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Ashok Leyland Inplant Training Report

FRONT AXLE:
The front axle is used to connect the two wheels of the vehicle.
It consists of Axle Arm, Air Booster and Bearing arrangements.
The King Pin connects the axle arm and the shaft.
The Grease Nipple is used to supply grease for the lubrication process to take place.
The bearing is place below the king pin.
First the inner bearing is fixed. Then the Hub Cap is attached which holds the outer
and inner bearing.
For even movement of the wheels, outer and inner bearings are fixed.
The purpose of air booster is to supply air which eventually engages the brake
system to stop the vehicle.
When the air booster supplies air the lever which is placed below the air booster
expands which causes the brake drum to expand and the coiled spring elongates
which helps the brake shoe to create friction and cause instant stopping of the bus.
The Brake Drum is made of Cast Iron.
The wheel alignment is checked using a Dial gauge.

REAR AXLE:
The axle pedestals are loaded and the correct positioning of the LHS and RHS is
ensured. The wire strips and axle shafts are removed and placed on the skid.
Plastic caps on both sides are removed. Dust covers on the brake shoes are assembled
and tightened. It must be ensured that the same kind of brake shoes is fitted on both
sides.
The brake is assembled with ten bolts and nuts and tightened at the next station.
Torque is applied on the brake mounting nuts to torque values 102-108 Nm.
A sub assembled antilock braking system sensor ring bracket is fitted to the ABS
axles.
The inner ring for oil seal, inner bearing, and distance piece shims are assembled
onto the hub, which is loaded onto the casing.
The A.T nut is tightened and the hub is checked for its end play value to spec
0.002to0.06.the A.T nut hole is matched with axle tube slot if endplay is within
spec match
A punch mark is made on A.T nut and axle tube. Grease is applied on bearing inner
races, hub and mud flinger for stage models.
The hub is mounted on the axle tube. The endplay is checked and if not within
0.002-0.006, the shims are altered.
Any damage in the components is checked at this stage. Any changes necessary are
made.
The induction heat pole wheel for ABS axle is pressed on the step provided on the
hub. It is ensured that there is no gap between hub and pole wheel.
Grease is applied on the mud flinger inner bearing. The sensor is pressed with a
5mm rod to the extreme distance for proper sensing.
The T bolt split pin is fixed the grease plug and hub stud are fixed. The brake drum
is assembled and tightened with two wheel nuts with driven hub studs.
The gaskets for the axle shafts are fixed. The axle shaft is assembled and tightened
with spring washers and nuts.
Torque is applied on the axle shaft mounting to values of 102-108 Nm. The cable is
routed to the rubber grommet in the hole provided in the brake carrier.
The cable is wound in the axle casing and tied with the nylon cable tie.
The axle is then unloaded on the skid.

CHASIS ASSEMBLY:
Stage I :Frame Loading
Antilock braking system, electrical hoarse, air tank, air drying unit, valve and air filter are
fitted on to the frame by bolting

Stage II :Front Axle Mounting

The front axle fitted with leaf springs is mounted on to the frame. The leaf springs are
mounted on to the front axle in an orientation parallel to the wheel hubs.

Stage III:Rear Axle Mounting

The rear axle with leaf springs is mounted on to the up turned frame.

Stage IV: Axle Torqueing

The I bolts are tightened and a specifically programmed computer checks the Torque of
the axles. (T= 350 Nm for pitch =98Nm)

Stage V:Silencer Mounting

The L angles are bolted on to the frame for the silencers and its air shafts. The silencer is
then mounted on to the frame.

Stage VI :Chassis Turn Over

With the help of a hook- chain-pulley mechanism the entire frame work is upturned so that
it is facing the right way. The rear indicator lights are fitting on to the frame work along with
the batteries.

Stage VII :Fuel Tank Mounting

A cylindrical fuel tank is mounted just adjacent to the silencer on the left side of the chassis.
Stage VIII :Engine Mounting

Previously assembled engine and the gear arrive to the assemble station and s mounted on
to the front of the chassis frame work.

Stage IX :Radiator Mounting

The radiator is fitted to the engine such that the cooling fan is positioned in front of the
engine and air filter is fitted along with the radiator. The horn is placed in between the
hydraulic breaks of the front axle.

Stage X :Oil Filling

The various oils are filled in Gear Box Oil 1 & 2, Front & Rear Axle oils, the coolants for
radiator and other components, Clutch Oil and Power Steering Oil.

Stage XI :Cabin Fitting

The pre-fabricated upper covering for the engine along with the gear stick, drivers seat,
steering wheel, dash board fittings and the pedals for the accelerator, breaks and clutch are
fitted. Front indicators and head lamps are also fixed.

Stage XII :Electrical

The wiring to the Tail lights, Head lights, Indicators, speedometer and other display units
are done at this stage and the connections are checked

Stage XIII :Wheel Mounting

The front and rear wheels are mounted on to their respective hubs by the means of a single
armed robot with a fork lift attachment.

Stage XIV :Wheel Torqueing

The Torque produced by the spinning wheels is gauged by a programmed computer and
proper wheel alignment and balancing is done if necessary.

Stage XV

Vehicle Starting

The body for the cabin is mounted and the vehicle is started and given a once all for any mal
functions or anomalies.

Stage XVI :Off Track

The assembled and completed vehicle is given the test drive as per the standards of the
company.
GEAR BOX ASSEMBLY :
One of the important part of entire design criteria which handles the speed and
control the vehicle is Gear.
Change in gear changes the speed of the engine with respect to the acceleration given
to the system.
But why exactly the gears are used and what exactly it does was clearly explained
and showed while they were being perfectly assembled into the system engine.
It was clearly explained from the process, any force that which rotates a body is
called torque. And it was understood that we must give maximum torque while
starting and for maximum torque the engine must run at slow speed. But we cant
run the engine at very slow speed because it will switch off and that is why we use
GEARS. They are used to reduce the speed or increase so that we get maximum
torque and the eventually the wheel stars rolling.
Once the wheel starts rotating we dont need that much torque. So we change it to
second gear and that increases the speed and principle follows.
Apart from learning what the principle is practically, the Gear box assembly was
shown.
There were various processes done which leads up to the perfect finish of the gear
box. They were:
Initially proper loading of the gearbox casing on the pedestal stand is done.
Then proper loading of coupled shafts assembly in the casing is done.
Tightening of dummy plugs on the either side of the casing is carried out
after that.
The above process is maintained to 35 +- 10% Nm.
The selector forks are fitted properly.
The selector plates are prepared as per the general specification
The application of Loctite on pivot screws is done.
Then the pivot screw with washer is fitted.
The torque tightness is given about 160 +- 10% Nm.
Suitable spacer on mainshaft is fitted.
The dimension will be about 0.9 to 1.2 mm.
Proper dowels are fitted.
Bell housing mtg bolts with washer is fitted.
Bell housing mtg bolts torque tightened to 46 +- 10% Nm
Suitable spacer for Layshaft front bearing is fitted
Input shaft cover gasket is fitted.
Detent plunger with tab washer is fitted
The above process torque tightness is about 65 +- 10% Nm
The tab washer is folded properly.
Input shafts are covered with mounting bolts
Torque tighten is about 25 Nm
Proper fitment of GCH gaskets bolts with washer is done.
Torque tighten is about 23 +- 10% Nm
Free engagement of gear movement of selector shaft is ensured
Reverse idler pin or ring is fitted.
Gear and two needles bearing are fitted.
Fitment of Rev idler locking plate mtg bolt is done
Rev idler cover gasket mts bolts are ensured.
Torque tighten is about 23 +- 10% Nm
Reverse light switch with washer is fitted.
Torque tighten is about 45 +- 10% Nm
Speedo worm and washer on main shaft is fitted.
Proper fitment of end cover with gasket is ensured.
Torque tighten is about 79 +- 10% Nm
Oil or grease is applied on oil seal lip
Oil seal on casing bore is fitted.
Flange is selected as per the specification.
Loctite is applied on threaded portion of main shaft
Torque tighten is about 360 +- 10% Nm

KEY CHARECTERISTICS

Correct orientation of PTO and mtg nuts is ensured.


Torque tighten is about 75 +- 10% Nm
Grease is applied on speedo gear is done
Washer is fitted along withit.
Torque tighten is about 100 +- Nm
Finally the finished gear box assembly is unloaded on the testing
pedestal.

CYLINDER BLOCK:
The cylinder block is otherwise known as Crankcase.
The cylinder block is cleaned in a machine using the required coolant.
Then the Oil Leakage Test is done using oil leakage testing machine.
The Bearing Cap is placed in the blocks which are fastened using bolts.
Inside the cylinder block crankshaft and piston are placed.
The Grooving and Facing operation are done respectively for getting the smoother
surface.
Honing process is done using Liner Bore. Honing machine which improves the geometric
form of a surface and its texture.
Crank Bore Brushing operation is performed to remove burrs from the bore which is made
in the cylinder block.
Both the sides of the cylinder block are made smoother by the finishing process
It is also known as Engine Block.
DOWEL PINS are the locating devices which are used for oil pump location.
The oil pump shaft diameter is made to allow oil flow.

CYLINDER HEAD:
The cylinder head comprises of inlet and exhaust valves.
The cylinder head is first cleaned using the machining process.
Facing and Drilling operations are performed
Wash and Air Blow operation is done to check the oil passage.
Air Leak Tester machine is used to check whether there is any air leakage.
Heat Balance Test is placed to locate the inlet and exhaust valves.
A Bore is made using the Boring machine to enlarge the diameter.
Then the Finishing operation is performed.

CAMSHAFT PROCESS:
Camshaft controls the opening of inlet and exhaust valves.
The material used in camshaft is FORGED STEEL.
The FACING operation is done to remove some materials to get smoother face.
The TURNING operation is used to reduce the diameter of the workpiece.
A groove is made on the camshaft using grooving machine which enables the oil
lubrication process to take place smoothly.
KEYWAY MILLING is done to connect the two shafts on both sides of the camshaft.
GUN DRILLING operation is used to drill holes for the oil flow purpose.
The machining operation are done using CNC(COMPUTER NUMERICAL
CONTROL) PLC(PROGRAMMABLE LOGIC CONTROL)
Induction Hardening process is carried out to avoid wear and tear of the camshaft
Tempering process is performed to achieve uniformity along the camshaft
LANDIS GRINDING is done to check the dimensional accuracy of the camshaft
MARPAUSS GAUGING instrument is also used to check the dimensions of the
camshaft
Camshaft deburring is a finishing operation to obtain a smoother camshaft
PHOSPHATING process,which ZINC PHOSPHATE is mainly used for softening
the camshaft
Camshaft oiling machining process is used to ensure the oil flow
The inspection process is carried out for avoiding damage and orderliness is
improved.

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