Inplant Training - Integral Coach Factory
-
Upload
sudarshan-mohan -
Category
Engineering
-
view
510 -
download
47
Transcript of Inplant Training - Integral Coach Factory
![Page 1: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/1.jpg)
IN-PLANT TRAINING REVIEW
INTEGRAL COACH FACTORY INDIAN RAILWAYS
Sudarshan. MRA1411002040113
Mechanical – ‘B’IIIrd Year
![Page 2: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/2.jpg)
Introduction• INTEGRAL COACH
FACTORY IS THE ONLY MANUFACTURER OF RAIL COACHES LOCATED IN CHENNAI. IT IS OWNED AND OPERATED BY THE INDIAN RAILWAYS.
• ICF is the first of its kind to be established after Independence for the manufacture of light weight, all steel and all welded Integral railway passenger coaches.
• The plant employs about 13,000 people and manufactures about 1500 coaches per year.
• A total of 50,000 coaches had been produced till 18 Aug 2015 by ICF since its inception
![Page 3: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/3.jpg)
A Brief History Of IcfTHE INTEGRAL COACH FACTORY WAS SET
UP IN 1951 WITH THE HELP OF M/S SWISS CAR AND ELEVATOR MANUFACTURING CORPORATION LTD., SCHLIEREN-ZURICH (SWITZERLAND).
IT WAS INAUGURATED BY THE THEN PRIME MINISTER OF INDIA PANDIT JAWAHARLAL NEHRU ON 02 OCT 1955.
PRODUCTION BEGAN IN A MODEST MANNER IN 1955 WITH THE MANUFACTURE OF SEVEN THIRD CLASS COACH SHELLS
![Page 4: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/4.jpg)
INTEGRAL COACH FACTORY
Shell Division Furnishing Division
SHOP 10 & 11 SHEET METAL
PROCESS
SHOP 22SIDE AND END
WALL ASSEMBLY
SHOP 21 ROOF ASSEMBLY
SHOP 30FURNINSHING
SHOP 37 AIR BRAKE ASSEMBLY
SHOP 54PAINTING
![Page 5: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/5.jpg)
SHOP 10: SHEET METAL PROCESSING• STAGE 1: STRAIGHTENING BY
ROLLERS• STAGE2: RELAXATION• STAGE3: CUTTING OF SHEETS
MATERIALS USED• COR-TEN Steel
6mm• Mild Steel 6mm• Stainless Steel
4mm
![Page 6: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/6.jpg)
SHOP 10: SHEET METAL PROCESSING
• CUT TO LENGTH MACHINE• ECCENTRIC PRESS• PROFILE BENDING• SEAM WELDING• BLANKING USING HYDRAULIC PRESS OF
TONNAGE 300-1000 TONS.
• LASER CUTTING CNC USING N2,H2, CO2
![Page 7: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/7.jpg)
SHOP 11: SIDE WALL ASSEMBLY • THE SIDE WALLS OF THE
COACHES ARE BEING ASSEMBLED HERE.
• THE SHEET WHICH ARE CUT IN SHAPE AND BENDED IN REQUIRED PROFILE FROM SHOP 10 IS WELDED TOGETHER HERE.
• SPOT WELDING AND SURFACE WELDING ARE USED.
• THE WALL FIXTURES ARE MOVED BY OVERHEAD HEAVY TONNAGE CRANES.
• IT TAKES ABOUT A WEEK TO PRODUCE APPROX. 4-5 COACHES.
![Page 8: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/8.jpg)
SHOP 21 AND 22: MAIN ASSEMBLY
![Page 9: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/9.jpg)
SHOP 21 AND 22: MAIN ASSEMBLY• Shop 21 – Roof Assembly• Roof is assembled by placing
the sheet on special fixtures called Roof Jigs
• Electric Arc welding is mainly used.
• Minor joints are welded by Gas Welding.
• Shop 22 – Body Assembly• The body of four different
coaches are made here.• They are General Coach,
Second Day coach, Second Class Night Coach and Second Class Loading Unloading
![Page 10: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/10.jpg)
METRO BOGIES SIDE FRAME
![Page 11: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/11.jpg)
SHOP 30:FURNISHING
• 1. PREPARATORY – BODY IS LINED WITH FOAM AND INSULATION
• 2. FLOORING – PLYWOOD FLOORING IS DONE. MICA SHEETS
• 3. WIRING – INTERNAL WIRING AND OTHER ELECTRICAL FIXTURES
• 4. PVC PASTING • 5. PANELING – I
![Page 12: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/12.jpg)
SHOP 30:FURNISHING
• 6. PANELING –II• 7. MOLDING• 8. FITTING – THE
FRAMES FOR SEATS OR BERTHS ARE FIXED
• 9. SEATS AND WORKS• 10. PIT LINE
INSPECTION – MANUAL INSPECTION IS DONE
![Page 13: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/13.jpg)
SHOP 37 - BRAKING SYSTEM
• Air brakes system is generally used.
• Vacuum Brakes are used for minor braking purpose.
• Air brakes is classified into three parts 1. Auto Brake
2. EP Brake 3. Emergency Brake
![Page 14: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/14.jpg)
SHOP 37 - BRAKING SYSTEM
• Electro Pneumatic Unit is used to control the system
• In this the brake assembly is made as designed.
• Leakage check is done using soap water.• The limit for verification is a 0.2kg pressure drop
in 15 minutes.
![Page 15: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/15.jpg)
SHOP 54 : PAINTING• DEWHEELING OF BOGIES • FIXING OF DUMMY BOGIE• MASKING
• SHOT BLASTING – SHOTS
OF 2 – 3 MM DIAMETER• DEMASKING• EPOXY PRIMER – A.K.A
METAL PRIMER (2 COATS)• ENAMEL • OVEN
![Page 16: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/16.jpg)
SHOP 54 : PAINTING• POLYESTER PATTY – TO COVER
DENTS• DUST CLEANING – AIR HOSE• SURFACER OR BASE PAINTING –
TO COVER PINHOLE GAPS• SURFACER FLATTENING – DONE
USING EMERY PAPER MANUALLY• WINDOW AREA SATIN GLUE
ENAMEL• AC BLUE ENAMEL• WHEELING • DISPATCH
![Page 17: Inplant Training - Integral Coach Factory](https://reader033.fdocuments.us/reader033/viewer/2022061311/587cc5171a28abfa018b4df1/html5/thumbnails/17.jpg)
THANK YOU FOR LISTENING