PROJECT REPORT ON:

BS IV to BS VI MIGRATION

VE Commercial Vehicles,Pithampur
Duration: - “05thjune - 05thjuly2019”
Submitted by:- Submitted to: -
Yogesh Choudhary Prof.Saurabh Jain
Prof.Veerendra Patil

Mechanical Engineering Department

Acropolis Institute of Technology and Research INDORE (M.P.)
 VE Commercial Vehicles,Pithampur
SUMMER INTERNSHIP
REPORT
(05/06/2019 -05/07/2019)

Acropolis Institute of Technology and Research, Indore

Session:- 2019-2020
SUBMITTED BY:
Yogesh Choudhary
0827ME161067

DEPARTMENT OF MECHANICAL ENGINEERING

ACROPOLIS INSTITUTE OF TECHNOLOGY& RESEARCH INDORE
Acknowledgement
I am very thankful to my Institute and Career Development Cell for
giving me the opportunity to undertake my Internship training at VE
Commercial Vehicles,Pithampur . It was a very good learning experience
for me to have worked at this organization.

I would like to convey my heartiest thanks to mr.V.S. Tomar, General

Manager, I would also like to give my heart-felt thanks to Mr. Nikhilesh
Singh, HR Manager, who heartily welcomed me for the internship, Mr.
Rajeev Kapil, who guided and encouraged me all through the summer
training and imparted in-depth knowledge of the programme. Also I
would like to thank Mr K.Vaidhyanathan, who guided me whenever I
needed. I would like to thank all the department heads of VE Commercial
Vehicles,Pithampur, for giving their precious time and valuable guidance
during my internship program. I am extremely thankful to Dr. Amit
Marwah, Head of department, Mechanical Engineering, Acropolis
Institute of Technology & Research Indore.

Last but not the least; I would like to thank all the staff of VE
Commercial Vehicles,Pithampur family, for being so helpful during this
summer training.

Yogesh Choudhary
 Contents

Sr. No. Chapter Heading

1 Introduction and motivation

2 Description of manufacturing process / Methodology

3 Project undertaken / Work carried out description

4 Learning and Outcomes

5 References
Description of manufacturing process used in VECV plant Pithampur

Pithampur is a town in the Dhar district of Madhya Pradesh, India. VECV plant at
Pithampur has working facility of 24 hours with manual and automatic operated
advanced machines. Vehicles are manufactured, designed and tested here. Both
vehicles i.e. Heavy Duty (HD 25 to 49 tonnes) and Low Medium Duty (LMD 4-12
tonnes) vehicles are produced here.

MACHINING

The plant contains various hi-tech machines in the machine shops MAZAK, Gun drilling,
Grinding Vertical surface, Line bore, Vertical bore, Robot washing etc. for cleaning,
drilling , mining, boring, tightening, surface finishing the engine’s cylinder head and block
sub assembly that is prepared by casting and imported to the plant.

WELDING

The cabin of truck is welded by robotic arms and manual spot welding of various parts
transferred by conveyers and crane to the modern paint shop where there is a single
line for both HD and LMD vehicles.

PRODUCTION LINES

Finally all assemblies are transferred to the production lines HD and LMD where all the
subassemblies are mounted on the chassis or the frame and the product is available at
the end of line where tests are done on the product for checking its proper working and
efficiency and safety of the driver. Both the lines i.e. LMD and HD work parallel to each
other and the product is achieved at the same end where the line begins (U-type
layout).
 Frame preparatory line - FP

Stations in FP line are as follows:

• DDU & APDA

Drying and Distribution Unit Removes moisture completely from the compressed air and was previously used in
BS III vehicles. Currently according to norms for BS IV vehicles Air Processing and distribution assembly (APDA).
• It performs DDU & APDA
Drying and Distribution Unit Removes moisture completely from the compressed air and was previously used
in
BS III vehicles. Currently according to norms for BS IV vehicles Air Processing and distribution assembly (APDA).
It performs the functions of the following devices:
• FRONT AND REAR HARNESS FITMENT:

• LEAF SPRING DROP:

• FRONT AND REAR AXLE DROP:

 HEAVY DUTY ASSEMBLY LINE (HD Line)

• NUMBER PUNCHING:
A number is punched on the chassis by the machine using program controlled machine. This number is generated by the
computer it is unique and stored for later purposes in case of warranty and recognition of chassis and model.
• ENGINE DROP:
4 Cylinder or 6 Cylinder engine assembly having the cylinder block, head and the gear box etc. is brought and dropped
by the hoist onto the frame where it is fixed and all the wiring is connected along with nut bolts sub-assembly.
• CABIN DROP:
The cabin that is painted, fitted, garnished, painted and inspected perfectly is brought to the lines using tugged and it is
fixed in front of the vehicle using torque guns and all the wirings of brakes ,headlamps all the fitments related to front
and rear are done.

•INSPECTION:
Inspection of the product is done when it is brought down form the conveyer line first and now it is manually driven and
checked for proper working of parts. A checklist is used to check if any part is not properly fixed or missing in the
product. This checklist contains all the list of tools used in the product along with their frequency.
Bharat Stage Emission Standards:

Pollution Issue in India

A new report from the World Health Organization, drawing on measurements and calculations as of 2016 from air monitoring stations in
4,300 cities, shows that air pollution is a global problem. A whopping nine in 10 people on Earth breathe highly polluted air, and more
than 80 percent of urban dwellers have to endure outdoor pollution that exceeds health standards, according to the WHO’s World Global
Ambient Air Quality Database.
But there are certain places on the planet where the air is now consistently, epically terrible.
For instance, India, when you look at the databases ranking of particulate pollution in cities, 11 of the 12 cities with the highest levels are
located there. Kanpur, India, population 3 million, tops the list with a yearly average of 319 micrograms per cubic meter of PM2.5, the
most hazardous particle commonly measured.
Bharat stage emission standards {BSES} are emission standards instituted by
the Government of India to regulate the output of air pollutants from internal
combustion enginesand Spark-ignition engines equipment, including motor vehicles. The
standards and the timeline for implementation are set by the Central Pollution Control
Board under the Ministry of Environment & Forests and climate change

The standards, based on European regulations were first introduced in 2000.

Progressively stringent norms have been rolled out since then. All new vehicles
manufactured after the implementation of the norms have to be compliant with the
regulations. Since October 2010, Bharat Stage (BS) III norms have been enforced across
the country. In 13 major cities, Bharat Stage IV emission norms have been in place since
April 2010 and it has been enforced for entire country since April 2017. In 2016, the
Indian government announced that the country would skip the BS-V norms altogether
and adopt BS-VI norms by 2020. In its recent judgment, the Supreme Court has banned
the sale and registration of motor vehicles conforming to the emission standard Bharat
Stage-IV in the entire country from April 1, 2020.
EMISSION-CONTROL STRATEGIES

BS VI standards have been met by manufacturers through a combination of DPF and SCR technologies, in addition to DOCs,
EGR and other advanced engine technologies. The move to a combination of DPF and SCR technologies requires a switch
from Vanadium to Zeolite catalysts for the SCR systems. The end result of this technology change and the improved test cycle
is that real-world NOX emissions much more closely match the emissions limits than was the case with previous standards,
especially at low vehicle speeds and cold start conditions. BS VI standards also require OBD systems to measure performance
of emission control systems in use and to provide early identification of any system failures. These systems operate in
addition to the driver inducements for use of urea additives that are necessary for the proper operation of SCR systems.

BSVI: HI-eSCR operating principle

BSVI TECHNOLOGY IMPLEMENTATION

• Engine
The new engine components serve two main purposes: to improve gas-flow and make sure the
exhausts reach the after-treatment system at optimum temperature.
Extra injector
A special diesel injector is used for heat management of the Diesel Oxidation Catalyst (DOC) and
ensures the efficiency of the Diesel Particulate Filter (DPF) and good Selective Catalytic Reduction
(SCR) functionality.
• Diesel oxidation catalyst (DOC)

The DOC produces the NO2 necessary for the DPF to efficiently combust the particulates. In cold conditions, it
also provides the heat needed for regeneration.

•Diesel particulate filter (DPF )

The filter collects particulate matter (PM) and stores it until it’s burned off during regeneration. If the temperature is not
achieved during the duty cycle there is a switch in the cab to regenerate the DPF when stationary. There is also a
regeneration gauge in the dash.

Selective Catalyst Reduction(SCR)

In the mixing zone, the exhaust gas is sprayed with AdBlue – which is an ammonia NH3 solution. When they reach
the catalyst, the oxides of nitrogen (NOX) are efficiently transformed into harmless nitrogen gas and water.

Change in BS-IV and BS-VI Engines:-

• Change in fuel injection system

• Change in fuel injection pump
• Single stage turbo charger used
• Change in fuel filter
• Injection pressure changed from 1600bar to 1800 bar
•Ammonia Slip Catalyst (ASC)
The last step before the tailpipe where the remaining ammonia (NH3), if any, is removed.

Exhaust Gas Recirculation (EGR)

In internal combustion engines, exhaust gas recirculation (EGR) is a nitrogen oxide (NOx)
emissions reduction technique used in petrol/gasoline and diesel engines. EGR works by
recirculating a portion of an engine's exhaust gas back to the engine cylinders

BS IV AND BS VI COMPARISON
BS IV
• In BSIV norms, limit of NOx has been reduced by 30% and that of PM by 80%.
• BSIV engine offer better performance regards peak torque and peak torque range as compared with
mechanical engines.
• BSIV vehicles engines have been undergoing intense field trials for past several months. Results
indicate
higher reliability and durability in comparison with BSIII vehicles.
A BS4 engine works the same as any a BS3 or BS2 or a poorer emission rating engine.
• Better quality fuel- with lower amounts of Sulphur
• Better quality fuel- with a good octane (for petrol) or cetane (for diesel) number
• Higher peak firing pressure- Achieved by turbocharging or supercharging or increasing the number of valves or changing
the shape of the piston bowl etc. for improving the volumetric efficiency.
• The exhaust after treatment systems- Catalytic converter, EGR system, SCR system, Diesel Oxidation Cat Con, Particulate
Oxidation Cat Con etc.
• Precisely controlled combustion using electronic or mechanical fuel injection.

BS VI

BSVI is in lines with Euro VI norm already adopted in European Countries. In fact, this new emission norm will also
address one major drawback in the EuroVI norm that allows emission of higher PM (particulate matter) in diesel engines
• NOx emission will come down by approximately 25% for the petrol engine and 68% for the diesel engines.
• The PM emission will see a substantial decrease of 80% in diesel engines.
• OBD will become mandatory for every vehicle and it will help monitor the pollution caused by the vehicle in real time.
•RDE (Real Driving Emission) will be introduced for the first time that will measure the emission in real-world conditions
and not just under test conditions.
• Bharat Stage VI norms will also change the way particulate matter is measured. It will now be measured by number
standard instead of mass standard thereby, regulating the fine particulate matter as well.

THE EFFECTS OF BS VI NORMS ON THE INDIAN AUTOMOBILE INDUSTRY

•Moving to BS6 will need 80,000 crores worth upgrade in oil refining infrastructure. So, we can expect
another cess to the government in the coming days. It could be integrated into fuel prices like most other
cesses.
•The biggest impediment to BS6 norms will be the availability of BS6 compliant fuel, both petrol and
diesel.
•In India, where small cars are preferred, fitting DPF in the limited bonnet space would involve major
design and re-engineering work. Bonnet length may have to be increased, which would make vehicles
longer than 4 meters, and attract more excise duty under existing norms.
 Learning and Outcomes:

Working with VE Commercial Vehicles has provided in-depth knowledge of working and technical details of BSVI used for
reducing air pollution and has enhanced my skills as a production engineer by teaching me how to tackle and overcome the
problems faced in real life scenarios. Here in general I learn, how the company works, what are the different department and
their works. It helped me in understanding the working of an industry and corporate world by providing practical exposure.
To be specific I worked for Manufacturing Engineering department which deals with the manufacturing of new vehicles
from part to a complete to be sold vehicle until it is made regular and is responsible for all the equipment and facilities
required in the assembly line from creating one to modifying it. I also got the chance to know about all the departments
involved and their working and what are the different protocols, process, requirements and engineering used in
manufacturing of a vehicle.
During the training I did project on “BSIV to BSVI MIGRATION" through which I get detailed knowledge about the
process of manufacturing a vehicle and was able to suggest some ideas for removal of NCR that is use of wrong hardware.