You are on page 1of 27

AUTO IGNITION LTD

A Report Submitted to the MDU University in partial fulfillment of the requirement for the degree of Bachelor in Engineering B.Tech (ME) Semester 5th

Submitted by: Gaurav Tanwar Roll no: 2k10-MRCE-ME-032 Branch: Mechanical

Semester 5th

Year: 3rd

Manav Rachna College of Engineering Faridabad

Index 1. Acknowledgement 2. AUTO IGNITION LTD. AN OVERVIEW a) Corporate Profile b) Research & Development c) Quality Policy d) Companys Products e) Companys Customers 3. Alternator a) What is an Alternator (AC Generator)? b) Why is an Alternator Required? c) Charging System Circuit d) Alternator Assembly e) Alternator Subassembly f) Rotor Assembly g) Stator Winding h) Diode Rectifier i) Electronic Regulator j) Voltage Regulation k) Brushes l) Working of Alternator m) Quality Assurance n) Performance Curve 4. Advantages of the alternator over dynamo 5. Packing 6. Dispatch 7. Quality Assurance 8. Conclusion

ACKNOWLEDGEMENT It is a great experience undergoing my six weeks training at AUTO IGNITION LTD. I got an opportunity to learn an experience ethos & environment of AUTO IGNITION LTD. With profound respect and gratitude, I take the opportunity to convey my thanks to the management of AUTO IGNITION LTD. for giving me chance to complete my training here. I am extremely grateful to all the technical staff of auto ignition for their co-operation and guidance that have helped me a lot during the course of my training. Last but not the least I would like to thank our training & placement officer of MANAV RACHNA COLLEGE OF ENGINEERING and all the faculty member of Mechanical Engg. Department for their constant co-operation that has played significant role in the accomplishment of my industrial training.

Submitted by:Gaurav Tanwar 2K10-MRCE-ME-032

AUTO IGNITION LTD. AN OVERVIEW Corporate Profile:-

AUTO-LEK - Recognized world-wide as the brand name of Auto Ignition Ltd is Indias leading manufacturer and exporter of heavy-duty auto electric components for commercial vehicles, tractors, off-road vehicles, stationary engines and 2-3 wheelers. Ever since its inception in the year 1971, AUTOLEK has been on a track of fast growth now commanding an annual turnover of over US$ 40 million, which is likely to increase exponentially over next few years. The company is headquartered in Faridabad and employs a team of over 650 people led by a professional management. In addition to this, it also has a contemporary production unit in Rudrapur, Uttarakhand. Today this market leader holds the maximum market share as a supplier to almost all domestic Tractor and Generator Set manufacturing companies. An ISO:TS 16949:2002 certified company, AUTO-LEK is the largest exporter of high quality auto electric components from India. It is also the first Indian company in its manufacturing domain to have its R&D centre approved by the Govt. of India a true mark of its merit. AUTO-LEK caters to the requirements of Indian O.E Manufacturers, AfterMarket Sales & Service and Exports. The Companys strategy is to focus on Tractors, Stationary Engines, And Mini Diesel Vehicles like three /four wheelers, LCVs/HCVs.

Research & Development:AUTO-LEK adopts various quality and operational management practices and follows 6-sigma, lean manufacturing, Kaizen and 5S practices making it a truly global company. The Business Process Re-engineering is headed by a highly experienced retired senior General Manager level Japanese expert. Quality Policy:It is the policy of the AUTO-LEK to delight its customers by meeting their stated and implied needs and in so doing provide fulfillment and pride to those who contribute towards this achievement.

This policy is implemented through: A Quality system conforming to International Standards A total commitment to continue improving productivity and Quality in all areas of Operations and reducing waste

A congenial work environment to promote and inspire innovation A close liaison with the customer and his market place

Delighting the Customers:


Quality & Reliability in our Products Unbeatable Prices Excellent after sales service Timely Deliveries Quickest response & resolution of customer needs

Future Plans:AUTO-LEK has well laid out plans for growth targeting: 80% share of Indian OE business in Tractors & Stationary engines. Expanding its base in SUV, LCV, HCV and Intracity 0.4/0.6 litre diesel vehicles. Establishing contact with OE customers in U.S & Europe and setting up manufacturing facilities as required.

Infrastructure:The companys infrastructure is spread across a combined area of over 10 acres amongst three state-of-art plants in Faridabad and Rudrapur. All the production units are connected using a SAP ERP system for integrated manufacturing and communications. Presently the company manufactures more than 600 thousand Starter Motors and 500 thousand Alternators per annum for domestic OEs, aftermarket and international market.

Companys Products:Alternator, Starter Motor, Battery, Ignition Coils

Companys Customers:Tata Motors Ltd., Kirloskar Oil Engines Ltd., Mahindra & Mahindra Ltd.(Tractor Division), Tractor & Farm Equipment Ltd.(TAFE), Escorts Ltd., HMT Tractor Ltd., John Deere Pvt. Ltd., Force Motors Ltd., Ashok Leyland Ltd.

Alternator What is an Alternator (AC Generator)? An Alternator is a key component of an automobile's charging system, which provides current to recharge the battery and develops electricity to power all other electrical components like Air Conditioning, starter motor, lightning, horns, ignition systems, power windows and power steering when the engine is running. It delivers reliable output under severe operating conditions and even while engine is running at ideal speed.

Why is an Alternator Required? The prime function of a battery in electrical system is to start the engine. After the engine is running, the generating system is supposed to supply all the electrical requirements of the vehicle plus additional charge that was taken away from the battery to start the engine. In the modern vehicular electrical system, the power requirement has increased enormously that the dynamo (DC Generator) is inadequate for the purpose of charging. In the heavy city traffic driving conditions or ploughing the fields, the engine is in the idling for most of the times, coupled with this if the demand due to Air Conditioners, lightning etc. is high, the battery will be discharged soon if the charging system is not adequate. Here, the Alternator plays a very important role in maintaining the charge of battery and to provide electrical current to electrical components under the worse conditions.

Alternator Circuit Diagram

Exploded View of Alternator

Charging System Circuit:-

Four wires connect the alternator to the rest of the charging system. B is the alternator output wire that supplies current to the battery. IG is the ignition input that turns on the alternator/regulator assembly. S is used by the regulator to monitor charging voltage at the battery. L is the wire the regulator uses to ground the charge warning lamp.

Alternator Assembly:-

Alternator Subassembly:The alternator contains: A rotating field winding called the rotor. A stationary induction winding called the stator. A diode assembly called the rectifier bridge. A control device called the voltage regulator. Two internal fans to promote air circulation. Brush Box to transfer current.

Rotor Assembly:-

A basic rotor consists of a iron core, coil winding, two slip rings, and two claw-shaped finger pole pieces. Some models include support bearings and one or two internal cooling fans. The rotor is driven or rotated inside the alternator by an engine (alternator) drive belt. The rotor contains the field winding wound over an iron core which is part of the shaft. Surrounding the field coil are two claw-type finger poles. Each end of the rotor field winding is attached to a slipring. Stationary brushes connect the alternator to the rotor. The rotor assembly is supported by bearings. One on the shaft the other in the drive frame.

Stator Winding:-

The stator is made with three sets of windings. Each winding is placed is a different position compared with the others. A laminated iron frame concentrates the magnetic field. Stator lead ends that output to the diode rectifier bridge.

Rotor/Stator Relationship:-

As the rotor assembly rotates within the stator winding. The alternating magnetic field from the spinning rotor induces an alternating voltage into the stator winding. The strength of the magnetic field and the speed of the rotor affect the amount of voltage induced into the stator.

Diode Rectifier:-

The Diode Rectifier Bridge is responsible for for the conversion or rectification of AC voltage to DC voltage. Six or eight diodes are used to rectify the AC stator voltage to DC voltage. Half of these diodes are use on the positive side and the other half are on the negative side.

Rectifier Operation:-

The Diode Rectifier Bridge is responsible for for the conversion or rectification the AC voltage into DC voltage. Two diodes are connected to each stator lead. One positive the other negative. Because a single diode will only block half the the AC voltage. Six or eight diodes are used to rectify the AC stator voltage to DC voltage. Diodes used in this configuration will redirect both the positive and negative polarity signals of the AC voltage to produce DC voltage. This process is called Full - Wave Rectification.

Diodes:-

Diodes are used as one-way electrical check valves. Passing current in only one direction, never in reverse. Diodes are mounted in a heat sink to dissipate the heat generated by the diodes. Diodes redirect the AC voltage into DC voltage so the battery receives the correct polarity.

Electronic Regulator:-

The regulator is the brain of the charging system. It monitors both battery and stator voltages and depending on the measured voltages, the regulator will adjust the amount of rotor field current to control alternator output. Regulators can be mounted both internal or external. Current technology uses an internal regulator. Voltage Regulation: The regulator will attempt to maintain a pre-determined charging system voltage level. When charging system voltage falls below this point, the regulator will increase the field current, thus strengthening the magnetic field, which results in an increase of alternator output. When charging system voltage raises above this point, the regulator will decrease field current , thus weakening the magnetic field, and results in a decrease of alternator output.

Drive Pulley:-

Alternator drive pulleys either bolt on or are pressed on the rotor shaft. Both V and Multi-grove types are used. Note this alternator does not have an external fan as part of the pulley assembly. While many manufacturers do use a external fan for cooling. This alternator has two internal fans to draw air in for cooling.

Brushes:-

Two slip rings are located on one end of the rotor assembly. Each end of the rotor field winding is attached to a slip ring. Thereby, allowing current to flow through the field winding. Two stationary carbon brushes ride on two rotating slip rings. Bushes are either soldered or bolted.

Working of Alternator: The regulator monitors battery voltage and controls current flow to the rotor assembly. The rotor produces a magnetic field. Voltage is induced into the stator. The rectifier bridge converts AC stator voltage to DC output for use by the vehicle.

Quality Assurance:To maintain the quality of product the final assembled product is checked on a various number of test rigs and a number of tests are performed on the product. The tests include:1. Performance Test a. Stabilized Performance 2. Reliability Test a. Normal speed Endurance Test. 500/ 8000 rpm. b. High Speed endurance Test. 9000/ 11500 rpm 3. Environment Test a. Elevated Temp. Rain & dust Endurance Test. b. Corrosion Resistance Test/Salt spary Test. c. Hot Box (110oc) d. Acceleration & deceleration Test. e. Vibration Test.

Performance Curve:For an alternator of output of 190 amps and 12 V.

Advantages of the alternator over dynamo:1. Alternator is more compact in size as its weight to output ratio is better than dynamo. 2. Alternator delivers more output at low speed as compared to dynamo and even charges the battery at ideal speed. 3. In the alternator current through the brushes is 2 to 3 amperes, where as in dynamo the entire output current is through brushes thus resulting in increased brush life. 4. Alternator is running on bearing compare to bushes in dynamo on both sides resulting in low maintenance and increased life. 5. With alternator in circuit, battery life is much better as compared to dynamo. 6. In alternator as high as 160 amp. output can be drawn whereas it is not possible in dynamo. 7. Alternator is not affected by water whereas dynamo is.

PACKING 1. Compact and study cardboard packing, shrink wrapped or strong wooden pallets. 2. All boxes cleanly labeled. 3. Packaging with Antirust paper.

DISPATCH All the finished products are dispatched by this section as per instructions by customer support department. Only quality assurance suited products with green slip shall be received dispatch area. Either internal or external transport is used for delivery.

QUALITY ASSURANCE Its function is described in following steps: 1. Inspection of incoming material in the stores like steels, Iron etc. Auditing of these materials or lab testing is done. 2. In process inspection ; while assembling and after assembling (section wise) a green slip is credited if output is correct. 3. After folding and binding and before dispatch, again a quality assurance procedure is carried on. 4. An annual report is prepared for the exception i.e. the report about what was the defects and reason of the rejected samples.

CONCLUSION For my growth as a student of BE (Mechanical), it was a milestone to work in the field of production. It was a privilege to work in such an efficient field and under the supervision of professionals of AIL. I have learned and grown a lot during my training as a professional and a human being as well. I found my project extremely knowledgeable and informative. This was the first opportunity where I got practical experience. It made me familiar with present work culture as I learned dos and don'ts for a professional in Manufacturing. I am very thankful to all those professionals of Auto Ignition Ltd. who helped me in my project by giving their precious time to me. I am grateful to all the faculty members of my institute for making my report a success.

You might also like