PROCESS CONTROL CHART OF 3 PHASE ROTOR MANUFACTURE (At CLW)

Oven heating 160 C Rotor Stacking with Dummy Shaft Oven heating 160 C Rotor Copper Stamping Oven heating 160 C Placement of Dummy stack in Shaft under 300T press Rotor bar insertion for Induction braze heating 160 C Rotor bar insertion for MIG Rotor bar insertion for Copper stamping Brazing of Copper stamping with Rotor Bar MIG welding Shrink ring fitment Final machining Induction brazing Primer & Top coating Painting Inner Labyrinth fitment & distance maintain machining Bearing inner race fitment V groove machining in Resistance ring Face machining

Rotor Shaft Machining

Rotor balancing

Inspection

Despatch for Motor Assly

PROCESS CONTROL CHART OF 3 PHASE STATOR MANUFACTURE (AT CLW)

Stator Stacking

Stator tack welding under 70T Press

Stator Welding & Machining at HMS (Shop 08)

Stator slot regularization & Oven heating

Primer Painting

Stator Winding, Connection & Brazing

Testing

Stator Coil forming

Spreading

Insulation

Moulding

Testing

V.P.I. of Stator

Despatch for Motor Assly.

Inspection

Baking in Oven

PROCESS CONTROL CHART OF 3 PHASE MOTOR MANUFACTURE

Stator

End Frame (DE) Motor Assembly

End Frame (NDE)

Rotor

Dummy Pinion Extraction & Pinion Fitment

Final Inspection & Testing

Despatch to Bogie Shop

Troubleshooting Chart

Symptom
Earth fault signal

Possible fault
Connecting lead damaged with earth fault Winding insulation damaged

Means of checking
Check the connecting lead Check insulation resistances

Remedy
Renew the lead

Notes
Check route of lead for sharp edges and chafing points Determine the causes of the damage: foreign bodies in the motor

Repair after consulting manufacturer

Impermissible winding temperature of a single motor Fan is loose Fan deformed or broken

For self-ventilated motors only

Check seat through the exhaust opening Visual inspection through the exhaust opening

Secure the fan Renew the fan Determine consequential damage (e.g. stator winding damaged)

Impermissible winding temperature of all the motors Temperature indication is unrealistic of defective

Cooling ducts blocked in motor Overloading

Clean the ducts Reduce the load, localise any blockages and clear them Renew the resistance temperature detector Tighten terminal with required tightening torque and, where necessary, renew the cable lug Repair after consulting manufacturer

Resistance temperature detector is defective Connection terminal loose Open the terminal connection box and check the terminals

Check for damaged thread

Local overheating

Winding insulation damaged

Check the winding resistances, check the insulation resistances, measure the impedance Remove the bearing cover Lift the shaft and measure play with a dial gauge

Bearing fouled

Wrong bearing clearance

Renew the bearing, regrease at the N-end only Install a bearing with the correct clearance, check seating

Determine the causes of the damage: Foreign bodies in the motor, parts of rotor in motor Check the bearing seal and renew, where necessary Determine causes of change in bearing clearance

Symptom

Possible fault
Bearing damage

Means of checking
Remove the bearing cover

Remedy
Consult the manufacturer

Notes
Determine consequential damage: fragments in motor, rotor core assembly touches the stator core assembly Determine causes of seizing, failure of lubrication, excessive loading Reduced bearing service life

Bearing seized

Remove the bearing cover, bearing discoloured or deformed, bearing cover deformed

Consult the manufacturer

Bearing over or underlubricated Cooling ducts blocked in motor Smoke development Winding insulation damaged

Check the winding resistances, check the insulation resistances, measure the impedance Bearing cover discoloured, bearing discoloured or deformed can be determined only after dismantling

Lubricate bearing correctly Clean cooling ducts Repair after consulting manufacturer

Bearing seized

Shaft bent

Scorching smell

Lead damaged or interrupted Connection terminal loose

Check the connecting lead Check the winding resistances, check the insulation resistances, measure the impedance Check lead

Humming noise

Lead interrupted

Rubbing noise

Wrong bearing clearance

Lift the shaft and measure play with a

Determine the causes of the damage: Foreign bodies in the motor, parts of rotor in motor, overcurrent Remove the Determine causes of bearing, consult seizing, failure of the manufacturer lubrication, excessive loading Consult the Determine the cause, manufacturer localise consequential damage: Stator / rotor core assembly, stator winding, shaft attachments (e.g. transmitter wheel for speed controller) Renew the lead Check route of lead for sharp edges and chafing points Repair after Determine the causes consulting of the damage: manufacturer Foreign bodies in the motor, parts of rotor, overcurrent Renew the lead Check route of lead Disassembly of the for sharp edges and traction motor is chafing points necessary Install a bearing Determine causes of with the correct change in bearing

dial gauge

clearance, check seating

clearance

Symptom

Possible fault
Shaft bent

Means of checking
can be determined only after dismantling

Remedy
Consult the manufacturer

Notes
Determine the cause, localise consequential damage: Stator / rotor core assembly, stator winding, shaft attachments (e.g. transmitter wheel for speed controller) Determine the cause of current flow and take suitable measures Determine consequential damage: fragments in motor, rotor core assembly touches the stator core assembly

Knocking noise

Current flow at bearing

Visible only after Consult the dismantling the bearing manufacturer

Bearing damage

Remove the bearing cover

Consult the manufacturer

Transmitter wheel for pulse generator loose Motor suspension fractured

Remove the covers and check seating, check glands Check the suspension

Secure the pulse generator Consult the manufacturer Localise consequential damage: Shaft bearing assembly, gearing interface to motor

Motor suspension loose

Check screwed joint, check bearing assembly, check damping elements

Motor coupling loose Check screwed joint, or ruptured make visual check of critical locations for cracks

Tighten the screws at the specified tightening torque, renew the damping elements Tighten the screws at the specified tightening torque, renew fractured screws

Howling noise

Wrong bearing clearance

Lift the shaft and measure play with a dial gauge

Install a bearing with the correct clearance, check seating

Check seal for damage and renew, where necessary; with fractured screws consult the manufacturer, installation of screws of a different strength class may be necessary Determine causes of change in bearing clearance

Symptom

Possible fault
Bearing damage

Means of checking
Remove the bearing cover

Remedy
Consult the manufacturer

Notes
Determine consequential damage: fragments in motor, rotor core assembly touches the stator core assembly Determine the cause

Radial vibrations

Excessive bearing clearance

Lift the shaft and measure play with a dial gauge Remove the bearing cover

Bearing damage

Install a bearing with the correct clearance, check seating Consult the manufacturer

Balancing weights loose or lost

Consult the manufacturer

Transmitter wheel for pulse generator loose Motor suspension fractured

Check seating, check screwed joint

Check the suspension

Secure the transmitter wheel for the pulse generator Consult the manufacturer

Determine consequential damage: fragments in motor, rotor core assembly touches the stator core assembly Determine consequential damage: Small parts (screws, weights, etc.) in motor Transmitter wheel defines the radial position of the motor! Localise consequential damage: Shaft bearing assembly, gearing interface of motorbox

Motor suspension loose

Check screwed joint, check bearing assembly, check damping elements Visual inspection, balance

Rotor unbalance

Tighten the screws at the specified tightening torque, renew the damping elements Clean the rotor, refer to Section 5.5.1, Re-balance the rotor, refer to Section 5.6.1

For self-ventilated motors only Fan is loose Check seat through the exhaust opening Secure the fan Determine consequential

damage (e.g. stator winding damaged)

Symptom
Axial vibrations

Possible fault
Wrong bearing clearance

Means of checking
Lift the shaft and measure play with a dial gauge Remove the bearing cover

Remedy
Install a bearing with the correct clearance, check seating Consult the manufacturer

Notes
Determine causes of change in bearing clearance Determine consequential damage: fragments in motor, rotor core assembly touches the stator core assembly Localise consequential damage

Bearing damage

Motor suspension fractured Motor suspension loose

Check the suspension

Consult the manufacturer

Check screwed joint, check bearing assembly, check damping elements Check lead

Loss of torque of a machine Varying speed signals

Lead interrupted

Lead to pulse Check the lead, check generator interrupted the plug connections Tachometer loose Pulse generator defective Transmitter wheel for pulse generator loose N-end bearing overgreased Motor coupling loose or ruptured Check fastening

Oil / grease leakage

Remove the covers and check seating, check glands Remove the bearing cover Check screwed joint, make visual check of critical locations for cracks

Tighten the screws at the specified tightening torque, renew the damping elements Renew the lead Check route of lead for sharp edges and chafing points Renew the lead, repair the plug connection Secure the pulse Check seals generator Renew the pulse generator Secure the pulse generator Remove the excess grease Tighten the screws at the specified tightening torque, renew fractured screws Life-cycle lubrication Check seal for damage and renew, where necessary; with fractured screws consult the manufacturer, installation of screws of a different strength class may be necessary Determine the cause of current flow and take suitable measures Determine the cause of impacts and

Polluted or prematurely aged grease

Current flow at bearing

Visible only after Consult the dismantling the bearing manufacturer

Impacts or vibration

vibration