1. QUALITY CHECK MACHINE FOR OUTER
DOOR MIRROR
Submitted to: Mr. SUMIT KUMAR MISHRA Submitted By: SHASHANK TIWARI
Asst. Professor Enrollment No. A12405411032
AMITY SCHOOL OF ENGINEERING Roll No: 11046
B.TECH (7MAE)
AMITY SCHOOL OF ENGINEERING

2. 1

3. 2
ACKNOWLEDGMENT
The 49-days industrial training is indeed the most important and integral part of my curriculum at the
Mechanical and Automation Engineering Department at Amity University, Noida.
The 49-days industrial training gave me ample opportunity to develop a veritable and first hand industrial
experience not only towards technical but all round development also, being able to see and learn about the
actual implementation of the subjects we study is indeed a valuable experience.
Training at SANDHAR Automotive HSCI Division LIMITED has been beneficial in the technical aspect, as
it has given an unprecedented opportunity to exercise and put into practice some of the theoretical aspects of
engineering.
I would like to thank my Head of institution Dr. (Prof.) Ajay Rana for his efforts in maintaining a good rapport
with the industry and for keeping his faith and confidence in my performance and for being source of
continuous encouragement.
I would like to thanks my mentor Mr. Arjun Singh (Deputy Manager/ Engineering processing, SANDHAR
HSCI) for giving me an invaluable opportunity to do my project at SANDHAR Automotive HSCI Div. and
for assigning me the Design and Development department, working at which, I gain firsthand knowledge on
Designing and different Manufacturing processes.

4. 3
ABSTRACT
In these 49-days of my industrial training at SANDHAR Automotive HSCI Div. Gurgaon, I had to deal with
a variety of tasks. Each activity presented a unique challenge as well as great learning opportunity. This was
the perfect setting to further strengthen my understanding of the various technical processes by brushing up
the theoretical knowledge gained in the university with practical observations. More often than not, I was
entrusted with responsibilities and was expected to deliver the results within the stipulated time frame and of
required quality.
At SANDHAR, I was involved in a number of activities, which were directly involved, with the daily
functioning of the manufacturing process. This implies that the project assigned to me a live project, which
was actually relevant and the results of which has important implications on the market as well. The project
on which I was entrusted was” DESIGN DEVELOPMENT OF QUALITY CHECK MACHINE”.

5. 4
Certificate
This is to certify that Mr. SHASHANK S.TIWARI, student of B. Tech. in Mechanical and Automation
Engineering has carried out the work presented in the Industrial work report on ‘DESIGN AND
DEVELOPMENT OF QUALITY CHECK MACHINE FOR OUTER DOORMIRROR’ as a part of third
year program of Bachelor of Technology in Mechanical and Automation Engineering from Amity School
of Engineering, Amity University, Noida, Uttar Pradesh under my supervision.
(Mr. SUMIT KUMAR MISHRA)
Asst. Professor
ASE, Noida.

6. 5
INDEX
S.No. DESCRIPTION PAGE NO.
1
2
3
4
5
6
7
8
9
SCOPE
SPECIFICATIONS
BILL OF MATERIAL
STRUCTURAL DESIGN
OPERATING SEQUENCE
IN-PUT/ OUT-PUT LIST
ELECTRICAL CIRCUIT DIAGRAM
MAINTANENCE CHECK POINTS
TECHNICAL DRAWINGS
• DIMENSIONAL VIEW
• ISOMETRIC VIEW
5
6
7
9
15
16
17
19
20

7. 6
SCOPE
This manual covers operating instruction for O.K. Marking Machine of outer Door Mirror As per HSCI
Div.

8. 7
SPECIFICATIONS
This machine will check mirror motor wiring connection by making the following
SEQUENCE TEST: DOWN UP LEFT RIGHT
The machine will take a decision on OK/NG depending upon the sequence of mirror plate movement. The
OK sequence is shown above.
After OK mirror testing, machine will put a punch mark on mirror coupler assy.
MODEL: UH
OK MARK
OK MARK

9. 8
BILL OF MATERIAL (BOM)
Door Mirror QC Checker M/c
BILL OF MATERIAL (MECHANICAL PARTS)
MECHANICAL PARTS: DATE: 06/6/14
SR.
NO. DESCRIPTION
FINISH SIZE
(in mm) MATERIAL QTY.
1 DMQC_BASE PLATE 2CV 400X400X15 M.S 1
2 DMQC_2_BASE PLATE 2CV 160X100X10 MS 1
3 DMQC_PILLOR_HOLDER_2CV 160X50X55 EN-31/ MS 1
4 DMQC_HOLDER_SUPPORT_2CV 160X35X24 EN31/MS 1
5 DMQC_PILLOR_2CV Ø30X560 EN31 2
6 DMQC_MOUNTING_BLOCK_2CV 50X50X65 EN31 6
7 DMQC_BASE_SLIDE_UNIT_2CV 350X150X10 MS 1
8 DMQC_ANGLE_BRACKET_2CV 65X70X50 EN31 1
9 DMQC_GUIDE_BLOCK_STOPPER_2CV 45X50X50 EN31 1
10 DMQC_PANNEL_MOUNT_BLOCK_2CV 110X35X50 EN31 1
11 DMQC_PANEL_PILLOR_2CV Ø30X340 SS 1
12 DMQC_PANNEL_BLOCK2_2CV 120X50X50 MS/EN31 1
14 DMQC_MAIN_CYL_MOUNT_PLATE_2CV 100X45X25 MS/EN31 2
15 DMQC_PANNEL_MOUNT_PLATE_2CV 150X150X8 MS 1
16 DMQC_CARRIER_VERTICAL_PLATE_2CV 150X165X10 EN-31 1
17 DMQC_CARRIAGE_RIB_2CV 75X75X8 EN-31 2
18 DMQC_COUPLER_FORK_2CV 35X32X30 EN-31 1
19 DMQC_CARRIAGE_HOR_PLATE_2CV 250X180X12 EN-31/MS 1
20 DMQC_LMK_L_LM8_2CV Ø34X46 EN-31 4
21 DMQC_COULPER_PLATE_2CV 70X42X32.5 EN-31 1
22 DMQC_COUPLER_PIN_2CV Ø10X40 EN-31 1
23 DMQC_CONTROLPANEL_HMETR_2CV 210X150X3 SS 1
24 DMQC_CYL_CXSM_MOUNTING_2CV 150X23X20 MS/EN31 2
25 DMQC_CYL_CXSM_MOUNTING_L_2CV 150X23X20 MS/EN31 2
26 DMQC_LEVELING_ROD_HOLDER_2CV 40X56X23 MS/EN31 2
27 DMQC_ROD_LEVELING_2CV Ø8X145
EN31/HRC-
45
4
28 DMQC_JIG_SPACER_2CV 50X150X250 AL. 2

10. 9
29 DMQC_S.MOTOR_SPACER_2CV 40X40X30 AL. 1
30 DMQC_LINER_TRANS_MOUNTING_2CV 70X50X30 NYLON 1
31 DMQC_LINER_RAIL_SMALL_MOUNTING_2CV 90X70X15 EN-31 1
32 DMQC_LINER_RAIL_SMALL_M_ROUND_2CV Ø50X40 AL. 1
33 COUPLER CLAMP 150X18X25 MS 4
34
O K PUNCHING CYLINDER MOUNTING
PLATE
60X25X10 MS 2
35 O K PUNCHING CYLINDER SPACER PLATE 25X25X12 MS 2
36 O K PUNCHING CYLINDER BASE PLATE 60X12X150 MS 2
37 COUPLER SUPPORT 25X25X12 ACCRALIC 2

11. 10
STRUCTURAL DESIGN
ALIGNING
UNIT
TABLE
START
SWITCH
FIXTURE
CONTROL
PANEL
PRESSURE
REGULATOR
MAIN ON
SWITCH

12. 11
CONTROL PANEL
MAIN ON
SWITCH
DISPLAY UNIT
NG BUZZER READY SWITCH
+ INDICATOR AUTO/MANUAL LEFT/RIGHT OK INDICATOR

13. 12
OK MARKING UNIT
COUPLER
MODEL - LK
COUPLER
MODEL - UH
PUNCHING CYL.
PUNCH

14. 13
ALIGNING UNIT
ALIGNING PINS
ALIGNING
SENSOR
MOVEMENT
CHECK SENSORS
MOVEMENT PINS
ALIGNING
CYLENDR

15. 14
DISPLAY UNIT
PRODUCTION SCREEN TIMER SCREEN
FUNCTION KEYS NUMERIC KEYS

16. 15
MANUAL OPERATIONS SCREEN OK SCREEN
FIXTURES
LEFT (MODEL-UH) RIGHT (MODEL-UH)

17. 16
OPERATING SEQUENCE
MIRROR SETTING PROCEDURE:
OPERATING SEQUENCE:
STEP 1: PUT ON MAIN SWITCH
STEP 2: SELECT AUTO MODE & CHOSE MIRROR TYPE (LEFT / RIGHT)
STEP 3: SET DOOR MIRROR ON FIXTURE
STEP 4: INSERT MIRROR SWITCH INTO COUPLER (UH / LK)
STEP 5: PRESS START SWITCH.
STEP 6: MAIN CYL. GO DOWN & ALIGNING CYL. MAKE MIRROR PLATE TO ALIGN.
STEP 7: NOW MOVEMENT PINS MAKE THE REQUIRED SEQUENCE TEST.

18. 17
STEP 8: MACHINE WILL MAKE DECISION ON OK/NG DEPENDING UPON SEQUENCE
OF MIRROR PLATE MOVEMENT.
OK SEQUENCE: DOWN UP LEFT RIGHT
IN PUT/ OUT PUT LIST
S.No. INPUT I/P No. OUTPUT O/P No.
1 START 0 OK 1000
2 1 FAULT 1001
3 LEFT/RIGHT MIRROR SELECTION 2
MAIN CYLENDER
DOWN 1002
4 AUTO/MANUAL 3 ALIGNMENT CYL. 1003
5 RESET 4 DOWN MOVE 1004
6 MAIN CYLENDER DOWN SENSOR 5 UP MOVE 1005
7 ALIGNMENT CYLENDER DOWN SENSOR 6 LEFT MOVE 1006
8 DOWN MOVE CHECK SENSOR 7 RIGHT MOVE 1007
9 UP MOVE CHECK SENSOR 100 READY 1100
10 LEFT MOVE CHECK SENSOR 101 1101
11 RIGHT MOVE CHECK SENSOR 102 MAIN CYL. UP 1102
12 103 PUNCHING CYL. 1103

19. 18
ELECTRICAL CIRUCIT DIAGRAM
PLC WIRING

20. 19
POWER & DISPLAY UNIT CONNECTION
L: 220v
N: Neutral
P24v: +24v
Z: -24v
G: Ground
CIF-01: Communication Unit b/w PLC & NT-11

21. 20
MIRROR MOTOR CONNECTION
R: Relay
L: 220v
N: Neutral
P24v: +24v
Z: -24v
G: Ground
MAINTENANCE CHECK POINTS
S.No. CHECK POINTS FREQUENCY ACTION
1
2
3
4
5
6
MAIN AIR PRESSURE
OILING ON GUIDE ROD
CHECK FRL
CHECKING OF
SENSORS
GUIDE ROD DUST
CLEANING
CHECK FIXTURE
ADJUSTMENT
DAILY
WEEKLY
DAILY
DAILY
DAILY
AT START
SET AIR PRESSURE AT 5 bar
APPLY OIL IF REQUIRED
REMOVE DRAIN IF REQUIRED
TIGHT SENSORS IF REQUIRED
REMOVE DUST IF REQUIRED
MOVEMENT SENSORS SHOULD
NOT COME WHILE MIRROR IS
ALIGNED.