NARROW TRACK 75
REPORT
SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR
Six Month Industrial Training
at
SUBMITTED BY
SAMEER JOSHI
Mechanical Engineering
131101
1311680
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SONALIKA
INTERNATIONAL TRACTOR LTD
Sonalika Group is contributing to green revolution in India Since 1969. Initially it started with
Farm Equipments and Machinery. Brand name of the group products is "SONALIKA". Market
share in Farm Equipments is 80 % in India. Group turnover is 220 Million USD (INR 1000
Crores). Sonalika Group is one of the top five tractor manufacturers in India. Apart from
tractors its product line includes multi utility vehicles, three wheelers, engines , Hydraulic
Systems , Casting , Forging , Brake System , Automotive components manufacturing and
various farm equipments and implements. Sonalika group since the inception has tried to
understand customers need to be able to facilitate them with its value for money products. The
company has a state of art manufacturing facilities, spread in acres, located in the pollution free
suburbs of Punjab and Himachal Pradesh.
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MISSION
International Tractors Ltd. offer quality product with distinctive features at reasonable price.
The company ensure better than the best after sale service for the satisfaction of the customer.
The firm is ranked as best in terms of its quality and production front. Company is exporting its
tractors to different Asian as well as African countries.
MEMORANDUM OF UNDERSTANDINGS
The Indian tractor market is dominated by low price, no frills, rugged, versatile and low to
medium powered tractors. Tractors have an integral part of farm mechanization and have a
crucial role to play in increasing productivity. In India 90% of the tractors are financed by bank
credits at concession rates. Availability of credit therefore, is the most crucial factor impacting
tractor demand.
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ITL has signed MoUs with various banks all over the country for tractor retail finance, which is
giving a special impetus to company. It has resulted in easy availability of loans to farmers
coupled with quick disposal of cases. The payment rotations have also become faster from the
dealers to the company, which helps cost cutting.
WORK CULTURE
The I.T.L. seeks to create a culture where each employee, vendor, and dealer feels himself
responsible and integral part of the enterprises. The work culture at I.T.L is open &
participative. Learning is encouraged in the company. Every member respects 5F formulas
1. Fast 2. Focused
3. Fair 4. Friendly.
5. Fun
This governs its approach to business and relationships within the organization. It has designed
its management structure in response to the needs of quick decision-making and operational
flexibility even through hierarchies and designation does exit. It is a highly informal
organization where communication moves in all direction, decision-making is quick and to a
large extent delegated
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3. To attain leadership in developing, adopting and assimilating state of the art technology for
competitive advantage.
5. To faster a culture of participation and innovation for employees growth and conditions.
6. To cultivate high standards of business ethics and total quality management for a strong
corporate identity and brand quality.
7. To help enrich the quality of life of the community and preserve ecological balance and
heritage through a strong environment conscience.
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At present the company has a strong nationwide network of 528 dealers. The distribution in the
various states is
Andhra Pradesh 26
Assam 04
Bangladesh 01
Bihar 37
Gujarat 31
Haryana 37
Himachal Pradesh 04
Jammu & Kashmir 01
Karnataka 18
Kerala 01
Madhya Pradesh 68
Maharashtra 35
Mizoram 01
Nepal 09
Orissa 10
Punjab 48
Rajasthan 53
Tamil Nadu 25
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1. 3 VARIOUS MODELS OF TRACTORS
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1.4 DEPARTMENTS OF ITL AND THEIR H.O.Ds
DEPARTMENT IN-CHARGE
Q. C. - MR. N. C. KOHLI
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CHAPTER 2
2.1 PRODUCTION
ITL has fully integrated and state of the art assembly facilitation for producing world class
tractors. Several productivity improvements in assembly line over the years have made it
possible to manufacture nearly 37000 tractors per Year. Automation of assembly line not only
increased production capacity, but also provided a quantum jump to the quality of assembled
tractors. ITL assembly line producing tractors in broad range from 20HP to 120HP with
effective planning of resources.
Hydraulic Test Rig Up to 1600Kg Lifting Capacity
Millipore Testing Equipment. Torque calibrator
Hydraulic presses
A unique 3-Stage oil filtration system having modern facility of centrifuge filtration
Batch type Special purpose machines (SPM) at various locations for washing of heavy
castings, components & subassemblies
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Pipe flushing machine for proper cleaning of hoses & pipes
Induction Heaters for controlled heating of bearings
Roller Testing
Field Testing
Road Testing
QUALITY ASSURANCE
Inspection Phase
Quality Control Phase
Quality Assurance Phase
Total Quality Management Phase
Profile Projector used for inspection of Critical Parameters e.g. Thread, Gear profiles etc.
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The R&D designs the parts and sends them to the vendor to develop the parts as per R&D
design. R&D sends the design details to the ME department. Here starts the role of the ME
department. ME makes assembly procedure by managing line processes and new design.
Vendor Department (VD) gives the parts to protoshop to assemble parts in presence of ME
representative to validate the sample & procedure as per assembly line point of view. ME
department has the authority to approve & reject these parts.
All the approvals are to be made in the protoshop. ME gives the GO ahead for production line.
ME, Production & plant quality validates jointly on the production line for new models or
samples. After all the fitments found OK on production line, GO ahead for regularization of
new model or sample is given jointly.
Time Study
Line balancing
Tool design
Improvement of regular design
Therefore, ME department basically acts as the intermediate or the bridge between R&D
department and the production line.
MANUFACTRING
UNIT
GEAR HEAT
HEAVY LIGHT MACHINE
TREATMENT PRESS SHOP
MACHINE SHOP SHOP
SHOP
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2.3.1 Heavy Machine Shop:-
All the major components of Tractors are machined in HMS. These are
Crank Case.
Differential housing.
Gear Box Housing.
Clutch Housing.
Trumpet Housing.
This infrastructure is equipped with the advanced CNC Machining Centres, Special Purpose
and General Purpose Machines. All the components are thoroughly checked and inspected for
its Geometrical accuracy on the imported 3D Coordinate Measuring Machine.
2.3.2 Light Machine Shop: - It is a shop where manufacturing of sophisticated Control Valves
for high pressure (200 Bar) Tractor applications is done with Hardened (60HRC) Bush and
Spools for prolonged service life. This infrastructure have capabilities to Design, Develop and
Manufacture complete Hydraulic Assemblies for Tractor applications of Lift Capacity up to
3000 Kgs. and Flow rates up to 45 LPM.
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Control Valve.
Composite Valve.
Feathering Valve.
Relief Valve.
Release Valve.
Hardened Alloy Steel Bush & Spool Assemblies.
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2.3.3 Gear Heat Treatement Shop:-
Having World Class manufacturing facilities to deliver best quality of transmission gears,
shafts & assemblies for automobile and tractor applications. The Facility delivers all types of
gears & shafts like Main Shafts, Lay shafts, Input Shafts, Synchromesh Gears, Gears with Dog
Teeth, Shifter Sleeves, Synchro Hubs & Cones.
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List of Various Presses used in the Press Shop:-
Presses:- QTY.
The Press shop also includes two Rapido 5 Axis Laser Cutting machine from M/S Prima (Italy)
with a travel of 3.5 X 1.7 x 0.8 Mtrs. and can cut thickness up to 5 mm. These are used to cut
sheet metal of specified sizes , end products being used for further processing i:e for Pressing.
There were also two Injection Moulding Machines used for making Wet air cleaner unit or
other plastic accessories.
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2.4 ASSEMBLY
The State of Art assembly line for Engines is one of the best lines fitted with high quality
automated slat conveyor system having various safeties and DC Multi Nut Runner systems on
the different stages which ensures consistent production. The diesel engines assembled here are
from 28 HP to 90 HP. The Main Engine Assembly facility Includes:-
The conveyor is fitted with 28 fixtures for mounting of all engine models with facility for
360 degree rotation for various assembly operations.
All Stages are equipped with DC Multi Nut Runners for optimized and consistent
production.
The Complete Shop is Air Pressurized to ensure dust free environment for the quality
production.
Sonalika Group possesses two state of art assembly lines in India and two abroad. In India
assembly lines are situated at Punjab and Himachal Pradesh.
International Tractors Ltd. has tractor assembly line equipped with capacity of 80,000 tractors
and engines per year. The plant has in house facilities for producing transmission hydraulic
components and engines. To further enhance the quality of Tractors, Gears, Shafts and other
important components are manufacturers in house and are tested on high end testing facilities.
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2.5 ENGINE TESTING
Engine testing is done for checking the performance of newly assembled engine to found out
any assemble fault, their H.P., leakage and other faults. Engine testing shop of the I.T.L. is
equipped with latest digital control equipments. The engine testing is done with help of turbine
(water) or hydro dynamometer. The hydro dynamometer are four in number so that four engine
is tested at a time. The shop is equipped with heavy-duty oil filter, which is used to clean the oil
from dust or other large particle. The shop has bush pump tester which is used to test the pump
if there are any fault. The engine power is measured on the bases of S.A.E. ratings. The society
of automobile engineers U.S.A has specified the method of measuring the power output of the
engine for standardized purpose. The engine is run without generator, air cleaner, cooling fan
etc. However standard circulating pump, fuel pump is fitted to the engine. The horsepower of
the engine is measured with dynamometer and measured values are then corrected for the
standard pressure, ampere and humidity condition prescribed.
Before starting the engine the lubricating oil is filled into the engine and then engine is
mounted on the fixture. The flywheel is directly attached to turbine through connecting shaft
and engine is started. The engine is made to run for three hours to check the engines leakage
and if there is any leakage then that fault is found out and again put into the testing and if again
there is any fault then that engine is rejected. After minute running the tappet clearance is
checked. Tappet clearance is to be kept .25.005. The clearance is necessary otherwise the
thermal expansion of valve will alter the opening of closing of valve angles. After that engine is
run at 2400 r p.m. m. for 2.30 hours and then the engine is run at various r.p.m. and loads to
calculate the power, b.h.p. and s.f.c. . If the engine is seen to emitting too much smoke than
smoke level is also checked.
The engine shop is having latest technology and all the information is available digitally. The
load can be increased or decreased r.p.m. or s.f.c. can be changed from within the electronic
cabin. Power test is done. on 2200 r.p.m. (Maximum r.p.m. of engine is 2400) where torque is
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rated and is indicated on digital meter. The alteration in r.p.m. is made by varying the load and
fuel supply is kept constant. The power is calculated as follows
If the power calculated from above formula comes lower than prescribed limit than usually fuel
timing is altered. The fuel timing is altered with the help of F.I. pump. Usually the engine is
tested on 18 Celsius advancement By revolving the pump away from engine the timing is
reduced and by revolving F.I.P. toward the engine the time is advanced. The advancement
usually lower down the power, so timing is reduced unto possible limit to increased the power.
S.F.C.: -
It is one of the most important parameter for engine comparing. It is defined as the ratio of
amount of kg of fuel used per hour by the engine to power produced by the engine.
It is capacity of engine for maximum load that after the engine r.p.m. Will decreased to zero.
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T (max) is displayed by meter at 1500 + 100 r.p.m. T (max) is found by loss of r.p.m and
increased of torque. The engine is loaded till torque is max and after which the loaded cause
drop in torque.
After complete assembly of engine ,Engine comes to testing shop for testing. In engine testing
firstly engine put on the testing bed and then flywheel of engine attach with the dynmo , fuel
supply , water supply and air cleaner. Now engine is ready for testing. Testing is done to test
the engine for various problems like oil leakage , RPM checking , torque , fuel consumption.
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STAGE: 1
Washing of crankcase:-
i) Block is placed in a washing machine.
ii) Different nozzles are there in that washing machine.
iii) Water + chemical is sprayed for 15-20 min. Chemical used is COROSEAL -33. It is a
corrosion inhibitor, manufactured by Pratap Tex-chemPvt. Ltd. Pune
iv) Temp. range of washing machine is 45-60 degree C.
v) 2 Heaters are used to heat the water + chemical mixture.
STAGE:-2
1. Cleaning of crankcase--- After washing the crankcase is sent to second stage with the
help of roller belt. And then crank case is cleaned with the help of air pressure followed
by the rubbing of brush into the holes provided for the different components.
4. Cylinder liner fitment: -Fitment of cylinder liner into the crankcase bymandreling and
hammering.The liners available in I.T.L.. are of three grades i.e. A, B & C grades. The
A grade liner has dimension of +12 microns, B grade has dimension of +24
microns and Cgrade has dimension of +36 microns. The cylinder lining has 2 seats
one is for oil and other is for water. The grade sign of liner should be kept toward
camshaft.
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5. Fitment of tappetsTappet is also known as cam follower. It is attached to the rocker
arm with the help of push rod, which opens the inlet and outlet valve.
STAGE:-3
Crankshaft Fitting: -Firstly Crank caps are opened with help of opener. Then on the first crank
cap BIG gear is fitted with help of mandreling and pressing .Bush type liner are inserted into
the bearing holes. The linear is provided with recess to store a minimum amount of oil, which
wets the crankshaft during starting of engine. The bearing cup is opened and crankshaft
assembly is placed into it. The bearing cup is tightened again with 10-12-kgm torques and
crankshaft is checked, that it is revolving easily.
STAGE: -4
Cam shaft fitting:-
The camshaft is inserted into the camshaft hole with be-baring and bolt ends are locked by
circlip. The crankshaft is forged from alloy steel or cast from hardened cast iron and is case
hardened. The tap-pet used on cams is of spherical base and are slightly wear pattern preve-
nting edge loading which is major cause of failure. The one end of camshaft is provided with
gear, which is linked with idler gear Z-50. for exact-ct timing the camshaft gear mark is
matched with mark on ideal gear. Another gear is attached with idler gear, which serve the
purpose of driving the fuel injection pump.
The idler gear shaft is pushed into the crankcase and roller type bearing with lock is inserted
into the shaft. The idler timing gear is then pressed into the bearing. The timing gear is punched
at two places and punched sign has to be matched with the punched mark on crankshaft.
STAGE:-5
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The piston assembly is fitted into the linear and big end is tightened to the crankshaft with 8-10
kgm torque. The pistons are also grade as A, B, C has same that Agrade line is fitted with A-
grade piston assembly. the grade mark should be towards camshaft. The piston ring cuts should
be so adjusted that there should not be in same line.
STAGE: -6
Lubricating oil pump mounting: -
The lubrication oil pumps connected to crank shaft gear by an idler gear of 2-3 degree. The
crankshaft gear and pump gear are of 22 teeths each. The pump is provided with a relief valve
that opens at 4 kgf forces. In case there is over loading or some thing injected in main oil
gallery then pressure is released from this valve.
STAGE:-7
Rear cover and Front cover fitment: - The rear cover and front covers are cleaned properly with
air and then fitted to engine with seals in between. Main function of front cover is to cover the
timing gears and to prevent the oil leakage from crank case. Rear cover is fitted to cover the
rear side of crank shaft and to stop the oil leakage from crank case.
STAGE:- 8
Pulley mountingPulley is mounted onto the crankshaft with the help of mandrel.
Function of this pulley is to drive the alternator, water pump and fan.
Cylinder head mounting: - The cylinder head assembly is placed on the piston and studs
are passed through its. If the height of piston at T.D.C. from the surface is more than
0.1mm than the gaskets of given thickness are used. If it is 0.1mmto 0.5mm than 1.2mm
thick gasket is used If it is 0.5mm to 0.8mm than 1.5mm thick gasket is used. cylinder
head nuts are tightened by 21 kgm forces.
STAGE: -9
Flywheel mounting: - The flywheel is mounted the crankshaft and bolts are tightened with 8-9
kgm force. The F.I. pump is connected to the F.I.P. gear through theF.I.P. drive shaft. The
F.I.P. drive shaft is special desig-ned to advance the timing of injection. The both ends of F.I.P.
drive shaft is provided with spline on one side a key is provide which is locked to timing gear
and recess on other side is pushed into the the F.I.pump slots. The angle between the key and
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recess is of 18 degree. Thus the fuel injection is advanced by 18 degree. F.I.pump slots. The angle
between the key and recess is of 18 degree. Thus the fuel injection is advanced by 18 degree.
Oil pan fitment and disk plug fitmentOil pan covers the bottom end of crankcase and
preserve the lubricant oil .It also acts as a container for impurities and unwanted material.
STAGE: -10
Fitment of push rod and Rocker Arm
It attaches rocker arm and tappet . Its main function is that when cam shaft lift the tappet and
tappet lifts the push rod. After that push rod pushes the rocker arm from the back and the valve
is open. The rocker arms with spherical followers are inserted into galleries and connected to
the rockers arm. To compensate for thermal expansion the gap between inlet rocker arm and
valve is adjusted to 0.3mm. The gap between exhaust valve and exhaust rocker arm is 0.4mm.
STAGE: -11
Water body fitment: - The water body is mounted with thermostat control valve. The valves
open at 70 Celsius. Thus engine is kept at correct temperature. The pulley is mounted on
crankshaft. Water return line exhaust flange and inlet manifold mounting.
STAGE: -12
Fitment of valve cover and alternatorFitment of valve is present just to cover the rocker
arm. Fitment of alternator is done to convert mechanical energy into electrical energy and that
electrical is used to charge the battery.
STAGE: -13
Fuel injection pump mounting and set fuel injection pump.
The gear of F.I.P. is first of all meshed with the F.I.P. drive shaft (with recess) and is loosely
tightened. To set the timing of gear first of all pointer is tighten on the crankcase and flywheel
is rotated which is mashed for (6, 18, 20 & 24) angles. The pointer is set at 18 degree of
flywheel and then the pump is rotated clockwise till the oil from first nozzles stop out flowing.
At this position a cut mark is made on both the pump and crankcase for future settings. The
pump is tightened properly and pipes are tightened over nozzles and injectors.
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Fitment of oil filterFitment of oil filter done to filter the oil which is circulated to
crankcase.It takes oil from lubricate pump and then move this oil to the oil gallery.
STAGE: -14
Fitment of Fuel filter and Self Starter - After removing the engine from conveyer belt to
roller belt. Before removing the engine from conveyer belt the base plate, filters and other
accessories are properly tightened. The main function of fuel filter is tofilter the fuel.Fuel
coming from fuel tank goes to primary filter, then it moves to fuel filter. Then its filtered and
moves to main line of FIP.
Sonalika is equipped with Research & Development Centre which has on board more than 300
specialist engineers and most updated technology to provide customized solutions to our
customers. It manufactures products which have been thoroughly designed and tested by the
R&D personnel.
The main thrust of the R&D function is to accelerate innovation and maximize the value of
each product designed to provide economic benefit to customers at large. The highly skilled
and experienced man power develop products ranging from 20-110HP catering to both
domestic and international markets. The products undergo through multiple check points for
quality assurance before they go for production. They have been recognized both nationally and
internationally.
Situated at Hoshiarpur, Punjab, Sonalika ITLs R&D department has an in-house testing
facility for all the parts to ensure 100% quality. Equipped with the most updated technology it
provides solutions by creating a real time situation to understand the problem. And, then taking
into account other factors like the terrain and geography in which it is used, the product is
redesigned to suit the customers specific needs. Further, the R&D department works in
coordination with the production department to ensure smooth transition of technology from
design department to assembly line production.
Sonalika ITLs strength lies in manufacturing products which are a result of the efficient
designing and testing by its state of art R&D center. It has 3 sub departments which function in
full co-ordination to achieve the best possible standards.
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R&D Centre
The designs thus produced are actually manufactured in the Proto Shop which is
equipped with the Following:-
Horizontal Machining Centre HMC-500m
Vertical Machining Centre VMC-600m
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2.6.4 OTHER FACILITIES
computerized Lead & Profile Testers, Surface Roughness Testers, Contour Testers
LECO Micro hardness Tester, Microscopes with the Image Analyzer, Universal Testing
Emission test cell for conducting emission measurement Installed by AVL, imported
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CHAPTER 3
RESEARCH AND DEVELOPMENT CENTER
Under the assistance of Testing Head Mr. Dina Haran we were told to work under Mr. Parmod
Singh, Manager of DAQ lab.
He gave us exposure to the DAQ lab (Data Acquisition), to basically what actually is done
under this lab, which broadly divides it into 2 sets that is Loading and vibration testing. It
consists:-
4. Strain gauges.
Data acquisition is the process of sampling signals that measure real world physical conditions
and converting the resulting samples into digital numeric values that can be manipulated by a
computer. Data acquisition systems, abbreviated by the acronyms DAS or DAQ, typically
convert analog waveforms into digital values for processing. The components of data
acquisition systems include:
There are also open-source software packages providing all the necessary tools to acquire data
from different hardware equipment. These tools come from the scientific community where
complex experiment requires fast, flexible and adaptable software. Those packages are usually
custom fit but more general DAQ package like the Maximum Integrated Data Acquisition
System can be easily tailored and is used in several physics experiments worldwide or with the
help of instruments likeIMCs and LMSs
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Before conducting these test some reference value or we can say field value is required which
is provided by FLDAs (field load data analysis) road simulation or by CAE analysis. In DAQ
lab we are familiar with IMC and LMS for collecting data with accelerometers, different type
of sensors, Instruments and Strain gauges.
3.2 IMC:-
The IMC CRONOScompact is the single most comprehensive data acquisition system for
electromechanical testing on the market today. Integrating measurement, control and simulation
into one housing provides you with ther eliability of absolute synchronization, and the
convenience and ease of use of having all of your tools in one place.
Whether you are measuring highly dynamic vibrations beyond the audio range, using multiple
PID control loops for test stand automation, or monitoring process signals and fieldbus data
throughout an entire test cell, IMC CRONOScompact is there for you. From high voltage to
current fed, and strain gauges to thermocouples, the integrated signal conditioning of IMC
CRONOScompact also ensures every sensor you need is compatible. At a glance:-
3.3 LMS:-
The LMS SCADAS suite of data acquisition systems delivers the data quality and format that
you require for all types of noise, vibration and durability measurements in the laboratory or in
the field. Depending on your needs, you can use a LMS SCADAS system as an autonomous
recorder or as a frontend connected to a personal computer. Seamless integration with LMS
Test. Lab and LMS Test. Xpress software helps you accelerate measurement setups and
delivers correctly formatted results. LMS SCADAS provides you with best-in-class data
acquisition for reliable results and optimal testing productivity.
LMS SCADAS data acquisition systems cover a broad range of engineering applications for all
kinds of manufacturing industries and help you develop better products in a shorter timeframe.
Some of them are listed as under:-
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The Quality Leader in Data Acquisition Systems.
After conducting all these tests or simulations or on the basis of customer complaints and field
failures or according to new design improvements, parts are tested on testing machines or by
gauging. Objective of gauging is to study dynamic stress analysis of tractor or component with
implement for different agricultural operations.
3.4 ACCELEROMETERS:-
There are two broad categories for piezoelectric accelerometers those that contain built-in
signal conditioning electronics (ICP type, voltage mode) and those that do not (Charge
Mode). Generally, ICP accelerometers are preferred, due to ease of use, easier data system
calibration setup, and lower system cost. ICP accelerometers typically come in one of two
sensitivities: 10 mV/g (+/- 500 g) or 100 mV/g (+/- 50 g) ranges. Charge Output accelerometers
are typically used in high temperature environments, which would otherwise destroy the
electrical components in an ICP type accelerometer.
3.4.1 Single Axis Accelerometers:- Motion of a rigid body can be characterized within six
degrees of freedom. Providing mechanical excitation to simulate this motion as may be
encountered in the real world can entail a variety of test machines. There are various
pound/force vibration shakers for structural testing. Regardless of the apparatus, the goal is
always to ensure that the product under test can adequately perform, and reliably survive, in the
environment in which it will be deployed, or to which it will be exposed during transport.
PCB accelerometers provide the measurement signals needed to control the vibratory input
and to analyse the products reaction to such testing. Did the test achieve the acceleration
amplitudes and frequencies desired? Did the product react in a consistent manner? Did any
components or mounting techniques become altered? These are just a few of the questions that
can be verified by analysing the signals generated by PCB accelerometers.
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System Characteristics:- SONALIKA
Acceleration (sine) 85 g.
by the customer.
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3.6 Fatigue Rig:-
It is a Hydraulic Static and Cyclic Loading machine manufactured by MTS company, used to
check the endurance of various loading parts for example axles, universal joints, Brackets etc.
hydraulic actuators and piston apply load in one direction as in static loading and in 2 directions
as in cyclic loading to find the maximum load in kgf it can withstand without breaking .whole
Suitable fixtures are made to hold the testing components rigidly on the Bed (Bed having T-
slots cut all along the length). Various Sensors are mounted on the piston to check Fluid
Pressure, axial displacement like LVDT &RVDT, plus Servo motor valves to control and
maintain flow.
Fig. 3.17 Front Axle Bracket(FAB) testing under Cyclic loading on Actuator1.
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Fig. 3.18 Differential Sun &Planet gear testing under Static Loading on Actuator2.
Fig. 3.19 Fixture to hold the Front axle tightely on bed while under testing.
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CHAPTER 4
PROJECTS
SONALIKA, being one of the pioneer in tractor industry today, There is an urge to produce new
variants and models to remain as a strong contender in the market. As the industries are
exaggerating every minute, we come across some eye-popping inventions every now and then.
Furthermore, SONALIKA have various joint ventures and projects with worlds some great tractor
companies such as with TURKEY and JAPAN etcetera.
One such modification was required in SOLIS NARROW TRACK 75 which being one of its
kind did not have AC cabin till date. Moreover, it was a part of SONALIKAS joint venture
with TURKEY to develop a new variant.
Besides this, INDIA who houses agriculture as a major ingredient in its GDP needs renovation.
Farmers who plough their lands for almost 6-8 hours a day have their faces covered with dust and
sweat. With the addition of HVAC (Heating, Ventilation, Air condition) in tractors, farmers can
work in their fields for more than 15 hours per day as compared to the earlier used to. With extreme
weather conditions of high temperature in summers and minus degree temperature in winter these
tractors are assent to the farmers, thus ensuring the cabin is climate controlled for all season
comforts.
1. CABIN
HVAC tractors comes along with an embedded glass chamber such that even incursion of air
cant take place. These are designed by keeping in mind the comfort level required nowadays
and the harsh and severe temperature to which farmers come across in their field work.
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3. HANDLES
Basically, tractors have 450 mm X 300 mm floor rest size .But this was reduced by 50mm in
length.
6. CUSHIONING.
Cushioning is an integral part of a HVAC tractors. Thus, proper selection of material For
cushioning is very vital as it can lead to infiltration of outside air into the cabin and hinder its
performance.
7. LEVERS
In case of HVAC tractors, levers such as gear shift levers, hand brake levers, parking brake
lever etcetera are considerably smaller in size and are compact in design to aid the cabin.so, and
these were altered too.
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4.3 CABIN
PARTS OF CABIN
REAR LIGHTS 2
FRONT LIGHTS 2
FRONT GLASS 1
SIDE GLASS 2
REAR GLASS 1
GAS SPRINGS 6
LOCK HANDLES 3
FRONT GLASS WIPERS 2
SUN WISER 1
SPEAKERS 1
CABIN OVER HEAD LIGHTS 1
AIR OUTLET DUCT 2
AIR TEMPERATURE SELECTOR 1
DRIVER SEAT 1
SEAT BELT. 1
HOOK 2
FLOOR MATS 2
Lock handles : CD
TYPE : VRMO5
EC APPROVAL : C11;2009/752009/75307700
SERIAL NO : 2015-1322
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SONALIKA
TYPE OF TRACTORS FOR WHICH CABIN IS INTENDED
SOLIS 60N
SOLIS 75N
SOLIS 90N
INSTALLATION OF CABIN
CUSHIONING
Firstly, the drivers seat and steering wheels were removed. The reasons they being removed
were
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Normally, the tractors which are available in the market are bigger in size but these HVAC are
compact yet more efficient.
Floor rest size in particularly in case of basic tractors are of 450mm X 300mm in dimensions
and there is no need of ROPS in HVAC tractors.
However, the floor base was cut off of length 50mm intently to make floor base size as per the
requirements specified.
All the process of cutting took place in MOCKUP department and after cutting it was allowed
to cool down for 3 4 hours. Moreover, some other parts were removed too such as Bush
Holders.
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EQUIPMENTS USED FOR CUTTING
(4) M10 Nuts & Bolts were used for FLOOR REST 3 M10 Nuts & Bolts were used for SIDE
FLOOR
4. DRILLING
One of the main process involved in this whole mechanism was drilling holes for the proper
placement of the cabin in its pre designed locations which were made using drilling machine.
FLOOR REST 4
DASHBOARD 5
FRONT LIGHTS 4
REAR LIGHTS 4
SHEET COVER 15
MOUNTING COVER 12
FENDERS 8
5. CABIN INSTALLATION
After all the drilling process, cabin was lifted using overhauling cranes and was moved charily with
utmost care so that it fits the calculated positions and desired holes. After being placed on the
tractor, it was checked by the cabin whether it meets the requirements or not .and then the
fitting process begins.
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6. ELECTRIC CIRCUITS
After all the necessary work, all the various electric circuit were brought back to life by
connecting them to their respective equipments.
REAR LIGHTS
FRONT LIGHTS
SPEAKERS
DC OUTPUT
AIR TEMPERATURE SELECTOR
AIR OUTLET DUCT
FRONT INDICATOR LIGHTS
CABIN OVERHEAD LIGHTS.
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REASON:
ANALYSISOil leakage from oil pan drain plug due to damage of threads due to excess
torquing and due to more torque socket area also damage. And this causes oil leakage from
specified area. Oil pan is provided with drain plug to drain the lubricant oil from engine .Due to
thread damaging of drain plug, oil leakes from engine through the oil pan drain plug .Oil pan or
sump forms the bottom half of the crankcase. It is attached to the crankcase through set screws
and with a gasket to make the joint leak proof.
Suggestion-
1. If the screw is tightened up to appropriate torque of 3.5kgf; it will result in complete mating
of screw and hence no leakage will occur.
2. Avoiding cross tightening of the screw will also decrease the leakage because zero cross
tightening will result in complete mating of screw leaving no passage for leakage.
Sound in Engines
Causes:-
Remedies
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Suggestions
Full set of timing gears leads to loss of three gears with increase input costs. When the timing
gears are manufactured it must be checked whether these are getting properly aligned or not.
Timing Out
Causes:-
Remedies
2. Match the marking numbers on the timing gears and put them in proper order.
Suggestion
When gears are checked for alignment, numbers should be punched on them in such a way that
a set of gears has same set and these must be transported to engine assembly in a proper
packing with number written on the packing to avoid mixing of the gears.
SUGGESTIONS
2. Earlier pneumatic guns had tolerance of +-40 which causes excess tightening of caps but
now new guns have been installed which has tolerance limit of +-10; which results in
approximate desired torque.
BLACK EXAUST
REASONS
3. Poor compression.
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4. Incorrect type fuel.
SUGGESTIONS
1. Rocker arm clearance to exhaust is .40 mm and intake has .30mm. but due to large clearance
of pneumatic guns this limit increases results in improper tightening results in opened valve
most of time. This causes the problem of black exhaust.
2. Crank case has inlet and outlet water holes, these holes are closed due to not proper cleaning.
By cleaning these intake and exhaust holes with care we can overcome the problem of black
exhaust.
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