INTERNSHIP REPORT ON

PRODUCTION
Submitted by

AKASH A (211601002)

In the partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
In

ROBOTICS AND AUTOMATION ENGINEERING

RAJALAKSHMI ENGINEERING COLLEGE, THANDALAM

AN AUTONOMOUS INSTITUTION
AFFILIATED TO ANNA UNIVERSITY, CHENNAI

APRIL 2023
 ACKNOWLEDGEMENT

I would like to convey my deep regards to Dr. S.N.Murugesan,

principal for giving us the permission to attend the training and
to attend the training and to explore knowledge.

I would like to express my sincere and heartfelt thanks to our Head of

the Department Dr.R.Giri for extending his exemplary guidance and
constant support to approach the industry.

I Would like to thank Mr.Velu,Manager,Training Centre,Lucas TVS

Limited,Padi for providing me the better opportunity to do internship
within the organization.

I express my deepest thanks to Mr.Arun Kumar,Mr.Sathish

Kannan,Mr.Sathish,Training Officers,Training Centre,Lucas TVS
Limited,Padi for their careful and precious guidance.

It is indeed with a great sense of pleasure and immense sense of

gratitude that I acknowledge the help of the individuals for their greater
guidance on the particular sectors: Mr.Kishore
Kumar, Mr.Suresh, Mr.Sunil, Mr.Ramesh, Ms.Vinitha,
Mr.Venkatesh, Mr.Selavaraj and Mr.Noel Braide.

AKASH A (B.E R&A)

RAJALAKSHMI ENGINEERING COLLEGE (CHENNAI)
INDUSTRY
PROFILE
 INTRODUCTION
ABOUT LUCAS TVS:
Lucas TVS, established in 1962, is a leading provider of mechatronic
solutions for automotive, consumer and industrial goods companies, with
over 50 years experience in design, manufacturing and supply of products
to OEMs in India and abroad. With a work force of over 6,000 people and
state of the art engineering and manufacturing facilities integrating TQM,
TPM, 6 sigma and lean manufacturing principles. Lucas TVS has end to
end product development capabilities.We have 7 plants in India and a
global network with sales and sourcing offices in USA, China, South
Korea, Japan and Germany.

LUCAS TVS LIMITED: Established in 1962 as a Joint venture between

Lucas UK and TVS, Lucas TVS is a leader in Automotive electricals in
India, supplying a wide range of electrical components for two wheelers,
3 wheelers, cars, commercial vehicles, tractors and the industrial sector.
Lucas-TVS is a Deming Grand Prize certified for TQM Practices Group
Turnover / group employee count.
HISTORY:

Lucas - TVS was set up in 1961 as a joint venture of Lucas

Industries plc., UK and T V Sundaram Iyengar & Sons (TVS),
India, to manufacture Automotive Electrical Systems. One of the
top ten automotive component suppliers in the world, Lucas Varity
was formed by the merger of the Lucas Industries of the UK and the
Varity Corporation of the US in September 1996.

The company designs, manufactures and supplies advanced

technology systems, products and services to the world's
automotive, after market, diesel engine and aerospace industries.

The combination of these two well-known groups has resulted in

the establishment of a vibrant company, which has had a successful
track record of sustained growth over the last three decades.TVS is
one of India's twenty large industrial houses with twenty-five
manufacturing companies and a turnover in excess of US$ 1.3
billion.

The turnover of Lucas-TVS and its divisions is US$ 233 million

during 2003-2004.Incorporating the strengths of Lucas UK and the
TVS Group, Lucas TVS has emerged as one of the foremost leaders
in the automotive industry today.

Lucas TVS reaches out to all segments of the automotive industry

such as passenger cars, commercial vehicles, tractors, jeeps, two-
wheelers and off-highway vehicles as well as for stationary and
marine applications. With the automobile industry in India currently
undergoing phenomenal changes, Lucas-TVS, with its excellent
facilities, is fully equipped to meet the challenges of tomorrow.
TVS GROUP COMPANIES:
The TVS Group is India’s leading supplier of automotive
components and one of the country’s most respected
business groups.
With a combined turnover of more than over $ 6.5 Billion ,
the TVS Group employs a total workforce of close to over
39,000 employees . Charting a steady growth path of
expansion and diversification, it currently comprises
around over 50 companies.These operate in diverse fields
that range from two-wheeler and automotive component
manufacturing to automotive dealerships, finance and
electronics.Uniting these multiple businesses is a common
ethos of quality, customer service and social responsibility.
4 LUCAS TVS GROUP COMPANIES:

 Delphi TVS : Delphi TVS was established in 1989, combining the

vast expertise of 2 large automotive systems suppliers - TVS and
Delphi. Delphi TVS manufactures Diesel Fuel Injection Equipment
for cars, commercial Vehicles, tractors and single & 2 cylinder
engines. Delphi TVS is ISO certified and has been honored with
ACMA Gold Award for Manufacturing Excellence.
 Lucas Indian Service Limited:
Lucas Indian Services is a leader in aftermarket service for auto-
electricals with over 85 years of experience and more than 550
Service dealerships and a network of over 2,000 dealers, 15,000
retailers and 30,000 registered auto electricians / mechanics.
 India Nippon Electricals Limited:
India Nippon Electricals Ltd was established in 1986 as a joint
venture between Lucas Indian Services and MAHLE Electric
Drives, Japan and manufactures Electronic Ignition Systems, and
other auto electricals for two wheelers, three wheelers and General
Purpose Engines. INEL has 3 manufacturing plants – Hosur,
Rewari and Pondicherry.

 INDIA JAPAN LIGHTING: India Japan Lighting Pvt. Ltd. was

incorporated in December 1996. It is a 50:50 joint venture between
Lucas-TVS Limited, Chennai, and Koito Manufacturing Company
Limited, Japan. Lucas-TVS Limited is an acknowledged leader in
Auto Electricals in India, while Koito Manufacturing Company
Limited is the leader in automotive lighting in Japan. Koito have
been in the lighting business for 90 years.
 CUSTOMERS

MARUTI SUZUKI TATA KENT MINERAL

RO

FORD PACCAR HYUNDAI

FIAT TAFE MAHINDRA

TVS SWARAJ VOLVO

HERO KIRLOSKAR FIAT

BAJAJ DENSO HONDA

RENAULT NISSAN WABCO ARCTIC CAT

JOHN DEERE GODREJ KOMATSU

LIVPURE YAMAHA POLARIS

CATERPILLAR IVECO KOHLER

ENGINES
Main products that are manufactured in
Lucas TVS:
1. Alternator

2.Starter motor

3.Wiper motor

4.Compressor motor

ALTERNATOR:

High Efficient and Co2 Emission Friendly

Alternator
Features:
 Higher VDA Efficiency : 70%
 Compact in size
  Higher Power density
 Multi-Function Regulator
 High load dump capable Zener diode
 Solderless electrical joints – Resistance
 LIN regulator/ clutch pulley (Optional)

Customer Benefits:
 Improved Fuel Efficiency
 Lighter in weight
 Improved Power to Weight Ratio
 Better Ergonomics
 Welding for more reliability

Product Specification:
 Frame size : Ø 130mm
 Voltage : 12V
 Output : 140A
 Mass : 5.1kg (w/o Pulley)
 Range : 110A ~ 140A
 Dual Asymmetric Internal Fan Type
 Operating Temp : -30°C to +120°C
PERFORMANCE CURVE

CUSTOMERS OF ALTERNATORS:
 ASHOK LEYLAND
 TATA MOTORS
 TAFE
 MARUTI SUZUKI
 MAHINDRA
ALTERNATOR ASSEMBLY LINES:
 ROTOR ASSEMBLY

 STATOR ASSEMBLY

 RECTIFIER ASSEMBLY

 VACCUM PUMP ASSEMBLY

 SRE AND DE BRACKET ASSEMBLY

 MAIN ASSEMBLY
 STARTER MOTOR

A starter (also self-starter, cranking motor, or starter motor) is

a device used to rotate (crank) an internal-combustion engine so as to
initiate the engine's operation under its own power. Starters can
be electric, pneumatic, or hydraulic. The starter can also be another
internal-combustion engine in the case, for instance, of very large
engines, or diesel engines in agricultural or excavation applications.
The starter motor is responsible for turning the engine over during
ignition and allowing everything else to happen. When you turn the
ignition on, the starter motor engages and turns the engine over allowing
it to suck in air.
The starter motor has only one function which is the first and second
rotations the engine need. Apart from that the device is just an extra load
for the vehicles.

Starter motor that are manufactured in Lucas TVS,

 Commercial starter motor – used in heavy vehicles
 Gear reduction starter motor(GRS,used in light vehicles)

CHILD PARTS OF STARTER MOTOR:

 Armature
 Commutator
 Brushes
 Solenoid
 Plunger
 Field coil
 TYPES OF STARTER MOTOR

COMMERCIAL STARTER GEAR REDUCTION

STARTER
Large ,low speed motor Small, fast motor
Rotates a pinion in a 1:1 ratio Rotates a pinion ina4:1 ratio
Typically cheaper Typically more expensive

COMMERCIAL STARTER MOTOR

Features
 Compact in size and light weight
 Snouted D.E bracket design
 Wide operating Temperature range
 Better cold start ability
 High power to weight ratio
 Sintered Annulus with cushion pad
 Low Noise
 Shroud provided in solenoid assembly
 Higher durability -400 K Cycles (Optional)
 TCO and Fuse (Optional)
Applications
 PV/ LCV/ SUV/ 3W

Product Specification
 Frame size : Ø 70mm
 Voltage : 12V
 Output : 1.7KW @ 12D
  Mass : 3.0 kg
 Range : 1.2 ~ 1.7 KW

Customers Benefits

 Improved power weight ratio

 Longer life
 Less weight to improve fuel savings. 







GEAR REDUCTION STARTER MOTOR

Gear reduction starters feature a reduction in gear ratio between the

armature and the pinion gear of anywhere between 2.5 and 4.5:1,
and the armature is designed to rotate at a higher speed when energised
by the solenoid.

Features
 Snout/ Snout less DE bracket designs
 Internal fuse link to protect starter from extended locking
conditions
 TCP protection is optional
 Long life Overrunning clutch
 6 Pole permanent magnet type
 Planetary gear reduction
 External through bolt arrangement
Applications
 LCV and Tractor OEMS
Product Specification
 Frame size : Ø 78mm
 Voltage : 12V
 Mass : 4.4 kg
 Range : 1.9 ~ 2.5 KW @ 6.9 mΩ
Customers Benefits
 Sealed Gear reduction starter motor
 Compact in size
 Less weight than direct drive starters
EXPLODED VIEW OF GEAR REDUCTION STARTER
 WIPER MOTOR
Windshield wipers are powered by a small electric motor, usually
mounted on the firewall or under the cowl (the area under the
windshield’s base). The motor activates linkage that moves the wiper
arms back and forth. On vehicles with a rear window wiper, a separate
motor powers the one in the rear. Signs that a wiper motor is about to
fail include slow or intermittent operation, wipers that will operate at
only one speed, or arms that stop in the middle of the windshield when
turned off. If your wipers don’t work, the fault could also lie with other
parts of the wiper system.
Smart and Compact Wiper Motor

Product Specification
 Rated Voltage : 12V
 Technology : 4 Pole
 Frame size : Ø52 mm
 Torque range : 19 – 34 Nm
 Ingress Protection : IP66
 Rated Speed : 45 rpm Low speed, 65 rpm High speed
 RFI suppression : LC Filters ( 2 inductors and 2 capacitors)
 Motor Noise : 45 dBA in Low speed 55 dBA in High speed

Applications
 Cars and Utility Vehicle

Features
 Over load protection
 EMI / EMC as per CISPR 25 class3
 Built in Mechanical Snow clutch (Optional)
 Life – 1.5 Million cycles as per SAE J 903 C
 Weight – 880gms
Customer Benefits
 Light weight
 Compact
 Low operating current
 COMPRESSOR MOTOR

Air compressors are machines that provide power to machinery. These

are used in many places, from the refueling stations to water purification
units and everything in between you will come across a lot of these
devices being used. The basic purpose of these devices is to provide
power and hence its output is measured at the crankshaft, just like with
automobile engines.
Compressor Motor for Air Suspension

Product Specification

 Frame Size : 76.5 mm

 System Voltage : 12.0 Volts
 Power : 384 Watts
 Mass : 2.2Kgs
 2 Pole permanent magnet type Motor. Motor drives the reciprocating
air pump with twin piston technology

Customer Benefits
 Lighter in weight
 Low cost
 Customized design to customer specification
Features
 720 hours of Salt Spray Life
 EMC: Class 5 of CISPR 25
 Operating Life – 1000 Hours. Duty Cycle – 20%
 Motor Service life -15 years
 It is a eco-friendly product with no heavy metals
 Protection class IP69

Applications
 Luxury Cars like Audi, Tesla, Porsche
EXPLODED VIEW OF COMPRESSOR MOTOR
CONCLUSION:
The components and the products manufactured are high in
quality,good in life at the best of customers satisfaction,lead the
company to te greater vantage point makes the profit and its lifetime
to the next level. The way of manufacture and the culture ensures the
greater good and indestructible company that been made those
years,its been a proud to spend few days in the company learning
something academic and ethical in the way that LUCAS-TVS been
all these years and sure paves way to the best.