Training Report
Submitted
In fulfillment
2018-2019
====================================================================================================
CERTIFICATE
Nitesh Yadav
15EVJME044
CONTENTS
CHAPTER 1
1. Introduction…………………………………………………….…6
2. History…………………………………………………………….6
3. Products ….……………………………………………………….7
4. General layout……………………..……………………………...7
CHAPTER 2
1. Paint shop...................................................................................8
2. Main line assembly.....................................................................10
3. PDI..............................................................................................12
4. Welding equipment......................................................................14
CHAPTER 3
1. Frame shop...................................................................................16
2. Main line assembly.....................................................................18
3. PDI..............................................................................................20
4. Welding equipment......................................................................22
CHAPTER 4
1. BIW
shop…………………………………………………………………………………………..
……23
2. Process flow
digram…………………………………………………………………………..……25
3. Main supply line
…………………………………………………………………………….…………26
CHAPTER 5
1.Transale
shop……………………………………………………………………………………………….
….27
2.Main supply line
…………………………………………………………………………………………….…28
3.Engine dressing line
……………………………………………………………………………………………30
CHAPTER 6
INTRODUCTION
TATA Group
The Tata group’s core purpose is to improve the quality of life of the communities it serves
globally, through long-term stakeholder value creation based on leadership with trust
Brief Synopsis
Type Private Industry Global Diversified Enterprise
Founded 1868
Founder Jamsetji Tata
Headquarters Mumbai, Maharashtra, India
Area served Worldwide
Key people Cyrus P Mistry
Products Airline, Automotive, steel, IT, Electricity generation, Chemicals, Beverages, Telecom,
Hospitality, Retail, Consumer goods, Engineering, Construction, Financial services
o Integral Bus Factory - Assembly Plant for Module Buses catering to the needs of Tata
Marcopolo Motors Limited and FBV operations
o Transmission Factory - Gear Parts, Crown wheel & Pinion and Heat Treatment facility
o Production Engineering Shop catering to the tool design and manufacturing needs
o A well established Training Centre through which around 500 apprentices are trained in
various trades.
o Engineering Research Centre with specific focus on buses, including a Digital prototyping lab,
use of PLM software etc.
o Service Training Centre providing training to drivers and technicians of the STU's.
Brief Synopsis
Type Private Industry Automotive Founded 1945
Founder Jamsetji
Tata Headquarters Mumbai, Maharashtra, India
Area served Worldwide
Key people Cyrus P Mistry
Products Automobiles, Commercial Vehicles, Coaches, Buses, Construction equipment,
Military vehicles, Automotive parts Services Automotive design, engineering and outsourcing
services
Karnataka Plant
Tata Motors Karnataka (TML) was established in 1992 to meet the growing demand for
Commercial Vehicles in the Indian market.
This plant rolls out commercial vehicles & is specialized in the designing & manufacturing of
a range of modern buses which includes Low-floor, Semi Low-floor, and High Deck & CNG
Buses.
Plant has recently commissioned JV Company, Tata Marcopolo Motors Ltd. in the premises.
CHAPTER 2
FRAME SHOP
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection
FRM-110 MIG Weld assy MIG Welding MIG weld counter MIG Welding
frame complete GC Assembly of horn Horn mounting gun
mounting, cradle reinf bracket miss Elbow Lift
brackets
FRM-120 MIG Weld assy MIG Welding Spot counter MIG Welding
frame complete GC Stud Welding MIG weld counter gun
Bin fix is bolted to Elbow Lift
front suspension
Assembly of Fuel
filter bracket
mounting
FRM-130 Inspection and MIG Welding MIG weld counter MIG Welding
Rework Assembly of Fuel Fuel filter bracket gun
filter bracket mounting part miss Elbow Lift
mounting
Gas Metal Arc Welding (GMAW) is frequently referred to as MIG welding. MIG welding is a
commonly used high deposition rate welding process.
MIG welding is an arc welding process in which a continuous solid wire electrode is fed through
a welding gun and into the weld pool, joining the two base materials together.
A shielding gas is also sent through the welding gun and protects the weld pool from
contamination
Spot Welding:
Spot welding is one form of resistance welding, which is a method of welding two or more metal
sheets together without using any filler material by applying pressure and heat to the area to be
welded.
The process is used for joining sheet materials and uses shaped copper alloy electrodes to apply
pressure and convey the electrical current through the workpieces.
To create heat, copper electrodes pass an electric current through the workpieces.
The heat generated depends on the electrical resistance and thermal conductivity of the metal,
and the time that the current is applied.
Types of welding guns used:
C-Gun:
X- Gun:
CHAPTER 3
PAINT SHOP
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection
SL-06 Front panel, door, Load body sealant application and tail
gate wiping
Sealant Used:
o Terotex 3010 – 100 PC AAIN TEROSON (UB)
o Terotex 3010 – 100 PC AAIN TEROSON (SS)
Autophoretic coating:
Autophoretic, also known as auto deposition or A-coat, is a waterborne process which depends
on chemical reactions to achieve deposition.
The mildly acid bath liberates a small amount of iron from the steel parts being immersed,
causing an immediate surface reaction that releases iron ions. These ions interact with the latex
in solution causing coating deposition on the surface of the steel parts.
The newly deposited organic film is adherent yet quite porous. This allows the chemical
activators to diffuse rapidly in the film and etch the surface of the metal. The continuous
formation of coating provides a film with a high degree of surface protection and corrosion
resistance.
The coating thickness of the auto deposited film is time and temperature related.
A unique feature of the Autophoretic® process is the formation of a very uniform film over the
entire surface of the workpiece, even in difficult-to-reach areas.
Pre Delivery Inspection (PDI):
Check for
o Aquence coating
o ACC rough surface
o ACC oil patch
o ACC scratch
o Sealant bead
o Dry spray
o Oil spot
o Touch mark
o Sealant lump
o Paint missing
o Thin paint
o Run down
CHAPTER 4
BIW SHOP
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection
Entrance to BIW
CHAPTER 4
TRANSAXLE SHOP
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear nose Protection
o Wear hearing Protection
MA-05 Rear Housing dropping RH dropping and RI bolt torquing To ensure gap for sealant
Oil channel fitment & sealant dispense
MA-08 Snap ring fitment Shifter cap fitment To ensure the presence of
Snap ring fitment two snap rings
Fitment of air leak TA bar code scanning To check leak test for TA
MA-18 adaptor Leak test for transaxle & accepatable leak rate
15cc/min @ 0.3 bar
End of line testing Testing of transaxle for NVH, To check speed sensor
MA-20 Speed sensor and RI switch and switch working
working
ED-04 Assembly of hose and intermediate pipe, upper To ensure proper alignmnent of
cooling line fitment intermediate pipe with 2 hoses
ED-06 Assembly of hose and intermediate pipe, upper To ensure proper alignmnent of
cooling line fitment studs with starter plate
ED-08 Clutch cover assembly and screw tightening To ensure splines of clutch plate
C Mount fitment should be gear box side
To ensure torquing operation of C
Mount bolt
TA Mounting To check proper alignment of
ED-09 Bolt alignment to the Engine Transaxle to the engine
A parallel and co-planer shaft is connected by the spur gear. With straight teething parallelism to
the axis on the wheel, they form spur gearing. The type of gear is suitable for slow speed. Teeth
shapes should be determined by their cost effectiveness and purpose. However, they apply to any
speed as long as noise is not a problem.
Helical gears:
Their teeth are inclined to the shafts’ axis, assuming the shape like a helix. The name helical is
derived from their nature. Helical gear functions with high speed and hence, can handle a heavy
load. No noise or sound from their motion. When using a helical gear, one needs to put thrust
bearings. It is due to their management on the radical and thrust loads.
Spiral gear:
The umbrella name that is given to this gear is bevel. Both forms are cone-shaped applied in
shafts, which are intersecting. Spiral gear gets its name from their nature: they have spirally
shaped tooth trace. The other form has straight shaped tooth trace hence, named straight bevel
gear.
Herringbone
This gear is like a helical gear, position side by side. Mostly, people refer to them as double
helical. This arrangement the thrusts are balanced, and the bearings do not experience thrust
loading.
Hypoid
This gear is mainly found on the rear axle in vehicles. This gear is arranged to form forms a 90
degrees translation. Due to how they revolve on the same contact line, the gear is not
interchangeable. They are made from frusta hyperboloids. The centre lines on the shaft do not
come together, which makes the only difference between hypoid and spiral bevel gear.
This category is from the spur gear. Rack and pinion appears in a linear shaped variation. Their
variation is concerning the spur. Any rack gear is a bar that is toothed. It has a large curvature
radius, and it may be perceived as sector gear. A rack is meshed with a pinion to form a linear
force. As the pinion turns, the rack is in a straight line. This formation is mainly used in
automobiles.
Gear Nomenclature:
Pitch surface: The surface of the imaginary rolling cylinder that the toothed gear may be
consideredto replace
Pitch circle: Circle centered on and perpendicular to the axis, and passing through the pitch
point. A predefined diametral position on the gear where the circular tooth thickness, pressure
angle and helix angles are defined.
Addendum: Radial distance from the pitch surface to the outermost point of the tooth.
Dedendum: Radial distance from the depth of the tooth trough to the pitch surface.
Clearance: Distance between the root circle of a gear and the addendum circle of its mate.
Working depth: Depth of engagement of two gears, that is, the sum of their operating
addendums.
Backlash = Space width – tooth thickness
Circular pitch: Distance from one face of a tooth to the corresponding face of an adjacent tooth
on the same gear, measured along the pitch circle.
Axis: Axis of revolution of the gear; center line of the shaft.
Pitch point: Point where the line of action crosses a line joining the two gear axes.
Gear Box:
Gear box is device connected to engine which transmits the power from engine to drive shaft at
different required speed and torque.
This is one of the oldest type. It this, gears on the main shaft are moved right or left for
meshing them with appropriate gears on the counter shaft for obtaining different speed. This
type of gear box derives its name from the fact that the gears are meshed by sliding. One
disadvantage of it is that, special skill is required to operate this gear box.
Constant mesh gear box:
In this gearbox, all the gears are in constant mesh with each other all the time. The gears on the
main shaft rotates freely without rotating the main shaft. Constant mesh gear box consists two
dog clutches. These clutches are provided on the main shaft, one between the clutch gear and the
second gear and the other between the first gear and reverse gear.
This gear box is same as the constant mesh gear box except dog clutch is replaced by
synchromesh devices. Synchromesh gear devices works on the principle that two gears to be
engaged are first brought into frictional contact which equalizes their speed after which they
are engaged readily and smoothly. The synchromesh looks like as the cone clutch where the
outer surface of cone consist the frictional surface. This type of gear box is widely used in
automobile.
Safety Precautions:
o Wear head Protection
o Wear foot Protection
o Wear eye Protection
o Wear hand Protection
o Wear hearing Protection
Wiper motor, washer tank, accelerator peal brakcet, Torque wrench pokayoke
TR -10 relay bracket
Primer application
TR -12 Fitment of head lamp, bezel and secondary seal RH
Fitment of seat belt LH RH DC nut runner
TR -13 Seat belt adaptor LH RH
Door latch outer handle
Fitment of gear shifting mechanism & brake bundy Torque wrench pokayoke
TR -19 & cable routing
Fitment of rear glass, steering column, floor bellow Torque wrench pokayoke
TR -20 window winding mechanism RH
UB-04 Fitment of fuel tank, torquing of A mount arm Torque wrench pokayoke
UB-08
Engine loading
UB-11 Routing & setting of clutch cable, torquing of C Torque wrench pokayoke
& D shock absorbers, fuel filter, RH wheel
guard, Hub cap & stay rod
Mechanical Line
Station No Process Pokayoke
ME-13 Brake pedaling, steering wheel spoke alignment Torque wrench pokayoke
& torquing
RBT Roll and brake test Test results interfaced with SAP
TORQUE:
It is the tendency of a force to rotate an object about an axis, fulcrum. Just as a force is push or
pull, a torque can be thought of as twist to an object.
Devices used for application of torque:
Torque wrench:
A torque wrench is a tool used to apply precisely a specific torque to a fastener such as a nut or
bolt. It is usually in the form of a socket wrench with special internal mechanisms.
Nut Runners:
These are devices that use electrical or pneumatic power for torque application. Torque values
are not very precise but reduce human effort.
Roll and Break Test:
A roller brake tester is a method of allowing the dynamic assessment of the braking system of
a motor vehicle, whilst the vehicle itself is in a static condition. Roller brake testers consist of a
mechanical floor unit which contains electrical motors, two independent sets of three measuring
rollers, brake force transducers and additional safety sensors.
Tests carried out in roller brake test:
Brake Force Test:
o Brake force test is the force applied by the braker system to slow down and stop the
vehicle. Higher the brake force more effective is the brake system.
o The brake force must be between 600 to 1200N for front wheel and 170 to 330N for rear
wheel
o Ideally Break force at LH and RH wheels must be equal but actually it is not possible,
hence some deviation is allowed.
Pedal Force:
o It is the force applied by driver foot on brake pedal. This is measured by brake pedal
sensor. For Ace Zip pdal force must be between 10 kgf to 20 kgf.
Drag Force:
o Drag is a force that acts parallel and in the same direction as the airflow. The drag
coefficient of an automobile impacts the way the automobile passes through the
surrounding air reducing the drag coefficient in an automobile improves the performance
of the vehicle as it pertains to speed and fuel efficiency.
ELECTRICAL SYSTEMS:
Electrical Conduction:
Electrical Conductance is the ease with which an electric current passes. Electrical resistance
shares some conceptual parallels with the notion of mechanical friction. The SI unit
of electrical resistance is the ohm (Ω), while electrical conductance is measured in siemens (S).
Earthing System:
In an electrical installation an earthing system or grounding system connects specific parts of that
installation with the Earth's conductive surface for safety and functional purposes.
Key points for earthing:
o The positive cable is run from battery to the starter providing an uninterrupted
connection.
o A matching size ground cable needs to be connected between the engine and the frame
o All connections should be full metal to metal contact.
The storage battery or secondary battery is such a battery where electrical energy can be stored
as chemical energy and this chemical energy is then converted to electrical energy as and when
required.
Charging of batteries:
The discharge of a battery is connected to charger with its output voltage set at 13.6 volts. In
order to recharge a 12 volt battery with a fully charged terminal voltage of 12.6 volts, the charger
voltage should set at higher voltage. During the battery recharge cycle lead sulphate begins to
reconvet to lead and sulphuric acid.
Precautions for charging:
o For charging lead acid batteries an intelligent charging system that can vary the charging
voltage should be used.
o Overcharging leads to release of hydrogen and oxygen, pressure from these gasses will
cause caps to open and vent, resulting in some water loss.
Pre Delivery Inspection (PDI):
Check for
o Engine oil checking
o Spare wheel
o Wiring harness
o Engine oil leakage
o Earthing points
CONCLUSION