SUMMER TRAINING PROJECT REPORT

HONDA SIEL POWER PRODUCTS,GREATER NOIDA METHODS INVOLVED IN THE PROCESS OF PRODUCTION OF GENERATORS,PUMPSPUMPS UNDER THE SUPREME GUIDANCE OF MR.RAJIV SHARMA PRODUCTION HEAD HONDA SIEL POWER PRODUCTS PREPARED BY :ROHAN SINGH RAWAT B.TECH [MECHANICAL] IEC COLLEGE,GREATER NOIDA UTTAR PRADESH

PREFACE
Industrial exposure is the most crucial part of the technical studies in which a student is able to synchronize his technical knowledge with practical knowledge gained in any of the organization in which he gets his training from. I was allotted a project titled, Methods involved in the process of Production of Pumps, Engines in HONDA SIEL POWER PRODUCTS. I hope that the word of my project communicates the actual experience gained with subtlety and precision, which is unapproachable, by any other means. From the medium of this project report, I would like to thank each and every honorable employee of HONDA SIEL POWER PRODUCTS, who has helped me to gain all the knowledge in the respective production shop, where production process was involved.

INDEX
PREFACE ABOUT HONDA SIEL POWER PRODUCTS

MANAGEMENT TECHNIQUES HSPP BELIEVES IN

PRODUCTION PROCESS PDC SHOP ALUMINIUM SHOP STEEL SHOP PRESS SHOP WELDING SHOP PAINT SHOP ALTERNATOR SHOP ASSEMBLY SHOP BIBLIOGRAPHY

ABOUT HONDA SIEL POWER PRODUCTS, INDIA

COMPANY CEO AND PRESIDENT, INDIA MR. T.HAMASAKI HISTORY
Honda Siel Power Products Limited (HSPP), formerly known as Shriram Honda Power Equipment Limited, is a joint venture between Honda Motor Co. Japan and Siel Ltd., with 67% Equity Stake of Honda Motor Co. Japan. It is engaged in the manufacturing of Portable Generators, Water Pumping Sets and General Purpose Engines at its state-ofthe-art manufacturing facilities at Greater Noida and Pondicherry.

OFFICES
With strength of over 800 dealers and 15 Area Offices spread across the country, HSPP has been bringing joy and satisfaction to more than 1.5 million users and this makes HSPP the undisputed leader in the field of portable generators. It is a part of one of the worlds largest power products company manufacturing a complete range of 4-stroke range of Portable generators, Water Pumps, Engines & Lawnmowers, to suit your requirements. This gives you the choice to demand more from the world leader "Honda".

TECHNOLOGY
HSPP benefits from the rich experience of Honda Motors, Japan, the second largest engine manufacturer in the world, because of their strong emphasis on R&D and in-house technical innovation. Indias first LPG based Generator along with the Super Silent Key Start Generator portable kerosene generators are some of the products which exemplify Hondas pursuit of technological excellence. The product range of Generators conforms to the most stringent phase II Noise & Emission norms as laid down by the Central Pollution Control Board (CPCB), Government of India.

CERTIFICATION
It was in recognition of this that HSPP became the first power products manufacturing company in India to have been awarded the ISO 9001:2000 Certifications for its Quality Assurance Systems & ISO 14001 for its Environment Management Systems. While maintaining its leadership position in the domestic generator market, HSPP, is making active efforts in developing new applications for its General-Purpose Engines (GPE). The business of GPE and Water Pumpsets is expected to contribute significantly to the companys future growth plans. Besides, it also offers the customers in India a wide range of end-use appliances such as Electric and Engine Lawnmowers.

MANAGEMENT POLICY
Hondas business activities are based on fundamental corporate philosophies known as Respect for the Individual and The Three Joys. 1. Respect for the Individual defines Hondas relationship with its associates, business partners and society. It is based on sharing a commitment to initiative, equality and mutual trust among people. It is Hondas belief that everyone who comes into contact with Hondas activities will gain a sense of satisfaction through the experience of buying, selling or creating Hondas products and services. This Philosophy is expressed as The Three Joys. With these corporate philosophies as the foundation, Hondas business is guided by the

following Company Principle: Maintaining a global viewpoint, we are dedicated to supplying products of the highest quality at a reasonable price for worldwide customer satisfaction. Honda actively works to share a sense of satisfaction with all of its customers as well as its shareholders, and to continue improving its corporate value.

THE ENVIRONMENT
Honda will step up its effort to create better clean, fuel-efficient engine technologies and improve further the recyclability throughout its product lines. Honda will also advance alternative fuel technologies, including fuel cells. In addition, Honda will continue its efforts to minimize environmental impact, as measured by the * Life Cycle Assessment, in all of its business fields, including logistics and sales. In its production activities, Honda will promote environmental preservation issues under its Green Factory concept. Continuing to Increase Societys Trust in and Understanding towards Honda In addition to continuing to provide products incorporating Hondas advanced safety and environmental technologies, Honda will continue striving to earn even more trust and understanding from society by, among other things, undertaking activities for corporate governance, compliance, and risk management and contributing to society. Through these Company-wide activities, we will strive to materialize Hondas visions of value creation, globalization, and commitment to the future, with the aim of sharing the joy with Hondas customers, thus becoming a company that society wants

MANAGING TECHNIQUES HSPP BELIEVES IN

Managing a shop requires management of 4 Ms (Man, Machine, Method, Materials) along with the management of 5 Ss (Seiri, Seiton, Seiso, Seiketsu, and Shitsuke), according to the Japanese language.

THE 4 MS OF MANAGEMENT

1. MANPOWER

- Without manpower you are unable to get your work done.

Untrained man can cause damage to goods. 2. METHOD - Wrong method of doing the jobs can be expensive because you may not be able to attain the results. 3. MACHINE - If your machine of inferior quality it may take a longer process to get the work done and therefore time equals to money. Break down of machinery is down time and that cause is higher. You need to pay your manpower and pay for repairs and materials maybe perishable. 4. MATERIALS - Quality of material - use the material of different quantity or quality can affect the end results causing a loss.

5S MANAGEMENT:
The 5S Process, or simply "5S", is a structured program to systematically achieve total organization, cleanliness, and standardization in the workplace. A well-organized workplace results in a safer, more efficient, and more productive operation. It boosts the morale of the workers, promoting a sense of pride in their work and ownership of their responsibilities.

"5S" was invented in Japan, and stands for five (5) Japanese words that start with the letter 'S': Seiri, Seiton, Seiso, Seiketsu, and Shitsuke. Table 1 shows what these individual words mean. An equivalent set of five 'S' words in English have likewise been adopted by many, to preserve the "5S" acronym in English usage. These are: Sort, Set (in place), Shine, Standardize, and Sustain. Some purists do not agree with these English words they argue that these words have lost the essence of the original 5 Japanese words. Definitions Japanese Term Seiri Seiton Seiso Seiketsu Shitsuke English Equivalent Tidiness Orderliness Cleanliness Standardization Discipline Meaning in Japanese Context Throw away all rubbish and unrelated materials in the workplace Set everything in proper place for quick retrieval and storage Clean the workplace; everyone should be a janitor Standardize the way of maintaining

cleanliness Practice 'Five S' daily - make it a way of life; this also means 'commitment'

1.Seiri

The first step of the "5S" process, seiri, refers to the act of throwing away all unwanted, unnecessary, and unrelated materials in the workplace. People involved in Seiri must not feel sorry about having to throw away things. The idea is to ensure that everything left in the workplace is related to work. Even the number of necessary items in the workplace must be kept to its absolute minimum. Because of seiri, simplification of tasks, effective use of space, and careful purchase of items follow. 2.Seiton Seiton, or orderliness, is all about efficiency. This step consists of putting everything in an assigned place so that it can be accessed or retrieved quickly, as well as returned in that same place quickly. If everyone has quick access to an item or materials, work flow becomes efficient, and the worker becomes productive. The correct place, position, or holder for every tool, item, or material must be chosen carefully in relation to how the work will be performed and who will use them. Every single item must be allocated its own place for safekeeping, and each location must be labeled for easy identification of what it's for.

3.Seiso Seiso, the third step in "5S", says that 'everyone is a janitor.' Seiso consists of cleaning up the workplace and giving it a 'shine'. Cleaning must be done by everyone in the organization, from operators to managers. It would be a good idea to have every area of the workplace assigned to a person or group of persons for cleaning. No area should be left uncleaned. Everyone should see the 'workplace' through the eyes of a visitor - always thinking if it is clean enough to make a good impression.

4.Seiketsu The fourth step of "5S", or seiketsu, more or less translates to 'standardized clean-up'. It consists of defining the standards by which personnel must measure and maintain

'cleanliness'. Seiketsu encompasses both personal and environmental cleanliness. Personnel must therefore practice 'seiketsu' starting with their personal tidiness. Visual management is an important ingredient of seiketsu. Color-coding and standardized coloration of surroundings are used for easier visual identification of anomalies in the surroundings. Personnel are trained to detect abnormalities using their five senses and to correct such abnormalities immediately. 5.Shitsuke The last step of "5S", Shitsuke, means 'Discipline.' It denotes commitment to maintain orderliness and to practice the first 4 S as a way of life. The emphasis of shitsuke is elimination of bad habits and constant practice of good ones. Once true shitsuke is achieved, personnel voluntarily observe cleanliness and orderliness at all times, without having to be reminded by management.

THE PRODUCTION PROCESS

All functions

Sales Forecast

PSS Meeting

Marketing, production, Material etc

Day wise Plan

Monthly Plan

Three Months Plan

All functions Distributor

Production Shop

Shop Target Plan

Check Resource Availability

Machine Loading

PSS

- PRODUCTION, STOCK AND SALES

The first phase in the planning is the determination of sales forecast i.e. finding the number of products expected to be sold in a given year. In the next phase PSS meeting is held, and is attended by managers of all the departments like marketing, production, material etc. In this meeting head proposes plans for 3 months and constraints from any department, if any, are discussed and finally plans for three months are decided. These three months plans are again sub-divided into monthly plans and these monthly plans are converted into daily plans and thus we get shop target plan.

Once these plans are specified, we check whether we have capacity to produce the required no. of components (as spec. in shop target). In case we are not capable of producing the required no. of components, well ask the marketing people to reduce our target if possible. In case this reduction is not possible then we will try to find alternate ways to increase our capacity like increasing the no. of shifts of working, increasing work force, subcontracting etc. Once all this is done, we develop machine loading chart and we work according to that plan. The cycle of process followed is PDCA (Plan, Do, Check, Act)

1. PLAN the production 2. DO the work as you have planned, then 3. CHECK for discrepancy, if any. In case there is some problem. 4. ACT in order or rectify that, or if its not possible then again do the planning and follow rest of cycle.

PRODUCTION PLANNING AND SPEC CONTROL PURPOSE- to ensure proper production planning and systematic execution, verification and control of design.
SCOPE - This procedure covers

1. Production(PSS-Production, sales and stock)

2. New Models/Design 3. Control of design document and records

PREAMBLE Production Planning and specific control department is responsible for fixation of production, sales and stock targets. 1. Control of product design and documents are relevant for manufacturing, sales & service. 2. Control of drawings of existing products/models and effecting changes therein. 3. Control of standards is applicable to the existing product or parts thereof or otherwise relevant for the companys operation.

QUALITY ASSURANCE PROCEDURE

TITLE: Fixation of production, sales and stock targets. Purpose: To fix production, sales and stock targets. Scope: This procedure covers Annual PSS Monthly PSS

Procedure:

ANNUAL PSS The concerned PSS & spec. control person: Receives the Annual Sales Forecast data for each product model from marketing department as per the procedure [ D1000] and [E1000] and process

the data based on required monthly stocking norms, for review of management committee consisting of Vice President, Heads of marketing, material, works and approval of CEO. Keeping in view the infrastructural facilities, production capacity and corporate objectives/plans, the PSS is reviewed and approved [frozen].

MONTHLY PSS The concerned PSS and spec. control person : In the first week of the month organizes a meeting of concerned heads/ officials of materials, work and marketing/ exports for review of production, sales and stock of the current month and deciding plans for the forthcoming months based on latest product requirements.

QUALITY ASSURANCE PROCEDURE

TITLE: New Models/ Change in Product design PURPOSE: To facilitate systematic release of designs of new model received from ( KSS) HM, Japan and their execution/ implementation ensuring that the agreed specifications are achieved and relevant records are maintained. SCOPE: This procedure is applicable to Development of new models

Procedure: 1.0 New model 1.1 The complete development cycle of a new product is comprehensive

exercise, starting with the fixation of design input to product validation and

release of specifications, parts lists, drawing etc ( i.e. design of output relevant for manufacturing, sales and service of the product ) 1.2 The requirements for the new model are sent to HPP, Japan by product planning section of marketing department. 1.3 The fixation of design is done by HRID/HGH, Japan based on market requirements received from marketing HSPP through HSPP Japan. 1.4 Production planning and spec. control receives the new model design/ change notices along with the relevant drawings and parts list from (KSS) HM, Japan and release the same too concerned departments as CDDS. 1.5 The CEO nominates a project team, called SED team, consisting of the following members, for inter functional coordination during development of new models. - Large Project Leader LPL - Sales Project Leader SPL - Engineering Project Leader EPL - Development Project Leader DPL The DPL is form HGH/HRID of HM, Japan . 1.6 The SED team prepares a A00 condition table and overall broad schedule. This plan is reviewed with CE) and his approval is obtained. 1.7 Respective members execute the activities for which the responsibility has been assigned to them, document the output. 1.8 Regular review, meetings are organized and outcome of the review is recorded on review record sheet. 1.9 The Large Project Leader 1.9.1 Monitors the activity schedule and reuses/updates it as and when necessary in consultation with concern members.

1.9.2 1.9.3 1.10

Maintains summary of status of main jobs on model development Plans and organize the corrective action stemming from the review.

New standards, if any, applicable to the model or parts thereof are controlled as per procedure 2300.

1.11

The verification and validation of the New models is done by product test and marketing support as per procedure X2200

1.12

After the successful development of model, (KSS) HM, Japan releases the mass production drawings and parts list and the same is released to all concerned departments by production planning and spec. control.

SHOPS IN THE FACTORY

PDC SHOP ALUMINIUM SHOP STEEL SHOP PRESS SHOP WELDING SHOP PAINT SHOP ALTERNATOR SHOP ASSEMBLY SHOP

GREATER NOIDA

PRESSURE DIE CASTING SHOP

BRIEF DETAILS ABOUT THE SHOP
SECTION HEAD- MR. K.D RANA MANPOWER- 67 EMPLOYEES PRESSUE DIE CASTING MACHINES USED WITH HYDRAULLIC PUNCH1. 5OO TONNES 2. 650 TONNES 3. 800 TONNES

ACCURACY-ABOVE 98.5% REJECTED BELOW 1.5%

THE ABOVE MACHINES ARE ALL OF TOSHIBA USED FOR PRESSURE DIE CASTING.
The shop has two furnaces, both for the sole purpose for heating aluminium alloy above its melting point. One is near the raw material section, and the other is attached with the pdc machine (the one with input 500T).The furnace is fired with LPG and propane. The machine with input 500T is used or making cylinder components of Honda bike for Honda Motorcycle & Scooter India, Private Limited (HMSI)in Manesar,Haryana.The Machines of input 650T and 800T are used for making crankcases and cylinder barrels for making pumps and generators in HSPP,Greater Noida. Then, there is a section for storing the raw materials required for pressure die casting. The dies required for casting is maintenance in the die maintenance block, where all the working is done on the die n all the defects they have after they are used. Just right to it is the area where all the finished goods are kept and are ready. They are then send to HSPP or HMSI (depending upon the type of barrel or crankcase being made).

MAP OF THE SHOP

Above we have a detailed view of the PDC Workshop. The shop works in 2 shifts and has a capability of producing 300350 barrels per shift in each machine. The basic die casting process consists of injecting molten metal under high pressure into a steel mold called a die. Die casting machines are typically rated in clamping tons equal to the amount of pressure they can exert on the die

RAW MATERIALS
1.ALUMINIUM ALLOY- GRADE ADC-12. COMPOSITION 80% ALUMINIUM AND 20% ZINC,COPPER AND OTHER IMPURITIES. SUPPLIER- CENTURY NF CASTING,FARIDABAD. 2.SLEEVE- MADE OF CAST IRON. 3.FLUX- COVERAL 11(200GM PER 100KG). 4.SERVO-68 PETROL USED FOR MAINTAINING THE PRESSURE IN PDC MACHINE. 5.LIQUIFIED PETROLEUM GAS AND PROPANE FOR FIRING THE FURNACE.

COMPONENTS BEING MADE UP HERE1.EBK-2800BK 2.YAO BARREL 3.ZCO BARREL 4.YA0 CRANKCASE 5.ZA8 BARREL THE DESIGN CAN CHANGE DEPENDING UPON THE DESIGN CHANGE NOTE(DCN) 6.ZA8 CRANKCASE 7.WBK30 CASING 8.G300 COVERCRANKCASES 9.WBK15 CASING

WORKING
1. Firstly, the furnace is preheated to a temperature of 500degrees(to maintain the
temperature in the furnace).It is then allowed to heat even more further, so as to melt the aluminium alloy. The furnace is further heated to 750degrees.

2. The metal now becomes molten and is taken in a pouring bucket and directly
transferred to the holding furnace (which is controlled by an electrically control machine)

3. The Ladle (which is again controlled) takes a certain amount of molten aluminium
metal. If the metal taken is above the limit it throws it out and if below the limit then it takes some.

4. Now, the ladle pours the molten metal into the die (which is locked through toggle
mechanism) and a hydraulic punch is injected. The metal is poured in through the runner, the metal enters the main part through gate.Hence, the metal forms the shape of the die. The shape is now solidified by cooling it by spray. The spray lubricates and is used for solidification

5. The moving platen has a die, and the moving platen is because of toggle mechanism.

6. The pressure is used for giving the toggle mechanism 7. The pressure is provided by using oil/petrol which is Servo-68 8. After the metal is solidified it becomes a barrel/crankcase or cylinder and is taken out from the machine by the operator operating the machine

9. After this finishing touch is given to the crankcase byA) Pneumatic grinder-Pressure grinder for removing the waste in the barrel . B) Cutting Tool- Rimmer with diameter 6mm.

DETAILED VIEW OF THE PDC MACHINE

INPUT AND OUTPUT OF THE SHOP

LS
INPUT (AL ALLOY, CI SLEEVE AND FLUX)

OUTPUT(CYLINDER BARRELS,CRANKCASE AND CASING

HMSI, MANESAR, HARYANA HSPP, GREATER NOIDA, UTTAR PRADESH

ALUMINIUM SHOP

BRIEF DETAILS ABOUT THE SHOP SECTION HEAD MR. K.D RANA SECTION INCHARGE MR. S.SAXENA MANPOWER-40 EMPLOYEES INCLUDING 35 ASSOCIATES ACCURACY- 99.84 % REJECTED -0.17% In Aluminium Shop, all the cylinder barrels, cover crankcases and pump components being made in PDC shop are finished. Finishing is done with the help of various machines and various operations are done on the components like milling, drilling, tapping, boring, cutting, reaming, chamfering etc.The aluminium shop is a highly efficient and accurate shop. Working is quick and in accordance to the required production for selling. The products being finished are send to the assembly line in HSPP, Greater Noida and Pondicherry.

COMPONENTS BEING FINISHED IN THE SHOP

1.CYLINDER BARRELS AND CRANKCASE FINISH OF MODELA)GK 100 GROUP B)GE 100 GROUP C)GK 200 GROUP D)G300 GROUP 2. COVER CASING AND CYLINDER COMPONENTS OF MODELA) GK200 B) G200

INPUT AND OUTPUT OF THE SHOPINPUT(FROM THE PDC SHOP OR PRODUCT CONTROL ANDPART CONTROL)

OUTPUT (FINISHED BARRELS OF PUMPS, ENGINES &GENSETS)

ASSEMBLY LINE OF HSPP,GREATER NOIDA

ASSEMBLY LINE OF PONDICHERRY

MAP OF THE SHOP

The machine line consists of 1.Machine line 1 2.Machine line 2 3.Machine line 3 4.Office and Seating for break

WORKING
All the finishing is done on the machine operated by the operator. One operator is allotted a machine, which are used for the finishing of the barrel. The operation takes place in two lines

1. LINE 1- For Larger components like

GK200 Group G300 Group

2. LINE 2 For smaller components

GK100 Group GE 100 Group

3. LINE 3- Case covers of pumps

GK200 Group G200 Group

OPERATIONS INVOLEDFOR LINE 1 GK 200 AND G300 GROUP-

ROUND MILLING- Round milling is the process of finishing of the mating portion of
the cylinder. The operation is done on a round milling (Mating) machine. The machine has two cuttersRough cutter- Eliminating the roughness of the mating portion. Finishing cutter-Finishing of the mating is done. REVOLUTION Round (R)- 900 rpm Flat (F) - 1200 rpm CUTTING SPEED- R-850mm/min F-900 mm/min Cutting tool used is made of HIGH SPEED STEEL. The operation takes 2 mins and 28 secs for completion.

MULTI SPINDLE DRILLING AND TAPPING MACHINE (MDT MACHINE)After milling process, drilling and tapping of the the cylinder barrel is done on the mating holes. Drilling is done by drillers made of tungstens carbide. Since there are multiple drilling operation taking place at a time,that is why it is called multi spindle operation.

Same is the

case for tapping.

BORING AND DRILLING IN BFW MACHINE- Boring process takes place on

the cam bore and its fine drilling is done. In machining, boring is the process of enlarging a hole that has already been drilled (or cast), by means of a single-point cutting tool (or of a boring head containing several such tools), for example as in boring a cannon barrel. Boring is used to achieve greater accuracy of the diameter of a hole, and can be used to cut a tapered hole. The coolant used is SERVO CUT S.

REAMING AND TAPPING IN KIRA MACHINE(1)Cutting tool used is Servo Cut S.

In this process reaming

and tapping of the two holes on the upper sides of side view of the crankcase. The

We use carbide drill as a cutting tool. We use plug gauge for checking the hole dia. Vernier calliper is used for measuring hole depth. Hole position is checked by jigs and height gauge.

DRILLING IN BFW (2)MACHINE- In this process side drilling is done on the

crankcase of models GK200 and G300.The cutting tool used is tungsten carbide and cutting oil is Servo Cut S.It takes about a minute to complete the process.

DRILLING IN ARGO MACHINE- Drilling is done on the Insulator mounting wall of

the crankcases of Model GK200 and G300 Group. We use Servo Cut S as the cutting oil and we use carbide drill as a cutting tool. Carbide drill is made up of Tungsten Carbide.

DRILLING AND TAPPING IN KIRA 2-Tapping of governor holes takes place.

Governor hole is the hole from where the oil is introduced in the barrel. We use Servo Cut S as the cutting oil and we use carbide drill as a cutting tool.

MULTISPINDLE DRILLING AND TAPPING OF HEAD PORTION IN MDT (2) MACHINEIn this process, drilling and tapping takes place on the head holes. We use Servo Cut S as the cutting oil and we use carbide drill as a cutting tool. Height gauge, height master and jigs are used as inspection tools.

DRILLING AND TAPPING IN KIRA 3 MACHINE- Inlet and exhaust port

machining is done. They can also be called valves as well. Fine Boring of the valves is done. The cutting is done with High Speed Steel. We use Servo Cut S as the cutting oil. Special Gauge is used for inspection of the ports.

LEAKAGE TESTING MACHINE Leakage Testing Machine is used for testing

the barrel, i.e checking the finishing of the barrel. If the finishing is incorrect, then the barrel will leak. The leakage testing is done with Servo Cut S.

PRESS FITTING THROUGH HYDRAULLIC PRESS- This process includes

two steps

1. Install the guide and seat on the head portion of the case.
2. Press on the barrel through Hydraulic press machine.

CHAMFERING- Chamfering is done on a chamfering machine. The chamfer machine

has a Bit and a Reamer. The Reamer is done for reaming and the bit is used for chamfering the guide valve.

HONING- Honing is done on a honing machine .Honing is basically a super finishing

process, where the bore formed for the piston rod is finished with the help of honing machine. Honing is an abrasive machining process that produces a precision surface on a metal workpiece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture. We use Honilo-281 as a lubricant

PRESS OPERATIONS1. Press is inducted with a hydraulic press machine, for assembling the bearing on the cam bore. 2. Hand pressing is done from a burr, and the process is called burring. Burring is the process of giving projection to any side edge in a cylinder of engine/motor.

LINE 2
LINEAR INDEXING OF MILLING MACHINE (LIMM)-Milling is the process of
finishing of the mating portion of the cylinder. The operation is done on a LIMM Machine. Rough cutter- Eliminating the roughness of the mating portion. Finishing cutter-Finishing of the mating is done.

MULTI SPINDLE DRILLING AND TAPPING MACHINE (MDT MACHINE)After milling process, drilling and tapping of the cylinder barrel is done on the mating holes. Drilling is done by drillers made of tungsten carbide. Since there are multiple drilling operation taking place at a time, that is why it is called multi spindle operation. Same is the case for tapping.

BORING IN KN40 HS- Fine Boring of Cam Bore is done in this machine. REAMING AND TAPPING IN KIRA MACHINE (1) Cutting tool used is Servo Cut S. We use carbide drill as a cutting tool. We use plug gauge for checking the hole dia. Vernier calliper is used for measuring hole depth. Position of hole is checked by jigs and height gauge. In this process reaming

and tapping of the two holes on the upper sides of side view of the crankcase. The

DRILLING AND TAPPING IN KIRA 2-Tapping of governor holes takes place.

Governor hole is the hole from where the oil is introduced in the barrel. We use Servo Cut S as the cutting oil and we use carbide drill as a cutting tool.

TAURUS FINE BORING- Boring of stator of the crankcase is done. PRESSING- Pressing is done on the crankcase. A Connecting Plug is press fitted on
the case with the help of Hydraulic press machine.

MILLING IN LINEAR INDEX MILLING MACHINE-In this process, drilling and

tapping takes place on the head holes. We use Servo Cut S as the cutting oil and we use carbide drill as a cutting tool. Height gauge, height master and jigs are used as inspection tools.

MULTISPINDLE DRILLING AND TAPPING OF HEAD PORTION IN MDT (2) MACHINEIn this process, drilling and tapping takes place on the head holes. We use Servo Cut S as the cutting oil and we use carbide drill as a cutting tool. Height gauge, height master and jigs are used as inspection tools.

DRILLING AND TAPPING IN KIRA (3) MACHINE- Inlet and exhaust port
machining is done. They can also be called valves as well. Fine Boring of the valves is done. The cutting is done with High Speed Steel. We use Servo Cut S as the cutting oil. Special Gauge is used for inspection of the ports. INSIDE PORT DEBURRING IS DONE FROM A CUTTING TOOL AND HAMMER.

LEAKAGE TESTING MACHINE Leakage Testing Machine is used for testing

the barrel, i.e. checking the finishing of the barrel. If the finishing is incorrect, then the barrel will leak. The leakage testing is done with Servo Cut S.

PRESS FITTING THROUGH HYDRAULLIC PRESS- This process includes

two steps 1. Install the guide and seat on the head portion of the case. 2. Press on the barrel through Hydraulic press machine.

CHAMFERING- Now chamfering is done on a chamfering machine. The chamfer

machine has a Bit and a Reamer. The Reamer is done for reaming and the bit is used for chamfering the guide valve. We use a BFW Machine for chamfering.

BORING OF SLEEVE IN XLO FINE BORING- Fine Boring is done sleeve of

the crankcase. It takes 1 minute to complete the process.

HONING- Honing is done on a honing machine .Honing is basically a super finishing

process, where the bore formed for the piston rod is finished with the help of honing machine. Honing is an abrasive machining process that produces a precision surface on a metal workpiece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture. We use Honilo-281 as a lubricant

LINE 3
CASE COVERS OF PUMPS OF GK200 AND G200 AND WB30VMC MACHINE- Fine boring of spark plug is done. In this spot facing, boring and
tapping is done. We use Winner XL as machine.

LAPPING THROUGH LAPPING MACHINE- Lapping is a machining operation,

in which two surfaces are rubbed together with an abrasive between them, by hand movement or by way of a machine. In this case we use a lapping machine.

WINNER XL MACHINE MACHINE

LAPPING

After this the component is send to the assembly line in Greater Noida and Pondicherry. Some are used as spare parts as well.

WASHING MACHINE- Washing machine is used to wash all the components in the shop and eliminate the grease oil from it.

STEEL SHOP
STEEL SHOP INCLUDES1. CRANKSHAFT LINE

2. CAMSHAFT LINE 3. CONROD LINE SECTION HEAD MR. N.K PANT SHIFT INCHARGE MR. N.K BHATT AND MR. MAHENDRA SINGH MANPOWER- 40 EMPLOYEES, 20 PERSONS PER SHIFT QUALITY- 99.95% ABOUT CRANKSHAFT
The crankshaft, sometimes casually abbreviated to crank, is the part of an engine which translates reciprocating linear piston motion into rotation. To convert the reciprocating motion into rotation, the crankshaft has "crank throws" or "crankpins", additional bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder attach. It typically connects to a flywheel, to reduce the pulsation characteristic of the four-stroke cycle, and sometimes a torsional or vibrational damper at the opposite end, to reduce the torsion vibrations often caused along the length of the crankshaft by the cylinders farthest from the output end acting on the torsional elasticity of the metal.

RAW MATERIAL
1. SERVO CUT S(MIXED WITH WATER ) 2. CRANKSHAFT,CAMSHAFT AND CONROD FROM THE RESPECTIVE VENDOR

WORKING

CRANSHAFT LINE POWER HEXAIn this machine the cutting of PTO side of the crankshaft is done

with the help of a saw. The speed of the saw in this machine is being controlled.

FACING AND CENTERING-In facing the surface roughness is eliminated and the
side of the machine is done. The machine on which this operation is done is called Facing and centering machine. The cutting oil used is called Servo Cut S, and the revolution of the cutting tool is at around 1200rpm.The cutting tools being used are1. Center Drill- 6.5X12X63 mm standard measurement. 2. Centre Drill -4X12X64 mm standard measurement. 3. Facing Inserts Center drilling is done up to a certain depth in PTO and ACG.The depth is at about 3+0.20mm in PTO and 6+0.20mm in AC and it is checked with the help of vernier calliper.

CNC MACHINE FOR ACG TURNING-The process takes one and a half minute
to complete in this machine.ACG turning is done on a CNC machine First the Rough cutter does the rough cutting and then the final cutting is done. In this machine Snap Gauge and Taper Gauge are used for checking the measurement of the crankshaft. The cutting tool used in this machine are-

1. Insert TNMG type

2. Insert of DNMG type

3. Tool Holder

Cutting Speed of the instrument is 200m/sec, and the speed is 2500 rpm. Feed is 0.25

mm/rev.

CNC MACHINE FOR PTO TURNING- CNC lathe machine consists of left hand
side support called Chuck. The right hand support is known as Tail Stroke (It has a centre, for support). Then it has an insert for cutting. Insert has a sim. The cutting is done in two processes. The processes are: Rough Cutting-This type of cutting is done on ACG or PTO and is done on the upper side as well. Fine Cutting is done only on ACG/PTO. Cutting Speed of the instrument is 200m/sec, and the speed is 2500 rpm. Feed is 0.25 mm/rev.

PIN TURNING- In this turning the tail stroke is inside the machine for support and a
check for clamping the crankshaft is also inside the machine. It is done on a pin lathe machine. The cutting tool used are-

1. Tool holder (Of different types)

2. Turning insert Cutting speed is 200m/min. Revolution of the cutting tool is 1200rpm. Feed Speed is 0.25 mm/rev.The Pin width is about 17.20 with a clearance of about 0.20mm.

KEY WAY MILLING-In this process keyway cutting is done on the keyway with the
help of a wood ruff keyway cutter. The keyway cutter is made up of High Speed Steel. The machine has a chuck and a tailstock to clamp the object and then it is fixed on the fixture of the machine which is on the bottom of the machine. Cutting speed is 30m/min, and the speed is 340 rpm of the rotator cutting tool. The cutting tools used are 1. Woodruff Keyway Cutter-(25 X 4) 2. Collet (E 40 X 10) The width of the keyway is at 4.018mm and the depth is nearly 7mm.

DRILLING AND TAPPING In this process drilling and tapping is done on the
PTO side of the crankshaft. The operation is done on a VMC machine and takes 3 minutes for completion. The cutting tool used for cutting is of tungsten carbide. For checking the component we use a Thread gauge. If the component passes through the Go gauge, and does not pass through No-Go then it is correct type of component.

A DIAGRAM OF CNC LATHE MACHINE

VERTICAL MILLING MACHINE- Cutting of parallel keyway. The key cutting is

done on the PTO side and this operation is limited to models like G300, G200 and G100.The operation takes 1 minute for completion. INDUCTION HARDENING MACHINE-Hardening of the crankshaft is done in this machine. 1. PIN HARDENING The component is clamped on the fixture and is heated at 900deg Celsius and then water is induced into the component. This process is called Quenching. This process is takes about 18 seconds to complete.

ABOUT QUENCHING
A quench refers to a rapid cooling. In materials science, quenching is used to prevent low-temperature processes such as phase transformations from occurring by only providing a narrow window of time in which the reaction is both thermodynamically favorable and kinetically accessible. For instance, it can reduce crystallinity and thereby increase toughness of both alloys and plastics (produced through polymerization). In metallurgy, it is most commonly used to harden steel by introducing martensite, in which case the steel must be rapidly cooled through its eutectoid point, the

temperature at which austenite becomes unstable. In steel alloyed with metals such as nickel and manganese, the eutectoid temperature becomes much lower, but the kinetic barriers to phase transformation remain the same. This allows quenching to start at a lower temperature, making the process much easier. High speed steel also has added tungsten, which serves to raise kinetic barriers and give the illusion that the material has been cooled more rapidly than it really has. Even cooling such alloys slowly in air has most of the desired effects of quenching. Extremely rapid cooling can prevent the formation of all crystal structure, resulting in amorphous metal or "metallic glass". 2. GENERAL STATION- A pneumatic pressure load is provided to the metal.

GENERAL GRINDING IN A GRINDING MACHINE-The grinding machine has

a grinding wheel which is used for the grinding of the PTO side of the crankshaft. The job as well as the wheel rotates and hence the work is done. Grinding operation is done in the ACG side as well. This type of grinding is called angular grinding.

PIN HOLE GRINDING- This process is done on the pin grinder. The cutting oil
used is SERVO CUT S. Feed Speed is 0.15mm/rev, and the cutting tool used is grinding wheel and its size is 500X203.2X17 cubic millimeters. The diameter of the pin must be around 18 mm , circularity and ovality should be 0.004 maximum.

CAM GRINDING- Cam grinding is done with the help of a cam grinder. The feed
speed is about 0.015mm/rev. The cutting oil used is SERVO CUT S. This operation is done on the ACG of WBK 30,GK-300 and GK200.

PRESS FITTING Press fitting is a two fixing process-

1. Bearing Fixture- Bearing is installed on the PTO side of the crankshaft.

2. Gear Fixture- Gear is installed on the ACG side of the crankshaft. We use a clamp fixture for fixing the tool. The press is done on a Hydraulic press machine, which is controlled by a pedal.

PIN

PTO

ACG

BEARING GEAR

LINE 2 CAMSHAFTS AND CONROD LINE

SHIFT INCHARGE-MR. RAKESH SINGH AND MR.HEM SINGH MANPOWER- 17 EMPLOYEES PRODUCTION TARGET-500 FINISHED COMPONENTS PER SHIFT ABOUT CONROD AND CAMSHAFT
1.

In a reciprocating piston engine, the connecting rod or conrod connects the piston to the crank or crankshaft. Together with the crank, they form a simple mechanism that converts linear motion into rotating motion. Connecting rods may also convert rotating motion into linear motion. Historically, before the development of engines, they were first used in this way. As a connecting rod is rigid, it may transmit either a push or a pull and so the rod may rotate the crank through both halves of a revolution, i.e. piston pushing and piston pulling. Earlier mechanisms, such as chains, could only pull. In a few two-stroke engines, the connecting rod is only required to push. forms an integral part.

2. A camshaft is a shaft to which a cam is fastened or of which a cam

3. Conrod for all models came from Japan (K.D part) Except for the model
EBK 2000. Only for this model unmachined Conrod came for local vendor, it is a part of Indianization of K.D parts (developing of local source).

COMPONENTS BEING FINISHED HERE CONNECTING

RODS AND CAMSHAFTS ARE FINISHED OF THE MODELS 1. EM650 2. EBK 1000 3. EBK 2000

4. EBK 2800
5. EB 2000GP

SAME CONNECTING ROD

INPUT AND OUTPUT OF THE SHOP

INPUT-CAMSHAFT FROM GUJARAT METAL, RAJKOT AND CONROD FROM PC CASTING FARIDABAD AND SOME FROM JAPAN

ASSEMBLY LINE OF HSPP GREATER NOIDA

ASSEMBLY LINE OF HSPP,PONDICHERRY

SPARE PARTS FOR MARKETS

WORKING
CAMSHAFT LINE- In Camshaft line only press fitting is done as the camshaft
provided is already finished. HSPP orders all the components from PC Casting Faridabad and some components from Japan.

CONNECTING ROD OIL HOLE DRILLING- The drilling of the oil hole is done with the help of oil hole
drilling machine .The cutting oil used is SERVO CUT S. The cutting tools used in the machine are 1. Step Drill(3X9 sq. mm) The inspection tools used are 1. Plug Gauge For measuring the drill hole dia.

2. Vernier Caliper- For measuring the chamfer dia.

DRILLING AND TAPPING- Drilling and tapping is done on the
The inspection tool used arefront end of the conrod. The cutting oil used is SERVO CUT S. We use a drill and cut tap as cutting tool.

1. Plug Gauge- For measuring the drill hole dia. 2. Vernier Caliper- For measuring the drill depth.
FACING AND SLITTING- Facing and slitting is done on the Connecting Rod. The
cutting tool used in the machine is called slitting cutter, and we use a height gauge for checking the length of the Conrod and cap. The cutting oil used is SERVO CUT S.

BROACHING- Broaching is a machining process that uses a toothed tool, called a

broach, to remove material. There are two main types of broaching: linear and rotary. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to affect the cut. Linear broaches are used in a broaching

machine, which is also sometimes shortened to broach. In rotary broaching, the broach is rotated and pressed into the workpiece to cut an axis symmetric shape. A rotary broach is used in a lathe or screw machine. In both processes the cut is performed in one pass of the broach, which makes it very efficient. Broaching is used when precision machining is required, especially for odd shapes. Commonly machined surfaces include circular and non-circular holes, splines, keyways, and flat surfaces. Typical workpieces include small to medium sized castings, forgings, screw machine parts, and stampings. Even though broaches can be expensive, broaching is usually favored over other processes when used for high-quantity production runs. Broaches are shaped similar to a saw, except the teeth height increases over the length of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for semi-finishing, and the final one for finishing. Broaching is an unusual machining process because it has the feed built into the tool. The profile of the machined surface is always the inverse of the profile of the broach. The rise per tooth (RPT), also known as the step or feed per tooth, determines the amount of material removed and the size of the chip. The broach can be moved relative to the workpiece or vice-versa. Because all of the features are built into the broach no complex motion or skilled labor is required to use it.[2] A broach is effectively a collection of single-point cutting tools arrayed in sequence, cutting one after the other; its cut is analogous to multiple passes of a shaper. The inspection tool used are-

1. Special Gauge for checking the length. 2. Vernier Caliper for checking the length of the cap.
3. Roughness Tester for checking the roughness of the surface.

BOLT TIGHTENING-The process of tightening a bolt in the head portion of the

conrod is called Bolt Tightening. Bolt Tightening is done with the help of Pneumatic gun.

A PNEUMATIC TOOL

REAMING MACHINE(KIRA)

REAMING-

A reamer is a metalworking tool used to create an accurate sized hole. The

process is called reaming. They may be used as a hand tool or in a machine tool, such as a milling machine or drill press. The finishing of sleeve is done. The Cutting tools used are 1. Reamer (of dia 26 and 15mm ) 2. Deburring Tool

We use Bore gauge for determining the diameter of the sleeve. Vernier Caliper is used to determine thickness variation and chamfer width. Bench Centre and mandrel for checking the bending and bore gauge for finding taper length.

PRESS SHOP BRIEF DETAILS ABOUT THE SHOP

SHOP INCHARGE- MR. RK SHARMA SHIFT INCHARGE MR.MC OLI, MR.PRADEEP.K, MR. KALICHARAN AND MR. SK DUA MANPOWER- 27 EMPLOYEES. PRODUCTION 600 COMPONENTS PER DAY. PRESS SHOP IS USED FOR MAKING OF TANKS AND SUB TANKS OF THE GENERATORS OR PUMPS WHERE THE FUEL IS STORED. THE STEEL WHICH IS PRESSED IS CALLED MILD STEEL.

DETAILS ABOUT MILD STEELMild steel is the most common form of steel because its price is relatively low while it provides material properties that are acceptable for many applications. Mild steel contains 0.160.29%

Carbon, therefore it is neither brittle nor ductile. Mild steel has a relatively low tensile strength, but it is cheap and malleable; surface hardness can be increased through carburizing. The density of mild steel is approximately 7.85 g/cm3 (0.284 lb/in3) and the Young's modulus is 210,000 MPa (30,000,000 psi).

WORKINGSHEARING ON A SHEARING MACHINE-The machine has a blade which is

used for the cutting of the Mild steel sheet. The thickness of the sheet is 1.2mm. Machine used is of company Godrej. Shearing, also known as die cutting, is a metalworking process which cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curved then they are shearing-type operations. The most commonly sheared materials are in the form of sheet metal or plates, however rods can also be sheared. Shearing-type operations include: blanking, piercing, roll slitting, and trimming.

STAMPING IN PDU 200- Stamping includes a variety of sheet-metal forming

manufacturing processes, such as punching using a machine press or stamping press, blanking, embossing, bending, flanging, and coining. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages. Stamping is done on metal sheet which was earlier worked on the shearing machine. The pressure applied on this machine is 200T.The die in the machine is pressed on the sheet through a hydraulic press. The die actually forms a stamp in the sheet. The metal sheet is fixed on the fixture before stamping takes place.

DRAWING IN PDU200-

Drawing is a metalworking process which uses tensile

forces to stretch metal. It is broken up into two types: sheet metal drawing and wire, bar, and tube drawing. The specific definition for sheet metal drawing is that it involves plastic deformation over a curved axis. The success of forming is in relation to two things, the flow and stretch of material. As a die forms a shape from a flat sheet of metal, there is a need for the material to move into the shape of the die. The flow of material is controlled through pressure applied to the blank and lubrication applied to the die or the blank. If the form moves too easily, wrinkles will occur in the part. To correct this, more pressure or less lubrication is applied to the blank to limit the flow of material and cause the material to stretch or thin. If too much pressure is applied, the part will become too thin and break. Drawing metal is the science of finding the correct balance between wrinkles and breaking to achieve a successful part. The pressure applied on this machine is 200T.The die in the machine is pressed on the sheet through a hydraulic press. The metal sheet is fixed on the fixture. Main motor of the machine is connected and switched on. Gear runs which lets the running of flywheel. Clutch system attaches to the flywheel and lets to the rotation of the flywheel up to 3600. Then, the flywheel is attached with the conrod which leads to the movement of ram.

TRIMMING/PIERCING IN PUX 200 In this process piercing and trimming of the

component is done on a PUX 200. In piercing the punched out piece is scrap. The pressure implemented on the machine is 200 T.

A machine of AMETEEP (PDU200) used for the purpose of drawing operation

BLANKING IN PDU 200- Blanking and piercing are shearing processes in which a
punch and die are used to modify webs. The tooling and processes are the same between the two, only the terminology is different: in blanking the punched out piece is used and called a blank; in piercing the punched out piece is scrap. The different operations required in different components of EXK 2800 are as followPart Name Tank Upper Operation Draw Trim Pierce Pierce, bur Press PDU 200 PUX 200 PUX 200 Die No. 120 121 122

Tank Lower

Draw Trim Pierce Pierce, Bur

PDU 200 PUX 200 PUX 160

123 124 125

M.P Inner

Blanking Draw Re-strike, Pierce Trim, Pierce Cam Pierce Cut Of Bending

PUX 200 PDU 200 PUX 200 PUX 160 PUX 200 PUX 160

142 127 128 129 130 131

M.P Outer

Draw Re-strike Trim, Pierce Slide Pierce Louring

PDU 200 PDU 200/ 160 PUX 200/ 160 PUX 160 PUX 200

132 133 134 135 136

Cover Fan

Draw Re-strike Trim Side Pierce

PDU 200 PDX 200 PUX 200/ 160 PUX 200

137 138 139 140

After this tank the components are send to the weld shop for further working. Working on Muffler is done as well, drawing and pressing is done on it. The main objective of muffler is to throw away the unnecessary dust and air from the generator.

PRESSING OF A COMPONENT IN A MACHINE

WELDING SHOP BRIEF DETAILS ABOUT THE SHOP

MANPOWER- 40 EMPLOYEES SECTION INCHARGE- RK SHARMA AND D.C TEWARI SHIFT INCHARGE PRATAP SINGH AND SATYAPAL SINGH

QUALITY - 97.35% After the press shop the Sheet metal work proceeds in the welding shop. The components coming from press shop are welded here by different kind of welding as required by the component like tungsten inert gas (TIG) welding, spot welding, Metal inert gas (MIG) welding & seam welding & brazing. Welding Shop has to keep coordination with press as well as paint in order to maintain their schedule & take the component with sufficient time margin so that they can give it paint shop on time. Safety is important factor which all the associates observes in this shop like all other shops some of them are Welding arcs are intensely brilliant lights. They contain a proportion of ultraviolet light which may cause eye damage so they always wear goggles to avoid any of such events. Always wears apron to protect their self from spotter etc. In order to minimize the fumes effect they always wear masks. Gloves to handle the hot components.

INPUT AND OUTPUT OF THE MACHINE

INPUT (ALL THE COMPONENTS WHICH ARE WORKED ON THE PRESS SHOP)

OUTPUT (AFTER WELDING ALL THE COMPONENTS ARE SEND TO THE PAINT SHOP)

MACHINES USED 1. SPOT WELDER 2. MIG WELDER 3. TIG WELDER 4. SEAM WELDER MODEL COMPONENTS BEING MADE IN THE SHOP1. EBK 1000 2. EBK 2000 3. EBK 2800 4. EYK 2800 5. GK100 6. GK 200 7. GK 300 8. EYK 2000 9. EM SERIES

WORKING NUT PROJECTION- It is the process of assembling nuts on the component with the
help of resistance welding. Electric resistance welding (ERW) refers to a group of welding processes such as spot and seam welding that produce coalescence of faying surfaces where heat to form the weld is generated by the resistance of the welding current through the work pieces. Some factors influencing heat or welding temperatures are the proportions of the work pieces, the electrode materials, electrode geometry, electrode pressing force, weld current and weld time. Small pools of molten metal are formed at the point of most electrical resistance (the connecting surfaces) as a high current (100100,000 A) is passed through the metal. In general, resistance welding methods are efficient and cause little pollution, but their applications are limited to relatively thin materials and the equipment cost can be high.

DETAILED DIAGRAM OF THE SPOT WELDING PROCESS

SPOT WELDERSpot welding is a resistance welding method used to join two to four overlapping metal sheets which are up to 3 mm thick each. In some applications with only two overlapping metal sheets, the sheet thickness can be up to 6 mm. Two copper electrodes are simultaneously used to clamp the metal sheets together and to pass current through the sheets. When the current is passed through the electrodes to the sheets, heat is generated due to the higher electrical resistance where the surfaces contact each other. As the heat dissipates into the work, the rising temperature causes a rising resistance, and the heat is then generated by the current through this resistance. The surface resistance lowers quickly, and the heat is soon generated only by the materials resistance. The water cooled copper electrodes remove the surface heat quickly, since copper is an excellent conductor. The heat in the center has nowhere to go, as the metal of the work piece is a poor conductor of heat by comparison. The heat remains in the center, melting the metal from the center outward. As the heat dissipates throughout the work piece in less than a second the molten, or at least plastic, state grows to meet the welding tips. When the current is stopped the copper tips cool the spot weld, causing the metal to solidify under pressure. 1. Spot welding of Stay Tank A and Stay Tank B and Fuel cock (through a fixture) is done. Welding is done on 23 spots. 2. Spot welding to join Upper Tank, Sub Tank and Lower Tank is done. Welding is done on 4 spots.

NUT PROJECTION- Nut projection of the cover fan with the help of resistance
welding.3 nut projection is done in G200 and GK 200.

SEAM WELDING-Resistance seam welding is a process that produces a weld at the

faying surfaces of two similar metals. The seam may be a butt joint or an overlap joint and is usually an automated process. It differs from butt welding in that butt welding typically welds the entire joint at once and seam welding forms the weld progressively, starting at one end. Like spot welding, seam welding relies on two electrodes, usually made from copper, to apply pressure and current. The electrodes are disc shaped and rotate as the

material passes between them. This allows the electrodes to stay in constant contact with the material to make long continuous welds. The electrodes may also move or assist the movement of the material. In this process the upper tank and lower tank is joined, keeping in mind that sub tank is fitted on the hole of the upper tank between them.

OPERATIONS GOING ON DIFFERENT STATIONS ARE:

Model EXK 2000 Part Tank Upper Welding TIG Sub assembly of tank upper & guide cape is done by TIG welding. EB 3000 Cover Fan Spot Welding Nut projection is done EXK 200 Upper & Bottom Plate Spot Welding Plate A & B is being joined by Spot welding Description

EXK 2000

Fuel Tank

Spot Welding

Fuel tank Upper, Lower & sub tank is being assemble by spot welding

EXK 2000

Tank Upper

Spot Welding

Fuel filter & holder sub assembly.

GK 200

Stay Tank

Spot

Bolt projection is done

BRAZING- Brazing is an important process that is used in the weld shop some of the
important feature of brazing areBrazing is a metal-joining process whereby a filler metal or alloy is heated to melting temperature above 450 C (840 F) and distributed between two or more close-fitting parts. The filler metal is brought slightly above its melting temperature while protected by a suitable atmosphere or flux. It then interacts with a thin layer of the base metal and is then cooled rapidly to form a sealed joint. Brass is used as a filler metal whose diameter varies from 1.5-2.5 mm. Three types of brazing flam is used for different process 1. Neutral in which equal amount of gas is mixed (Temp. 3200). 2. Carburizing- in which diacetylene is more in proportion (Temp. 3100). 3. Oxidizing- in which oxygen is more, it is used for cutting purpose (3300).

LEAKAGE TESTING- In this process, checking of the component is done. The air is
first filled in the main tank and then it is introduced to the water in a vessel, if bubble is formed in any section of the tank, it means welding is not done accurately. It is hence worked again.

PAINT SHOP
SECTION INCHARGE- D. MATHPAL SHIFT INCHARGE J.PRASAD AND TILAK SINGH QUALITY 98.60%

Paint shop is the last processing shop for the sheet metal components before assembly. From here the sheet metal components are ready to assemble in the final product.

Press Shop Weld Shop

Paint Shop

Assembly

The paint shop is completely conveyorized. The component travel throughout on the belt and gone through many process necessary before & after the painting. The paint shop apart from conveyer system have also boiler plate, DM plat, Pre treatment chamber, Dry off oven , baking oven & painting booth etc. to carry out a effective and efficient work out there. Three color are being used in the paint shop to paint all the models and there codes are 1. R-280- RED

2. NH 105- Black

3. NH-31- White

WORKING
1. LOADING:
The component is loaded on the conveyer belt.

2. PRETREATMENT:
Control Point Spray pressure Standard 0.8-1.2kg/cm2 Why to proper spray Temperature 45-550c for oil removal Ph Processing time Nozzle condition no clogging for uniform spray 8-10 30sec do

3. PRE DEGREASING:
Control Point Standard Why

bath level Temperature

maintain bath 50-550c

For proper spray For all removal

Pointage Processing time Nozzle condition

10-12 30sec No clogging

10-12

For uniform spray

4. PRE TREATMENT:
Control Point Bath level Standard Maintain bath level Temperature Pointage Processing time Nozzle condition Over flow Over flow maintain No clogging 50-550c 10-12 30sec For all removal 10-12 For proper coating For uniform spray For remove contamination Why To proper spray

5. WATER RINSE 1:
Control Point Spray Pressure Free alkali PH Processing time Nozzle No clogging Standard 0.8-1.2kg/cm2 10 max 8- 9 30sec Why To proper spray To proper spray For all removal For proper coating For uniform

condition Over flow Over flow maintain

spray For remove contamination

6. WATER RINSE 2:
Control Point Spray Pressure Free alkali PH Processing time Nozzle condition Over flow Over flow maintain No clogging Standard 0.8-1.2kg/cm2 2 max 7- 8 30sec Why To proper spray To proper spray For all removal For proper coating For uniform spray For remove contamination

7. SURFACE CONDITIONING:
Control Point Spray Pressure PH Processing time Temperature RT Standard 0.8-1.2kg/cm2 8.5- 9.5 30sec Why To proper spray For all removal For proper coating

8. PHOSPHATING:
Control Point Bath level Standard Maintain bath Why To proper spray

level Temperature 43-480c For all removal

Zinc coating is there to protect the surface against rust.

9. WATER RINSE 3:
Control Point Spray Pressure Standard 0.8-1.2kg/cm2 Why To proper spray Free alkali 10 max To proper spray PH Processing time Nozzle condition Over flow Over flow maintain No clogging 8- 9 30sec For all removal For proper coating For uniform spray For remove contamination

10. WATER RINSE 4:

Control Point Spray Pressure Total acidity Processing time Nozzle condition Over flow Over flow maintain No clogging Standard 0.8-1.2kg/cm2 2 max 30sec Why To proper spray To proper spray For proper coating For uniform spray For remove contamination

11. DI WATER RINSE:

Control Point Spray Pressure Standard 0.8-1 kg/cm2 Why To proper spray Free alkali 10 max To proper spray PH Processing time Nozzle condition Over flow Over flow maintain Electro conductivity Less than 10 micro Siemens No clogging 6.5- 7.5 30sec For all removal For proper coating For uniform spray For remove contamination

DRY OFF OVEN

Its temperature is around 130 0c to dry the water, even the water traces

PROCESS INVOLVED AFTER DRYING ARE-

Paint mixing room The paint is mix in prefix ratio Air Blow Paint booth Flash off zone It is provided to give paint some same setting time & extra thinner evaporates Bake off oven Its for the baking of paint it is different from dry off oven because it is operates a bit high temp. Its temp. is 150 0c Final inspection

Assembly

THE PRETREATMENT PROCESS

This cleansing process creates optimal conditions for painting and coating through physical and chemical treatment of the product surface, removing all foreign material. The methods generally used for surface modification involve the formation of a physical barrier to protect the metal against its corrosive environment. Chemical conversion coatings are adherent, insoluble, inorganic

crystalline or amorphous surface films, formed as an integral part of the metal surface by means of a non-electrolytic chemical reaction between the metal surface and the dipped in solution. In such coatings, a portion of the base metal is converted into one of the components of the resultant protective film, which is much less reactive to subsequent corrosion than the original metal surface.

This film imparts an equal potential to the metal surface, neutralizing the potential of the local anodic and cathodic galvanic corrosion sites. They also serve as absorptive bases for improving the adhesion to paints and other organic finishes. Chemical conversion coatings are preferred because of their adherent nature and high speed of coating formation besides being economical. Further these can be formed using simple equipment and without the application of any external potential. Chemical conversion coating processes are classified as phosphating, chromating and oxalating. Metal cleaning is the essential process for the surface finish. Metal cleaning here is removal of grease, oil, soil, lubricating, oxide films etc. The pretreatment process followed here is shown in the adjoining figure. Basically water in different conditions and composition is sprayed on the components with the help of nozzles. The process starts with hot water rinsing. In this hot water with temperature around 45-55 deg Celsius and pressure 0.8 1.2 Kg/cm2 is sprayed on the component for a period of 30 seconds. This process helps mainly in removal of oil and other foreign material.

The next stage is the Predegreasing. The list of metals and their features explains how raw materials have natural surface conditions that interfere with coating adhesion and performance. In the process of being stored, handled and worked they will pick up additional some contamination on their surface. On metals, some of the probable contaminants are oily soils including petroleum products, animal fat, or vegetable oils, deposited during manufacturing operations for rust protection, drawing, machining and forming. There may also be heavy duty drawing compounds and lubrication greases or waxes and some solid soils such as carbon, graphite smuts, metal shavings, polishing products, metal oxides, welding scale, die release products, and red or white oxidation. Removal of soils prior to powder coating is essential to the successful life of the product. It affects the initial adhesion and the ultimate performance in the field. Soils that are present on metal parts can be removed by a variety of mechanical and chemical methods. What method should be used in a given situation is determined by the part to be coated (size, configuration, material), the type of soil to be removed (dust, wax, oil, salt crystals, etc.) and the performance requirements of the finished product. This is done at temperature of 50-55 deg Celsius and for a processing time of 30 seconds. After this, degreasing is done with same conditions but for a processing time of 90 seconds. After this Water rinse I & II is done for a processing time of 30 seconds each. In the next stage Surface Conditioning is done at the room temperature. The spray pressure is 0.8-1.2 kg/cm2 and pH value in the range 8.5 9.5. The processing time for this stage is 30 secs. Next we do phosphating which is one of the most important stages of the pretreatment. The presence of a phosphate coating on a metal substrate normally serves one or both of two major functions: - increasing the corrosion resistance of the substrate by comparison with an otherwise identical metal substrate that has no such conversion coating, an increase that may be measured either with or without a subsequent paint or similar protective coating

- serving as a strongly adherent "carrier" for an externally applied lubricant material that facilitates mechanical cold working. Phosphating (i.e., iron and zinc phosphating) is a process of depositing a conversion coating onto steel and galvanized steel to prepare the surface to receive a liquid, powder, or electrodeposited coating. The phosphate deposit is referred to as a conversion coating because it converts the surface of the virgin steel (no oxide present) to a roughened amorphous or crystalline phosphate composite. A phosphate deposit can enhance a paints and coatings application in essentially three ways: - Serving as a barrier to keep atmospheric oxygen and moisture from attacking the base metal. - Acting as a dielectric film that electrically insulates the substrate from the paint or other coating, slowing the process of galvanic corrosion. - Providing a rough surface for mechanical gripping of the paint or other coating for an improved bond. Establishing a strong bond between the primer-topcoat system and the substrate enhances the corrosion-resistance of the workpiece as well as the general resilience of the surface. Along with providing the foundation for this bond, however, this pretreatment step also plays another important role in promoting the durability of the finished piece. The phosphate coating acts as a secondary barrier against moisture and oxygen, inhibiting the electrochemical process that leads to galvanic corrosion of the metal substrate. This pretreatment step is specific to metal substrates. The phosphate coating process is not used on plastics or ceramics because neither can participate in an electrochemical reaction as can metals. The deposition of phosphates only takes place if an electric current can flow through the substrate/liquid system. Despite the enhanced durability afforded by application of a phosphate coating, for many paints and coatings operations the addition of this pretreatment step is not cost effective. Many steel products for the building and construction industry (e.g., metal ties, brackets), for instance, are not required to have a high-quality organic finish. Indeed, the higher price that manufacturers of such products would need to charge to recoup the cost of

additional pretreatment might undermine safes in this price-sensitive market. Similarly, the cost of phosphating particularly large work pieces can be preclusive. The alternative pretreatment approach for large structural members such as l-beams is abrasive blasting. Phosphate coatings are applied primarily to higher value goods or to products designed to provide long term performance. In the appliance manufacturing industry, for example, both iron and zinc phosphating are used extensively to achieve high-quality primertopcoat systems. As shown in Table 6-2, large and small parts alike receive this pretreatment at relatively high production rates.

COATING QUALITY AND BASIC PARAMETERS

The quality of a phosphate coating is determined primarily by its weight (in milligrams per square foot) rather than its thickness. For optimum process efficiency, phosphate coatings should be weighed regularly and the results tracked over time. Allowing too heavy a phosphate coating to form on a substrate can ultimately lead to failure of the primer-topcoat system. For example, an excessive coating can eventually split and cause delamination of the topcoat. Coating weight can be determined by immersing a preweighed, coated panel in a beaker containing heated chrome oxide. Results can usually be obtained within a few hours. Such a test, however, should only be conducted by a trained technician in a laboratory that is properly equipped with a fume hood. For high-quality work pieces, some operators also test the quality of phosphate coatings for corrosion resistance. A typical test involves subjecting a panel that has received a phosphate coating and then a primer to salt spray in a laboratory chamber. The results are then compared with the corrosion resistance demonstrated in the same test using a panel of known quality. Some operations also test phosphate coatings for electrical resistance (i.e., the ability to resist galvanic corrosion) with an impedance test. The key parameters that must be controlled to achieve a quality phosphate coating are concentration, temperature, pH, and dwell time. Concentration: Within a narrow range, deposition of iron phosphate tends to increase as the concentration of the purchased material in the phosphating solution is increased. That range tops out at 5 percent, beyond which the degree of deposition achieved on the substrate remains essentially unchanged. At concentrations above 5 percent, the process operator is likely to be wasting the phosphating chemicals. A concentration below 3 percent usually will deposit a coating that is too thin to achieve desirable adhesion or corrosion-resistance

characteristics. Thus, process operators generally mix phosphating solutions with a 3 to 5 percent concentration of the purchased material. Similarly, specific parameters apply for zinc phosphate. Thus, process operators are strongly advised to follow vendors recommendations. Temperature: As with concentration; within a given range deposition increases as the temperature of the phosphating solution is raised. Process operators typically maintain iron phosphate solutions at 120o to 140oF, in keeping with vendor recommendations. An exception applies when using low-temperature phosphate materials, for which the phosphating solution is maintained at 90F. At temperatures above or below the vendors recommendation, the phosphating reaction might be too fast or too slow, respectively. For instance, if phosphating occurs too quickly, the deposition may be extremely porous. Moreover, phosphating at a high temperature raises energy costs and increases the evaporation of water from the phosphating solution. Similarly, specific parameters apply for zinc phosphate. Phosphate baths and spray feeds are generally heated by either a burner-and-tube system or by a heat exchanger that incorporates steam. Although the burner and tube method has been in use for many years, the more recently installed phosphating equipment tends to incorporate heat exchanger technology, which is more energy efficient and does not generate fumes. pH: The pH of an iron phosphate bath gives an indication of the acidity. Typical iron phosphating solutions are slightly acidic, in a pH range of 3 to 6 for both immersion and spray applications; zinc phosphating solutions generally are more acidic, in a pH range of 1.8 to 2.4 for immersion and up to 3.0 for spray application (4). Control of pH is critical because the phosphate precipitates out from the solution only when the pH at the substrate/liquid interface is in the correct range. Because the pH range is specific to the particular phosphate formulation, vendor recommendations must be followed exactly. Dwell Time: For both iron and zinc phosphating, the dwell time required to achieve an adequate conversion coating differs significantly between immersion and spray application. Depending on the concentration of the purchased material, a workpiece immersed in an agitated bath of phosphating solution generally requires a dwell time of 3 to 5 minutes. Agitation brings the fresh chemical in the bath to the substrate/liquid interface, where the electrochemical reactions occur. Thus, agitation is recommended to achieve uniform deposition and to maximize chemical use. In sharp contrast, with spray application the phosphating solution only has to make contact with the workpiece for 60

to 90 seconds. The conversion reaction occurs faster because the spray solution continuously supplies fresh chemicals to the surface of the workpiece.

BEST MANAGEMENT PRACTICES

Recommended practices that enhance process efficiency as well as the quality of the phosphate coating include the following: - To promote proper adhesion for high-durability primer-topcoat systems and to extend the life of immersion baths, process operators should ensure that work pieces are thoroughly rinsed before and after phosphating. - To maximize the effectiveness of phosphating formulations, operators should confer regularly with vendors and thoroughly test various combinations of acids, accelerators, and surfactants. For many operations, it may be necessary to customize the phosphating formulation to the specifications of the particular coating system. - To ensure the cost-effective use of chemicals, facility operators should automate the addition of the phosphating formulation to processing tanks. Although capital cost outlays for the installation of flow controllers can be somewhat high, this measure can yield process input savings in the near term. - To avoid contaminating the phosphated surface with perspiration, skin oils, or general grime, facility operators should require process line workers to wear clean gloves when handling freshly phosphated work pieces. Such contaminants can undermine adhesion of the primer-topcoat system and mar the finish by photographing through. Zinc Phosphating In most operations where the corrosion resistance of finished work pieces must be especially high, conversion coatings are applied using zinc phosphate. This approach is widely used in the automotive industry and in certain sectors of the appliance and electronics industries. Similarly, zinc phosphating is often specified by the armed services, especially for equipment that may be exposed to severe environments. Moreover, many operations using electro coating or powder coatings, particularly when a one-coat finish will be exposed to the weather, pretreat work pieces with zinc phosphate.

The electrochemical process whereby zinc phosphate deposits on a substrate is similar to the iron phosphating process. As soon as the workpiece is subjected to the acidic solution, metal dissolves at anodic sites. As in iron phosphating, accelerators (i.e., oxidizers) are an important addition to zinc phosphating solutions. In zinc formulations, accelerators oxidize the iron ions and use up the hydrogen at the metal surface. This lowers the acid content, or pH, at the cathodic sites to the point at which zinc phosphate naturally precipitates onto the steel surface. This process continues until all cathodic sites are coated. The accelerator performs two basic functions: - The excess ferrous ions in the solution tend to slow down the phosphating process. The accelerator speeds up the process by oxidizing the excess iron ions, causing them to precipitate out as a ferric phosphate sludge, which extends the life of the bath. (The sludge must later be filtered out of the solution and disposed of as a hazardous waste.) - By reacting with hydrogen as it is formed at the anodic sites, the accelerator prevents hydrogen gas formation. If an oxidizer were not used, the formation of gas would interfere with the deposition of the phosphate. Thus, addition of an oxidizer (also known as a depolarizer) frequently prevents hydrogen embrittlement of high-strength steel. Accelerators specifically used with zinc phosphate range in reactivity from mild nitrates to the fairly aggressive chlorates and peroxides. Calcium compounds are particularly favored as accelerators for the low coating weights and compact grain sizes they yield. These typically are used when higher temperature phosphating solutions (i.e., 112o to 130F) would otherwise slow conversion kinetics. They can also be used in lower temperature baths when accelerators or initiators such as nickel, iron, manganese, and borium are also used. In general, the crystals that result from zinc phosphating have low porosity and provide a strong base for adhesion of the primer-topcoat system and superior long term corrosion resistance. The performance of zinc phosphate formulations increases in the following order: - Zinc phosphate - Zinc-calcium phosphate - Zinc-nickel-fluoride phosphate

- Zinc-nickel-magnesium-fluoride phosphate Crystal size also is affected by the method used for subjecting the workpiece to the phosphating solution and by the thoroughness of the rinsing steps. The particular phosphating method used, however, often depends on the type of workpiece. Typical zinc phosphate coating weights are 100 to 1,000 mg/ft2 using spray application, whereas coatings can range from 150 to 4,000 mg/ft2 using immersion tanks. Fewer process variations are applicable to zinc phosphating, given that process operators must thoroughly rinse drag-out and contaminants from work pieces before and after phosphating. Also, each spray or immersion step must be specific to the particular process stage. Thus, for instance, the degreasing and phosphating steps cannot be combined, as they are sometimes in the iron phosphating approach. For operations using zinc phosphating, the process line includes five or more steps in which work pieces are degreased, tap water rinsed, phosphated, tap-water rinsed, and then rinsed with deionized water. Phosphating is followed by Water Rinse III and IV and then we have DI water rinsing and direct DI water rinsing. This finishes the pretreatment process.

ELECTROSTATIC SPRAY PAINTING

The principles of electrostatic charging apply equally to liquid and powder coatings. In electrostatic coating, the fluid is atomized, and then negatively charged to the object, thus having a less negative charge than the paint. Increased transfer efficiency is achieved, up to 95%. For instance, it is possible to spray paint a cyclone fence electro statically with fair transfer efficiency. Both sides of the fence can be painted from only one side due to the electrostatic attraction. The principle of Manual Liquid Electrostatic Spray Gun for Electrostatic Coating In using the liquid electrostatic spray gun, the high compress air tends to throw the paint away when the paint passes through the special nozzle, the droplets pick up the charge from an electrically charged electrode at the tip of the gun by charged electrode. The charged particles are given their initial momentum from the fluid pressure/air pressure In this case, the expelling effect appears between the paint carrying electrostatic

and the live particles as to cause further atomization of paint and thus, forming much finer thin fog. Due to the occlusion of electrostatic, the lost paints are sucked back to the workplace in generating a kind of surrounding electrostatic effect and the over spraying phenomenon is thus minimized. In this way, the machine has achieved the purpose of electrostatic coating. An electrostatic paint spray system is a highly efficient technology for the application of paint to specific work pieces. Negatively charged atomized paint particles and a grounded workpiece create an electrostatic field that draws the paint particle to the workpiece, minimizing overspray.

For this technology, an ionizing electrode, typically located at the paint gun atomizer tip, causes paint particles to pick up additional electrons and become negatively charged. As the coating is deposited on the workpiece, the charge dissipates through the ground and returns to the power supply, completing the circuit. The electrostatic field influences the path of the paint particles. Because the charged particles are attracted to the grounded workpiece, overspray is significantly reduced. Paint particles that pass a workpiece can

be attracted to and deposited on the back of the piece. This phenomenon is known as "wrap". The transfer efficiency is the percent of sprayed paint that is applied to the workpiece. Paint that is not applied to a workpiece is captured in the paint spray booth's emission control system and ultimately disposed as waste. The typical transfer efficiency for an electrostatic paint spray systems is 75%. In conventional paint spray systems, pain atomization occurs via high velocity air jets forcing paint through small air holes in the paint gun face caps. Air pressures used in these systems range from 40 to 80 psi, with air volumes of 8 to 30 standard cubic feet per minute (scfm). The atomized paint particles travel at high velocities and have a greater tendency to bounce off the object being painted, as compared to electrostatic systems. Transfer efficiencies of 50% are typical for conventional painting systems. No new wastes are generated when a conventional paint spray system is converted to an electrostatic paint spray system. Significant reductions in waste generation are achieved due to the electrostatic systems increased transfer efficiency. A potential drawback to electrostatic finishing, particularly for coating complicated surfaces, is the Faraday cage effect: a tendency for charged coating particles to deposit around entrances of cavities. The Faraday cage effect allows electric charges on a conductor to reside on the outer surface of the conductor. In the case of coating complicated surfaces, the electric charge resides on the entrances of cavities. High particle momentum can help overcome Faraday cage effects, since particles with greater momentum (larger particles or particles traveling at higher speeds) are influenced less by the electrostatic forces. However, high particle momentum also lowers efficiency. Electrostatic paint equipment is available in three basic types: air atomized, airless, and rotating discs and bells. High-speed discs atomize the coating more finely than air atomization and direct more paint to the target. This technology is particularly efficient for the application of difficult to disperse, high-solids paints. However, the Faraday cage effect is generally greater with rotary atomizers than with air or airless types. Rotary atomizers, therefore, may not provide adequate coverage for complicated surfaces.

MATERIALS COMPATIBILITY:
Any material that can be atomized can accept an electrostatic charge, regardless of the coating conductivity. The workpiece must be groundable. Metal and some wooden pieces can be painted electro statically, but plastic, rubber, ceramic, and glass cannot.

SAFETY AND HEALTH:

Electrostatic paint spray systems operate at high voltages (30 to 150 kV). Hence, operator safety is a major concern. All items in the work area must be grounded, including the operators, the paint booth, the application equipment (unless applying conductive coatings), and conveyors. Ungrounded items should be removed from the work area. Removing paint buildup from the paint booth helps assure that work pieces are grounded. Workers should never wear rubber- or corked-soled shoes (special shoe-grounding devices are available.). Adequate skin contact is required when using hand-held guns. Painters should grasp the gun with bare hands or use gloves with finger tips and palms cut out. Consult your local industrial health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing this technology.

BENEFITS:

Higher transfer efficiencies results in a significant reduction in the generation of waste and reduction in paint usage. Less maintenance is required for pollution control equipment serving the paint booth.

DISADVANTAGES:

High capital cost and more spray equipment maintenance is required. The electric charges tend to repel on complicated surfaces. Faraday Cage Effect

Surface imperfections are possible due to air molecules becoming trapped in the coating surface.

ALTERNATOR SHOP
SECTION HEAD A.K. MOURYA SECTION INCHARGE- DK CHAUHAN MANPOWER- 51 EMPLOYEES IN BOTH SHIFTS QUALITY- 99.80%

Alternator shop is another important shop in the production especially for the product- generator. Many machines like Stack

welding, core winding, forming, lacing M/c etc is there to assemble the alternator within the required parameters. Alternator shop directly effects the production of Generator so it has to meet the aimed target in order to keep assembly running.

ALTERNATOR MADE OF MODELS1. EXK 1200 2. EXK 2800S 3. EXK 2000 4. EB 3000 5. EBK 2000 6. EBK 2000 7. EBK 1000 8. EBK 2800 9. EM 650 10. EK 400 ABOUT ALTERNATOR
An alternator is an electromechanical device that converts mechanical energy to electrical energy in the form of alternating current. Most alternators use a rotating magnetic field but linear alternators are occasionally used. In principle, any AC electrical generator can

be called an alternator, but usually the word refers to small rotating machines driven by automotive and other internal combustion engines.

PRINCIPLEAlternators generate electricity by the same principle as DC generators, namely, when the magnetic field around a conductor changes, a current is induced in the conductor. Typically, a rotating magnet called the rotor turns within a stationary set of conductors wound in coils on an iron core, called the stator. The field cuts across the conductors, generating an induced EMF, as the mechanical input causes the rotor to turn. The rotating magnetic field induces an AC voltage in the stator windings. Often there are three sets of stator windings, physically offset so that the rotating magnetic field produces three phase currents, displaced by one-third of a period with respect to each other. The rotor magnetic field may be produced by induction (in a "brushless" alternator), by permanent magnets (in very small machines), or by a rotor winding energized with direct current through slip rings and brushes. The rotor magnetic field may even be provided by stationary field winding, with moving poles in the rotor. Automotive alternators invariably use a rotor winding, which allows control of the alternator generated voltage by varying the current in the rotor field winding. Permanent magnet machines avoid the loss due to magnetizing current in the rotor, but are restricted in size, owing to the cost of the magnet material. Since the permanent magnet field is constant, the terminal voltage varies directly with the speed of the generator. Brushless AC generators are usually larger machines than those used in automotive applications.

SYNCHRONOUS SPEEDS
The output frequency of an alternator depends on the number of poles and the rotational speed. The speed corresponding to a particular frequency is called the synchronous speed for that frequency. More generally, one cycle of alternating current is produced each time a pair of field poles passes over a point on the stationary winding. The relation between speed and frequency is N = 120f / P, where f is the frequency in Hz (cycles per second). P is the number of poles (2, 4, 6...) and N is the rotational speed in revolutions per minute (RPM). Very old descriptions of alternating current systems sometimes give the frequency in terms of alternations per minute, counting each half-cycle as one alternation; so 12,000 alternations per minute correspond to 100 Hz.

RAW MATERIAL1. RUST PROOF OIL 2. VARNISH OIL

3. COPPER WIRES 4. LAMINATION FOR ROTOR AND STATOR 5. HARDENER 6. THINNER

INPUT AND OUTPUT OF THE SHOP

INPUT (Material from PCPC)

OUTPUT (ALTERNATOR TO THE ASSEMBLY SHOP)

WORKING STATOR ASSEMBLY

Process M/C TIG Welding M/C 3 Nos. of torch Welding speed4mm/s Gap b/w tip & job- 1.52mm Description 0.5mm thick stack are join together to form the core, different models have different thickness

Stator core welding

Washing

Ultra sonic washing

Core is washed by

M/C

water and chemical to remove dust and oil on it after it is dry around temp. 75C & the dipped in rust preventive oil (RP oil) to protect against rust

Inserting Of I Sheet

Slot cell M/C

Inserting of I sheet is done to provide insulation to stator surface, the material of sheet is polyester

Winding

Stator coil winding M/C

Mainly three type of winding s provided in the stator Main, exciter & DC stator have different no of slot depending upon the model.

Coil & wedge insertion

Wedge Insertion M/C

Coil is inserted with the help of insertion M/c Wedge width-14 .1mm Height from

core-.3mm Thickness-0.35mm

Coil forming

Coil forming M/C

Pressure of insertion is 25kg/ cm3

Stator coil End connection

Crimping M/C Lacing M/C Forming M/C

Cord connection & end cutting wire fastening and inserting varnish pipe using fasteners Lacing & forming to fix its I.D & O.D

Resistance & HV Tests

Different Measuring instrument & load bank is used

Resistance of combination of wire is measured to insure that there not short circuit or wrong connection

Varnish Drip Impregnation

varnish drip impregnation M/C

It is done for proper insulation

ROTOR ASSEMBLY
1.Rotor Shaft fitting Rotor shaft press Press fitting of rotor

fitting M/C 2.Rotor winding Rotor winding M/C

shaft in rotor core it is done by using CNC rotor winding M/C

3.Assembly

Bolts Magnets N & S in bobbin holder Insulators There are different no. of turns in N & S side

4.PCB assembly in

Different measuring instruments

Pilling Diode mounting HV & insulation resistance check

rotor

5.Insulation

Load banks & Measuring instruments

Test Voltage- 500v Test time-15s Leakage current10ma

resisting testing

6.Varnishing

varnish drip impregnation M/C

Preheating Temp.-130 C 5 C Surface temp of core 90- 105 C Tack time 1.5 min

7.Tapering 8.Bearing fitting

Tapering M/C

Tapering of rotor shaft

Press fitting M/C

Bearing is fitted in rotor & fan support

ALTERNATOR ASSE MBLY 1. STATOR COUPLER CONNECTION

(a) Diode coupler point (c) One earthing coupler point 2. ALTERNATOR HOUSING (a)Mounting of alternator in alternator case housing & Gormet fixing in case (b)Mounting of stator bend (b) Main + Exciter coupler point

3. PERFORMANCE TESTING OF ALTERNATOR

Parameters to check:

1. Rotor speed (RPM)

2. DC load current (V)

5. DC no load voltage (V)

3. AC load Current (V) 4. AC no load voltage (V)

CONTROL PANEL ASSEMBLY-

Different components assembled are-

1.
2. 3. 4. 5. 6.

Frame Circuit breaker Bond cable Socket lamp Condenser Diode

7.Oil Alert

All the components are assembled with the help of a pneumatic tool called AIRGUN. After this the inspection of the Control panel is done with the help of high voltage test.

SLOTS

STATOR

CONTROL PANEL

ALTERNATOR

ASSEMBLY SHOP SECTION HEAD- A.K MORYA MANPOWER -56 EMPLOYEES QUALITY- 99.53%

Assembly is the main shop responsible for the production of the generators, pumps etc. since all the components are brought down here for the complete installation of the equipment.

MODELS ASSEMBLED IN THE SHOP

1. EM 650Z
2. EBK 650

22. EB 1000/900

3. EB 650GP/2000GP
4. EM 650 5. EBK650 6. EBK 2000 EXP. 7. EBK1200 EXP. 8. EBK 1200 DOM 9. GK 200,WBK 30 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. G200,WK 30 G200 EP650 EP600 EP2200 EBK2800 EB3000 GK 300 G300 E1000K E1000 GK100/WBK 15

HANDY SERIES GENERATORS

SILENT SERIES

INVERTER

WORKING
THE ASSEMBLY IN WORKSHOP IS IN THREE BASIC STEPS 1. ASSEMBLY OF THE ENGINE 1. Governor holder pressing Setting of the drain plug bolt with the washer and temporary tighten in case cover 2. Setting of the O ring on cap oil filler and now tighten case cover. 3. Piston Conrod Sub Assembly- Setting of piston ring oil, second and top. After this piston ring is fitted and then fitting of conrod is done. 4. Conrod Assembly installation 5. Fitting of the crankshaft

6. Oil Level switch assembly 7. Cylinder head and stud installation8. Carburetor assembly 9. Installing of flywheel 10. 11. 12. Tapret room cover installation Fan cover installation Installation of Carburetor-The main work of carburetor is to mix

oil. The spring and rod of carburetor are installed 13. 14. Installation of Top Cover Leakage Test is done to check whether there is any leakage on the

engine or not. This is done to check whether the assembly is done properly or not. 15. ENGINE ASSEMBLY COMPLETE

2. GENERATOR ASSEMBLY

1. Alternator assembly-Fixed accordingly with the crankshaft. 2. Housing front installation 3. Housing Rear is installed 4. Recoil sub assembly5. Frame Assembly 6. Bottom Assembly- Supporting (legs)of the generator are installed in this process. 7. Muffler Assembly-Muffler is assembled on the generator just above the glass wool.

8. Muffler Projector Cover is installed.

9. Assembly of the control panel with the help of grommet fitting 10. Air cleaner assembly-Air cleaner is assembled near the

Carburetor. 11. Frame assembly- The frame is installed on two sides

1. L-SIDE The left side frame of the front view of the generator.

2. R-SIDE- The right side frame of the front view of the generator. It has an
AC switch. 12. 13. 14. 15. Fuel Tank Assembly Handle Assembly Installing of the cover Check of the Generator(Bolt Tightening)

16.

ASSEMBLY OF GENERATOR IS FINISHED

All the assembly operation is done with the help of Pneumatic tool called air gun, and we use bolts of different sizes (6mm, 5mm) for complete assembly of the component.

3.INSPECTION
The testing of the generator is done with a help of a load testing machine It takes an accurate account of1. Voltage of the Generator(V)

2. Frequency of the Generator (Hz)

3. Rated Output of the Generator(VA) 4. Maximum Output of the Generator(VA) If the generator doesnt show its standard rating then it will be rejected and hence reworking on the model takes place.

5. PACKING- Packing of all the generators and pumps being made

up here is done.

BIBLIOGRAPHY
Some picture from Google image search. Some data from textbooks and encyclopedia.