VOCATIONAL TRAINING REPORT

At

SML ISUZU LIMITED

Submitted in partial fulfillment of the requirements for the award of
the
Degree of

Bachelor of Engineering

in
MECHANICAL ENGINEERING

Submitted to: Submitted By:

Dr. Jatinder Madan (HOD, ME) Sagar Virk
& CO15143
Er.V.Senthil (Training In-charge) FOURTH year

Department of Mechanical Engineering

Chandigarh College of Engineering and Technology (Degree Wing), Chandigarh
August, 2018
(Affiliated to Panjab University, Chandigarh)
 i

DECLARATION

I hereby declare that the work, which has been presented in this Training Report, in partial
fulfillment of the requirements for the awards of degree of Bachelor of Engineering in Mechanical
Engineering submitted to the Mechanical Engineering Department, CCET, Chandigarh, is
an authentic piece of work carried out from 11/06/2018 to 11/07/2018, under the supervision
of Mr. Bikramjeet Singh (Technology Deptt.) at SML ISUZU LTD.

The matter in this Training Report is not submitted by me for the award of any degree elsewhere.

Sagar Virk
CO15143
This is to certify that the statements made by the candidate are
correct to the best of my knowledge and belief.

Bikramjeet Singh
(TECHNOLOGY)
SML ISUZU

Er.V.Senthil Dr. Jatinder Madan

(Training In-charge) (HOD, ME)
 ii

ACKNOWLEDGEMENT

I would like to put forth my regardful thanks to all those who had helped me in guiding me
to get the most out of this golden opportunity to learn the most during such a period of my
training at SML ISUZU LIMITED.

I pay my special thanks to Mr. C.M. Sharma (Technology), Mr. Bikramjeet Singh
(Technology), Mr. Charanjeet Singh (Technology) and whole team of Sml Isuzu limited who
helped me in carrying out my training in the Technology Department. Apart from the technical
knowledge I also got a real feel of working in a corporate office. I would like to acknowledge
Sml team and the engineers for their unconstrained support for our industrial practical training in
the field of engineering. This training has helped me to learn operations of technology. So I look
forward for giving my support to any project initiated by the company.

I also put forth my special thanks to all the concerned persons as well as Dr. Jatinder
Madan, (HOD, Mechanical), Er.V.Senthil (Training In-charge, Mechanical) and Dr.
Manpreet Singh, Principal C.C.E.T. (Degree Wing), Chandigarh, Ms. Sakshi Sharma (HR
Deptt.) SML ISUZU Ltd. who have enabled me to have an opportunity to work at the prestigious
organization.

Thankful,

Sagar Virk
Figure 1 ..................................................................................................................................... 1
Figure 2 ..................................................................................................................................... 2
Figure 3
Figure 4 ..................................................................................................................................... 5
Figure 5 ..................................................................................................................................... 6
Figure 6 ................................................................................................................................... 10
Figure 7 ................................................................................................................................... 12
HIGH DECK .......................................................................................................................... 13
LOW DECK ........................................................................................................................... 13
CANOY 1 ................................................................................................................................ 13
Figure 8 ................................................................................................................................... 14
Figure 9 ................................................................................................................................... 15
Figure 10 ................................................................................................................................. 16
Figure 11 ................................................................................................................................. 16
Figure 12 ................................................................................................................................. 17
Figure 13 ................................................................................................................................. 19
Figure 14 ................................................................................................................................. 21
Figure 15 ................................................................................................................................. 22
DIFFRENT TYPES OF CABINS......................................................................................... 23
Figure 16 ................................................................................................................................. 27
Figure 17 ................................................................................................................................. 30
DIFFRENTIAL EXPLODED VIEW 1................................................................................ 31
Figure 18 ................................................................................................................................. 32
Figure 19 ................................................................................................................................. 32
Figure 20 ................................................................................................................................. 33
Figure 21 ................................................................................................................................. 36
Figure 22 ................................................................................................................................. 43
Figure 23 ................................................................................................................................. 44
Figure 24 ................................................................................................................................. 45
Figure 25 ................................................................................................................................. 45
DRAWING TOP COVER ..................................................................................................... 47
DRAWING TOP COVER BIN............................................................................................. 48
DRAWING REAR COVER.................................................................................................. 50
DRAWING REAR COVER BIN ......................................................................................... 51
CAR SUSPENSION ............................................................................................................... 53
COIL SPRING ....................................................................................................................... 54
LEAF SPRING ....................................................................................................................... 54
DAMPERS .............................................................................................................................. 55
AIR SUSPENSION ................................................................................................................ 55
BELLOW ................................................................................................................................ 56
AIR TANK .............................................................................................................................. 57
DRYING AND DISTRIBUTION UNIT .............................................................................. 57
SUPPLY LINES ..................................................................................................................... 57
Position of the leveling valve ................................................................................................. 58
DAMPERS ASSEMBLED ON THE REAR AXLE ........................................................... 58

iii
TABLE OF CONTENTS

S NO. PARTICULARS PAGE NO.

1 Declaration i
2 Acknowledgement ii
3 List of figures iii
2 Sml Isuzu 1-4
3 Evolving Journey of Sml Isuzu 5-7
4 5S Activity in Sml Isuzu limited 8
5 Various Departments of Sml 8
6 Flow
IsuzuDiagram of The Plant 9
7 Sml isuzu ltd Shop Classification 10
8 Body Shop 10-16
9 Paint Shop 17-20
10 Assembly Shop 22-34
11 Engine testing 35-40
12 Quality Engineering Department 40-41
13 Metrology Lab: Metrology 41-42
14 Chemical Composition 42
15 Standard Room 43-45
16 PROJECT 1 46-48
17 PROJECT 2 49-51
18 PROJECT 3 52-59
SML ISUZU LIMITED1

Sml Isuzu limited was promoted in 5th October 1984 in technical and financial
collaboration with Punjab tractors limited, Mazda motors corporation and Sumitomo motors
corporation, Japan, for manufacturing of light commercial vehicles (LCV’s). Sml isuzu limited
represents two powerful brands: SML- symbolizing best Indian technology and engineering
and ISUZU- an international player. Mazda Motors Corporation of Japan, established in 1920,
is an enterprise of international repute. Mazda started manufacturing trucks as back in1931.
Today this enterprise has the distinction in being the only company in the world producing
petrol and diesel engine as well as the revolutionary rotary engines. Isuzu is ever seeing the
new areas of product excellence and innovation. It adheres audaciously to 2000 check point
before declaring any vehicle road worthy. The use of robots, latest technology and world class
production enables Isuzu to produce vehicles of outstanding quality and performance. No
wonder Sml isuzu limited has won appreciations all over the world for the quality products that
are rolling out its plant.
The assembly unit of Sml isuzu limited is located at village Asron district Nawanshahar
(Punjab) near the city of Ropar and at a distance of 40kms from the capital city of Chandigarh
the plant has a captivating site. It is spread over a quaint, sprawling 100 acres of land ringed
by shiwalik hills on the three of its sides and river Satluj on the other.

Figure 1

1
About ISUZU

Isuzu Motors Ltd. is a Japanese car, commercial vehicle and heavy truck
manufacturing company, headquartered in Tokyo. In 2005, Isuzu became the world's largest
manufacturer of medium to heavy duty trucks. It has assembly and manufacturing plants in
the Japanese city of Fujisawa, as well as in the prefectures Tochigi and Hokkaido. Isuzu is
famous for producing commercial vehicles and Diesel engines. By 2009, Isuzu had produced
over 21 million diesel engines, which can be found in vehicles all over the world Isuzu diesel
engines are used by Renault, Opel and General Motors.

In most of Asia, Africa and Europe, Isuzu is mostly known for trucks of all sizes, after Isuzu
small automobile sales drastically plummeted and Isuzu had to drop all sales of sedans and
compact cars in the late
1990s. In 2009, Isuzu
abandoned the United
States consumer market
due to lack of sales Isuzu
has a contract with Budget
Truck Rental to
manufacture their rental
trucks. This contract is
also shared with Ford,
GMC, and Navistar.
Figure 2

On November 7, 2006, TOYOTA acquired 5.9% of Isuzu, making them the third largest
shareholder behind ITOCHU and MITSUBISHI CORPORATION.

Discipline and its right enforcement is an important hallmark of the Sml Isuzu. It is a great
significance in evolving work culture. All the employees, irrespective of their position or
status, have to punch their position or status, when they report for duty. As a result, strict
punctuality has become a way of life and work with them.

2
To ensure industrial peace i.e. absence of the strikes and lockouts, Sml isuzu limited believes
in creating a contented labour force with a very low rate of absenteeism and turn over.
Reasonably fair wages and various perks like subsidized uniform and transport, mess
facilities go a long way in creating identification with the job. Earnestness, sincerity and spirit
of co-operation pervade the entire atmosphere of the company.
No politics of confrontation is found in Sml Isuzu. Problems if any are sorted out through
mutual negotiations in an amiable atmosphere of give and take. These positive steps have
been instrumental in evolving work ethos. The happy absence of industrial disputes in the
enterprise speaks volumes for the success of these and cultivation of work culture. Work
culture of work ethos is given high priority. It is fully recognized that the objective of the
enterprise – higher and higher production, productivity and indigenization can be attainted
through commitment in to commonness of goal in each and every member of Sml isuzu
family. The entire planning is undertaken in such a way as to inculcate the spirit of dedication
in each member whether he is a semi-skilled worker or belongs to the managerial cadre.
Many effective steps are taken to bring this about and important among them are:
• Common canteen and mess for all. Same meals are served to all and in identical
utensils. Everybody has to stand in a queue to get his or her meals.
• Common uniform is there for all new members irrespective of their status.
• No separate cabins for the members of a higher hierarchy. All the members of a
department or a section there of sit and work in one hall with the manager.
The LCV’s are manufactured in five colors- Santos red, Nile blue, Light Beige, White and
Golden Yellow. In addition to this other color can be made on demand. The most distinguish
feature of these vehicle is that beneath the design and sleek looks are the study box section
tubular crossed braced chassis. The chassis are more than three times stronger than another
vehicle on the road. Sml isuzu vehicles are not only stronger on the road but also fuel
efficient. Fully loaded they give an average of 13.5 Km/l at 45 Km/hr. A hydraulic
assisted diaphragm reduces the clutch pressure by 37 percent. A low RPM high torque engine
assures long life and hanging speed for uphill driving. A spacious three-seater cab with three
level air vents make the cab extremely comfortable and driving a treat
Prominent among the load carriers Sml isuzu limited is also manufacturing:
• 4-wheel drives;
• Extended wheel base long chassis mini buses which carry up to 44 passengers.
• Deluxe buses carry up to 40 passengers.

3
 • Ambulance developed with active involvement of senior specialist from post graduate
institute of medical science and research, Chandigarh.
• Hydraulic operated dumpers.
• Dual cabin load carriers.
• Integrated garbage collection and disposal system for urban centers.
Sml isuzu limited vehicles population today stands over 70,000. Sml isuzu limited gives due
attention to the marketing part and the employees are highly qualified and trained to fit the
job. Sml isuzu limited has a vast network of over 128 dealers spread throughout the country
including the A & N Island. Zonal office opened in Chandigarh, Lucknow, Calcutta,
Ahmedabad, Mumbai, and Chennai. This helps substantially in sales promotion, especially
for hi-tech products, is also being emphasized. Discipline and rigid enforcement without
discrimination are important hallmark of Sml Isuzu. It is of great significance in involving
work culture. All the employees, irrespective of their position and status, have to punch their
cards when they report for duty; as a result, strict punctuality has become a way of life and
work with them. To insure industrial peace, i.e. absence of strike and lockouts Sml isuzu
limited believes in making a contended labor force with a very slow rate of absenteeism.
Reasonably fair wages and various perks like subsidized uniform and transport, mess
facilities go a long way in creating identification with the job the entire planning is
undertaking in such a way so as to inculcate the spirit of dedication in each member, whether
he is a skilled or semi-skilled worker or belongs to the managerial cadre. The corporate
profile of SML ISUZU LTD. projects a bright future for the company. It is adding its share to
the real assets and job opportunities in the areas thus bringing socio-economic reforms in
whole of Punjab.

4
Evolving Journey of Sml Isuzu limited

1983: SML vehicles limited (SVL) in corporate in July.

1984: joint venture and technical assistance concluded between Punjab tractors limited, Isuzu
motors corporation and Sumito corporation Japan.
1985: Project set up with the capacity of 5,000 LCV’s at a capital outlay of 200 million.
1985: Trail production and test marketing of SML truck WT-48 WT- 49 WT-50 LCV’s
commenced.
1986: commercial operation started.
1988: Introduction of indigenously developed bus.
1989: In-house tooling of local production of chassis long member.
1990: In-house developed second truck model (SWARAJ MAZDA Super) launched.
1991: Transmission components indigenized.
1992: Components of trucks supplied to ministry of defense (MOD). 500 vehicles supplied to
defense.
1993: Third truck model (SWARAJ MAZDA PREMIUM) launched.
1994: Declared a sick company under SICA (due to rupee devaluation of 1991-93)
1995: BIFR approves rehabilitation.

.
Figure 3 Figure 4

5
1996: 4- wheel truck developed
1997: Company ceases to be a sick industrial company on the basis of positive net worth. 4-
years of BIFR scheme projection.
1998: complete wipe of accumulated losses.
1999: Bharat Stage-1 emission norms compiled.
2000: Maiden dividend declared @ 10% technical assistance agreement with Isuzu extended
up to October 2004.
2000: Cumulative sales crosses 50.000 vehicles, 4- wheel drives ambulance launched in March,
economy truck “SARTAJ” launched in August, and CNG bus for NCR Delhi launched in
October, and Bharat Stage 2 emission norms compiled.
2002: Profit before tax for FY-2002 crosses Rs100 million and dividend raised to 25%.
2003: Cumulative vehicles sales reached 68,000, profit before tax for
FY-2003 grows 115% to Rs 225 million, dividend enhanced to 45%.

Figure 5

6
 ORGANIZATIONAL SET UP OF SML ISUZU LIMITED

MANAGING DIRECTOR

EXECUTIVE DIRECTOR

VICE PRESIDENT ASSOCIATIVE VICE

PRESIDENT

GENERAL MANAGER DEPUTY GENERAL

MANAGER

SENIOR MANAGER CHIEF MANAGER MANAGER

ASST MANAGER

ENGINEER SENIOR ENGINEER ASST ENGINEER

JUNIOR ENGINEER

7
5S Activity in Sml Isuzu limited

In order to achieve the goals set up by the concerns effectively and efficiently the organization
follows the 5S activity that is:
• SIEIRI: Classify the things into necessary ones and unnecessary ones. Discard the
unnecessary ones.
• SEITION: Put the things in order so that they are available when needed.
• SEISO: Keep the work area and the machine /tool clean so that abnormal conditions
are detected.
• SEIKETSU: keep the work area clean as well as the personal cleanliness. The
conditions of the company should be hygienic.
• SHITSUKE: There should be all around discipline. The workers should be taught to
work in a disciplined manner.

The result of all this has been rapid increase in output of vehicles and sharp reduction in cash
loses. The turn over for 2007-2008 exceeds Rs. 300 crores. Today the company manufactures
light commercial vehicles like trucks, buses, police vans, water tankers, ambulance, and special
vehicles and also exports to the countries like Nepal, Zambia, Bangladesh, Kenya, Sri-Lanka
and Jordan.

Various Departments of Sml isuzu Limited

1. Personnel Department
2. Research and Development
3. Quality Engineering Department
4. Technology Department
5. Accounts Department
6. Purchase Department
7. Maintenance Department

8
SML ISUZU LIMTIED SHOP CLASSIFICATION

Flow Diagram of the Sml Isuzu Plant

ENGINE BODY CABIN CABIN & CARGO

ASSEMBLY SHOP WELDIN ASSY & PAINTING

CABIN PRE
ENGINE LONG MEMBER PARTS FROM TREATMENT CARGO BOX
COMPONENTS FROM STORAGE STORE & BLACK FROM STORE
WASHING MACHINE DIPPING

TEMPORARY PART FLOOR BAKING CARGO BOX

ENGINE ASSEMBLY SETTING ASSEMBLY. ASSEMBLY
AND TESTING

SEALANT SLEEPER
TACK/FULL CABIN AND PRIMER ASSEMBLY
WELDING ASSEMBLY APPLICATION
T/M
ASSY CARGO BOX
WELDING
STRAIN RELIEVING DOOR WELDING BAKING
& ASSEMBLY

TRANSMISSION
COMPONENTS FROM CHASSIS PAINTING FINAL CARGO
WASHING MACHINE FINAL FITTING PAINTING WASHING
AND FINISHING SEALANT
APPLICATION

TRANSMISSION BAKING
ASSEMBLY AND BAKING
TESTING TO PAINT SHOP
VEHICLE
ASSEMBLY
INSPECTION
LINE FINAL
PAINTING

PAINTED
FRONT/REAR AXLE & PRE DELIVERY CABIN TO
DIFFERENTIAL ASSY. INSPECTION VECH. ASSY.
BAKING

ROAD/SHOWER
TEST CABIN
AXLE COMPONENTS DRESSING INSPECTION
FROM WASHING WITH SUB
MACHINE ASSEMBLY
CARGO BOX
MOUNTING

AXLE
ASSY LINE RUST PREVENTIVE
APPLICATION

VEHICLE TO
STOCK YARD

9
BODY SHOP

The Body shop consists of three lines

Frame line
Cargo line
Cabin line

FRAME LINE

Figure 6

In frame assembly line, six different chassis frames are assembled. These are WT 48, WT 49,
WT 50, WT50L and WV26, ELWB. The assembly of these 6 different chassis is completed
through 5 different stations which are as follows:

10
TEMPORARY ASSEMBLY STATION
At this station all cross members are fitted to the side members placing these on the special
type of jig. Then the temporary assembly is taken to the next station which is known a Tack
Welding Station. The temporary assembly is also known as Side Member and Cross Member
Assembly Jig.

TACK WELDING STATION

At this station other components like brackets, hangers for load springs etc are positioned on
this temporary assembly. At this station small tacks are made to temporary mount the various
components like bracket, hangers for load spring etc. Then this tack welded assembly is taken
to the next station where full welding of the frame assembly is done. This station is known as
Full Welding Station.

FULL WELDING STATION

At this station full welding is carried out with the help of MIG welding.

STRAIN RELIEVING STATION

A special type of fixture is there in the strain relieving station .The fixture has clamping
arrangement along with hydraulic and mechanical operated jacks fitted on it. The purpose of
the jack is to relieve the assembly of the strain developed during welding. The distortion caused
by welding is detected by a scale fitted on the hydraulic jig. Then this distortion is corrected
by applying described pressure through the hydraulic jacks.

BLACK PAINTING STATION

At this station the complete frame assembly is cleaned by pressurized air and then black paint
is sprayed in the paint booth. From this station the frame is taken to the vehicle assembly shop
sometime by the trolleys and sometime by the fock lifters.At this station finishing of frame is
done like grinding, MIG welding and paint touch up etc and location of components are
checked with the help of gauges.

11
 CARGO LINE

Figure 7

The SML ISUZU LIMTIED has four types of cargo that are assembled and mounted on the
truck: -

1) HIGH DECK
2) SEMI DECK
3) DROP SIDE
4) FIXED SIDE

12
HIGH DECK

LOW DECK

CANOY 1

13
 CABIN LINE

Figure 8

The cabin is assembled through five different stations. These are as follows:

FLOOR ASSEMBLY JIG

Floor assembly has two different jigs. The first jig has pneumatic clamps, where as the second
jig is a rotating jig. The parts which are resistance spot welded are firstly clamped on the
pneumatic clamps. These parts are cross member No-1, filler plate lamp housing, cross member
No -2, bracket master, cylinder gusset plate, wheel apron, side members, floor pan assembly.
Some parts are coated with a zinc rich primer before being spot welded; those parts are Wheel
Apron, Gusset Plate etc. On the first floor jig some area remains inaccessible so the floor is
taken to rotating jig for spot welding.

SIDE MEMBER ASSEMBLY JIG

Two different jigs are used to assemble the L.H.S. and R.H.S. frames. The other parts which
are assembled are Pillar A- Out, Pillar B-Out, Pillar B-in, and Hinges and Stiffeners etc.

CABIN ASSEMBLY JIG NO-1

The side frames are welded to the floor assembly. The front panel, cross member front and
header are spot welded at this station. The assembly of cabin is done on two jigs. The first one
has its poles operated hydraulically whereas clamps are pneumatic. All above stated parts are
assembled on jig.

14
CABIN ASSEMBLING JIG NO-2
In this jig roof is being welded and remaining spots of front panel etc are also welded. Then
assembly is taken to other jig which is approximately 2m above the ground level to enable spot
welding of side frames with the floor assembly from the bottom to make the cabin water proof.
Rubber Sealant is applied to the bottom floor assembly.

Figure 9

CABIN FINISHING STATION

From cabin assembly station cabin is taken to this station by Fitting on the trolley. At this
station punches caused by spot welding are repaired by brazing. Doors are also fixed to the
cabin at this station. Before the cabin is taken to the paint shop, cabin number is punched to the
cabin. Minimum weld penetration required is 20 percent of the sheet thickness. The cabin for
WT48 & WT49 is same where as it is different for WT50.

15
TYPES OF WELDING OPERATIONS IN BODY SHOP:
Two types of welding operations are used in body shop these are:

GAS METAL ARC WELDING:

MIG is an arc welding process in which heat for welding is generated by an arc between a
consumable electrode and work metal. The electrode of M.S. Copper coated wire having
diameter 1.2 mm is continuously fed to the weld area by means of a D.C. Motor at speed of 9-
12 m/min. This speed of feeding

Figure 10

RESISTANCE SPOT WELDING:

Resistance spot welding is a process in which surfaces are joined by the heat generation by
resistance to the floor of electric current through work piece that are held together under force
by electrodes.

Figure 11

16
 PAINT SHOP

In the paint shop painting and other surface treatment process are carried out on cabin
assemblies and cargo boxes.
This shop is again divided into two stations, which are:
Pretreatment Line
Paint line

PRETREATMENT LINE

Figure 12

The pre treatment processes are carried out in the following sequence :
1) Kerosene cleaning.
2) Degreasing.
3) Rinsing.
4) Derusting.
5) Surface conditioning.
6) Phosphating.
7) Rinsing.
8) Passivation.
9) Black dipping.
In paint shop cabin and cargo boxes are painted before these are sent to the vehicle assembly
shop. The painting of cabin is done after being pretreated. So we can divide the total paint shop
in the two lines. These are Pre-treatment Line and Paint Line.
Sheet metal painting is required to improve life and static appearance.

17
PRE-TREATMENT LINE
Pre- treatment line is having series of different operations. The detail of these operations is as
follows:
DEGREASING
• Chemical used in degreasing is caustic solution of nipaklin 22-25
• The chemical in the tank is maintained at a temperature of 55 +5 oC
• The dipping time for cabin in Degreasing Tank is 3-5 minutes.
• The purpose of the degreasing is to remove dust and grease.
SIMPLE WATER TANK (WATER RINSING)
After dipping in degreasing tank, the cabin is dipped in a simple water tank for Water Rinsing.
This operation is used to clean the chemical which is used in the Degreasing Process.

DERUSTING TANK
• The chemical used in the tank contains 30 % Phosphoric Acid Solution
• This operation is done to remove the light rust.
• Dipping time for cabin in Derusting Tank is 3-5 minutes.

Surface CONDITIONER
Chemical used in surface conditioner is Detonium Salt .The dipping time cabins 25 seconds.
The process is to prepare cabin for phosphating.

PHOSPHATE TANK (PHOSPHATING)

After surface conditioning operation, cabin is taken to phosphate Tank. The chemical used in
this Tank is Zinc phosphate. The chemical in the tank is maintained at a temperature of 45 +
5oC. The dipping time in the tank is 3-5 minutes.

PASSIVATION
The chemical used for passivation operation is chromic acid solution. This operation is done to
increase corrosion resistance of phosphate coating.

18
DM WATER RINSING
After passivation no, other chemical operation required. So, DM Water rinsing is done.
Demineralized Water is used for DM Water Rising. This operation is used to achieve acid
neutralization. The cabin is dipped 2 or 3 times. Water is maintained at room temperature.

BLACK DIPPING

Figure 13

Black dipping of the cabin is done to increase the strength of the part of the cabin to increase
the strength of the floor, only floor is black dipped in water soluble black paint which is
chemical resistant. The paint is maintained at a temperature of 30oc.

BAKING
After black dipping, the cabin is placed on the trolley and pushed inside the oven where the
temperature is maintained at 160°C. After placing cabin for 30 minutes in the oven, it is taken
out of the oven and sends for next operation.

19
 PAINT LINE

The Pre-treated Cabin is firstly coated with Thermosetting Primer surface spray, then sent for
paint coating whereas cargo boxes are directly sent for paint cooling after some operations of
cleaning and rubber sealing etc. The various operations in paint line are as follows:

COATING OF SOUND DEADNER

Sound deadener is a rubber compound. Sound deadener layer is coated over the wheel
curvature of cabin and also at the lower side of mudguard. Sound deadener destroys the sound
created by stone hitting the mudguard and prevents it from being transmitted to the inside of
the cabin. Sound deadener is applied in the booth between the pre- treatment line and paint
line.

CLEANING
Cabin is cleaned by using sand papers of different numbers and then using often cloth pieces
to remove dust particle from the cabin surface. The operation is done, for proper adhesion of
primer on the cabin surface.

PRIMER COATING
After cleaning operation cabin is then taken to paint booth. In the paint booth thermosetting
primer surface spray is sprayed on the surface of the cabin. In paint shop all paint booths are
given filtered air that flows from roof to the floor with pressure which grinds the overspray
paint particles to flow with the running water. Sufficient air pressure is given within the booth
so that painters feel comfortable during painting.

FLASH OFF
After painting operation cabin is kept for 5-10 minutes in another booth to enable the primer
to settle down to some extent. After 5-10 minutes it is wheeled inside the oven and exposed to
oven temp.

20
BAKING
Cabin is placed inside the oven which is maintained at a temp of 140 * C for 30 minutes so that
Primer gets adhere properly to the surface of the cabin, Sealant is applied at all joints of the
cabin to make the cabin water proof. After sealant operation cabin is wheeled inside the oven
to allow the sealant to get hardened due to Baking.

CLEANING
Before painting operation, cabin is cleaned in order to remove a possible impurity on the primer
coated surface of the cabin. This makes the surface ready for proper adhesion of the paint on
the cabin surface.

PAINT COAT
After cleaning operation, cabin is taken inside the paint booth. The paint booth has the capacity
of storing the cabin at a time. Top coat paint is sprayed on the cabin surface. This top coat has
high glass, high weather durability and high chemical resistance.

FLASH OFF
After painting operation cabin is kept for 5-10 minutes to another booth to enable the paint to
settle down to some extent. After 5-10 minutes it is wheeled inside the oven and exposed to
oven temperature.

BAKING
Cabin is placed inside the oven which is maintained at a temp. of 140oc fro 30 minutes. So that
the paint gets adhere properly to the surface of the cabin. The paint coat sequence for the cargo
box is same as the above cabin.

Figure 14

21
 ASSEMBLY SHOP
The assembly shop consists of:
• CABIN ASSEMBLY LINE
• AXLE SHOP
• ENGINE & TRASMISSION ASSEMBLY LINE
• MAIN LINE
• PIT INSPECTION
• CARGO BOX ASSEMBLY

CABIN ASSEMBLY LINE:

The different types of cabin assembled on the cabin assembly line are:-
1) CABIN SHELL W/O DOOR
2) CABIN SHELL WITH DOOR
3) CABIN SHELL DUAL CAB
4) CABIN SHELL 4WD TRUCK
5) COWL CABIN
6) SIMPLER COWL
7) FACELESS

Figure 15

22
FACELESS

DIFFRENT TYPES OF CABINS

23
In Cabin Assembly Line cabins received from the paint shop and various parts are assembled
to it. It has got five stations. The stations are designated as F-1, F-2, F-3, F-4, and F-5. This
line has got the manpower of 17. The different Stations are discussed as follows:-

F-1 Station
This station is further divided into three shops.
BRAKE ASSEMBLY SHOP
This is the first shop in station F-1. In this shop brakes are assembled. The main parts are as
follows: -

• Vacuum master: It is used in brakes to create vacuum. These are of two types:
• Big Vacuum Master-: It is large in size. It has 90mm dia. It has low power as compared
to the small Vacuum master.
Applications-: Big Vacuum Master is used in Sml Isuzu’s SARTAJ 26 and 48 models.
• Small Vacuum Master-: It is small in size as compared to Big Vacuum Master. It is
used in models except 48 and 26.

CLUTCH ASSEMBLY SHOP

In Sml Isuzu’s LCV`s, Single disc or plate clutch is used. The main parts of the clutch which
are assembled in the clutch assembly shop are:
• Clutch Pedal
• Bracket with bush
• Hose lever assist BKT
• Clutch cylinder
• Electronic devices

HAND BRAKE ASSEMBLY SHOP

In this shop the hand brakes are assembled. They are also known as parking brakes, power
brakes. Main Parts of the Hand Brake are:
• Hand brake assembly
• Unit control clip and switches
• Wiper motor Sub. Assy. fitment

24
F-2 Station
This station is divided into two parts A and B.
Station F-2A
The following accessories are fitted to the cabin.
a. Water pipe
b. One air pipe / vent pipe / vent hole
c. Tool box
d. Jack lever clamp, Crank lever clamp, Seat locker.
e. Roof sealing.

PROCEDURE
a. First of all water pipe is fitted in the inner side below the front glass.
b. Then one air pipe or vent pipe is fitted in left hand side vent hole. It is
c. Made up of plastic and is fitted for the continuous circulation of air in cabin.
d. After fitting vent pipe tool box is fitted with clamps at the rear side
e. Then the Jack lever clamp, crack lever clamp are fitted on inner back side and
f. Are used to hold Jack lever and lever.
g. Seat locker is fitted on inner back side and is used to hold the seats.
h. After lifting seat lockers, roof sealing is attached on the inner top of the cabin

Station F-2B
a. In this Station following attachments are fitted.
b. Vacuum Master
c. Acc. Assy
d. Clutch Assembly
e. Wiper motor sub assy and wiper linkage
f. Hand brake assy

PROCEDURE
a. In this shop first of all Vacuum master is fitted on right-hand side below the inner side of
front glass.
b. Then clutch assembly is fitted just left-hand side of Hand brake Assy.
c. After fitting clutch assembly, hand brake is fitted with Vacuum master.
25
d. Acc. Assembly: Accelerator is used to increase the speed of engine and is fitted at the
extreme right hand side. With this an acc. Switch is also fitted on support.
e. The wiper motor is fitted. It is used to give to and fro motion to the wipers with the help of
a rod known as wiper linkage rod. After fitting the attachment trolley is passed to next station.

STATION F-3
In this station instrument panel is fitted which contains a meter grill in which Speedo meter,
fuel meter, voltmeter and amp meter are attached.

STATION F-4
In this station the following attachments are fitted: -
a.) Washer Tank
b.) Change Lever
c.) Left hand side door trim
d.) Right hand side door trim
e.) Gear lever
f.) Ventilator Grill
g.) Room Mirror
h.) Crank Rod
i.) Room Lamp
j.) Clutch Switch
k.) Door Lock
l.) Key Lock
m.) Lock Fastener
o.) Steering Shaft

STATION F-5
In Station F-5 following attachments are fitted:
a. Foot Step
b. Rear glass fitment
c. Front glass fitment
d. Left hand glass fitment
After assembling all parts to cabin, it is sent to the station ISZ-55 of main line, where it is
attached with the cabin.
26
 AXLE SHOP
In axle shop front axle, differential and rear axles are assembled. There are two shops of rear
axles, two shops for front axles and two for differential. This shop also has a dip washing
machine to wash the parts before assembling them to remove any contamination of grease, oil
etc.

Front Axle shop

The main parts of front axle are as below:-
1) Axle beam
2) Knuckle
3) Steering Arm
4) Tie rod
5) King Pin
6) Sim cap
7) Shocker Bolt
8) Brake drums

Figure 16

27
FRONT AXLES

AXLE BEAM: It is made up of cast Iran and is fitted at the front side of chassis. Axle beam is
main part of the front Axle.
KNUCKLE JOINT: - It is joined with axle beam with the help of king pin. It has a hub like
shape. It is square in shape at the top and then it slopes or tapered down towards the end where
brake drums are mounted.
KING PIN: It is used to connect the knuckle with axle beam at both ends. It is made up of
Cast Steel.
ARM: It is also known as steering arm and is connected with the steering gear with the help of
drag link. It is also used to turn the vehicle. When we rotate the steering wheel, it in turn rotates
the steering gear with the help of steering shaft. When steering gear rotates it in turn rotates the
link which pushes the arm in backward or forward direction and thus turns the vehicle left or
right.
TIE ROD: It is used to connect the brake drums which are mounted on the both ends on the
axle beam for steering purposes and Toe in and Toe out purposes.
SHOCKER BOLT: It is used to connect the dampers with axle and chassis to give shock
resistance to the vehicle.
BRAKE DRUM: In the Brake drum assembly is mounted. On the brake drums tyres are
attached. In Sml isuzu limited. 90 mm dia and 110 mm dia size brake drums are used.

28
29
CONSTRUCTION: - Rear axle is made from sheet steal of 10 mm thickness by casting
process. It is made in two halves and then joined with the help of seam welding process. Rear
axle consists of a differential casing in which gears are attached.

DESCRIPTION: -Rear axle contains two brake drums, in which brake assembly is mounted.
On the brake drums tires are mounted. It may be mentioned here that the power is transmitted
from the engine to the rear axle with the help of propeller shafts. These shafts at one end are
attached with engine’s transmission and at another end, these are attached with differential.
From the rear axle shop the axles are passed to the leaf spring assembly line where according
to the model and load capacity leaf spring are attached to the axle.
When the engine starts up it rotate the crankshaft, which rotate the flywheel in turn flywheel
rotates the main shaft. From main shaft power is transmitted to differential with propeller shaft.
When the propeller shaft rotates it rotates a differential gear which in turn rotates the wheel.

Figure 17

30
Differential Assembly

DIFFRENTIAL EXPLODED VIEW 1

The differential is used in the rear drive of an automobile has following functions; to rotate the
rear wheels at different speeds while the automobile is taking a turn.

As long as the automobile is running on a straight path the rear wheels are driven directly by
the engine and speed of both the wheels is same. But when the automobile is taking a turn the
outer wheel will run faster than the inner wheel because at that time outer rear wheel has to
cover more distance than the rear inner wheel. This problem does not arise with front wheels
as they are greatly used for the steering purposes and are mounted on the separate axles and
can run at different speeds. This is achieved by the epicyclic gear train with bevel gears.

31
 Figure 18

ENGINE AND TRANSMISSION ASSEMBLY LINE

Figure 19

The Engine Assembly Line and Transmissions Assembly Line as it is clear from the name it
has two lines-Engine Assembly line and Transmission Assembly Line. The detail of each line
is given below:

32
Engine Assembly Line

Figure 20

It has six work stations which are as follows-

1. E-1 STATION
Crank caps are removed from the cylinder block. The cylinder block is placed on the engine
mounting fixture and also at this station engine No. is marked.

2. E-2 STATION
The parts those fitted are: oil filter, oil pump, timing gear cover in line fuel injection pump.
The sub – assembly that is done here are: timing gear case and oil cooler. Timing adjustment
is also done here.

3. E-3 STATION
The parts those fitted here are: cylinder Head, Water pump, Flywheel, Clutch Plate, Lower
and Upper Oil Pan.

4. E-4 STATION

33
At this station the parts like Fuel Pipes, Injection pipes, Rocker Arm and Fuel Filters are fitted
here.

5. E- 5 STATION
At this station the important assemblies include Inlet Manifold, Fan Alternator, Air Heater,
Pulley and Vacuum Pump. After the assembly of engine, it is sent to engine testing room on
trolley for testing before being sent to the line.

NUMBER PUNCHING ON CYLINDER BLOCK, REMOVE CAPS AND

MOUNT CYLINDER ON FIXTURE

ATTACHMENT OF CAM SHAFT METAL SET BEARING CRANK

SHAFT AND CYLINDER BLOCK CAPS

SUB ASSEMBLY OF
ATTACH PISTONSUB ASSEMBLY AND PISTON AND
SELECT CYLINDER HEAD GASKET CONNECTING ROD

MOUNT GEAR CASE, CAM GEAR, CRANK GEAR, FIP

GEAR AND GEAR COVER

ATTACH BODY ASSEMBLY WITH CYLINDER BLOCK

ATTACH CYLINDER HEAD S/A AND ROCKER ARM.

TIGHTEN CYLINDER HEAD A/S WITH CYLINDER BLOCK
AND ATTACH CYLINDER HEAD COVER AND
ALTERNATOR

SUB
ASSEMBL
REMOVE ENGINE FROM FIXTRE AND PUT ON TROLLEY Y
FOR TESTING. ATTACH EXHAUST MANIFOLD, OF
BREATHER PIPE ETC. CYLINDE
R HEAD
COVER
FILL ENGINE OIL PUT ENGINE ON HOT BED TESTING

MOVE ENGINE TO MAIN LINE FOR DOCKING

WITH TRANSMISSION 34
ENGINE TESTING:
1. Hot test: This is done at the highest and lowest rpm and the temperature of the water is
checked.
2. Lubrication test: in this test engine is tested for the oil consumption in the engine for
lubrication.
3. Vibration test: In the vibration of the engine is checked at idle (730 rpm) and full throttle
conditions (3830 rpm).
4. Acceleration test: This is done to check the reliability of the V belt.

Transmission Assembly Line

Transmission Assembly line also has six work stations. The detail of the parts, those are fitted
to complete the transmission assembly at different stations are given below.

1. T-1 STATION
At this station the counter shafts sub. assembly and main shaft sub assembly are done.
2. T-2& T-3 STATIONS
At these stations the sub-assemblies of T-1 station are assembled in the transmission case along
with gear main drive. Counter shaft and main shaft form a synchromesh gear system.
3. T-4 STATION
At this station transmission case is mounted on a jig which moves on a pneumatic conveyer.
Also assembly of rear cover, transmission mounting bracket and shifting fork is done.
4. T-5 STATION
At this station bearing and clutch housing are assembled. After this the transmission is
subjected to a leakage test the case is them dipped in the water tank to detect leakage from any
point.
5. T-6 STATION
At this station the assembly of brakes and brakes drum is done. Then it is taken for noise test.
After engine and transmission tests these are brought to the main line for further assembly
operations.

35
 Figure 21

MAIN ASSEMBLY LINE

As the name suggest it is the important line because in this line all the parts which comes from
different shops are mounted on chassis whether it is cabin or engine and other different parts
are mounted.
MAIN ASSEMBLY LINE
This line has 7 stations from ISZ-51 to ISZ-57 and a Pit Shop. The parts mounted on the chassis
are discussed station wise below:
ISZ-51 (SUB ASSEMBLY):
1) Front and rear Sub assembly of suspension
2) QRV sub assembly to rear suspension
3) Attach hose flexible to rear axle hose pipe
4) Mount brake pipe rear to rear axle

36
ISZ-51 (FRAME MOUNTING)
1) Suspension rear to frame
2) Suspension front to frame
3) Rubber stopper
4) Rubber sheet
5) Attach front and rear stabilizer bar
6) Attach ALSV, DDU and tight sensing valve/dryer and distribution unit
7) Attach arm of ALSV to brkt. QRV and tight.
8) ALSV angle setting(15-20deg)
9) Chassis number punching
10) Power steering pipes, holder and clamps
11) Power steering oil tanks and brkts.

ISZ-52
1) Attach stay intercooler
2) Attach stay radiator
3) Attach engine mtg. brkt. and T/m mtg. brkt.
4) Attach brkt. Cabin mtg.
5) Attach protector battery
6) Install holder brake hose and hoses
7) Attach 3 way joint hyd. brake
8) Attach clutch pipe, clip and protector brake pipe
9) Attach LSGV brkt. And valve, brake pipe
10 ) Attach and tight air brake pipe, hose and clip.

ISZ-53
1) Tight brake pipes
2) Docking of engine and transmission
3) Attach water hose up
4) Installation of starter assembly
5) Attach release cylinder and hose flexible
6) Attach pipe assembly fuel
7) Attach relay heater and wire fuel stop
37
 8) Enter engine and transmission number
9) Mount engine
10) Attach brkt. Intercooler
11) Attach brkt. Sub tank low
12)Sub assembly relay and starter harness
13) Install protector harness
14) Oil level recording
15) Attach brkt. Ignition coil and ignition coil.
16) Attach and tighten damper front and rear

ISZ-54
1) Attach radiator
2) Routing and mounting wiring harness rear to the engine
3) Attachment of fuel pipe assembly
4) Install battery carrier
5) Connect and tight clutch plate
6) Mounting of intercooler
7) Attach pipe assy. Air intake
8) Attach apron wheel
9) Fill coolant and water in the radiator
10) Power steering hose fitment
11) Attach reducer and its hoses

ISZ-55
1) Attach front flap and air cleaner brkt.
2) Attach front mtg.
3) Attachment and adjustment of accelerator cable, wire fuel stop, filling of water
4) Attach rubber low and mount cab rear
5) Install relay, starter, elec. Connections and clipping on t/m, battery +ve and –ve wire.
6) Attach model plate, fix fender screws
7) Attach stay cabin tilt, wedge sub assembly, anchor assembly
38
8) Attach rubber seal
9) Attach cabin tilt parts to the cabin
10) Attach brkt rear mtg. , rubber up and mtg. bolts
11) Check tilt cabin operation

ISZ-56
1) Attachment of horizontal air cleaner
2) Air intake hose fitment clip tight
3) Propeller shaft1/2/3 fitment yoke direction/ tight
4) Centre bearing support
5) Attach battery and battery cables
6) Attach connector short CNG
7) Nozzle spray adjustment
8) Sub assembly and mounting of electric horn and connections

ISZ-57
1) Sub assembly and attach front flap
2) Attach tyres
3) Attach stay front
4) Attach spare tyre
5) Attach grill lower
6) Fill fuel and cap filler
7) Attachment of face bumper and number plate
8) Attachment of bracket spare tyre carrier
9) Attachment of rear bumper
10) Check meter operation
11) Air bleeding (clutch, fuel and brake)
12) Air bleeding diesel
13) Power steering bleeding

FOR AIR BRAKE

1) Attach and tight compressor delivery pipe 3
2) Attach reservoir mtg brackets
3) Attach and tight air reservoirs
39
4) Connect transducer couplers
5) Attach DDU pipes and tight
6) Final tightening of all brake pipe joints
7) Air pressure building and rear spring actuator tightening

PIT INSPECTION
Operation of warning lights, functions of instrument panel and leveling of engine oil, coolant,
transmission oil and differential oil etc. are checked. Toe in and toe out angles of wheels are
adjusted as 31o + 1 o and 42 o + 1 o respectively. RPM of the engine are checked by magnet
type tachometer. Vehicle is also checked for any defect of loose fitment/ wrong fitment.
Shower test is performed by sprinting water from all the sides on the cabin with pressure to
check leakage inside the cabin.
After shower test the vehicle is taken for road test. The PDI department holds the responsibility
after this to check that the vehicle is ready to be sold and safe to drive.
The vehicle is taken to test track to check brakes, emission, balance of vehicles, gears, steering
control etc.
After final inspection the vehicle is ready for delivery.

QUALITY ENGINEERING DEPARTMENT

This department is the most crucial department. The responsibility of this department is to
ensure the quality of incoming and outgoing components. Structure of quality engineering
department is as shown in figure. This department is to ensure that s has passed the various
manufacturing, checked and controlling facilities for quality production.

1. Quality Manufacturing: An LCV in brief has to pass through strict test numbering about
250. Similarly, at sub assembly states etc. Like body shop, paint shop, day to day report of
quality goes to department for necessary action.

2. Quality Development: Quality development has given more stress on prevention of

defects rather than setting it right by rectification. In quality development for proper insurance
40
of quality, reliability, service and other aspects in manufacturing products through and
scientific activities. The job of evaluating the companies with respect to quality, reporting the
result of evaluation to all concerned department for necessary action and information.
Quality Engineering (receipt): It is responsible for every item that is being received at the
receipt store from various vendors. Since it is not possible to check each and every item,
therefore random sampling is done.

3. Quality Engineering Lab: This department is responsible for all type of lab work in the
organization her all the critical dimensions are checked in the standard room with sophisticated
aides, and precision instruments. Various gauges like height gauges, dial indicators, profile
projector, thread gauges are used. Hardness test and tensile tests are conducted in this lab. Also
chemical compositions of various components are checked.

Metrology Lab:
Metrology lab is the place where all the material testing like hardness, chemical composition
of the materials and microstructure of the materials is done. Quality parameters which are tested
under this lab are:

Hardness: In the hardness test mainly components which are forged, casted, induction
hardened and carburized hardened have been checked.

a) Rockwell hardness machine: Rockwell hardness machine is used for harder materials.
In this machine there are three scale RC scale, RB scale and RA scale. Through this scale we
find the hardness number of the material.
1) On RC scale the load is 150 kg and indenter is of diamond
2) On RB scale load is 100 kg and indenter is of steel ball of diameter 1/16 inch.
3) On RA scale the load is 60 kg and indenter is of diamond.

b) Brinell hardness tester (BHN): This machine is used for testing material which is less
hard than which are tested under Rockwell hardness machine. In this hardness is finding as
Brinell hardness number (BHN). Load is 3000kgs and the indenter is steel ball of diameter 10
mm or 5mm.

41
c) Micro hardness tester: This tester machine is used for carburized components to check
the case depth of the components.

Chemical Composition
Chemical Treatment: In this we test the material with different chemical to check the
composition of material. This method is very time consuming but less expensive.
Spectrometer analysis: In this method we put the testing material in argon atmospheric vacuum
tube and spark is strikes on material and different elements emits different radiation so we
differentiate the composition of material.

Microstructure Analysis: Microstructure analysis is done to check the different phases of the
material during that state like whether it is martensite, bainite, or combination of some other
phases. In this component is first is cleaned properly then cutting is done then grinding and
after that fine grinding is done with ivory paper and after that polishing is done with diamond
paste and kerosene mixture. In the end nival picral (2% nitric acid in ethanol) is put on the
material and then under microscope microstructure of components is studied.

Magnaflux Crack Testing Machine: This machine is used for checking the cracks in the
components. In this machine the components is magnetized with electric current and a
florescent powder is put on it, after that in florescent light the cracks can easily be detected.

42
 Standard Room

As the name indicates standard room it’s the room where all the instruments are standard and
all the instruments which are used for measuring the dimensions of the parts of the components
of body parts of trucks assembly are calibrated with these instruments. There are some
standards instruments which are used for measuring the dimensions of engine parts and for
calibration of the other instruments which are as follow.

1. PROFILE PROJECTOR: Profile projector is the machine which is used for

projecting the projection of very small parts in the magnified way on the projector. It has
vertical optical axis and the image formed is inverted and reversed. Projection lenses have the
magnification of 5X, 10X, 20X, 50X, and 100X. It has the magnification accuracy of
upto.05%of contour illumination and .075% of surface illumination. Its weight is 800kg.it has
3 lens of screw type.

Figure 22

2. COORDINATE MEASURING MACHINE: AS we know that micrometer vernier

caliper and height gauges are used for measuring only one direction and profile projector
measure two dimensions in spite of these entire coordinate measuring machines is used for
three dimensions of the components of engine in X, Y, Z direction. Coordinate measuring
machine is also used for measuring the dimension of any part with respect to some other
dimension. Suppose we have to find the pitch circle diameter of the part with respect to some

43
other point it give us that dimension. It also helps to calculate the diameter of circle accurately
as it is electronically operated.

Figure 23

3. UNIVERSAL LINEAR MEASUREMENT MACHINE: this machine is used for the

calibration of the ring gauges and plug gauges. It is mainly used for the measuring the pitch of
the gears. It is also known as light machine as it is optically operated.

4. TORQUE WRENTCH TESTER: It is the instrument which is used for the calibration
of the torque wrench. (Torque wrench is the device which is operated up to specify torque it
means that if torque wrench has the specification of 10kgm then in tightening bolt after 10kgm
it becomes free.) It is electronically operated.
5. AIR GAUGES AND BORE GAUGES: these are mainly used for measuring the
internal diameter of any part. Air gauge are operated by air by air pressure and bore gauges are
operated mechanically or by hands. Bore gauges has the range from12mm to 300mm.
6. STANDARD PINS AND SLIP GAUGES: These are the standard ones and used for
measuring the accurate dimensions of any parts and used or calibrated other instruments. Slip
gauges are used for measuring the width of any parts and has the range 300mm. and standard
pins are used for measuring diameter of any hole and it has the range from.5mm to 300mm.

44
 Figure 24

7. ELECTRONIC AND MECHANICAL HEIGHT GAUGES: These are mainly used

for the height of any part, mechanical height gauges has the range up to 300mm and electronic
height gauges has the range up to 600mm.

HEIGHT GAUGE

Figure 25

8. SQUARNESS TESTER: It is used for checking the perpendicularity of two surfaces

of the components.
9. HEIGHT MASTER: It is the master which is used for the calibration of the height
gauges. It has the least count of 1 micron.
10. BARO PROTECTOR: It is the additional accessory which is used for
measuring the helix angle of the gear and threaded parts
11. VERNIER AND MICROMETER: Last but not the least vernier and micrometer are
the instruments which are used for measuring the dimension.
45
PROJECT NO. 1

DESIGN OF WASHING CUM FEEDING BIN OF TOP COVER OF

TRANSMISSION UNIT

OBJECTIVE: -

To design a washing bin for stacking more than 10 components together in washing Machine,
without damaging the component.

Software Used: - SOLIDWORKS

THEORY: -
Some components before being assembled are washed in component washing machine. In
this machine the water is sprayed from all the directions at high speed. The component in the
machine can’t be placed directly as the high-speed water may cause them to strike other
metallic surface causing major damage to the component so, the feeding cum washing bin is
used to place component properly.

Design consideration: -

• Bin has to be smaller the 650mm x 650 mm x 350 mm to be placed in machine.

• Bin material should be able to withstand hot water, should not rust and should be
strong enough to withstand improper handling.
• There should be some material used to avoid metal to metal contact between bin and
component.
• Placing of component should only involve pick and place, no complex fixation
should be involved.
• Accumulation of water in bin should be avoided.
• Bin should be light enough to be picked by single individual.
• No more then 5 mm a side spacing between a component wall and bin member

46
DRAWING TOP COVER

47
 48

DRAWING TOP COVER BIN

PROJECT NO. 2

DESIGN OF WASHING CUM FEEDING BIN OF REAR COVER OF

TRANSMISSION UNIT

OBJECTIVE: -

To design a washing bin for stacking more than 8 components together in washing Machine,
without damaging the component.

Software Used: - SOLIDWORKS

THEORY: -
Some components before being assembled are washed in component washing machine. In
this machine the water is sprayed from all the directions at high speed. The component in the
machine can’t be placed directly as the high-speed water may cause them to strike other
metallic surface causing major damage to the component so, the feeding cum washing bin is
used to place component properly.

Design consideration: -

• Bin has to be smaller the 650mm x 650 mm x 350 mm to be placed in machine.

• Bin material should be able to withstand hot water, should not rust and should be
strong enough to withstand improper handling.
• There should be some material used to avoid metal to metal contact between bin and
component.
• Placing of component should only involve pick and place, no complex fixation
should be involved.
• Accumulation of water in bin should be avoided.
• Bin should be light enough to be picked by single individual.
• No more then 5 mm a side spacing between a component wall and bin member

49
Material: Aluminum 7073

50

DRAWING REAR COVER

DRAWING REAR COVER BIN
51
PROJECT NO. 3

STUDY OF THE SUSPENSION SYSTEMS

USED IN AUTOMOBILES

INTRODUCTION: -

The job of a car suspension is to maximize the friction between the tires and the road surface,
to provide steering stability with good handling and to ensure the comfort of the passengers.

The study of the forces at work on a moving car is called vehicle dynamics, and you need to
understand some of these concepts in order to appreciate why a suspension is necessary in the
first place. Most automobile engineers consider the dynamics of a moving car from two
perspectives:

• Ride - a car's ability to smooth out a bumpy road

• Handling - a car's ability to safely accelerate, brake and corner

These two characteristics can be further described in three important principles - road isolation,
road holding and cornering. The table describes these principles and how engineers attempt to
solve the challenges unique to each.

52
Car Suspension Parts

The suspension of a car is actually part of the chassis, which comprises all of the important
systems located beneath the car's body.

CAR SUSPENSION

These systems include:

1) THE FRAME - structural, load-carrying component that supports the car's engine and
body, which are in turn supported by the suspension
2) THE SUSPENSION SYSTEM - setup that supports weight, absorbs and dampens
shock and helps maintain tire contact
3) THE STEERING SYSTEM - mechanism that enables the driver to guide and direct
the vehicle
4) THE TIRES AND WHEELS - components that make vehicle motion possible by way
of grip and/or friction with the road

SO, THE SUSPENSION IS JUST ONE OF THE MAJOR SYSTEMS IN ANY

VEHICLE.

With this big-picture overview in mind, it's time to look at the three fundamental components
of any suspension: springs, dampers and anti-sway bars.

53
 SPRINGS

Today's springing systems are based on one of four basic designs:

• Coil springs - This is the most common type of spring and is, in essence, a heavy-duty
torsion bar coiled around an axis. Coil springs compress and expand to absorb the
motion of the wheels.

COIL SPRING

• Leaf springs - This type of spring consists of several layers of metal (called "leaves")
bound together to act as a single unit. Leaf springs were first used on horse-drawn
carriages and were found on most American automobiles until 1985. They are still used
today on most trucks and heavy-duty vehicles.

LEAF SPRING

54
 DAMPERS: SHOCK ABSORBERS

DAMPERS

A shock absorber is basically an oil pump placed between the frame of the car and the wheels.
The upper mount of the shock connects to the frame (i.e., the sprung weight), while the lower
mount connects to the axle, near the wheel (i.e., the unsprung weight). In a twin-tube design,
one of the most common types of shock absorbers, the upper mount is connected to a piston
rod, which in turn is connected to a piston, which in turn sits in a tube filled with hydraulic
fluid. The inner tube is known as the pressure tube, and the outer tube is known as the reserve
tube. The reserve tube stores excess hyd. Fluid.

THE LATEST TECHNOLOGY

AIR SUSPENSION

Air suspension is a type of vehicle suspension powered by an engine driven or electric air pump
or compressor. This pump pressurizes the air, using compressed air as a spring. Air suspension
replaces conventional steel springs. If the engine is left off for an extended period, the car will

55
settle to the ground. The purpose of air suspension is to provide a smooth ride quality and in
some cases self-leveling.
The air suspension consists of the following main parts:-
1) Air compressor
2) Bellows ( air spring )
3) DDU-Drying and Distribution unit
4) Supply lines
5) Leveling valve
6) Dampers
7) Air reservoirs/tanks
1) AIR COMPRESSOR: - The function of the air compressor is to suck in air from the
atmosphere and compress it to keep it inside a tank for further use. The compressor
used is a reciprocating type compressor and works by a belt driven pulley from the
engine.
2) BELLOWS/AIR SPRINGS: -

BELLOW

The bellow or the air spring is the replacement that took place in the air suspension that
differentiates it from the normal spring suspension system. The air spring is made up of
hardened rubber with spring inside it, and this bellow inflates and deflates as the air passes into
or exits it. It receives air via the leveling valve that controls the air flow into it.

56
3) AIR RESERVOIR/TANK: - The air tank store in the air that is supplied to the air
springs. It receives air from the DDU.

AIR TANK

4) DRYING AND DISTRIBUTION UNIT:- The function of drying and the distribution
unit is to remove the moisture from the compressed air coming from the air compressor
and keeps on filling the air tanks and releases the air from time to time to avoid the rise
in pressure.

DRYING AND DISTRIBUTION UNIT

5) SUPPLY LINES: - The function of the supply lines is to supply air from one part to
another.

SUPPLY LINES

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6) LEVELING VALVE: - The function of the leveling valve is to check that the position
of the chassis is stable with respect to the axle or not. If load on one side of the chassis
is more than the other, then in any normal vehicle the result of it will be that the vehicle
will lower down from that side, but in the air suspension vehicle the leveling valve
senses it and automatically varies the supply of air into the bellows and inflates the
bellow of that side of the chassis that has lowered down due to weight.

Position of the leveling valve

7) DAMPERS: - Dampers slow down and reduce the magnitude of vibratory motions by
turning the kinetic energy of suspension movement into heat energy that can be
dissipated through hydraulic fluid.

DAMPERS ASSEMBLED ON THE REAR AXLE

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COMMON AIR SUSPENSION PROBLEMS

1. AIR SPRING/BELLOW FAILURE: - This is usually caused by wet rot, due to old age,
or moisture within the air system that damages it from the inside. Air ride suspension
parts may fail because rubber dries out. Punctures to the air bag may be caused from
debris on the road.
2. AIR LINE FAILURE: - This is a failure of the tubing which connects the air bags or
struts to the rest of the air system and is typically DOT-approved nylon air brake line.
This usually occurs when the airlines, which must be routed to the air bags through the
chassis of the vehicle, rub against a sharp edge of a chassis member or a moving
suspension component, causing a hole to be formed.
3. COMPRESSOR FAILURE: - This is primarily due to leaking air springs or air struts.
The compressor will burn out trying to maintain the correct air pressure in a leaking air
system.

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