15Pic 6 parts of Ni-Fe battery.15Pic 7 boiler.16Pic 8 battery acid dilution cylinder. 16Pic 9 hydrometer...16Pic 10 DC motor..19Pic 11 AVR22Pic 12 coil removed stator..23Pic 13 removed coil.23Pic 14 major contain of an engine 25

Pic 15 bands.25Pic 16 commutator...25Pic 17 armature parameter.26Pic 18 balancing machine...27Pic 19 balanced armature...28Pic 20 pole test.29Pic 21 main generator windings 30Pic 22 cubical of control.. 32Pic 23 traction motor and gear wheel32Pic 34 main generator..33Table 1 organization chart of CGR...08Table 2 organization chart of chief mechanical engineer head office.09Table 3 fire cylinder usage.10Table 4 repairing table.20Table 5 armature parameter ...31Table 6 locomotive wiring color cods33


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1. CHAPTER 01

1.1 INTRODUCTION OF CGR RATMALANAThe Ceylon railway, which was originally intended to bring the products of plantation in the center province to

the sea port of Colombo for shipment overseas and to transport machinery, fertilizers and other goods from

Colombo to the plantation area, has grown into a general major transport industry in the island covering all

populous districts by a network of railroads. Today fifty five percent of tea products in Ceylon is carried by rail

but the revenue derived from the transport of the commodity is 2.9 percent. Only of the gross receipts from all

sources, the railway has to cater to other needs of transport to earn balance 97.1 percent to revenue. The

subsequence of traffic has been in two major directions, viz,

The suburban traffic to and from the city of Colombo

The long distance passenger traffic and transport of fool, agriculture and other products.

There are three types of departments In the CGR

Civil engineering department

The civil engineering department of the railway during the last fifty years has carried out a number of major

products, which may be grouped in to two periods, viz, the per-independence period and the post-

independence period

Mechanical engineering department

In the year 1933 the workshop were transferred from mardana to ratmalana. The total area of the workshop

77acres out of which 12.6 acres are covered the chief mechanical engineers head office is a two storied

building.

The workshops are divided into 4 main groups namely

1.1.1 Locomotive group

1.1.2 Carriage and wagon group

1.1.3 Production group

1.1.4 Electrical group1.1.5 Electrical group

The section on charge of five electrical engineers, fifteen electrical foremen, who are responsible for electrical

plant and ancillary gear in the railway. Generation of electricity is also available by using diesel generators in

when electricity is not available from local authorities.

Repairs of all electrical machinery, switchgear, etc.. is attended to at ratmalana.


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1.2 ADDRESSSrilanka germany railway technical training centerRatmalana

1.3 MAPThe google map of the workshop is in the picture 1

1.4 VISIONTo provide technical training conforming to international stranded in order to produce competent and skilled

man power required to maintain timely operated efficient steady and reliable passenger and good train series.

1.5 MISSIONTo become the training institute with the highest level of acceptance in srilanka in order to produce skilled

craftsman having national vocational skill level who are capable to go forward with a new technical

developments to railway and srilanka.

Picture 1: map


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1.6 ORGANIZATION CHARTThe organizational structure is prepared to show the levels the workers and officers, in a company

management the organizational structure is an important one, each officers can understand their work and

there power in the organization And while a worker reporting to the higher level by following the structure, it

will easy to solve problems, take decisions and passing information. The organization chart is in table 1

GTMGMA

GMO

Main mechanical engineer sub department

Main way & works engineering sub department

Main motive power sub department

Signal & telecommunication sub department

Srilankan railway superintendent

Transportation superintendent

Sales manager

Chief accountant of railway

Commercial superintendent

Srilanka german railway technical trainingcenter

GMR

Srilanka railway force superintendent

Table 1:organization chart


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1.7 CHIEF MECHANICAL ENGINEER (CME) SUB DEPARTMENTSThe table 2 is the chief mechanical engineer division organization chart.

MEC-mechanical engineer of carriage

MES-mechanical engineer of special project

MEF-mechanical engineer of foundry

MEP-mechanical engineer of production

MEL-mechanical engineer of locomotive

MED-mechanical engineer of drawing

CHIEF MECHANICALENGINEER

DEEPUTY MECHANICAL ENGINEER CHIEF ELECTRICAL ENGINEER

STORE KEEPER

TECHINICAL OFFICER

BUILDING DEPARTMENT FOREMAN

RAILING BUS PROJECT

ELECTRICAL ENGINEER OFTRACTION

ELECTRICAL ENGINEER OF POWER

ELECTRICAL ENGNEER OFCARRIAGE

MEC MES MEF MEP MEU MEDMEL(E)

FOREMAN

SURPERVISOR TRAINEESTIME KEEPER CLARK

MEL (P)MEL (H)

1ST CLASS TECHNICIAN

2ND CLASS TECHNICIAN

LABOURS

3RD CLASS TECHNICIAN

Table 2: chief mechanical engineer division O/C


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3. CHAPTER 03 (WORKSHOP NO 30)

3.1 INTRODUCTION OF WORKSHOP NO 30This is the battery workshop that doing battery repairing, charging, battery testing air condition wiring,

tinkering and battery installation, there are two foreman, three supervisors and thirty of workers are working in

the workshop, the whole workers of workshop are divided as into three groups

3.1.1 Battery group

3.12 Tinkering group

3.13 A/C wiring group

3.2 TYPES AND PARTS OF BATTERIESThe batteries are mainly classified as into three categories, they are

3.2.1 PRIMARY CELLS OR NON RE CHARGEABLE BATTERIES

3.2.2 SECONDARY CELLS OR RE CHARGEABLE BATTERIES

3.2.3 BATTERIES BY APPLICATIONS

3.2.1 PRIMARY CELLSThe primary cell is the very simple mechanism of a battery. These batteries are not re chargeable so after

finished the saved energy of the batteries; this must to replace or repair to reuse. So this type of battery usage

is becoming rare in industries.

The output accuracy of the battery is very good. The tolerance of the primary cell is 0.2V. Because of thisonly one reason this type of batteries are still used in industries.

Examples of primary cells

Alkaline battery, aluminum ion battery, aluminum air battery, chromic acid cell, dry cell

But in train the alkaline cell was only used.

3.2.2 SECONDARY CELLS

This type of cells are mainly using in industries because of law cost, ease of maintenance and can charge

directly from utility power supply. The size of the batteries is small and the variable output batteries are

available in market. So the usage in the industries is become large.

Examples of secondary batteries

Fuel cell, lead acid battery, nickel cadmium battery, lithium ion and lithium air batteries. Molten salt batterBut

the lead acid battery, lithium ion battery and nickel cadmium battery were only used to repair


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3.2.3 BATTERIES BY APPLICATIONS

This a type of classification that the grouped according of the usage.ExamplesBackup battery, battery pack, car battery, button cell, bio battery

In CGR the car battery was taken under repair.

The batteries which are under taken for repair in CGR.

3.2.4 ALKALINE BATTERY

Alkaline batteries are a type of primary batteries dependent upon the reaction between zinc and manganese

dioxide (Zn/MnO2). A rechargeable alkaline battery allows reuse of specially designed cells. Alkaline battery

in the pic 3

OVERALL REACTION:

Zn(s) + 2MnO2(s) ZnO(s) + Mn2O3(s) [e = 1.43 V]

VOLTAGE

The nominal voltage of a fresh alkaline cell is 1.5 V. Multiple voltages may be achieved with series of cells.

The effective zero-load voltage of a non discharged alkaline battery varies from 1.50 to 1.65 V, depending on

Pic 3: Alkaline battery


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the purity of the manganese dioxide used and the contents of zinc oxide in the electrolyte. The average

voltage under load depends on level of discharge and the amount of current being drawn, varying from 1.1 to

1.3 V. The fully discharged cell has a remaining voltage in the range of 0.8 to 1.0 V.

CURRENT

The amount of current an alkaline battery can deliver is roughly proportional to its physical size. This is a

result of decreasing internal resistance as the internal surface area of the cell increases. A general rule of

thumb is that an AA alkaline battery can deliver 700 mA without any significant heating. Larger cells, such as

C and D cells, can deliver more current. Applications requiring currents of several amperes, such as powerful

flashlights and portable stereos, will require D-sized cells to handle the increased load.

3.2.5 LEAD ACID BATTERY

Despite having a very low energy-to weight ratio and a low energy-to-volume ratio, its ability to supply high

surge currents means that the cells have a relatively large power-to-weight ratio. These features, along with

their low cost, makes it attractive for use in motor vehicles to provide the high current required by automobile

starter motors. The led acid battery in the pic 4

THE TOTAL CHEMICAL REACTION CAN BE WRITTEN ASPb(s) + PbO2(s) + 2H2SO4(aq) 2PbSO4(s) + 2H2O(l) These are general voltage ranges per cell

Open-circuit at full charge: 2.10 V

Open-circuit at full discharge: 1.95 V

Pic 4: led acid battery


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Loaded at full discharge: 1.75 V

Continuous-preservation

Charging: 2.23 V for gelled electrolyte; 2.25 V for AGM and 2.32 V for flooded cells

All voltages are at 20 C (68 F), and must (for a 6 cell battery) be adjusted by 0.0235 V/C for

temperature changes.

Float voltage recommendations vary among manufacturers.

Precise float voltage (0.05 V) is critical to longevity; insufficient voltage is almost as

Detrimental as excessive voltage typical (daily) charging: 2.37 2.4 V

Equalization charging (for flooded lead acids): 2.5 V for no more than 2 hours, 12 minutes, and 18

Seconds. Battery temperature must be absolutely monitored.

Gassing threshold: 2.4 V

3.2.6 VEHICLE BATTERY

Electric vehicle batteries differ from starting, lighting, and ignition (SLI) batteries because they are designed togive power over sustained periods of time. Deep cycle batteries are used instead of SLI batteries for these

applications. Traction batteries must be designed with a high ampere-hour capacity. Batteries for electric

vehicles are characterized by their relatively high power-to-weight ratio, energy to weight ratio and energy

density; smaller, lighter batteries reduce the weight of the vehicle and improve its performance. Compared to

liquid fuels, most current battery technologies have much lower specific energy; and this often impacts the

maximum all-electric range of the vehicles.

A vehicle battery can be a

Led acid battery, nickel metal hydride battery or a lithium ion battery. The picture 5 &6 are the car battery andthe Ni-Fe battery.


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PARTS OF A BATTERY (NI-FE STORAGE BATTERY)

3.3 PREPARING DISTILLED WATER AND BATTERY ACID SOLUTION

Prepare distilled water to make the acid solution. The sulfuric acid of 35% and the distilled water of 65 % are

mixed and allowed to cool. To produce the distilled water, a boiler was used. Then the water was used to

mixed with the pure sulfuric acid.

This was a very danger process the concentration sulfuric acid is a dangerous one, it can burn the skin, so we

have to fallow the safety first. Picture of 7 & 8 are the boiler and mixing cylinder.

Pic 5:A car battery

Pic 6: parts of a Ni-Fe battery


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boiler

Pic 7: boiler Pic 8: The battery acid dilution cylinder

3.4 BATTERY TESTSThe battery was tested at three times when after repaired, charging and discharging, at this time the battery

have to have some specific characteristics. After repair the battery that means after filled with the battery acid,

the battery solution was checked with a hydro meter. The density of solution and the concentration of sulfuric

acid were being more. So the hydro meter will read a high value.

Charging test was did when the batteries were on charge, while charging the batteries terminal voltage was

varying with the time, after full charged the terminal voltage was became to around 1.5V 0.1.

The discharging test was did when discharge the batteries, to discharge the batteries a dis charger was used

to discharge; the discharger has a nichrome coil which can convert the battery power into heat. When

discharge batteries they were heated and ant they take different times to fully discharge. The temperature was

noted down every hour and the total discharge time and the density of the battery acid solution density were

noted down after fully discharge, a hydrometer is in the picture of 9

Pic 9: hydrometer


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3.5 BATTERY MAINTENANCE

The battery case are using as the very first starting energy source in the automobiles (train). So the batteries

must to maintain in a proper way, so the every battery manufactures are release a maintenance schedule with

their products, the user must to follow the instructions to get high efficiency. The common maintenanceschedule is given bellow.

Maintain the electrolyte level in the range of lower upper level only. If it is bellow that range, top up only with

demineralized water. Do not use sulfuric acid

Keep the battery practically the venting of any dirt.

Check cables and, clamps, fastener, and case for obvious damages or loose connections.Clean terminals and connectors as necessary.

General precaution

Never let your battery be punched by any sharp edges.

Keep battery away any sparks or flame.

Charge your battery in well-ventilated area.

3.5.1 A GIVEN BATTERY INSTRUCTION OF OPERATING MANUAL

For a new charged battery, fill all cells with sulfuric acid of 1.260 1.280. in sulfuric gravity until reach the

upper level, plug all vent holes with the provided vent plugs the clean battery top cover and terminals.

Disconnect the all battery, ground terminal first, (usually negative terminals) then followed by the other

terminals. Never do this in reversed order. Please check cables and clamps. Ensure it is rust free.

Properly put and fasten the new battery on the car battery component. Tightly connect the terminals in

reversed order with the disconnection order above. Cover all terminals with grease from corrosion prevention.Then the battery is ready to use.


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3.6 CARRIAGE WIRINGThe carriage wiring was mainly divided as in to two parts

Engine room control board wirings

Train box wiring

The engine board control board was fed from both battery and power generator. But the other train boxes

were power fed from the lightning generator.

The train engine box 78 cells of batteries each of them have 1.5V terminal voltage. Those batteries are used

when starting to give an instantaneous power to start the engine and to energized the engine box controlled

equipment when the engine is off until the engine start.

To wire the lights and fans in the box, 1mm20.44/cu/pvc cables were used to terminate and 1mm2/cu/pvc

cables were used to wire the engine box control board devices.

The battery was connected to starting motor. The starting motor is the starter of the engine. The starting motor

has to energize for an instantaneous time then the power feed will start by the power generator. The power

generator is operating by the train engine. 25mm2/cu/pvc cables were used to connect the starting motor and

batteries.

3.7 AIR CONDITION WIRINGThere are only one air conditioned box in some trains. The air condition boxes there were two air conditions

were fixed in each boxes. they were fed from power generators. 25mm2/cu/pvc/pvc cable was used to wire

the air conditions. The air conditions control switch was fixed on the engine control board.

3.8 TINKERINGTinkering train boxes also coming under this workshop, the body of the train was polished and painted, but

those works were supervised by a mechanical supervisor. After complete all wiring and repairing, the tinkering

work will start by the tinkering group. The tinkering group was help to lay the wire in the train box and they

help to hide the cables on the roof of the train.


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4. CHAPTER 4 (WORKSHOP NO 35 ELECTRONIC CONTROL, DC ELECTRICALMACHINE AND REWINDING)

4.1 INTRODUCTION OF THE WORKSHOP NO 35

This the workshop which is deal with dc electrical machines and electronic control devices. There are threemajor areas in this workshop. They are

4.1.1 DC MOTOR REPAIR SECTIONThe DC motors mean mainly the starting motors were repaired and serviced in the workshop. The scheduleservices of motors are maintained here. Every type of motors has got a different period of schedule services. After the period of the schedule time the motor will take for services.

4.1.2 REWINDING SECTIONRe winding of the starting motors and all other motors were done in this workshop, if the winding burn or shortcircuited or other problems happened the motor will rewind to solve those types of problems.

4.1.3 AUTOMATIC VOLTAGE REGULATOR DESIGNING SECTIONThis is an electronic part which is done in this workshop, the AVR of a train repaired and serviced in theworkshop.

4.2 DC MOTORSThere are veriable size of DC motors. Mainly the DC series motors are using as starting motors inautomobiles (train). When start the vehicle the starting motor use to give the starting torque to the engine. Sothe staarting motor works for a instantinous time.the motors are feeding by the batteries of the vehicle. Somedifferent types of starting motor has got permanent magnet to produce the magnetic field. And some large

size motors has got cooling fane. The fans are directly coupled with the motor shaft.

The hole system are installed into a iron housing and the field windings are fixed on the inner surface of thehousing and the rotarry part are fixed on bearing. Pic 10 show a DC motor

Pic 10: DC motor


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4.3 REPAIRING AND SERVICIES OF DC MOTORSWhen start the repairing the fault of the motor have to find first. There are some common problames, normaly

in a motor, those faults are happening

Fault Resons of faults solutions

Burned windings Rapid using, over current, cooling failures

or long time usage

Rewind the coils or some times (rarely), use

a joint peace to to connect the both broken

ends of the cupper string.the rewing is a

huge repairing, so it will charge more, so the

user must to fallow the user gide and

maintenance instructions.

Break brushes orcorrotions

Long time usage, un balanced armature,or smoothless commutator

When the fault happen the brushes must toreplace to solve the problame, if the motor

has unbalanced armature or smoothless

commutator, the brushes will get break till

the problams solve. So we have to balance

the armature or smooth the surface of the

commutator first.

Bearing failure Low maintanance, unbalanced armature,

over load

Mainly the bearing failure is happening

because of law maintanance. If dry grease

in the bearing the bearing will get fail, once

the bearing get failure, it must to change,

otherwice motor will be noicey and there are

chance to burn coil. The broken bearing is

not a big issue but it will cause so many

problams, so the bearings must to

immediately, the user can find the failure

form sound changes of the motor.

Unbalance

armature

Attrition or along time usage, cooling

failure

While using the motor along time, the

armature get unbalance. When the armature

is unbalnce, the motor vibration will more,

and noice of the motor also get increase.

Table 4 repairing table


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4.5 SCHEDULE OF SERVICIESThechhedule of servicies will be prepaired according to the size, usage and environment of usage of a motor,

some large size of motors has a time counter to calculate the running time, the productor release a common

shedule chart with ther product to help the user. The shedule must to fallow to get a good performance of

theat motor, some time the maintanance shedule of a motor can be difference to same type motor.

According to the maintanance shedule the motors will taken under the servicies. Some of number of motors

will take under servicies before the shedule time but most of them will taen for servicies after finish the

shedule time.

Cleaning, painting, tinkering, and graesing works only do when the motor is faultless, if the motor has any

fault, they will solve first before servicies.

While servicies a motor

4.1.1 Greasing

the grease can dry in the bearings and other moving parts of the motor. So that must to chack when service a

motor, if the lubrication become dry then the motor bearing will break, will get got quckly and finaly there is a

chance to burnthe coil.

4.2.2 Check the brushes

mostlt brushes failure filure is happening in motor, if there is a brushes fault in a motor, there will be createsparks.

4.2.3 Check the windings

there is a rare of chance to break the winding of a motor, (armature or field windings), so they also checked

when under taken a motor.

4.2.4 Check the bearings

the bering failure is a common problam in the motor repairing. So they also checked when repairing. When

over load condition work is the main reason to break the bearing.

Small generators als taken under repair, the motors was used in workshop, they were single phase

generators.


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The perameters were taken from the burned winding

The coil coupper string diameter

Number of turns

Winding style (top to top or bottom to bottom)

The details must to fallow when rewind to keep the same charactristic of themotor.

4.6.6 THE REWIND ORDER

4.6.6.1 Remove winding

Remove the burned winding carefully from the stator or the rotor slots. Measure the winding shape and the

diameter of the coil string are the important perametesrs of a winding.the pic of 12 & 13 are the stator and a

coil.

4.6.6.2 Make a former

The winding former is wooden block, this is a coil former, the new coil will wind on this former first according to

the original shape and sutable demension. Every motor has got different shape coils, so when start to rewind

we need to make a new former. A former in pic 14

Pic 12: Coil removed stator

Pic13:Removed winding


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4.6.6.3 Clean and paint the stators and rotors

The stator and the rotors were cleaned with water vapors and put into a hot oven to dry. Then the iro hosing

was painted with a specal paint. It was painted to protect from corrotins and dust the motor surface.

4.6.6.4 Re installed the motor

The new coil was inserted into the slots and the rotor was sentered by adjest the bearings, then commutatoe

was electricaly connected. Then the housing closed. Then chached by using a multimeter. The possibility of

working of the motor was confonmed and delevered to install in train.

Pic 14: a former


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5. CHAPTER 5 WORKSHOP NO 39

5.1 INTRODUCTION TO THE WORKSHOP NO 39This is the workshop deal with heavy A/V and D/C generator, traction motors, DC traction, controls and control

cubical works and armature balancing. One foreman, two assistant foreman, 7 supervisors and hundreds oflabors are working in this workshop. This is the largest workshop in CGR ratmalana. This workshop is divided

as mechanical part and electrical part to make and control the work easy.

5.2 ROTOR REPAIRINGSThe major contains of an engine box shown in pic14

5.2.1 Rotor banding

a steel string was banded on both ends of the rotor to band on rotor 600n force used to band, the bandsshown in pic 15

the rotor banding was banded to collect the segments together

5.3 COMMUTATOR

shaft

lighting generator

starting motor and generator

engine3 generator

bands

Pic 14: major contains of an engine

Pic 15: bands

Pic 16: comutator


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the surface of the commutator was smoothed and the edges of the segments were mounted to save the

brushes from attenuations.

And the mica canals were cut to stop electrical short while running a lone time the motor. in some time carbon

dust from the brushes can make short between two segments, so canal were cut to protect from short. In the

pic of 16

5.4 TYPES OF WINDINGSThe main generator is using as a generator and a starting motor. There are three types of windings in each

pol. They were

Compensating field- helps prevent the armature from distorting the magnet flux created by the armature field

Differential flux alters generators characteristic so that relatively small changes in the level of excitation is

sufficient to obtain a constant kilowatt generator output

Battery field a separately excided field connected to the battery and auxiliary generator circuit. The battery

field is under control of the load regulator which serves to maintain a constant

there are two types of windings in the pols, the open and close coils shown in pic 17

Open coil and closed coilThe both coil were used to change the polarity of pols (n and s)

The coils were removed and re insulated. Each coil has a number identification to identify the position after

removed.

The glass tape and a special type resins were used to insulate the coils.

Then fixed again in the same position after complete the insulations. Then we measured the resistance of the

coil.

Pic 17: open and close coil


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5.5 ARMATURE BALANCINGThe parameters of an armature is shown in pic 17

The armature balancing machine shown in pic 18

un balanced armature was balanced here to determine the unbalanced amount a balancing machine , at the

begins we have to give five parameters of armature. The parameter in table 5

Parameter Description

Dl and Dr - before doing balancing we have to decide the external weight which can be

fixed of thickness. The parameters must to measure from the center of the point of

external weight to the other edge of cover plate.

A Distance from the balancing machine wheel to center of cover plate

B The distance between the both side end cover plate

C Distance from the balancing machine wheel to center of the right cover plate

5th parameter Distance from the balancing machine wheel to center of the right cover plate

Table 5: the parameter of an armature

Dr

1. A 2.b

Dl

Pic 17:armature parameter

Pic 18: balancing machine


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the armature divide as 360 and a cellophane tape was stacked on the zero (to tachometer )

Then we can get a weight and angle in display according to the given parameters and un balancing amount.

A balanced armature

5.6 INSULATING WINDINGS5.6.1 Steps

covered by glass tape

The removed windings were insulated first by the glass tape, the glass tape has very high heat consumption

and a good insulator. So the glass tape was cut accurately and wound on the windings

pasted varnished

a special type of varnished was pasted on the glass tape wound winding. this will collect the glass tape

strictly and do not allowed to remove.

painted

Then they painted ay a special type paint which can absorb very high heat

dried in an oven

Cellophane tape

10

3590

Pic 19 : a balanced armature


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Finally, the windings were put in an oven before assembled together.

5.7 DEFINE THE POLS OF THE STATORSThe stator pols must to in correct order when install. a compass was used To find the polarity of the windings.

When find the polarities the field windings where connected as series to a combination of a battery case, then

a permanent magnet compass was taken near to the winding, the compass arrow was turned by the field of

the winding.

If the N is attract the pole is S, if the S is attract the polarity of the winding is N. the N and S were

fixed rapidly in the inside of the stator core. Because to produce a magnetic field rapidly. Polr test is shown in

pic 20

After did this test the generator was closed with the cover plate. And the repair work is completed. This was

the final test of the repaired motor.

The given winding instruction of a main generator is shown in pic 21

N pole S polePic 20: pole test


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Pic 21 main generator winding


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The cubical control is a power electronic device. In some case, the cubic will control automatically, sometimeill will control manually and some time the cubical giving alert signals to the operator, so the function of thecontrol cubical must by consider the operator. When repair them the all deal with electronic devices, the

cubical of control in the pic 22

6.3 TRACTION MOTORSThe traction motor is a type of DC series motor. This motor is directly connected with the train wheel through agearwheel. Characteristics of the traction motors that were used in workshop.

Rated current 1000 A and rated voltage 885V,

This motor can give a very high starting torque, so at the starting this character is very useful.

Suitable for high speed, a long term and continuous operations. The traction motor and the gear wheel are inthe pic of 23

Pic 22: cubical of control

Pic 23: traction motor and gear wheel


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6.4 THE AV MAIN GENERATORThe A/C main generator is the power feeder of the traction motor and other important electrical operations,this was taken under schedule services in the workshop.

The output rated current 4000A and rated voltage 885V. this main generator can act as a motor and a

generator as well. So this generator has wound a DC motor winding and a A/C generator winding. Shown inpis 24

At the beginning the main generator will supply power from battery then the engine will get start, but in sometypes of engine the starting motor is separated. The huge coil is the generator coil and the small coil is thestarting motor coil.

6.5 LOCOMOTIVE WIRINGSThe locomotive wiring is a different and mess one from house wiring. So many color cords, terminatingsystem and different size of cables were using in wiring. The color codes of locomotive wiring shown in table 6

Color usage

Red From right hand rail power pick-up (or center rail,outside third rail, traction overhead wire) to motor orinterface

Orange From the interface to brush (+) connected to righthand rail.

Black From left hand rail, power pick-up to motor orinterface.

Gray From interface to motor, brushes (-) connected to theleft hand rail.

White Front head light.

Blue Common (+) head lights / function power source.

Yellow Rear hear lights

Black with white strips Common (-)

Pic 24 main generator

Table 6: locomotive wiring color code


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Documents

CGR Final Report Sendable