INTERNSHIP REPORT

CIE - 02
PRESENTED BY
RAJASHEKAR L AND BASAVARAJU
COHORT OWNER
157ME21043 -157ME22301
SHOBA K K
GUIDENCE BY SELECTION GRADE LECTURER
AJAY GOVT POLYTECHNIC ARAKERE
SUPERVISOR OF AUTOMOTIVE AXLES
 INTRODUCTION ON JOB TRAINING

INTRODUCTION OF ASSEMBLY LINE (PLANT NO – 04 NX)

PLANT NO – 04 NX ASSEMBLY

An assembly line is a manufacturing process where a product is built step by step along a
conveyor belt or line of stations. Each station focuses on a specific task, allowing for
efficient mass production. This method revolutionized industries by increasing
productivity and reducing production costs.
 DEPARTMENTS IN PRODUCTION LINE

HOUSING DROPING ADDING PLUG AND DROPING DRIVEHEAD

TO MOVING SEALANT BEFORE AND ADDING BOLT AND TORQUING
CONVEYOR DRIVEHEAD DROPING WASHERS

DEMASKING AND ADDING PINION AND

PACKING MASKING &PAINTING LEAK TEST
ADJUSTING

I WAS ASSIGNED TO WORK IN LEAK TEST DEPARTMENT

 LEAK TEST
 The differential pressure type air leak tester uses the same principle as the balancing scale. The
same air pressure is charged to both the work (tested work) and the master work (work with no
leak) and the change in pressure balance within a fixed time is checked for the presence of a leak
 For the differential pressure type leak test, the leak test is performed through four processes;
pressuring, balancing, detection and exhaust
 STEPS OF LEAK TEST

• Scan the 2D matrix of axle Nameplate for Auto program and Coupler selection
• Select the Coupler from the Stand where light is glowing and insert into both the spindle
ends
• Connect air value and QDC for coupler at both the ends for coupler expansion and testing

• Plug the breather hole by using quick change coupler

• Press the start button for cycle start
 Apply soap water on all the fastening and welding joints to ensure no leakage during
detection stage
 If the Air leakage found in the joints tag the component for rework

 If leak test is ok remove the plug and fix rubber or metal plug to breathing hole

 Take a print out of leak test ok component and paste it On back side of the
respective check list

OBSERVATIONS

 Apply 100% soap water solution by spray gun during detection stage as mentioned in MIG parameters

 For both indications (red & green) if leakage observed on any area as mentioned in
the assembly with rework Tag (Sensor switch seating area ,Diff,lock,tube)
 Pinion cage seating face and mounting bolts ,carrier mounting face ,pinion lock nut
seating area seam welding area
 Snrockle welding area brake adapter welding Area,Ring & cover welding, air shift
assembly area,Drain & filter plug ans ensure “NO LEAKAGE”

 If no leakage observed then pass to the next process

GRAPH SHOWS WHILE AIR LEAK TESTING

 USE CASE – 01
INTRODUCTION OF DRUM BRAKES
We are driven by safety. We work daily to engineer safety into every brake system, detail
and control. Safety directs our innovation into every braking product we make, from drum
and air disc brakes, to hubs and drums & friction products

325 mm dia S-Cam Drum Brakes come in large variety of shoe widths (120/140) and liner grades for
different braking/life requirements. Flexible mounting configuration eases vehicle packaging while the fast
shoe replacement design minimizes repair/service time. The brakes are designed to suit a wide torque
requirement band for broad range of applications. With asbestos free liners Meritor brakes offer the best in
durability, performance and safety
 STEPS INVOLVES IN THE DRUM BRAKE ASSEMBLY

 Preparation: Gather all the necessary components, including the brake

drums, shoes, springs, adjusters, wheel cylinders, and hardware.
 Cleaning: Ensure that all components are clean and free from debris, rust,
or corrosion. This is crucial for optimal performance and longevity.
 Installation of Wheel Cylinder: Mount the wheel cylinder onto the
backing plate and secure it in place with bolts.
 Attaching Brake Shoes: Install the brake shoes onto the backing plate,
making sure they are positioned correctly with the friction material facing
the brake drum.
 Adjuster Installation: Place the adjuster mechanism between the brake
shoes and ensure it is properly positioned for adjustment.
 Spring Installation: Attach the brake shoe return springs and other retaining springs as per the
manufacturer's instructions.
 Drum Installation: Slide the brake drum over the brake shoes and onto the wheel studs.
Ensure that the drum rotates freely without any resistance.
 Adjustment: Adjust the brake shoes using the adjuster mechanism to achieve the proper
clearance between the shoes and the drum. This ensures effective braking without excessive
wear.
 Final Checks: Double-check all connections, fasteners, and adjustments to ensure everything
is secure and functioning correctly.
 Testing: Before putting the truck into service, test the brakes to ensure they are operating
smoothly and effectively. This may involve a road test or dynamometer test, depending on the
available resources.
Following these steps will help ensure a properly assembled truck drum braking system
promoting safety and performance on the road
 CONCLUSION

the assembly of a truck drum braking system involves a systematic

process of preparing, cleaning, installing components such as the wheel
cylinder, brake shoes, adjusters, and springs, followed by adjusting and
testing to ensure proper functionality. Attention to detail and adherence
to manufacturer guidelines are essential for optimal performance and
safety on the road.