INDUSTRIAL TRAINING

PISTON CONROD SUBASSEMBLY FIXTURE

PRESENTED BY

GOURAV MITTAL

14352
MED
 GENESIS OF ASHOK LEYLAND

• Formed in the year 1948 by “Mr. Raghunandan Saran” as

“ASHOK MOTORS”, to assemble Austin Cars.

• Renamed & Started Mfg. Commercial Vehicles in 1955 with

equity participation by “LEYLAND MOTORS”.

• 2nd Largest Commercial vehicle company in India.

• Market Share of 28% (2007-2008) in Medium & Heavy

Commercial Vehicle.

• Market Leader in Bus Segment , and Claims to carry 60 Million

Passengers Daily.
 B.O.D

MR. DHEERAJ G.
HINDUJA MR. R. SESHASAYEE MR. VINOD K. DASARI
(CHAIRMAN) (EX. VICE CHAIRMAN) (MANAGING DIRECTOR)
 PRODUCTS

 Buses

 Trucks

 Light Vehicles

 Defence Vehicles

 Power Solutions
 MISSION
• Large Production.

• Modernization.

• Global Benchmarking our Product, Process &

People.

• Identifying with Customer.

• Good Relationship Management.

 VISION

Be in the global Top 10 in Medium & Heavy Commercial Vehicle

Trucks (>7.5t GVW) and global Top 5 in Medium & Heavy
Commercial Vehicle Buses (8 m and above) in volume terms
PERFORMANCE HIGHLIGHTS
 COMPETITOR ANALYSIS

Major Competitor of Ashok Leyland :

-
• TATA MOTORS
• EICHER MOTORS
6% 6% Market Capital

ASHOK
LEYLAND
TATA MOTORS
EICHER MOTORS

88%
 EARLY VEHICLES
 Bus powered by Hino Engine
 CURRENT VEHICLES
 U-Truck
 CURRENT VEHICLES
 U-3723H
ASHOK LEYLAND DEFENCE
SYSTEMS
CURRENT VEHICLES
 FACILITIES
 Manufacturing Units
 India:
 Ennore, Tamil nadu in North Chennai [estb. 1948] – Trucks, Buses,

Engines, Axles etc.

 Hosur, Tamil nadu in Krishnagiri District - [estb.-1980] -Has Two plants

adjacent for Trucks, Special Vehicles and Power Units.

 Alwar, Rajasthan – [estb.-1982] - Bus Manufacturing Unit
 Bandara, Maharashtra – [estb.-1982] – Gearbox Unit
 Pantnagar, Uttarakhand – [etsb.-2010] – 75,000 annual capacity greenfield

Unit for new generation Platforms and Cabs.

 Sengadu, Kanchipuram District in Tamil Nadu - [etsb.-2008] -Technical and

Production facility for Ashok Leyland Defence Systems. Another separate

technical center for Nissan Ashok Leyland Vehicles.
ASHOK LEYLAND LTD PANTNAGAR
 SHOPS IN PNR PLANT
 Frame manufacturing shop:
 Crown wheel and pinion shop:
 Axle shop:
 Cab painting:
 Engine Shop
 Chassis and vehicle testing shop:
 Cab Weld shop
 Engine rough machining
INTRODUCTION TO NEPTUNE ENGINE
 The future-ready ‘Neptune’ engine will be available in
BS-III and BS-IV versions and is also package
protected for BS-V and BS-VI. The highly modular
sub-system design ensures maximum vehicle uptime
and better NVH characteristics while the CRS with
electronic-governance ensures high fuel efficiency,
easy serviceability, lower life cycle cost and reliability.
NEPTUNE engines will range from 160 HP to 380 HP
and will be deployed across a range of trucks and buses
in a phased manner
 Components of an N-series engine:
 Oil pump– N series engine employs a force feed
gear type lubrication pump. Oil is drawn from the
sump through the strainer by the gear type oil
pump. The pump is driven by timing gears.
 Oil Sump–The bottom of crankcase contains an oil
sump on which the lubricating oil is pumped to
various engine components. After lubricating these
parts, the oil flows back to the sump by gravity.
 Fuel injection pump -Three different types of fuel injection
pump (FIP) are employed in various models of H-series engine,
viz. 1. Inline 2. Distributor type 3. Common rail type
  
 Air compressor– reciprocating type air compressor, meshed
with the idler gear is incorporated in the engine.
 Water pump - The engine is water cooled, and forced circulated
by a volute type water pump. It is driven by the poly v belt.
 Alternator -24V - 55 Amps alternator is used which is driven by
poly v belt.
 Starter motor - 24V, Axial type, pre-engaged
 Turbocharger- It is driven by the exhaust gases which are
normally wasted.
 Thermostat- Wax type thermostat with bottom bypass
system is used.
 Flywheel housing- It is the casting that encloses the
flywheel. It is attached to the cylinder block by eight M12
and six M8 bolts
 TG Case - It is casing that forms the outer cover of timing
gears
 Timing gears – It consists of following five
gears: 1. Crankshaft Gear 2. Idler Gear 3.
Injection Pump Drive Gear 4. Oil Pump Drive
Gear 5. Camshaft Gear
 Salient features of this engine are
 It is an inline, four cylinders, water cooled, 4-stroke Diesel Engine with
direct fuel injection into a hemispherical combustion chamber arranged in
the piston crown.
 The engine employs the Micro Mixing Combustion System (MMCS) which
features a specially shaped combustion chamber in the piston crown.
 Another characteristic is the special shape and arrangement of the intake
ducts in the cylinder head which allows the air to enter only from one
direction.
 Upon entering, the air is given a swirling motion causing the fuel to mix,
which is injected through a multi hole nozzle into the combustion chamber.
 PROJECT WORK
My project is to based on a process design into a
version that can be more easily mass-produced. It is
almost always a necessary step in the development of
any product, since it is rare that the initial design is free
from flaws or construction methods which make it
difficult or more expensive to manufacture.
Processing fixtures are very often constructed by hand,
or with more limited tooling. This is done to save costs
where the design may not even be subsequently
approved for manufacture.
PROBLEMS IN PISTON CONROD SUBASSEMBLY

1. The connecting rod may be assembled in opposite direction.

 
Observation – If the connecting rod is assembled in other direction, the
axial play of connecting rod will be disturbed because the geometry of
connecting rod is such that it may cause noise and vibration during
operation.
 
Action – the connecting rod grade side should be in the direction in which
the ‘O’ mark on the piston head is there.
2. The connecting rod cap may be assembled in opposite
direction.
 Observation- The cap is fractured with the connecting rod
so it only matches with the same ends which are fractured.
Opposite ends may mismatch with the connecting rod.

Action – The grade mark side of conrod cap should be in the

direction of grade side of connecting rod .
3. The piston orientation may be wrong.
  Observation- piston is designed in such a way that inlet
port should coincide on the groove cut on the piston head.
If the orientation of piston changes the inlet valve will hit
the piston head surface and overheating takes place.
 

Action – the ‘o’mark on the piston head should in the right

side.if by mistake operator would place place the piston
wrong , it doesn’t fit in the fixture.
4. The dismantling of conrod cap manually is
sometimes difficult.
Observation – Manual dismantling requires more
space and fatigue to the worker.
 
Action – hydraulic system is installed in this
fixture.
PISTON CONROD ASSEMBLY FIXTURE
 CONCLUSION
 Thus the objective of this training to have technical
knowledge in manufacturing area has been successfully
completed.
 My project was completed successfully within deadlines
on piston connecting rod subassembly fixture in neptune
engine.
 My training in ASHOK LEYLAND LTD. was indeed a
very good experience. It has helped me to remove the gap
between the theoretical and practical knowledge, and to
have a better understanding of mechanical engineering.