FINAL in there) 3. Engine room 2. Electrical

FINAL SHED (for
final inspection)

STAGE WISE
INSPECTION:

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First of all
under frame will be ready the car body. Then car body put it on under frame.

4. Cooling room(compressor ,radiators ,motors and
bloore are fitted in there)

3. Engine room

2. Electrical room

1.  Driver cab
(in which driver and operators are sitted)

CAR BODY SECTION:

Under frame and
care body prepare in fabrication section

Every locomotive
have their own drawings for electric wirring. Every wire have their own
specific number and lable.

WIRRING SECTION:

All electronics
parts are import from China OR German.

Latter of project
compilation to distributors

      Light trial from factory to peshawar or
attok

INSPECTION SHED:

v MECHANICAL SECTION

v PIPING SECTION

v ELECTICAL SECTION

5. Batteries

4. Generators

3. Alternator

2. Motor

1. Compressor

ASSEMBLY SECTION

BREAKWAN:

Production
section:

MAIN
STORE: for small parts (Assembly needed like nut , bolt , revert etc)

CAR
BODY SECTION:

5. Traction Motors(395-600 HP) 6 motor for Each :
for wheel movement

4. Springs

3. Suspension tubes

2. Different parts

1. Wheel

1_
Rear bogie, 2_ Front bogie

BOGIE
ASSEMBLING SECTION:

11.        
Radial
Drill machine

10.        
Bogie
frame milling machine with heads and head carrying 42 types of tools

9. Master copy Section (for tools)

8. Universal Grinding machine

7. Slotting machine

6. Vertical lathe

5. Universal lathe machine

4. Leveling machine

3. Threading machin

2. Drilling Machine

1. Lathe machine (all types)

MACHINE
SHOP: for tool

33.        
Chemical
treatment plant

32.        
Layout
marking machine

31.        
Marking
surface plate

30.        
Painting
section

29.        
Grid
blasting for whole bogie

28.        
Annealing
furnace “heat process”

27.        
Gear
cases “train part”

26.        
Bogie
section “jis k ooper engine rakha jata hai” : train part

Punch
presses are large machines with either a ‘C’ type frame, or a ‘portal’ (bridge)
type frame. The C type has the hydraulic ram at the top foremost part, whereas
the portal frame is much akin to a complete circle with the ram being centered
within the frame to stop frame deflection or distortion.

A
punch press is a type of machine press used to cut holes in material. It can be
small and manually operated and hold one simple die set, or be very large, CNC
operated, with a multi-station turret and hold a much larger and complex die
set.

PUNCH
PRESS MACHINE:

 

Since
any particular component might require the use of a number of different tools –
drills, saws, etc. – modern machines often combine multiple tools into a single
“cell”. In other installations, a number of different machines are
used with an external controller and human or robotic operators that move the
component from machine to machine. In either case, the series of steps needed
to produce any part is highly automated and produces a part that closely
matches the original CAD.

 

In
modern CNC systems, the design of a mechanical part and its manufacturing
program is highly automated. The part’s mechanical dimensions are defined using
computer-aided design (CAD) software, and then translated into manufacturing
directives by computer-aided manufacturing (CAM) software. The resulting
directives are transformed (by “post processor” software) into the
specific commands necessary for a particular machine to produce the component,
and then are loaded into the CNC machine.

 

Computer
numerical control (CNC) is the automation of machine tools by means of
computers executing pre-programmed sequences of machine control commands. This
is in contrast to machines that are manually controlled by hand wheels or
levers, or mechanically automated by cams alone.

C.N.C
MACHINE :

Band
saws dedicated to industrial metal-cutting use, such as for structural steel in
fabrication shops and for bar stock in machine shops, are available in vertical
and horizontal designs. Typical band speeds range from 40 feet (12 meters) per
minute to 5,000 feet (1,500 meters) per minute, although specialized band saws
are built for friction cutting of hard metals and run band speeds to 15,000
feet per minute. Metal-cutting band saws are usually equipped with brushes or
brush wheels to prevent chips from becoming stuck in between the blade’s teeth.
Systems which cool the blade with cutting fluid are also common equipment on
metal-cutting band saws. The coolant washes away swarf and keeps the blade cool
and lubricated.

BaND
SAW MACHINE:

25.        
Grid
blasting machine 2 types S M

The
machine may be foot powered, less commonly hand powered, or mechanically or
hydraulically powered. It works by first clamping the material with a ram. A
moving blade then comes down across a fixed blade to shear the material. For
larger shears the moving blade may be set on an angle or “rocked” in
order to shear the material progressively from one side to the other; this
angle is referred to as the shear angle. Setting the blade on an angle
decreases the amount of force required, but increases the stroke. A 5 degree
shear angle decreases the force by about 20%. The amount of energy used is
still the same. The moving blade may also be inclined 0.5 to 2.5°, called the
rake angle, to keep the material from becoming wedged between the blades.
However, raking the blade compromises the squareness of the edge

Shearing
machine:

for
5-6mm sheet cutting

grid
blasting equipment typically consists of a chamber in which sand and air are
mixed. The mixture travels through a hand-held nozzle to direct the particles
toward the surface or workpiece. Nozzles come in a variety of shapes, sizes,
and materials. Boron carbide is a popular material for nozzles because it
resists abrasive wear well.

 

grid
blasting or bead blasting is a generic term for the process of smoothing,
shaping and cleaning a hard surface by forcing solid particles across that
surface at high speeds; the effect is similar to that of using sandpaper, but
provides a more even finish with no problems at corners or crannies. grid blasting
can occur naturally, usually as a result of particles blown by wind causing
aeolian erosion, or artificially, using compressed air. An artificial grid blasting
process was patented by Benjamin Chew Tilghman on October 18, 1870.

GRID
BLASTING FOR PARTS:

 

Grinding
is used to finish work pieces that must show high surface quality (e.g., low
surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is of the order of 0.000025 mm, in most applications it
tends to be a finishing operation and removes comparatively little metal, about
0.25 to 0.50 mm depth. However, there are some roughing applications in which
grinding removes high volumes of metal quite rapidly. Thus, grinding is a
diverse field.

 

A
grinding machine, often shortened to grinder, is any of various power tools or
machine tools used for grinding, which is a type of machining using an abrasive
wheel as the cutting tool. Each grain of abrasive on the wheel’s surface cuts a
small chip from the workpiece via shear deformation.

GRINDING
MACHINE:

Laser
cutting is a technology that uses a laser to cut materials, and is typically
used for industrial manufacturing applications, but is also starting to be used
by schools, small businesses, and hobbyists. Laser cutting works by directing
the output of a high-power laser most commonly through optics. The laser optics
and CNC (computer numerical control) are used to direct the material or the
laser beam generated. A typical commercial laser for cutting materials involved
a motion control system to follow a CNC or G-code of the pattern to be cut onto
the material. The focused laser beam is directed at the material, which then
either melts, burns, vaporizes away, or is blown away by a jet of gas, leaving
an edge with a high-quality surface finish. Industrial laser cutters are used
to cut flat-sheet material as well as structural and piping materials.

LASER
CUTTING MACHINE:

24.        
(manual
laser cutting machine)

The
basic plasma cutting process involves creating an electrical channel of
superheated, electrically ionized gas i.e. plasma from the plasma cutter itself,
through the work piece to be cut, thus forming a completed electric circuit
back to the plasma cutter via a grounding clamp. This is accomplished by a
compressed gas (oxygen, air, inert and others depending on material being cut)
which is blown through a focused nozzle at high speed toward the work piece. An
electrical arc is then formed within the gas, between an electrode near or
integrated into the gas nozzle and the work piece itself. The electrical arc
ionizes some of the gas, thereby creating an electrically conductive channel of
plasma. As electricity from the cutter torch travels down this plasma it
delivers sufficient heat to melt through the work piece. At the same time, much
of the high velocity plasma and compressed gas blow the hot molten metal away,
thereby separating i.e. cutting through the work piece.

flame
cutting is a method of cutting ferrous metals in which the metal is heated by a
torch to about 800°C and is oxidized by a stream of oxygen from the torch.

23.        
(flame-able
cutting machine)/gas cutting section cutting “capacity 10-60mm”

hydraulic bending press is a machine tool that
changes the shape of a workpiece by the application of pressure.

22.        
(hydraulic
bending press machines 4 for) 500 tons

21.        
(under
frame welding position)

20.        
(under
frame section)

FABRICATION
SECTION:

20ton,30ton,40ton

OVERHEAD CRANES:

 

 

 

Punch
presses are large machines with either a ‘C’ type frame, or a ‘portal’ (bridge)
type frame. The C type has the hydraulic ram at the top foremost part, whereas
the portal frame is much akin to a complete circle with the ram being centered
within the frame to stop frame deflection or distortion.

A
punch press is a type of machine press used to cut holes in material. It can be
small and manually operated and hold one simple die set, or be very large, CNC
operated, with a multi-station turret and hold a much larger and complex die
set.

PUNCH
PRESS MACHINE:

Since
any particular component might require the use of a number of different tools –
drills, saws, etc. – modern machines often combine multiple tools into a single
“cell”. In other installations, a number of different machines are
used with an external controller and human or robotic operators that move the
component from machine to machine. In either case, the series of steps needed
to produce any part is highly automated and produces a part that closely
matches the original CAD.

In
modern CNC systems, the design of a mechanical part and its manufacturing
program is highly automated. The part’s mechanical dimensions are defined using
computer-aided design (CAD) software, and then translated into manufacturing
directives by computer-aided manufacturing (CAM) software. The resulting
directives are transformed (by “post processor” software) into the
specific commands necessary for a particular machine to produce the component,
and then are loaded into the CNC machine.

 

Computer
numerical control (CNC) is the automation of machine tools by means of
computers executing pre-programmed sequences of machine control commands. This
is in contrast to machines that are manually controlled by hand wheels or
levers, or mechanically automated by cams alone.

C.N.C
MACHINE :

Band saws dedicated to industrial
metal-cutting use, such as for structural steel in fabrication shops and for
bar stock in machine shops, are available in vertical and horizontal designs.
Typical band speeds range from 40 feet (12 meters) per minute to 5,000 feet
(1,500 meters) per minute, although specialized band saws are built for
friction cutting of hard metals and run band speeds to 15,000 feet per minute.
Metal-cutting band saws are usually equipped with brushes or brush wheels to
prevent chips from becoming stuck in between the blade’s teeth. Systems which
cool the blade with cutting fluid are also common equipment on metal-cutting
band saws. The coolant washes away swarf and keeps the blade cool and
lubricated.

BaND
SAW MACHINE:

The machine may be foot powered, less commonly
hand powered, or mechanically or hydraulically powered. It works by first
clamping the material with a ram. A moving blade then comes down across a fixed
blade to shear the material. For larger shears the moving blade may be set on
an angle or “rocked” in order to shear the material progressively
from one side to the other; this angle is referred to as the shear angle.
Setting the blade on an angle decreases the amount of force required, but
increases the stroke. A 5 degree shear angle decreases the force by about 20%.
The amount of energy used is still the same. The moving blade may also be
inclined 0.5 to 2.5°, called the rake angle, to keep the material from becoming
wedged between the blades. However, raking the blade compromises the squareness
of the edge

Shearing
machine:

grid
blasting equipment typically consists of a chamber in which sand and air are
mixed. The mixture travels through a hand-held nozzle to direct the particles
toward the surface or work piece. Nozzles come in a variety of shapes, sizes,
and materials. Boron carbide is a popular material for nozzles because it
resists abrasive wear well.

grid blasting or bead blasting is a generic
term for the process of smoothing, shaping and cleaning a hard surface by
forcing solid particles across that surface at high speeds; the effect is
similar to that of using sandpaper, but provides a more even finish with no
problems at corners or crannies. grid blasting can occur naturally, usually as
a result of particles blown by wind causing aeolian erosion, or artificially,
using compressed air. An artificial grid blasting process was patented by
Benjamin Chew Tilghman on October 18, 1870.

GRID
BLASTING FOR PARTS:

 

Grinding
is used to finish work pieces that must show high surface quality (e.g., low
surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is of the order of 0.000025 mm, in most applications it
tends to be a finishing operation and removes comparatively little metal, about
0.25 to 0.50 mm depth. However, there are some roughing applications in which
grinding removes high volumes of metal quite rapidly. Thus, grinding is a
diverse field.

A
grinding machine, often shortened to grinder, is any of various power tools or
machine tools used for grinding, which is a type of machining using an abrasive
wheel as the cutting tool. Each grain of abrasive on the wheel’s surface cuts a
small chip from the work-piece via shear deformation.

GRINDING
MACHINE:

Laser cutting is a technology that uses a
laser to cut materials, and is typically used for industrial manufacturing
applications, but is also starting to be used by schools, small businesses, and
hobbyists. Laser cutting works by directing the output of a high-power laser
most commonly through optics. The laser optics and CNC (computer numerical
control) are used to direct the material or the laser beam generated. A typical
commercial laser for cutting materials involved a motion control system to
follow a CNC or G-code of the pattern to be cut onto the material. The focused
laser beam is directed at the material, which then either melts, burns,
vaporizes away, or is blown away by a jet of gas, leaving an edge with a
high-quality surface finish. Industrial laser cutters are used to cut
flat-sheet material as well as structural and piping materials.

LASER
CUTTING MACHINE:

The basic plasma
cutting process involves creating an electrical channel of superheated,
electrically ionized gas i.e. plasma from the plasma cutter itself, through the
work piece to be cut, thus forming a completed electric circuit back to the
plasma cutter via a grounding clamp. This is accomplished by a compressed gas
(oxygen, air, inert and others depending on material being cut) which is blown
through a focused nozzle at high speed toward the work piece. An electrical arc
is then formed within the gas, between an electrode near or integrated into the
gas nozzle and the work piece itself. The electrical arc ionizes some of the
gas, thereby creating an electrically conductive channel of plasma. As
electricity from the cutter torch travels down this plasma it delivers
sufficient heat to melt through the work piece. At the same time, much of the
high velocity plasma and compressed gas blow the hot molten metal away, thereby
separating i.e. cutting through the work piece.

flame
cutting is a method of cutting ferrous metals in which the metal is heated by a
torch to about 800°C and is oxidized by a stream of oxygen from the torch.

PLASMA
CUTTING MACHINE:

The hydraulic press depends on Pascal’s
principle-the pressure throughout a closed system is constant. One part of the
system is a piston acting as a pump, with a modest mechanical force acting on a
small cross-sectional area; the other part is a piston with a larger area which
generates a correspondingly large mechanical force. Only small-diameter tubing
(which more easily resists pressure) is needed if the pump is separated from
the press cylinder

hydraulic bending press is a machine tool that
changes the shape of a work piece by the application of pressure. its power is
500 tons and capacity of banding is 10-60mm sheet. when a work piece is
required t bend then machine operate insert work piece into the machine and
hydraulic force applied on it for bending. there are lots of angle have in this
machine for bending.

HYDRAULIC
PRESS MACHINES:

Mobile
Tailstock allows you to adjust from very short to very long weldments(unit
formed by welding together an assembly of pieces) and clear the shop floor when
using only the headstock. 2 Post machines with Fixed, Adjustable or Mobile tailstocks;
from 8000 to 75,000 LB capacity. Single Post Postioners, 2 or 3 axis. Elevating
and Non-Elevating Positioners are available, with or without horizontal travel.

This
machine Lift wide work pieces up to a height of 144″ in 35 seconds, rotate and
lower to the most auspicious elevation/position for flat welding or assembly. appropriate
positioning for maximum welded quality and discharge rates. Reduced Handling
Time compared to turning with a crane = huge cost savings Increased throughout
in less time. Adjustable tailstock helps you for smooth and efficient
horizontal movement to entertain
shifting work piece lengths.

      The ability to lift-and-rotate huge
components with welding Positioners for Welding and Assembly will crucially
increase your manufacturing strength and profits.

UNDER
FRAME POSITIONER:

      a locomotive frame is the structure that
forms the backbone of the railway locomotive, giving it strength and supporting
the superstructure elements such as a cab, boiler or bodywork. the vast
majority of locomotives have had a frame structure of some kind. the frame may
in turn be supported by axles directly attached to it, or it may be mounted on
bogies, or a combination of the two. the bogies in turn will have frames of
their own. Under frame welding positioner is the main machine of Under fame
section, on this machine, they easily joint all the parts with welding process.

      in this section, railways under frames are
manufactured. under frame are defined below.

UNDER
FRAME SECTION:

19.        
layout
marking machine

18.        
marking
surface plate

17.        
painting
section

16.        
grid
blasting for whole bogie

15.        
annealing
furnace “heat process”

14.        
Gear
cases “train part”

13.        
bogie
section “jis k ooper engine rakha jata hai” : train part

12.        
punch
press machine

11.        
C.N.C

10.        
bend
saw machine

9. grid blasting machine 2 types S M

8. shearing machine for 5-6mm sheet cutting

7. grid blasting for parts

6. grinding machine

5. (manual laser cutting machine)

4. (flame-able cutting machine)/gas cutting
section cutting “capacity 10-60mm”

3. (hydraulic press machines 4 for bending) 500
tons

2. (under frame welding position)

1. (under frame section)

fabrication section is the main section of Pakistan
locomotive factory. it is held in main workshop of factory. lots  of work done in fabrication section like
cutting , welding and grid blasting etc which is listed below.

FABRICATION SETION:

Carrying capacity of a hopper wagon is 70 ton.
it has 4 doors two doors on both sides for unloading. doors are totally automatic
with compressor system. it can also be operated by manually. they designed on
hopper style for easy unloading.

Hopper wagon is basically a
vehicle type which is use to carrying and traveling the coal from mines to coal
factory. it also use for coal distribution. they convert old passenger bogies
into hopper wagon by putting mechanical works on it like cutting, welding and
molding processes etc .they also doing maintenance for old locomotives.

Recently Pakistan Locomotive
Factory has been completed a project of 110 hopper wagons which is converted
for old passenger bogies to hopper wagon. and handed over to Pakistan railway
in this project they get old bogies from Pakistan railway and convert them to
hopper wagons.

All projects history define that
Pakistan locomotive factory mostly import their parts from China & German
or we can say that China & German is the partner in business of locomotive
with Pakistan Locomotive Factory.

ü 5 diesel electric locomotives of
3000 horse power (import from china) manufactured from 2014-15.

ü 44 diesel electric locomotive
3000 horse power (import from China) were also manufactured during 2003-08.

ü 25 diesel electric locomotive of
2000 horse power (import from China) were manufactured from 2003-08.

ü 21 diesel electric locomotive of
2000-2400 horse power (import from German) were rehabilitated during 2001-03.

ü 30 diesel electric locomotive of
3000 horse power (import from German) were manufactured during 1999-2001.

ü 5 diesel electric locomotive of
2000 horse Power (import from German) were rehabilitated from 1997-98.

ü Total 23 diesel electric
locomotive (2000 Horse Power import Hitachi) were manufactured from 1993-97.

Projects:

Pakistan
Locomotive Factory first commissioned on Jan 1993. Very first locomotive “which
were rolled out from factory” on 2nd December 1993. 102 locomotives
manufactured in Pakistan locomotive factory from 1993-2007. After that no more
ne locomotive were made in factory and rehabilitation work started for Pakistan
railway. total 26 locomotives were rehabilitated in factory from 2008-08. 478
no of employees against sanction strength of 1530 as per PC-1. 1422 millions foreign
exchange saved by the factory since commissioned.

Pakistan
Locomotive Factory’s production capacity is 25 locomotive per year on single
Shift Basis. They can increase the production capacity by starting double
shift. 1500 workers are doing their jobs in one shift then factory able to
complete production capacity of locomotives which is 25 locomotive per year.

Total
Area Of factory is 257 Acres in which Factory area is 100 Acres and colony area
is 157 Acres. And covered area is 11 Acres.

Total
cost of Pakistan Locomotive Factory was 2284 Millions in which the Foreign exchange
amount was1496 Millions and local funds amount was 788 Millions.

      Pakistan Locomotive Factory, is a
manufacturer of locomotives for Pakistan Railways, located in Risalpur, Khyber
Pakhtunkhwa, Pakistan. The company was established in 1993. A total of 2130
coaches have been manufactured at Carriage Factory Islamabad since 1971. The
factory has also rehabilitated (overhauled) 1039 coaches up to 30 June 2015.

Introduction: