Professional Documents
Culture Documents
1.1.1 TVS MOTOR INDUSTRY TVS Motor Company Limited, part of the TVS Group, is one of Indias leading motor industries. Two wheeler manufactures with a turnover of over RS.2800 cores (U$D 574.94 million), the Company manufactures a wide range of motorcycles scooters, mopeds. 1.1.2 LAKSHMI AUTO ACOMPONENTS LIMITED Large OE supplier of two wheeler gears and camshafts 1.1.3 LUCAS INDIAN SERVICE LIMITED Company looks after the distribution of auto electrical components all over India.
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1.1.4 AXLES INDIA LIMITED Axles India Ltd is a joint venture with Ealton Limited U>L Manufactures axle housings and five heads of heavy and light commercial vehicles. 1.1.5 BRAKES INDIA LIMITED A JOINT VENRURE WITH Lucas Automotive, U>K Manufactures foundation and hydraulic brakes as wells as other products for automotive and non automotive applications 1.1.6 HARITA GRAMMER LIMITED Manufacture of automobile seats in collaboration with Grammer, world leader in the category 1.1.7 INDIA MOTOR PARTS AND ACCESSORIES LIMITED One of the Indias largest distributors of spare parts 1.1.8 INDIA NIPPON ELECTRICALS LIMITED A joint venture with Kokusan, Denki, Japan involved in the manufacture of magnetos. 1.1.9 LUCAS TVS LIMITED A joint venture with Lucas Industries, UK Manufactures a range of auto electric systems Also develops and produces vacuum pumps and gear starters with Hitachi Limited, Japan. 1.1.10 MADRAS AUTO SERVICE Indias largest retail network of auto spares. 1.1.11 SOUTHERN ROADWAYS LIMITED Giant in the Indian road transport industry, company operates largest parcel service all over South India.
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1.1.12 SUNDARAM BRAKE LININGS LIMITED First Indian company top manufactures asbestos-free brake linings woven clutch facings and disc plates for automotive applications. 1.1.13 SUNDARAM FASTENERS LIMITED India largest manufacturer t=of tensile fasteners .The first company to receive ISO- 9002 certification. Also principal supplier of radiator caps to GM in USA. 1.1.14 SUNDARAM FINANCE LIMITED Leading consumer finance company in India 1.1.15 SUNDARAM INDUSTRIES LIMITED With a reputation built over five decades, comprise several divisions custom mould rubber products and coach building. Also specializes in refrigerated trucks and bund beds. 1.1.16 SUNDARAM MOTORS Major dealers for Indian and foreign cars in South India 1.1.17 SUNDARAM CLAYTON LIMITED Manufacture of air brake systems in India. 1.1.18 WHEELS INDIA LIMITED One of the Indias largest manufacturers of Wheels, Rims and Air Suspension for both heavy duty and light vehicles it produce 2000 wheels per year.
1.1.19PRODUCT LINE
Two wheelers Axles Brake systems Auto Electricals Tires & Tubes Wheels and rims Brake linings Freight service High tensile fasteners Bus body building Auto rubber products Distribution of Cars & Trucks Computer Hardware Air Suspension Hydraulic cylinders
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1.2 INDUSTRY DETAILS 1.2.1 WHEELS INDIA LIMITED Wheels India limited (WIL) incorporated in 1960, it entered into a technical aid agreement with Dunlop Rim &Wheel Co Ltd., on 27th June, for the supply of technical know-how for a period of 20 years for the manufacture of wheels. 1961 - The company was incorporated on 28th march at Tamil Nadu. The main objects of the company are to manufacture wheels and rims, components and accessories thereof and to carry on the business of iron and steel 1974 - 54,567 shares held by T.V. Sundaram Iyengar& Sons,Ltd.,24,807 shares by Southern Roadways, Ltd., 17,181 shares by Sundaram Finances, Ltd., and 7,87,660 shares by Dunlop Holding, Ltd., U.K. 1981 - The company received a letter of intent for the manufacture of air suspension system for commercial vehicles. 1983 - The Company received a letter of intent for setting up a second wheel manufacturing unit at Rampur, U.P. with a capacity of 6,00,000 wheels per annum. 2000 Mr.Srivats Ram has been appointed Director of the company effective October1. 2002 T.S Santhanam, Chairman has resigned from the Board w.e.f October30, 2002. And Mr. S Ram was elected unanimously as the Chairman of the BOD by the Board. Presently, Wheel India is leading manufacturer of steel wheels for passenger cars, utility vehicles, trucks, buses, agricultural tractors and construction equipment in India. The companys manufacturing units have received ISO 9001:2000 and ISO/TS 16949:2002 for its quality management.
The company exports 18% of its turnover to North America, Europe, Asia Pacific and South Africa. Globally, the company has clientele namely Caterpillar, Komatsu, Volvo, JCB, Kawasaki Heavy Industries, Hyundai Heavy Industries, Mitsubishi Heavy Industries, Bell Equipment are among others. In domestic front the company has customer base namely JCB India, during the year 2012, Wheels India limiteds Padi plant won the All India Organization of Employers (AIOE) Industrial Relations Award for the year 2010-11. Wheels India limited received awards from TAFE, Toyota, Caterpillar and Maruti Suzuki for its performance; quality and supply of products are amongst others. Wheel India is planning to set up plant in Maharashtra spread across in 30 acres of land. The plant will undertake manufacturing of steel structural parts for power plant projects. Wheels India designs and manufactures wheels for heavy and light vehicles, agricultural applications, construction equipment, wire wheels and air suspension. For the year 2004 to2005, total income increased to Rs 7.9 bn, up 48.9% over the previous years. Net prot increased33% to Rs 286.5 mn. As per un audited results for the nine months ended Dec 31, 2005, the company recorded an income of Rs 6.4 bn and a net prot of Rs 164.8 mn as compared with an income of Rs 5.7 bn and a net prot of Rs 203.8 mn in the corresponding period previous year. During the year 2012, Wheels India limiteds Padi plant won the All India Organization of Employers (AIOE) Industrial Relations Award for the year 2010-11. Wheels India limited received awards from TAFE, Toyota, Caterpillar and Maruti Suzuki for its performance, quality and supply of products.
1.2.2 Manufacturing locations: Padi the unit located in padi, Chennai. The company is engaged in manufacturing of wheels for trucks & buses, passenger cars and utility vehicles, off-road construction equipment, agricultural tractors and farm equipment, tracked vehicles and wire wheels. This unit stretch across 29 acres of land. The company exports 18% of its turnover to North America, Europe, Asia Pacific and South Africa. Sriperumbadur- the unit located in Sriperumbadur, Chennai. This company manufactures wheels for trucks & buses, off-road construction equipment, agricultural tractors and farm equipment, and for the customers of Caterpillar, Komatsu, Volvo, JCB, Kawasaki Heavy Industries, Hyundai Heavy Industries, Mitsubishi Heavy Industries, and Bell Equipment. It manufactures air suspension for TATA, Ashok Leyland, and etc. Pune- the unit located in pune, Maharashtra. The unit is spread across 15 acres of land. The company is manufacturing wheels for passenger cars and utility vehicles, off-road construction equipment, agricultural tractors and farm equipment and trucks wheels. Rampur- this unit located at Rampur, Uttar Pradesh. The unit is spread across 14 acres of land. The company manufactures wheels for agricultural tractors and farm equipment. Bawal- the unit located in bawal, Haryana. The company is manufacturing wheels for passenger cars and utility vehicles, agricultural tractors and farm equipment.
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Chapter 2
INTRODUCTION
2.1 FIXTURES It is a work holding device that holds supports and locates the work piece for a specific operation but does not guide the cutting tool. It provides only a reference surface or a device. What makes a fixture unique is that each one is built to fit a particular part or shape. The main purpose of a fixture is to locate and in some cases hold a work piece during either a machining operation or some other industrial process. Fixtures should be securely clamped to the table of the machine upon which the work is done. Fixtures are specific tools used particularly in milling machine, shapers and slotting machine. Gauge blocks may be provided for effective handling. Fixture is a production tool used to accurately manufacture duplicate and interchangeable parts. Fixtures are specially designed so that large numbers of components can be machined or assembled identically, and to ensure interchangeability of components. Fixtures are used to securely locate (position in a specific location or orientation) and support the work, ensuring that all parts produced using the fixture will maintain conformity and interchangeability. Using a fixture improves the economy of production by allowing smooth operation and quick transition from part to part, reducing the requirement for skilled labor by simplifying how work pieces are mounted, and increasing conformity across a production run. Economically speaking, the most valuable function of a fixture is to reduce labor costs. Without a fixture, operating a machine or process may require two or more operators; using a fixture can eliminate one of the operators by securing the work piece.
Fixtures must always be designed with economics in mind; the purpose of these devices is to reduce costs, and so they must be designed in such a way that the cost reduction outweighs the cost of implementing the fixture. It is usually better, from an economic standpoint, for a fixture to result in a small cost reduction for a process in constant use, than for a large cost reduction for a process used only occasionally. Fixtures may also be designed for very general or simple uses. These multi-use fixtures tend to be very simple themselves, often relying on the precision and ingenuity of the operator, as well as surfaces and components already present in the workshop, to provide the same benefits of a specially-designed fixture. Fixtures can be designed for optimal performance and ergonomics since additive manufacturing places few constraints on a tools configuration. Each component of a fixture is designed for one of two purposes: location or support.
2.1.1 Location Locating components ensure the geometrical stability of the work piece. They make sure that the work piece rests in the correct position and orientation for the operation by addressing and impeding all the degrees of freedom the work piece possesses. For locating work pieces, fixtures employ pins (or buttons), clamps, and surfaces. These components ensure that the work piece is positioned correctly, and remain the same position throughout the operation. Surfaces provide support for the piece, pins allow for precise location at low surface area expense, and clamps allow for the work piece to be removed or its position adjusted. Locating pieces tend to be designed and built to very tight specifications.
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2.1.2 Support In designing the locating parts of a fixture, only the direction of forces applied by the operation are considered, and not their magnitude. Locating parts technically support the work piece, but do not take into account the strength of forces applied by the process and so are usually inadequate to actually secure the work piece during operation. For this purpose, support components are used. To secure work pieces and prevent motion during operation, support components primarily use two techniques: positive stops and friction. A positive stop is any immovable component that, by its placement, physically impedes the motion of the work piece. Support components are more likely to be adjustable than locating components, and normally do not press tightly on the work piece or provide absolute location.
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(f)
It reduces the production cycle time so increases production capacity. Simultaneously working by more than one tool on the same work piece is possible.
(g)
The operating conditions like speed, feed rate and depth of cut can be set to higher values due to rigidity of clamping of work piece by fixtures.
(h)
Operators working become comfortable as his efforts in setting the work piece can be eliminated.
(i)
Semi-skilled operators can be assigned the work so it saves the cost of manpower also.
(j)
There is no need to examine the quality of produce provided that quality of employed fixtures is ensured.
2.1.4
IMPORTANT
CONSIDERATIONS
WHILE
DESIGNING
FIXTURES Designing of jigs and fixtures depends upon so many factors. These factors are analyzed to get design inputs for jigs and fixtures. The list of such factors is mentioned below: (a) (b) (c) (d) (e) (f) (g) Study of work piece and finished component size and geometry. Type and capacity of the machine, its extent of automation. Provision of locating devices in the machine. Available clamping arrangements in the machine. Available indexing devices, their accuracy. Evaluation of variability in the performance results of the machine. Rigidity and of the machine tool under consideration
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absorbers and linkages that connects a vehicle to its wheels and allows relative motion between the two. Suspension systems serve a dual purpose contributing to the vehicle's road holding/handling and braking for good active safety and driving pleasure, and keeping vehicle occupants comfortable and reasonably well isolated from road noise, bumps, and vibrations, etc.
Figure 2.1: Air suspension system Air suspension is a type of vehicle suspension powered by an electric or engine driven air pump or compressor. This pump pressurizes the air, using compressed air as a spring. Air suspension is often used in place of conventional steel springs, and in heavy vehicle applications such as buses and trucks. If the engine is left off for an extended period, the vehicle will gradually settle to the ground. The purpose of air suspension is to provide a smooth, constant ride quality and in some cases it is self-leveling.
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Air pressurizes the bag and in turn raised the chassis from the axle. Although traditionally called air bags or air bellows, the correct term is air spring. The air suspension replaces the conventional steel spring system. Air suspension systems are able to automatically adapt the damping and spring characteristics of the suspension according to the preferences of the driver as well as to adjust the body level of the vehicle to changing driving conditions and loads. Due to their many advantages, air suspensions systems are more and more specified for future platforms. This is an important development trend as car manufacturers strive to improve gas mileage by weight reduction and thus utilize active suspension technology to maximize the car performance 2.2.1 History In 1901 William W. Humphreys patented a 'Pneumatic Spring for Vehicles'. The design consisted of a left and right air spring longitudinally channeled nearly the length of the vehicle. The channels were con-caved to receive two long pneumatic cushions. Each one was closed at one end and provided with an air-valve at the other end. An early attempted implementation of air suspension was by Messier in the 1920s.Vehicles that use air suspension today include models from Maybach, Rolls-Royce, Lexus, Jeep Grand Cherokee, Cadillac (GM), Mercedes-Benz, Land Rover/Range Rover, Audi, Subaru, Volkswagen, and Lincoln and Ford, among others. Citron now feature hydractive suspension, a computer controlled version of their Hydro pneumatic system, which features sport and comfort modes, lowers the height of the car at high speeds and continues to maintain ride height when the engine is not running.
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The air suspension designs from Land Rover, Subaru and some Audi, Volkswagen, and Lexus models, feature height adjustable suspension controlled by the driver, suitable for clearing rough terrain. The Lincoln Continental and Mark VIII also featured an air suspension system in which the driver could choose how sporty or comfortable they wanted the suspension to feel. These suspension settings were also linked to the memory seat system, meaning that the car would automatically adjust the suspension to individual drivers. The control system in the Mark VIII lowered the suspension by about 25 mm (1 inch) at speeds exceeding about 100 km/h (60 mph) for improved aerodynamic performance. Due to the many advantages air suspensions provide, and with the advancement of new materials and technologies, these systems are being designed on many future platforms. This is especially important as car manufacturers strive to improve gas mileage by reducing weight and utilizing active suspension technology to maximize performance. The electric car maker Tesla Motors offers "Active Air Suspension" as an option on the Tesla Model S as a means to automatically lower the vehicle for optimized aerodynamics and increased range while allowing the user to change the setting as desired. An air suspension supports the vehicle on the axles with an arrangement of air bags instead of some type of steel spring, leaf or coil, or some type of torsion spring arrangement. The air bags are sometimes referred to as air springs or bellows. Suspensions that have steel or torsion springs that are supplemented by the use of air bags are not considered air suspensions. There are combination systems that have both air and steel springs. Usually the air suspension components are used on the rear of the vehicle.
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leaking air system. Compressor burnout may also be caused by moisture from within the air system coming into contact with its electronic parts. In Dryer failure the dryer, which the functions to remove moisture from the air system, eventually becomes saturated and unable to perform that function. This causes moisture to build up in the system and can result in damaged air springs and/or a burned out compressor.
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2.3 Dip painting Dip painting is a popular way of creating thin films for research purposes. Uniform films can be applied onto flat or cylindrical substrates. For industrial processes, spin coating is used more often. Design constraints of product, customer preferences, and local government regulations related to environmental control - all affect the painting process decisions. Pretreatment is carried out in number of stages. All surfaces of the bodies are thoroughly cleaned and degreased before the application of zinc phosphate (Low zinc, nitrate free process is the present trend), as the improper cleaning inhibits the proper phosphating of surfaces. Main objective of phosphating is for good paint adhesion and to assist to protect the metal surface against corrosion. For pretreatment of steel and aluminum parts, Quality Paint and Coatings (QPC) offers applications of zinc phosphate and trivalent chromium through the use of dipping tanks, large containers that objects can be dipped into that.
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The dip coating process can be separated into five stages: Immersion: The substrate is immersed in the solution of the coating material at a constant speed (preferably jitter-free). Start-up: The substrate has remained inside the solution for a while and is starting to be pulled up. Deposition: The thin layer deposits itself on the substrate while it is pulled up. The withdrawing is carried out at a constant speed to avoid any jitters. The speed determines the thickness of the coating (faster withdrawal gives thicker coating material). Drainage: Excess liquid will drain from the surface.
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Evaporation: The solvent evaporates from the liquid, forming the thin layer. For volatile solvents, such as alcohols, evaporation starts already during the deposition & drainage steps. In the continuous process, the steps are carried out directly after each other. Prior to the dipping process, pieces go through:
degreasing to remove heavy soiling cleaning to remove residual dirt and surface impurities
Components and parts are then ready to be dipped into an alkaline cleaning solution, and finally processed through the corrosion resistant applications:
Zinc phosphate for steel parts application of a zinc coating to steel by immersing the material in a bath consisting primarily of ionic zinc. Zinc phosphate coatings are the treatment of iron or steel by immersion in a solution of phosphoric acid and other additives. The resulting chemical reaction provides a surface of the metal which is chemically converted to a protective layer of insoluble zinc and iron phosphate crystals. These galvanizing forms a bond between the zinc and the steel, providing a vital element for protection from corrosion. Zinc is used in applications which require reduced light reflection, or for appearance characteristics.
Trivalent chromium for aluminum parts application of a chromate coating to aluminum to achieve maximum protective properties. This application provides an ideal pretreatment for priming and coating since it provides a clean, essentially inert surface. To aid in these processes, Quality Paint and Coatings (QPC) is
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which convey the parts through the dip-tank processes. The crane system connects the individual dipping processes, facilitating:
the pretreatment the draining off the drying of parts At this point, components are virtually free from impurities, and are
in an ideal state for priming, painting or coating to meet our customers needs. After every paint coating, ovens are required to cure the coating in addition to drying off the wet surfaces. The type of oven system generally depends on the type of paint coat used. Typically in a paint shop, the ovens are: pretreatment water dry-off oven, electro-deposition oven, underbody sealer oven, and surface coat oven, dry-off oven after wet sanding, finish coat oven, metallic finish coat oven, and repair oven. 2.3.1 Process of dip painting The dip coating process can be separated into five stages:
Immersion: The substrate is immersed in the solution of the coating material at a constant speed (preferably jitter-free).
Start-up:
and is starting to be pulled up. Deposition: The thin layer deposits itself on the substrate while it is pulled up. The withdrawing is carried out at a constant speed to avoid any jitters. The speed determines the thickness of the coating (faster withdrawal gives thicker coating material).
Drainage:
Evaporation: The solvent evaporates from the liquid, forming the thin layer. For volatile solvents, such as alcohols, evaporation starts already during the deposition & drainage steps.
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2.3.2 PAINTING PROCESS FOR AIR SUSPENSION COMPONENTS: (Air Suspension Paint Plant)
LOADING
DEGREASING
WATER RINRSE
SURFACE ACTIVATION
PHOSPHATING
UP LOADING
DIP PAINTING
SPRAY PAINTING
UNLOADING
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Figure 2.5: Paint plant lay out at WIL 2.3.4 Paint Plant DE - Degreasing W R - Water rinse S A - Surface activation P P - Phosphating DM W R - DM Water rinse WDOWater drying oven
DIP - Dip painting P B O - Primer baking oven F C Z - forced cooling zone S P - Spray painting T C B O - Top coat baking oven
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2.3.5 Air suspension paint plant process: Table 2.1 paint plant process
S no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Loading Degreasing Water rinse Surface activation Phosphating DM water rinse Water drying oven Unloading & Loading Dip painting Primer baking oven Forced cooling zone Top coat baking oven Forced cooling zone Un loading Total time taken Paint plant process Time taken by existing fixture 15 min 4 min 2 min 2 min 4 min 2 min 15 min 30 min 20 sec 30 min 30 min 20 min 15 min 15 min 3 hrs 24 min
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2.3.6 WORKING: These are the process have been done for dip painting to paint the air suspension components Loading the shot blasted parts for pretreatment in basket Check the components free from rust, if found rust send for reshot blasting Ensure basket welding joints & rigidity before loading the components Load sub frame with equal loading Place the basket in tank properly in v block to avoid damage Place the basket in rubber lining tank properly Then dip the basket into the degreasing unit for 4 to 5 minutes with the temperature of 55-65deg After the process dip the basket into the water rinse tank for 1-2 minutes at room temperature Then dip the basket into the surface activation tank for 1-2 minutes at room temperature Then dip the basket into the phosphating tank for 3-4 minutes with the temperature of 40-50deg Then move the basket into water drying oven for minimum 10 minutes at the temperature of 100-120deg These process are known as pretreatment process After pretreatment the components upload separately and dip in to Paint filled tank for 1 minutes After dipping the components were hang in a trolley Inspect the components for paint finish is required do rework Then pull the trolley into various oven for drying purpose
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Then after the trolleys get into the forced cooling zone for reduce the heat energy in the component for 30 minutes Then it get into spray coating and leave it to top coating baking oven Then get into the forced cooling zone Then check the component Dry Film Thickness (DFT) minimum of 25 microns After those process the components ready for packing. 2.3.7 Paint defects A paint defect is in many cases due to a number of causes. In some cases, several defects may occur simultaneously and hinder the
determination of the causes and redemption works. To achieve good painting work, applicators and site supervisors should understand the causes and preventive measures of common defects that occur at different stages of works. They should also be familiar with the remedial measures that can be taken to rectify any unforeseen defect. In general, paint defects can occur during: Paint storage; Application, drying and curing; Service life. Paint defects can have many causes. Maybe your customer had an accident, or maybe the car was exposed to aggressive atmospheric conditions. It is also possible, that mistakes were made during the coating process maybe the coat thickness was not right or drying times were too short. Sometimes such damage is due to badly prepared substrates. And last but not least, the conditions prevailing in the workshop also play an important role.
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incompatible or thinner
accordance manufacturers
recommendation
Painting
of
paint sand,
excessively thick film layer at one time dilution Application paint paints of on or Excessive
Lower dilution ratio where operability is poor Sand clean receiving surface before application and even
part gloss
without
appearance
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and
paint film. This tends to occur when drying is expedited high temperatures Painting over at
appropriate coat accordance with manufacturer s recommendat ion Avoid painting in thick film
Crawling Slipping or
Painting
over
and
surfaces that are not e.g. and the surface prepared, sand, dirt
re-paint as in
manufacturers recommendation
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Painting
over
and
paint sand,
Use
of
coat
as
contaminated tools and water/solvents 6 Lifting Attacking successive coating existing paint
recommende d by
manufacturer Use of Observe over coating intervals as paint sand, Remove film, clean
recommended by manufacturer Allow under coating to dry before application of successive coating Sand and clean receiving surface before application
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Mix
as
recommended by manufacturer
re-paint Discard paint if as in Preventive Measure 8 Loss of Gloss Reduction of Application on rough unclean surfaces In adequate or excessive or Increase frequency of paint sand, Remove film, clean
it is defective
painting in thin film Paint adequate thickness of of film Use appropriate thinner as
dilution Use unsuitable thinner Application of excessively thin film Result blushing occur the Drying occurs in presence of as
recommend ed by
excessive
moisture
and pollutant
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Select
colors
Repaint with appropriate coating system that stable Select colors are more
UV degradation Use of paint with sensitive pigments 10 Yellowing Use of paint with certain Use water
non- surface
Prepare and
contaminants 11 Saponification based cement materials. alkalis from Use of alkydpaints on based The the Avoid using alkydpaints based on Remove paint
2 3 4 5 30
Chapter 3 EXISTING FIXTURE 3.1 THE EXISTING FIXTURE AT WHEELS INDIA LIMITED
Figure 3.1: Existing fixture at WIL 3.2 CHARACTERISTICS OF EXISTING FIXTURE The fixture is look like a bucket The fixture capacity is 600 kg to 700 kg In this fixture each and every component placed not separately. And allow for further pretreatment process. After pretreatment all the parts pick and fix in the jig separately based on the dimensions of the part. And dip into the dip tank for even apply in the structure of Component Number of parts placed in the bucket also based on dimensions of the component The fixture will not allow the various size of components This fixture is not enough to take all the parts in the air suspension kit for single period
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3.3 DISADVANTAGES OF EXISTING FIXTURE: Cycle time is high for the production of an air suspension kit and delay in packing. Fixture capacity is low This will only useful for pretreatment process. After pretreatment a separate jig and trolley is must need for further process. Withstand capacity is also low. There is no space to keep cow horn. 3.4 Tank details:
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11
10
12
42k1
10
33
13
42k1
10
14
42k1
50
10
15
42k1
50
10
16
42k1
17
18 19 1 2 3 4 5 6 7 8 9 10
SUPPORT BKT ASSY LH SUPPORT BKT ASSY RH Cow horn LH/RH Hub bracket LH/RH Sub frame Air spring bracket LH/RH Front cross member F.Gusset LH/RH Flitch LH/RH Beam Support bracket LH/RH hanger link bkt&others
42k1 42k1 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
30 30 0 10 4 12 8 20 30 30 40 40
10 10 4 5 1 5 4 10 10 10 10 10
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1 2 3
2 3 4
3 4 5
4 5 6
5 6 7
6 7 8
7 8 9
8 9 0
9 0 1
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0 1 2
1 2 3
2 3 4
3 4 5
4 5 6
5 6 7
6 7 8 36
7 8 9
8 9 0
9 0 1
0 1 2
1 2 3
2 3 4
3 4 5
4 5 6
5 6 7
4.2 Design of new fixture: We design the fixture with the dimension of the tanks and the dimensions of the components. The length of the first five tanks (degreasing tank, water rinse tank, surface activation tank, phosphating tank, and DM water rinse tank) is 2000mm, and the width of the five tanks is 1800mm, and the height of the five tanks is 2600mm. The length of the dip tank is 3000mm, and the breadth of the dip tank is 800mm, and the height of the dip tank is 2860mm. Hence we design the fixture with the length of 1700mm, and the width of 1600mm, and the height of 2200mm. We divide the fixture in two parts for hanging the components by their limitation. The first beam is placed in the length of 700mm, and the upper beam is placed in the length of 2000mm. We design the fixture by using the design software PROENGINEERING WILD FIRE 4.0. We require using cast iron for our fixture because of its strength. We show in figure 4.2 is the three dimensional view of the new fixture. The two dimensional, third angle projection view of the fixtures front, top and left side views are given below.
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2 3 4
3 4 5
4 5 6
5 6 7
6 7 8
7 8 9
8 9 0 41
8 43
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4.6 CHARACTRISTICS: This modified fixture having capacity to lift up to 1 tone. This fixture is having capacity to hold up to 31 different parts and with various dimensions also. In this fixture there is four hooks were used to lift, this avoid shaking and it will reduce the wear and tear between the object. This fixture is used as trolley also because wheels were given below. This fixture is also used as jig, (i.e.) we can dismantle and assemble each and every separate beam which is holding the components. Dismantle the beam with that holding component and
assemble after dip paint process. After assemble move it as trolley and send it to the oven. By this fixture, the full air suspension kit will ready at the two time use of the fixture In a single shift we get 15 full air suspension kits by the use of our new fixture By the use of this fixture the loading time and unloading time is reduce And the two man power will reduce by this fixture
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Chapter 5
5.1 RESULT Reduce the cycle time Production of Air Suspension kit will increase. No need of separate jig and separate trolley. Production cost and maintenance also low. Can fix components with any dimensions because of the inconsistence of the beam in fixture. This fixture having capacity to carry all parts of air suspension kit of dip paint process. Wear and tear between the parts was low because the fixture hangs on four edges sufficient gap has been provided between all parts. Withstand and space is comparatively high then existing one. Two cow horns can fix in this fixture. It will reduce two man power in paint plant Fabrication can do by recycling of iron. So it is economic.
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9 0 1
0 1 2
1 2 3
2 3 4
3 4 5
4 5 6
5 6 7
Chapter 7
CONCLUSION: Modular fixtures are assembled from various quick acting universal elements designed and manufactured to meet the need for faster and economical fixturing. They enable us to assemble fixtures of different sizes as well as shapes, required to meet the fixturing requirements of components of different shape and size. The level of skill required to assemble and operate these fixtures are very low, making it more and more economically variable apart from reducing the cycle time required to fabricate the components. We conclude that fixture is designed successfully. Major defect in the air suspension paint plant got a solution. Now the departure rate of air suspension kit will increase due to the reduction of cycle time. Fabrication of fixture is also economic. Thus the designing fixtures for new air suspension plant project attain its goal successfully.
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References
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1. Colvin, Fred H.; Haas, Lucian L. (1938). Jigs and Fixtures: A Reference Book. New York and London: McGraw-Hill Book Company. 2. Hoffman, Edward G. Jig and Fixture Design. Fifth edition. New York: Delmar Learning, 2003. ISBN: 1-4018-1107-8. 2. Flexible Manufacturing Systems - A Review. 3. Henriksen, Erik K. (1973). Jig and Fixture Design Manual. New York, N.Y.: Industrial Press Inc. 4. Reza N. Jazar (2008). Vehicle Dynamics: Theory and Applications. Spring. p. 455. Retrieved 2012-06-24. 5. http://www.strutmasters.com/luxury-suspensions/air-ride-problems.htm
6. http://airride.co.uk/air-suspension-explained/what-is-an-air-compressor-12v-dc/
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