STUDY OF SIGMA AND ROCAM ASSEMBLY LINE AND ENGINE PLANT

ATAVTEC LIMITED

In Pithampur

Submitted to Submitted byPrashant Shrivastav Rohan gangwani

Chetan Chauhan

Guided by-Mr. Praveen Singh

AVTEC Ltd.

INDORE INSTITUTE OF SCIENCE AND TECHNOLOGY.

Contents

1.) AVTEC profile

2.) AVTEC alliance

3.) Mile stone

4.) Learning from the training

5.) Engine assembly Process

6.) Conclusion

Company Profile

AVTEC India Ltd. is a pioneer in the Indian automobile sector and is one of the G.P.-C.K.Birla groups companies that came into existence in 1942 at Port Okha .Later the company was shifted to Uttarpara (West Bengal) near Kolkata. The company has produced many automobiles including Ambassador. Recently it has started producing a new automobile for the Indian masses called RTV (Road Trusted Vehicle) at HM, Pithampur.

During their journey towards excellence HM, Pithampur got ISO9001 accreditation in 1994 to be renewed in 1997 and 2000. In addition to this they were certified as ISO14001company for their envoirnmental management system implementation in November, 2000.The journey for the excellence continues with the effort in embracing total productive maintenance (TPM) as a religion in addition to institutionalizing QS9000 standards.

AVTEC: its alliances:MITUSIBUSHI MOTOR CORPORATION, JAPAN

Mitusibushi Motors has marked the cutting edge if automotive innovation for more than 75 years. Since 1971, Mitusibushi has

consistently introducing innovation to make its vehicle perform at higher level, as well as to make them reliable and safer. Today

Mitusibushi is one of the leading automakers in Asia and the world producing a complete line of vehicle from mini cars to giant and buses.

Mitusibushi vehicle are acclaimed worldwide for their outstanding styling performance and safety. Many prestigious awards and accolades are the result of the desire to create products, which distinguish themselves by excellent quality and engineering. AVTEC India Ltd. and Mitsubishi Motors both of them sharing the common

theme of putting customer's view point first, both in though and action, and serving the society large have joined hands to bring in the most

latest all new Lancer model to India.

OKA MOTORS COMPANY. AUSTRALIAOKA Motors Company, Australia, established in 1985, has carved a

niche for itself in the international market. As manufacturers of custom built, four-wheel drive, heavy-duty forward control utility vehicle OKA

Motors Company has highly acclaimed for innovation, engineering and workmanship in producing state-of-the art multipurpose vehicle.

OKA Motors Company is making its felt through its sales outlets in various parts of the world including Malaysia, UAE, Saudi Arabia, UK, Argentina, China, New Zealand, Canada and various

African countries.AVTEC India Ltd. And OKA Motors Company have found the

right partner in each other to develop and manufacture a flexible Rural Transport vehicle for carrying a mix of goods and people the proposed vehicle, which is going to be 100% indigenized from the beginning, is

being developed exclusively for Indian roads and condition.

MILESTONES: 1942- AVTEC India Ltd. was incorporated at Port Okha in Gujarat as a

small assembly plant for passenger cars.1948- AVTEC India Ltd. Shifted its activities to Uttarpara in West Bengal and set up facilities for manufacture of cars and trucks.

1985- AVTEC India Ltd. Commenced a Power Products Division at Hosur, Karnataka for manufacture of heavy duty transmission required

for Earth moving Equipments.1986- The Commercial Vehicle Division for the manufacture of Heavy Commercial Vehicles at Vadodara, Gujarat was commenced. Due to increase in project was abandoned. The company sold a part of the assets of this General Motors India Limited, for manufacture of "Opel

Astra range of passenger cars in the premium segment.1987- AVTEC India Ltd. Commenced production of petrol engines and

transmissions at Pithampur, Madhya Pradesh, in collaboration with Isuzu Motor Company, Japan.

1996-AVTEC India Ltd. Modernized, upgraded and expanded its three existing divisions Earthmoving Equivalent Division, and Power Plant

Division and the Uttarpara Plant.

1997- AVTEC India Ltd. Began the production of the Road Trusted Vehicle.

1998- Commenced the Mitsubishi Lancer Car project.2001- The Earthmoving Equipment Division plant was sold off

Caterpillar, USA.2002-Launch of the Mitsubishi Pajero (in collaboration with Mitsubishi

Motors Japan), India.2002-03- Agreement for supply of Power Units to General Motors of

India (GMI) & Ford.

POWER UNIT PLANT (PUP) :-Power Units manufactured at the Pithampur plant are supplied to:

FG Wilson UK- for generator set applications.Kirloskar: Pneumatics for buses air conditioner applications.

Godrej Voltas: Forklift application, Industrial forklifts.AVTEC India Ltd. Plant in Uttar Para for the Ambassador and

Contessa.AVTEC India Ltd. Plant in Pithampur for RTV.

AVTEC India Ltd. Plant in Tirvallur for Mitsubishi Lancer.Eicher Motors Limited: Various types of Gears.

Mahindra & Mahindra: Transmissions for Bolero Vehicle.

Objective of industrial training :The objective of undertaking industrial training is to provide work experience so that students engineering knowledge is enhanced and employment prospects

are improved , the student should take this course as a window to the real world of work and should try to learn as much as possible from real life

experiences by involving and interacting with industry staff. Industrial training also provides an opportunity to students to select an engineering problem and

possibly an industry guide for their Major project in final semester.Industrial training of students is essential to bridge the wide gap between the class room and industrial environment. This will enrich their practical learning and their will be better equipped to integrate the practical experiences with the

classroom learning process.

What we learnt through this Industrial training:Industrial Environment and work culture.

Organisational structure and interpersonal communication.Machines/equipments/instruments their working and specification.

Product development procedures and phases.Project planning monitoring and control.

Maintenance system Layout of Plant.

Problem related to various areas of work .

ASSEMBLYPROCESS

S No.

STN.

No.

M\C

USED

NAME OF

COMPONENT

PARAMETER WORKING

1 WM1 +WM2

Automatic

Washing

m\c

Conrod, Black , Head,Cam shaft, Fly wheel, oil pan

Temp. 45c

Pressure 5 Bar

Washing of component by

Coolant & then by pneumatic pressure .

2 M1 - - - Labeling & bar-coding of

Engine.

3 M2 Measuring

m\c (widia)

Block ,con. Rod Least count 10ˉ²Mn

Measuring of cylinder bore & crank shaft Dia

4 M3 Manual Lower bearing ,upper

Bearing

4 type of bearing

Fit upper bearing to half crank pin & lower bearing to another half

5 M4 Manual Lower bearing ,upper

Bearing

4 type of bearing

Fit upper bearing to half crank pin & lower bearing to another half

6 M5 MNR Bolts of M10 T=18.6+1 Nm Install crank shaft to cylinder bearing & tight by MNR

7 M6 Rotation testing m\c

Crank shaft sub assembly

T=0-20 Nm Crank shaf Sub assembly rotate in block with pistonif value exceed 20 Nmrejects it.

8 M7 Pulse cut Off torque

Oil gallery plug T=46+/-2 Nm Assemble oil gallery pug pn front face of Block

9 M8 MNR Oil pump assembly +

M6*55bolts &baffle plate

T=9±2 Nm Assemble oil pump assembly and baffle plate.

10 M8 Pulse cut off torque machine

Oil suction tube Oil dispenser 5cc

Join oil suction tube and tight by pulse cut of torque machine

11 M9 MNR+ Press machine

ROSR+ Front oil seal

Front =5.8ROSR=80cc/ min at 0.8bar

Tight ROSR + Front oil seal by pressing machine.

12 M10 Testing machine

ROSR + Front oil seal

Pressure 5 bar Leak testing of ROSR and front oil seal one by one

13 M12 MNR Oil pan +11bolts of M10

T=19.5±3.5 Nm

Assemble oil pin over guide pin, fit 11 bolts and tight

14 M12 MNR Oil pan +11bolts of M10

T=19.5±3.5 Nm

Assemble oil pin over guide pin, fit 11 bolts and tight

15 M13 Torque wench with stamp

Oil filter nipple + oil filter

T=45±5Nm T=14.5±2.5Nm

First tight oil filter nipple and then oil filter

16 M13 - Oil pan drain plug T=27.5±2Nm -

17 M14 Turning machine MNR 10

Sub assembly of head+ M12 bolts

T=35±3Nm at 75±5 angle

First turn by 180º then assemble head sub assembly and block sub assembly by gasket

18 M15 WIDIA (marposs machine)

Cam shaft +tappets Least count 10ˉ²mm

Place cam shaft on WIDIA machine and select Tappet on coming reading.

19 M15 MNR10 M8 bolt of cam shaft

T=7±.5Nm Place cam shaft and tight by MNR of 10 spindle

20 M16 Manual Tappet gap measure

0.17-0.23mm for 1.4L

Measure gap between cam and tappet if more then range then rejected.

21 M17 Pulse cut off torque Wrench

Water pump T=30±2Nm Assemble water pump assembly to the block.

22 M18 Pulse cut off torque wrench

Flywheel + 6 bolt of M8

T=30±2Nm Assemble flywheel to spigot end of crankshaft

23 M19 Manual crank sprocket T=20±2Nm Fit crank sprocket in flange end

24 M20 Manual Tensionar pulley T=40±4Nm Fit tensionar pulley and tight by hand wrench

25 M21 Manual Timing belt - Fix timing belt to crank sprocket and fit the belt cover.

26 M22 Pulse cut off torque wrench

2 crank sprocket T=9±2Nm Fix cam sprocket to the cam shaft.

27 M23 Manual Timing tool 21-23 open end spanner

- Check timing of cam shaft with respect to crank shaft

28 M24 A MNR12 spindle

Camshaft cover + gasket +12 bolt of M10

T=9±1Nm Place gasket on top of head and fix cover and tight byMNR

29 M24 B Pulse cut off torque wrench

Water pump pulley + 4 bolt of M8

T=19.5±3.5 Fix water pump pulley to water pump using 4 bolt of M8

30 M25 Torque wrench

Knock sensor - Assemble knock sensor to block

31 M25 Pulse out off torque

Crank ventilation cover+7 bolt of M6

T=9±2 Assemble crank vetilation cover using 7 bolt

32 M26 Torque wrench

Fuel rail sub assembly

- Fit fuel rail sub assembly and tight by wrench

33 M27 Pulse cut off torque wrench

Water outlet sub assembly + ignition coils assembly

T=19.5±3NmT=12Nm

Join water outlet sub assembly and tight by bolt

34 M27 Pulse cut off torque wrench

Engine wiring + cam sensor + spark plug

T=15±2Nm Fix engine wiring harness to fuel injector throttle position sensor spark plug leads to spark plug ignition coil and tap with rubber mille

35 M28 Pressure oil pump

Engine oil 1.6L-4.5lts

1.4L-4.15lts

After complete all assembly fill engine oil

36 - Testing machine

Hot testing At 2000 rpm Attach all supply line like fuel , air , water and all sensor and test at idler speed that is at 900 rpm

• TESTING OF ENGINE:-• After complete engine assembly it must to test with idler rpm. But because

of requirement we divided two type of testing.• 1. Hot testing:-• This type of testing is done for every assemble engine. First

assemble engine are attach by all type of sensor with fuel, water, oil, air, & vacuum supply & then fix at starter & start starter & run the engine at idler speed for 2 min. check abrupt noise if any & then increase speed to 2000 RPM & again check the same observation & then with the help of ultraviolet lamp test the leakage of oil from all the side of engine. If all parameter is under the range then it is ready for dispatch. If it has some type of problems then go for rectification department.

• • 2. Dyno-testing: -• From every 100 engine one should be tested so that we

decided the production control & modification in the parts. If some component is replaced or new product are used dyno test is used. In this test engine is run at 2000 rpm to 3000 rpm for 600 hours & check for different condition from which the engine has to suffer i.e. climate, slope of hill. This testing is very costly so it runs for randomly selected engine from the lot. Another engine is run for 12 hours or 30 hours

Differences between Rocam and Sigma Engine ROCAM SIGMASingle camshaft Double cam shaft 8 valve engine 16 valve engine1.3 ltr engine 1.4 and 1.6 ltr engine Both have different bore diameters. SPECIFICATION’S OF ROCAM ENGINE ENGINE MODEL ROCAM1.6L ROCAM 1.3L

ENGINE TYPE Multipoint fuel Multipoint fuel Injection injectionFIRING ORDER 1-3-4-2 1-3-4-2

PEAK TORQUE Nm/rpm 132/2500 116/2500

IDLE rpm 880±30 880±30

CONCLUSION

At the Major training we really got a Great opportunity enhance our knowledge and improve our employment prospects. For us It was really a window to real world of work and we had real life experiences by getting ourselves involved and interact with the industry staff.It certainly bridged the gap between the classroom and industrial environment.All the real life experiences which we had their at AVTEC limited will help us in the future when we enter the professional world.

• ENGINE PLANT• A n internal combustion engine mainly consists of following five

components which are also called five C’s of an engine.• Cylinder Block • Cylinder Head• Crank Shaft• Connecting Rod• Cam Shaft• Other than this five parts there are other five parts which are peripherals.• HM manufactures these components for the following companies • General Motors (TRAVERA )- 4C’s except connecting rod.• • LANCER • Petrol: Cylinder Block, Camshaft• Diesel: Camshaft• ISUZU • Petrol and diesel: All five C’s.• Specific case of GMI Cylinder block is taken herein all the components

except connecting rod.•

Specifications:-1.)Type of engine : Diesel, 4cycle type2.) Engine size : 7045×660×753.) Engine weight : 250 kg4.) Cylinder arrangement : inline, 4 Cylinder 5.) Ignition order : 1-3-4-26.) Bore and stoke : 93 927.) Engine displacement : 2499 cc.8.) Compression ratio : 18.59.) Combustion chamber : Direct jet type 10.) Valve arrangement : Over head valve system.11.) Valve drive system : Belt and pulley type12.) Cooling system : Water cooled.

• Over Head Valve (OHV):

In an overhead valve (OHV) engine , the valve are mounted in the cylinder head above the combustion chamber. Usually this type of engine has the camshaft mounted in the cylinder block , and the valves are opened and closed by push rods.Engine plant into five cells of respective components:-Cylinder Block:- Cylinder Block is the foundation of an engine. Everything else is put inside of or attached to block. Cylinder is supported in the position by the cylinder block and at the top of the end is covered by cylinder head. Cylinder block is complicated casting. It consists of large hole for the cylinder bore, oil gallery, water jackets, bolt holes, core clean out holes. Spark ignition cylinder blocks and compression ignition cylinder block are very much alike. However C.I block is heavier and stronger because the compression ratios and internal pressures in the combustion chambers of diesel engine are high.Raw block is in the form of castings. It undergoes various operations which are as follows:-Op 30Finish machining of sump face, bearing seat, oil pump and tappet bore.Op 40Finish machining of joint face, front and rear face, cylinder bore, assembly dowel and thrust face.

• Op 50Finish cam parent bore, s/f crank bore and rear dowel holes.Op 60 Cam bush fitment by cam bush press.Op 70Finish cam bore, crank bore and front and rear dowel holes by line boring machine. Op 80Intermediate washing of cylinder block.Op 90Automatic measurement of crank bore, cam bore manual punching of crank bore grades.Op 100Honing of cylinder block.Op 110Final washing of cylinder block.Op 120Sealing cup fitment.Op 130Air leak testing.Op 140Automatic measurement and grading of cylinder bore without liner.

Op 150Press fit liner.Op 160Gauging and grading of cylinder bore with liner.Cylinder head :- Cylinder head encloses one end of the engine cylinder and form the upper end of the combustion chamber. The piston head and the piston ring form the lower end. It accommodates the valve assembly i.e valve, valve seat, valve guide. It has inlet and exhaust manifolds. It covers the top of cylinder block. Gaskets made of steel, copper and asbestos are used between the cylinder block and engine block. Because the engine expands and contracts with heating and cooling. It is easy for the joints to leak, so the gaskets have to be soft and “springy” enough to adapt to expansion and contraction. They also have to make up for any irregularities in the connecting part. The following operation are done on a semi finished casting:Op 70Finish machining of joint face, ad holes valve seat and guide, parent bore.Op 80Press fitting of valve seat and guide.Op 90Valve seat and guide generation.

• Op 100 Final washing of cylinder head.Op 110Final washing of cylinder head Op 120Sealing fitment Op 130 Air leak testing of water jacketConnecting Rod : Connecting Rod is used to transmit motion from the piston to the crankshaft. It makes connection between the piston and crankshaft by joining the wrist pin of the piston with the throw or crank pin of the crankshaft. It must have strength and rigidity combined with the lightweight. Generally connecting rods are made of steel forging although aluminium alloys can be used. Differences between the petrol and diesel connecting rod: 1. Centre distance is more in diesel (150) than in petrol (133). 2. G.P size (25 and 22 in diesel and petrol respectively). 3. drilling of oil hole takes place in G.P.(DSL) and C.P.(PTL.)

• It undergoes the following operations:• Op 10• Thrust face grinding.• Op 20• Rough boring and chamfering of the gudgeon pin. Boring is done with the

help of • an insert.• Op 30• - Crank pin boring and chamfering • Op 40• Broaching:• It involves three operations• Finishing of big face.• Nut and bolt seat finishing• Slitting of crank pin.• Op 50• - Joint face grinding .• Op 60• - Bolt hole drilling, hole milling and reaming.• -

• Op 70• Notch milling . • Op 80• - Oil hole drilling• Op 90 • - Press fitting of bolt and bush (only in diesel).• Op 118• - Finish boring of G.P and C.P.• Op 120• - C.P bore honing.• Op 130• - G.P bore burnishing (petrol). It is a super finished operation

which is done with the help of rollers.• Op 140 • - crack detection • Op 150• - Washing and cleaning of connecting rod.• Op 160• - Inspection by Marposs guage.

• Crank Shaft:• Crank shaft is one of the most important rotating part of an

automobile engine. Most of the engine power is delivered to the crank shaft from expanding gases in the combustion chamber through the piston, connecting rod rod and their bearings. To meet these requirements the shaft must have the necessary shape and be made of proper materials.

• The following operations are performed on the crank shaft casting:• Number punching.• Reference web milling.• Rough turning of all journals and finished turning of all flange ends.• Milling of the crank pins.• Finish turning of all journals and stub end.• Oil hole drilling.• Front and rear drilling tapping.• Pilot bore finishing and centre forming.• Grinding of flange ends.• Grinding of stub ends.• Crank pin grinding • Keyway milling • Crack detection• Dynamic balancing and drilling • Super finishing of journals, pins and oil seals.•

• Camshaft:• It undergoes the following operations:• 1. Facing and centering • 2. Turning of journals, columns and rear end.• 3. Drilling and tapping front end.• 4. Front end grinding • 5. Gear Hobbing on journals (only in G.M.I operation) for driving the oil pump.• 6. Grinding of cam and journals.• 7. Masking by yellow tape.• 8. Phosphating.• It is done to cover a cam with a sort of protective layer so as to withstand the minor

shocks. The layer also has anti rusting and lubrication properties. It involves the following steps:

• Digressing is done at 70 degree Celsius with a chemical called pyrocelean for washing purpose.

• Keep it in running water to remove soap.• Activation ( pyrolite powder ) at 50-60 degree Celsius to prepare surface better for

phosphating.• Phosphating (pyrolubrite) at 96-99 degree celcius.• Cleaning (hot water rinsing)• Keep it in oil for de watering, cooling and anti rusting.