With a view to cope up with technological advancement and continuous improvement in equipment in the transportation systems and to cater to the on-going requirement of Indian Railway – one of the major customers of BHEL, steps are being taken by BHEL for Modernization of its facilities with state-of-art technology to meet the challenges and expectations. This has resulted into:

·         Increase in productivity by automation, quality improvement and managing operations
·         Improvement in material handling & storage facilities
·         Shorter deliveries
·         Low level rejection
·         Reduced failures
·         Capable to cater to the need of Indian & Export market
·         Better performance of products

Some of the salient features of the measures adopted towards modernization by BHEL are:

·         Computer aided design and drafting systems
·         CNC notching line for stampings
·         Electro-slag welding for stator magnet frames
·         Vacuum pressure impregnation plants for field coils and armatures
·         TIG welding equipment for armature coil to commutator connection joints
·         Plant for high speed dynamic seasoning of commutator
·         CNC machining center for magnet-undercutting & commutator surface finishing equipment
·         Field coil forming equipment
·         Automatic taping machines for armature coils
·         Microprocessor controller induction hardening equipment for gears
·         Gear teeth cutting, grinding and profile checking equipment
·         CNC lathes and copy turning lathes
·         Internal & external; grinding machines
·         High frequency brazing equipment for traction generator commutator risers
·         Traction test plant with pulsating current testing facility
·         Sophisticated quality control equipment with 3-D measuring systems
·         Advanced test facilities for materials and components
·         Completely automated modern plant for zinc, tin, silver, nickel & manganese phosphate
·         Automatic plant for powder coating
·         Computerized automated test facility for control gear equipment with the help of Hewlett Packard
·         Automated storage & retrieval system for handling components from Kardex, Germany
·         Auto wire stripping & cutting machine from ARTOS, UK
·         Special purpose Induction Brazing machine for resistor terminals

R & D Efforts of BHEL towards modernization of Railway Fleet

The Centre for Electric Transporation (CET) has been established by Bharat Heavy Electricals Limited at Bhopal with assistance from United Nation Development Programme (UNDP). The centre is envisaged to act as focal point for systems oriented research in the area of electric transportation.

Scope of CET

Evaluation of propulsion system of rail vehicles under simulated load conditions by:

• Computer simulation (empirical models)
• Testing on Performance Simulator (Roller Rig).
• Study of vehicle dynamics of rail vehicles by computer simulation using mathematical models with in-house validation facility.
• Automation system for real time computer control and data acquisition
• Assistance in evaluation, selection and introduction of mass transit systems in large cities
• Technology scanning and technical documentation library
   

Facilities in the centre

• Performance Evaluation Lab
• Vehicle Evaluation Lab
   

Performance Evaluation Lab

Evaluation by computer simulation and testing on performance simulator

 

Computer Simulation

Software capable of evaluating propulsion system performance

 

Performance Simulator (Roller Rig)

Capable of testing powered rail vehicles for:

• Powering
• Coasting
• Braking
• Speed Limit
• Wheel Slip
   

Vehicle Evaluation Lab

 

Dynamic/Structural Analysis and Testing

Dynamic Analysis of vehicle as multi-body by math-modeling

• Stability Analysis
• Vertical Dynamics
• Steady State Curving
• Ride Quality Analysis

Structural Analysis

• Structural Integrity analysis by finite element method

Test set up

Servo hydraulic closed loop test system for:

• Component characterization
• Validation of simulation results
• Life cycle test of components and sub-assemblies

CET at BHEL also assists in introduction of appropriate technology for Urban Mass Transit System for large cities. It has the capability to carry out feasibility and detailed project report.