intro to conclusion

1
CHAPTER 1
INTRODUCTION
1.1 ROBOT SPOT WELDING IN CAR MANUFACTURING COMPANIES:
Spot welding is one of the most mature applications in robotics. The speed,
precision, efficiency, and resulting cost reductions afforded by automated
resistance spot welding are well documented and accepted, particularly in the
automotive industry. However, industry requires that even the most mature
solutions continue to evolve. End users, including experts from the Big Three
automakers, seek ever more speed and economy from their robotic applications.
These engineers want more modular, lighter-weight systems with increased cycle
times and improved end of arm tooling (EOAT), and vendors are answering the
call as new automobile designs require more of their spot welding robots.
Motoman has introduced manipulators specifically for spot welding - the
ES165 and ES200, with 165- and 200-kg payloads, respectively - Fig. 3. These
robots have utilities (air, water, and power) routed in cable harnesses through the
arm and out to the robot wrist. The standard cable harness supports either servo-
controlled or pneumatic guns. The internal harness eliminates the need for supports
and swivels associated with external "dress-out" packages.
"The internal harness for robot motors has been providing years of reliable
service with mean time between failure criteria of 24,000 hours," said Chris
Anderson, Motoman Inc. "Integrating the welding harness provides similar results
and greatly reduces downtime associated with external cables. They wear quicker
due to greater flexing and rubbing on surfaces. Quick connectors facilitate easy

2
changing and it can be scheduled as preventive maintenance with the main robot
motor harness."
Other advantages include reducing teaching time by 20% or more because
off-line programs can be used directly without touch-up due to cable interference,
the cables are integrated in the slim arm profile, allowing better access into
confined spaces, and OEMs like the fact the internal spot harness is covered in the
robot manufacturer's warranty.
FIGURE 1.1 ROBOT SPOT WELDING
The largest source of failure in a robot spot welding cell is the weld gun and
the cabling (robot dress) used to operate the gun. The dynamic action of the robot
motion can fatigue the robot dress, causing downtime, while the spot welding gun
is susceptible to damage from a crash. By putting the weld gun on a stationary
pedestal, the robot dress is minimized as the tool required holding the panel uses
only air and signaling power. The simpler robot dress makes for a more robust
application and more cell uptime, explained Crawford of EOA Systems.

3
1.2 PROBLEM DESCRIPTION:
The Renault Nissan plant was opened on may 2010. This alliance company
started manufacturing cars like Renault fluence, Renault duster, Renault scala,
Nissan terrano, Nissan tiana. These cars are SUV car model. The manufacturing
line and production areas were developed to manufacture like this cars. On June
2012 this alliance company decided to manufacture a car named Nissan micra.
This Nissan micra car is small in size than those suv cars.
In between 2012 – 2015, these three years they are meeting one particular
damage in the car body production that is improper robot spot welding. That is the
spot welding is not placed at a correct area. Due to this problem, the company
meeting a major problem like, waste of time cycle, robot timing, and replacement
cost etc.
FIGURE 1.2 PROBLEM DESRIPTION

4
On Feb 13 2015, senior engineer of the body shop area in Renault Nissan
Company gave us a project to,
 Inspect this problem,
 Cause and effect of the problem,
 How to rectify the problem,
 Management theories for analyzing the problem.
 Design and fabrication of the problem detecting device.
1.3 AIM
 To eliminate roof spot hole.
 To eliminate robot waiting time.
 To improve Overall equipment effectiveness of the body shop.
 To eliminate the body scrap.
 To eliminate the body repair time
1.4 OBJECTIVE
 Our objective is to inspect and reduce the problem by using both
mechanical engineering theories and management theories to improve
quality and to give the 99.99% of the problem reduction technique.
 And our problem detecting device should be in nominal size, less
maintenance, occupying less area, highly accuracy, less cycle time
process, works automatically without manual power.

5
CHAPTER 2
LITERATURE REVIEW
2.1 LASER INSPECTION METHOD FOR WRONG SPOT WELDING:
Laser Projector-Based Spatial Augmented Reality in Industrial Applications
VOLKESWAGEN AND FORD WERE USING THIS METHOD FROM 2012
AUTHOR - JIANLONG ZHOU (DOI 10.1007/978-1-4419-9845-3_13)
SAR in automobile industries:
SAR is used to highlight spot welding to be inspected on an unpainted metal
car part. The use of SAR can help operators to improve the efficiency of spot
welding inspection in an automobile industry. The approach aims to remove the
paper-based operation description sheet from operators’ hands and relieve them
from the heavy tiresome work, in order to improve the accurateness and efficiency
of the inspection of spot welding.
Spot welding inspection in convenient ways:
In the industry of automobiles, the quality of spot welding on car bodies
needs to be inspected in regular intervals. For example, in an automobile company,
a typical car has thousands of individual spot welds. In the process of making the
vehicle, subassemblies are made and these assemblies have around 30–200 spot
welding. The spots have to be checked randomly from one to the next, even if the
same type of part is checked — this has statistical reasons dealing with the
occurrence of false negatives. Operators often do not check all spots on each body.
They only check different certain number of spots on different bodies in a

6
sequence. When all 200 spot welds are checked in a sequence, operators start a
new spot sequence for checking. A variety of different methods are used to check
spot welding: visual inspection, ultrasonic test, and destruction test. The current
procedure that operators use to check spot welding is as follows: the operator has a
drawing of the testing body. The spots to be tested are marked in this drawing.
First, the operator has to find the spot in the drawing. Then he has to find on the
body. After this, he has to choose the corresponding control method to finally
perform the inspection. This manual inspection process has potential problems: the
operator is easy to check wrong locations and wrong numbers of spot welding; it is
also difficult for the operator to remember where to start and where to finish the
checking on the checked body.
Using Laser Projector-Based SAR in Spot Welding Inspection:
SAR benefits to spot welding inspection in the automobile industry. It
facilitates presentation of projected digital AR information onto surfaces in
structured work environments. Specifically, the portable laser projector-based SAR
allows to project visual data onto arbitrary surfaces for the express purpose and
providing just-in time information to users in-situ within a physical work cell. It
enables operators to do the spot welding inspection efficiently and effectively.
In this example, a laser projector mounted on a movable stand is employed to view
and interact with digital information projected directly onto surfaces within a
workspace. SAR provides guidance to operators of the next set of spot welding to
inspect. The data items are projected onto the car body, providing instructions to
operators. This removes the need to constantly refer to the instruction manual such
as the operation description sheet, thus speeding up the operation and reducing

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2.1.2 ULTRASONIC INSPECTION METHOD FOR WRONG
SPOT WELDING:
Ultrasonic testing of spot-welded joints on coated steel sheets and optimization
of welding parameters
KOREANS AND JAPANEASE MASS PRODUCTION AUTOMOBILE
COMPANIES USING THIS METHOD FOR INSPECTION
AUTHOR - RICHARD KAMINSKI (NO. SD 296)
INFERENCE
The requirement for improved corrosion prevention in today’s automotive
production has led to increased fabrication of galvanized steel sheets. This also
applies in particular to the passenger car type Monde currently produced by
HYUNDAI at Genk (KOREA). The nondestructive ultrasonic testing of spot welds
has been extremely successfully applied by Ford all over Europe, and also in
Taiwan, for many years now. It was at first only used as a supplement to the
classical hammer- and-chisel test method. However, the ultrasonic test method has
meantime proved to be indispensable, especially in connection with galvanized
steel sheets, and in that case mainly in optimizing the parameters of welding
machines for series production. The spots to be tested are marked in this drawing.
First, the operator has to find the spot in the drawing. Then he has to find on the
body. After this, he has to choose the corresponding control method to finally
perform the inspection. This manual inspection process has potential problems: the
operator is easy to check wrong locations and wrong numbers of spot welding; it is
also difficult for the operator to remember where to start and where to finish the
checking on the checked body.

8
PRINCIPLE OF ULTRASONIC TESTING OF SPOT WELDS
A weld spot with an ultrasonic probe positioned on it and transmitting sound
pulses into the weld metal, as well as the echo sequence generated on the screen
display of the ultrasonic instrument. Let us start by assuming that the weld spot
was flaw free. In addition, only one sound pulse is viewed at first this sound pulse
is transmitted from the probe into the weld spot and partially reflected from the
interface between the probe and weld spot. This reflection appears as interface
echo at sound entry (1st indication to the farthest left) on the screen display of the
ultrasonic instrument. The continuous part of the pulse enters the weld spot and is
only reflected from its rear boundary, provided there is no flaw. This reflection is
displayed as 1st back wall echo to the right of the interface echo. The sound pulse
can run several times back and forth between the front and rear end of the weld
spot, and delivers a part of the sound pulse to the probe every time it hits the front
end. This ever decreasing part of sound pulse is displayed as 2nd, 3rd, 4th back
wall echo at the same intervals on the screen. In this connection, the interval
between the individual back wall echoes corresponds to twice the material
thickness (round trip within the material). If there is a flaw in the weld spot, e.g. in
the form of a gas pocket, a part of the sound pulse corresponding to the size of this
flaw is additionally reflected from it. As the flaw is situated between the front and
rear end of the weld spot, the corresponding flaw echoes also occur between the
back wall echoes. In the case of major weld flaws, the flaw echoes are higher and
possibly only recognizable by the fact that the intervals between them are shorter
than those of the back wall echoes.

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2.1.3 ULTRASONIC TESTING OF SPOT WELDS IN THE
AUTOMOTIVE INDUSTRY
AUTHOR- WERNER ROYE (NO. SD 297)
THE COMPUTER-ASSISTED SPOT WELD INSPECTION
The type of ultrasonic testing of spot welds described above can be carried
out using any portable ultrasonic instrument showing an adequate bandwidth and
consequently also the required resolution of the acoustic signals. With the large
number of spot welds to be inspected, however, it takes quite a lot of time to
document all results by hand. For this reason, many users today make use of the
computer technology in order to automate as many work processes as possible. The
notebook-type ultrasonic instrument USLT 2000 is suitable for the mobile
inspection. It combines all ultrasonic features with the possibilities of state-of-the
art computer technology. The application program Ultra- LOG was especially
designed for the spot weld inspection. It contains the ―live‖ (active) A scan on the
one hand, and the adjustment facilities required for the ultrasonic inspection on the
other hand. Moreover, the Ultra- LOG program features the following functions:
 As soon as the inspector has positioned the probe correctly on
the spot weld (it is not yet possible to automate this according
to the state of the art), the A-scan is automatically frozen.
Within the framework of inspection planning, the criteria for
the positions and amplitudes of the first two back wall echoes
are defined for every metal sheet combination.

10
 When an echo display has been frozen, the software issues an
evaluation result, in the present example: ―OK‖ since the first
evaluation criterion for the drop in the echo sequence, and also
the second criterion referring to the intermediate echoes which
must not exceed the 10% threshold, are met.
2.1.4 FEATURES AND PERSPECTIVES OF
ELECTROMAGNETIC ACOUSTIC TRANSDUCERS USE FOR
TESTING
AUTHOR- ANDERY A. SAMOKRUTOV (BOOK OF ABSTRACTS. TS3.24.3. P. 88.)
INFERENCE
The methods of electromagnetic acoustic (EMA) excitation and reception of
longitudinal and SH ultrasonic waves with radial and linear polarization with the
Use of constant or pulse magnetizing of signal inductor were researched. The
settings and operation modes for pulse magnetic field were defined, the
magnetizing system was chosen and specifications for the power supply unit for
the electronic unit were developed. The specification for parameters of the EMA
Transducers (EMAT) was defined and the EMATs with apertures from 3 to 10
mm, small in sizes and weights and with high efficiency were developed. The
results of the practical use of EMAT for acoustic thickness measurement and
estimation of the anisotropy level for objects from aluminum alloys, titan, copper,
brass, various carbonaceous and stainless steels are represented. The possibilities
of various EMATs application for assessment of one axial stressed condition at
testing tightening strength of demountable connections and perspectives for testing
of two axial stressed conditions are shown The method of point weld testing of

11
aluminum alloys and various steel plates using EMA devices with pulse magnetic
transducers was considered. Considering that the parameters specifying the
character of the welding process are propagation time, amplitude and bending line
of the echo signal, it is recommended to use devices with EMAT and correlation
signal processing for point welding testing to measure thickness of welding point.
The characteristics of the device with automatic monitoring, when the thickness is
out of the set limits with accuracy up to 0.01mm, allowing automatic control of the
welding points are given The examples of the successful use of EMAT in
aerospace industries and in metallurgic industry are shown, the perspectives of use
in automobile and machine building industries are detailed.
2.1.5 IMPROVEMENTS IN ULTRASONIC INSPECTION OF
RESISTANCE SPOT WELDS
AUTHOR- JOE BUCKLEY
INFERENCE
Resistance welding is an electrothermic process commonly used in Industry
for joining sheet metal, particularly steel, in applications such as automobile bodies
and chassis assemblies. The method is suitable for partial or total automation, and
is very reliable. However, as with any process, problems can occur and inspection
is therefore necessary. Although ultrasonic inspection of spot welds has been used
for many years, the technology still has problems with production rate and
reliability, and is very operator dependent. This paper will look at the analysis of
ultrasonic signals from weld inspection, and present some improvements in both
probe technology and automatic analysis. Together these result in significant

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improvements in inspection reliability, and allow the inspection to be fully
automated.
2.1.6 A DETAILED STUDY OF DIFFERENT TYPES OF NDT
TECHNIQUES IN INDUSTRIES
AUTHOR - DR. RAJ KUMAR ( TESTING. DIAGNOSTICS. 2003, ¹ 11, PP. 6-8, 13-19.)
INFERENCE
Non-destructive Testing is a very vast field which helps the industries to
check the material they are manufacturing without damaging them. Most of the
industries take up NDT as the premier way to check the products, like Construction
companies, Boiler industry, Automobile industry, Welding setups etc. In different
industries different types of NDT techniques are used like Visual Testing,
Magnetic Particle Testing (MPT), Ultrasonic Testing (UT) and Liquid Penetrating
Testing (LPT) etc. Each technique has its significance and their results may vary,
so we choose the best NDT technique for the product to be tested and in
accordance with the budget. This paper is review papers on different types of NDT
techniques which shows a trend between their working and let the scholars
understand the know-how of latest in NDT.
NDT means Non- Destructive Testing, where any work-piece, product or
material can be tested without harming its integrity. This means if we have
manufactured any product then with the help of any mechanical operation like
welding, forging, casting etc then the strength of that product can be tested without
damaging that product. With the help of NDT we can even check the life of a
product by inspecting its wear and tear and then calculate how long it can be used

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before getting fractured. NDT is only concerned with the detection and location of
the flaw and after the inspection the defective portions are machined. The need to
use NDT arrived when we could no longer damage our product for the sake of
inspecting it e.g Jet Aircraft, Missiles, Nuclear Energy. Now-a-days NDT is
finding its application in many fields, methods and techniques and it basically
depends upon Material Type, Defect type, Defect Size and Defect Location. Thus
the need and demand of NDT will continue to grow.
Ultrasonic Testing: This method uses ultrasonic waves to detect any type of flaw
within the material. The sound waves are of the frequency of 1MHz to 15 MHz
and usually go up to 50 MHz. The sound waves of such high intensity penetrate
inside the material and are used to detect to internal flaws and disabilities.
Ultrasonic testing is mostly used on metallic structures because it gives high
efficiency, though it can also be used on concrete and wooden elements but the
efficiency reduces to a greater extent and the values obtained are not desirable.
This testing is done with the help of a probe (transducer) which is attached to the
diagnostic machine. A liquid solvent like oil, water etc is added between test
product and the transducer to let the probe move smoothly over the surface of the
product which in turn sends back the signals by reflection or attenuation to the
same probe. More the speed of sound more will be the penetrating effect which in
turn increases the detection strength and accessibility.

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2.2 DISADVANTAGES OF LASER AND ULTRASONIC
INSPECTION TECNIQUES:
 The initial cost of the SPA sensor is high.
 There may be chance occurring defect keeping sensor in the helmet.
 This inspection occurred only at the final step in the quality area.
 This doesn’t reduce cycle time in the company.
 If the head of the worker is just deviated, then the inspection area will passed
away.
 100% of accuracy is not expected.
 This is slow process.
 In ultrasonic inspection, it will inspect only two layered sheet in the body,
but the spot occurred in third layer means this ultrasonic waves could not
able to identify the defects.
 This inspection is carried out only at the quality area at the end of the
process. Due to this, there will be a waste of time at production and
assembly area.
 In lean manufacturing companies, this wastage and time consumption is
playing a major role. So, the quality inspections were not useful for them.
 Skilled employees needed to handle this type of inspections.
 More time is taken for ultrasonic inspection.
 We cannot get 100% defects in these types of inspection.
 Due to this inspections, we cannot able to analyses initial step for this defect
arising area, if we find this initial defect area means we easily rectify the
mistake.

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CHAPTER 3
ALTERNATIVE METHODOLOGY FOR REDUCING THE
DEFECT
3.1 SIX SIGMA METHODOLOGY:
The term Six Sigma originated from terminology associated with
manufacturing, specifically terms associated with statistical modeling of
manufacturing processes. The maturity of a manufacturing process can be
described by a sigma rating indicating its yield or the percentage of defect-free
products it creates. A six sigma process is one in which 99.99966% of all
opportunities to produce some feature of a part are statistically expected to be free
of defects (3.4 defective features / million opportunities), although, as discussed
below, this defect level corresponds to only a 4.5 sigma level. Motorola set a goal
of "six sigma" for all of its manufacturing operations, and this goal became a by-
word for the management and engineering practices used to achieve it.

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3.2 FLOW CHART:
Defining a problem
in production line
Measuring the dimension of
the system were the problem
is there and design of the
alternative idea should be
generated
The alternative design should be
analyzed here, many parameters is
considered here, like life time of new
device, area covered by device,
accuracy of the device
After installation of the new device,
check the improvement of the
production and to check the working
process
Check our goal got successful
with 99.97% of good defect
fewer products

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CHAPTER 4
IDENTIFICATION OF SOLUTION METHODOLOGY
4.1 DEFINING THE PROBLEM:
We went to the pallet line were the car body roof got spot welded. Then we
have noticed all the area in the pallet line, that any variation in the seating area.
During the time of discussion we founded that the bottom of the car body doesn’t
properly seated in the clamp of the pallet line. Due to this variation, the top body
roof slightly deviated from its original area. This variation leads to wrong spot
weld. The robot only programmed to weld in the roof area. It does not know that
welding is carried out in the correct area.
FIGURE 4.1 ERRORS IN BODYSEATING
And we have decided to calculate the defects in one day’s production. We
have noticed that every shift i.e. (8 hours), maximum 20 pieces of car body got
defected from this improper seating condition.

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FIGURE 4.2 ACTUAL SPOT WELDED AREA
FIGURE 4.3 WRONG SPOT WELDING AREAS
And we have referred, latest journals that how they are rectifying this error.
Leading automobile companies, identifying this wrong spot weld error at the
quality area only. By using laser inspection methods and the ultrasonic inspection
method. But in lean in manufacturing for an every wastage is responsible, and they
don’t need an separate area for inspection, because during this time, there will be a

19
waste of time by keeping the robots in off, waiting in assembly section, and
recycling the defect products, at lost this results in increasing in cycle time process.
4.1.1 FISH BONE DIAGRAM (CAUSE AND EFFECT DIAGRAM)
Here, we have decided to design and implement a new device to overcome the this
issue. To do a complete study of the below mentioned factors, have been
completed by brainstorming

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4.1.2 FACTOR TO BE CONSIDERED FOR OUR NEW DEVICE:
Our inspecting device should be smaller in size.
 It shouldn’t disturb the pallet line while inspecting.
 Maintenance should be less.
 No separate man power needed.
 99.9% of accuracy needed.
 Cost required for installation is less.
 All inspection should be carried out automatically.
 Device should cover only less in the production line.
 It should be eco friendly.
 Less electricity needed to operate.
 Less cycle time period..
 It should be a combination of electro-mechanical operation.
4.1.3 SELECTING OF AUTOMATION AND MECHANISM FOR
MOVEMENT OF THE DEVICE:
After completing our, we want to give a movement for the device, which
should not disturbs the line and the workers who they are directly involved in the
production process.
We have selected two major mechanisms for the movement for our project,
these mechanisms are experimentally verified in many situations and we have
collected the both advantages and disadvantages of those mechanism and we
finally select a mechanism which should be installed.

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METHOD 1:
PIVOT MECHANISM
A mechanical linkage is an assembly of bodies connected to manage forces
and movement. The movement of a body, or link, is studied using geometry so the
link is considered to be rigid.[1]
The connections between links are modeled as
providing ideal movement, pure rotation or sliding for example, and are called
joints. A linkage modeled as a network of rigid links and ideal joints is called a
kinematic chain. Linkages may be constructed from open chains, closed chains, or
a combination of open and closed chains. Each link in a chain is connected by a
joint to one or more other links. Thus, a kinematic chain can be modeled as a graph
in which the links are paths and the joints are vertices, which is called a linkage
graph. The deployable mirror linkage is constructed from a series of rhombus or
scissor linkages.
FIGURE 4.5(B) PIVOT MECHANISM SETUP

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METHOD 2:
SLIDING MECHANISM
Sliding mechanism, arrangement of mechanical parts designed to convert
straight-line motion to rotary motion, as in a reciprocating piston engine, or to
convert rotary motion to straight-line motion, as in a reciprocating piston pump.
The darkly shaded part 1, the fixed frame or block of the pump or engine, contains
a cylinder, depicted in cross section by its walls DE and FG, in which the piston,
part 4, slides back and forth. The small circle at A represents the main crankshaft
bearing, which is also in part 1. The crankshaft, part 2, is shown as a straight
member extending from the main bearing at A to the crankpin bearing at B, which
connects it to the connecting rod, part 3. The connecting rod is shown as a straight
member extending from the crankpin bearing at B to the wristpin bearing at C,
which connects it to the piston, part 4, which is shown as a rectangle.
A slider crank mechanism converts circular motion of the crank into linear
motion of the slider. In order for the crank to rotate fully the condition L> R+E
must be satisfied where R is the crank length is the length of the link connecting
crank and slider and E is the offset of slider . A slider crank is a RRRP type of
mechanism i.e. It has three revolute joints and 1 prismatic joint. The total distance
covered by the slider between its two extreme positions is called the path length.
FIGURE 4.5(B) SLIDING MECHANISM SETUP

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After making a detailed study about those mechanisms, finally we have decided to
use sliding mechanism for our device movement.
REASON FOR SELECTING SLIDING MECHANISM OVER PIVOT
MECHNIASM:
 The installation of sliding mechanism is than the installation of pivot
mechanism kid.
 The time cycle of pivot is slower than the slider mechanism.
 Some risk is arising in the production line, if we install pivot.
 Slider mechanism doesn’t disturb both the line and the workers.
 The operation pivot mechanism requires some additional equipment like
springs and compressors
 Pivot assembly requires large amount of area in the platform.
 Separate lubrication system is required for pivot setup.
 Maintenance is required for pivot setup, because even small dust block also
make major defect in pivot mechanism.
 A simple linear guide rail is used for the sling mechanism movement.
 The economy of installation of sliding mechanism is less than the pivot
setup.
 Sliding mechanism can achieve remote operation; facilitate the
implementation of automated casting operations.
 The jogging trails that control the motion and hold make the closed door
very secure and ensure that sliding garage openers are amongst the mοѕt
powerful & mοѕt impenetrable systems аbοut. Thеу саn аlѕο be locked іn a
lot of distinct means аnd offer high resistance to wind аnd impact dаmаgе.

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4.1.4 DESIGNING OF OUR ALTERNATIVE DEVICE:
4.1.4 (A) ROUGH AND PENCIL SKETCH DESIGN:
After finding a problem and factors to be followed, again we went to the line
and we took a measurements that our devices were to be placed and it shouldn’t
disturbs fixed production line.
We have took the measurements like,
1. Basement area of the platform,
2. Measurement of the clamp,
3. Thickness and width of the bottom car body,
4. Distance from platform to clamp,
5. Calculating the time of movement of each car body.
FIGURE 4.6 PENCIL SKETCH DESIGN

25
After finishing the measurements, we have planned to design a device in a
rough sketch manner. And this design should to accurate and must be in clear
manner. Because, we know this rough sketch plays a major role in further
generation of this optimized design.
We have implemented all of engineering graphics skill, here to develop this pencil
sketch.
4.1.4 (B) 3D MODELLING:
After completing our pencil sketch, we again went to the pallet line and we
compare our sketch and real time view. After getting approval from the
engineering department. We have started our designing procedures.
FIGURE 4.7 NX-CAD DESIGN
In nx cad software we can make a design of component to our material which is to
be really used to prepare a material.

26
FIGURE 4.8 LAYOUT OF BSC DEVICE
We have decided to develop design in NX-CAD mechanical software.
Because, nx cad software is user friendly than other software’s like, cero, pro-e,
catia. First we have developed a each component and we have decided to assemble
it separately. Because, if there is any problem in measurement at particular
component, we can change it easy in the part model and we can re-assemble again.
Product and manufacturing information (PMI) is used in 3D CAD and
product development systems to convey design information for manufacturing.
PMI includes information such as geometric dimensioning and tolerance (GD&T),
text annotations, surface finish and material specifications
Sensor carriage block
L- Block component
Guide rail
Base plate
Square tube rod (connecting rod)

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4.5 COMPONENT DESCRIPTION
4.5.1 TABLE FOR COMPONENT DETAILS:
SL.
NO
COMPONENT USED MATERIAL DIMESIONS
(ALL
DIMENSIONS
IN mm)
NOS
1. L-BLOCK EN8 80×15×80 1
2. SENSOR CARRIAGE
BLOCK
EN8 120×15 1
3. BASE PLATES MS STEEL 300×300×20
120×100×20
200×200×20
1
1
1
4. SQUARE TUBE ROD MS STEEL 80×2000×5 1
5. GUIDE RAIL ALUMINIUM
(GUN
MATERIAL)
2000 LENGTH
WITH TWO
CARRIAGE
2
6. SINGLE ACTING
CYLINDER
_ _ 1
TABLE 4.1 COMPONENT DETAILS

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4.5.2 REASON FOR USING EN8 MATERIAL AND MILD STEEL
MATERIAL:
EN8 also known as 080M40. Unalloyed medium carbon steel. EN8 is a
medium strength steel, good tensile strength. Suitable for shafts, stressed pins,
studs, keys etc. Available as normalized or rolled. EN8 is supplied as round
drawn/turned, round hot rolled, hexagon, square, flats and plate
EN24 also known as 817m40 comes treated in the T condition to 850/1000 N/mm2
we can offer EN24T in plate from 10mm thick up to 300mm, diameters from
10mm up to 950mm, squares from 20mm to 300mm and flats 20 x 10 up to 3000 x
300mm from stock. AISI 4340, worst-off 1.6565.
ADVANTAGES OF EN8 MATERIAL
EN8 or 080m40 can be tempered at a heat of between 550°C to 660°C
(1022°F-1220°F), heating for about 1 hour for every inch of thickness, then cool
in oil or water. Normalizing of EN8 bright mild steel takes place at 830-860°C
(1526°F-1580°F) then it is cooled in air. Quenching in oil or water after heating
to this temperature will harden the steel.
Chemical Composition of EN8 Steel
Min 0.35 0.600.05 0.015 0.015 0 0 0 0
Max 0.45 1.000.35 0.06 0.6 0 0 0 0
TABLE 4.2 EN8 CHEMICAL COMPOSITIONS

29
Mechanical Properties of EN8 Steel
Modern EN8 bright mild steel contains a lot less carbon then it use to, this
mean that it is possible to weld pieces up to 18mm thick without preheating using
MIG wire (SG2) or a 7018 electrode. Over 18mm would require a pre-heat of
100°C (212°F) in order to prevent cracking. Anneal afterward is recommended to
prevent breaking.
Condition Yield
Stress
x 106 Pa
Tensile
Stress
MPa
Elongation
%
Normalized 280 550 16
Cold drawn
(thin)
530 660 7
TABLE 4.3 EN8 MECHANICAL PROPERTIES
MILD STEEL MATERIAL
To create MS steels, the austenite that exists during hot-rolling or annealing
is transformed almost entirely to martensite during quenching on the run-out table
or in the cooling section of the continuous annealing line. The MS steels are
characterized by a martensitic matrix containing small amounts of ferrite and/or
bainite .Within the group of multiphase steels, MS steels show the highest tensile
strength level. This structure also can be developed with post-forming heat
treatment. MS steels provide the highest strengths, up to 1700 MPa ultimate tensile
strength. MS steels are often subjected to post-quench tempering to improve
ductility, and can provide adequate formability even at extremely high strengths.

30
FIGURE 4.8 MECHANICAL PROPERTY OF MILD STEEL
4.6 LIST OF MACHINING PROCESS DONE.
The following machining process adopted in BSC device,
 Hardening en8 material,
 Milling operation,
1. Face milling,
2. Thread milling.
 Cutting operation in CNC machine,
 Tapping and drilling operation
 Grinding operation,
 Welding operation,
1. Plasma arc welding operation,
2. Gas welding operations.

31
4.7 INSTALLATION OF BSC DEVICE:
After assembling the component, the device is to be installed in the
production line, before installing the device, the basement area of the platform is to
be measured for removing. Here accurate measure is to be taken, because if excess
amount of material is as been removed, there will be a problem raised in line. So,
we have take measurements easily.
And we also want to keep in mind the, there is horizontal and vertical sensor
placed in the platform, so during the time of installation, those sensors must be in
safer condition. Our device should not damage any important component in the
pallet line.
FIGURE 4.9 INSTALLATION OF BODY SEATING
CONFORMATION DEVICE
Body seating
Sensing device
Car body
Platform

32
4.8 FEEDING THE PROGRAM IN THE SYSTEM:
After installing the device in the line, the program for automation is to be
developed ant it should be coded in the controlling system which is placed in the
quality and production area, there will separate operator will be there to control
this device. Programmable logic controller unit is used to operate this device,
this program were is very easy to develop and it is user friendly.
FIGURE 4.10 PLC LADDER DIAGRAM OF CONTROLLING BODYSEATING
CONFORMATION DEVICE

33
The input sources convert the real time analog electric signals to suitable
digital electric signals and these signals are applied to the PLC through the
connector rails. These input signals are stored in the PLC external image memory
in locations known as bits. This is done by the CPU The control logic or the
program instructions are written onto the programming device through symbols or
through mnemonics and stored in the user memory.
The CPU fetches these instructions from the user memory and executes the
input signals by manipulating, computing, processing them to control the output
devices. The execution results are then stored in the external image memory which
controls the output drives. The CPU also keeps a check on the output signals and
keeps updating the contents of the input image memory according to the changes in
the output memory. The CPU also performs internal programming functioning like
setting and resetting of the timer, checking the user memory. The operation of a
programmable controller is relatively simple.
The input/output (I/O) system is physically connected to the field devices
that are encountered in the machine or that are used in the control of a process.
These field devices may be discrete or analog input/output devices, such as limit
switches, pressure transducers, push buttons, motor starters, solenoids, etc.
Although not generally considered a part of the controller, the programming
device, usually a personal computer or a manufacturer’s mini programmer unit, is
required to enter the control program into memory. The programming device must
be connected to the controller when entering or monitoring the control program.

34
CHAPTER 5
IMPLEMENTATION AND OBSERVATION OF BSC DEVICE IN
PRODUCTION LINE
5.1 PRODUCTION LINE CONTROLLING UNIT:
FIGURE 5.1 PRODUCTION LINE CONTROLLING UNITS
The above chart explains that, our body seating device is controlled with
statistical evaluation data with computing manipulated. The PLC data is coded in
the production and quality controlled area, this inspects the operation of the device
and it will typically used to see the cycle timing of the inspection. This computer
controlled device mounted in production line A1 and A2.

35
These A1 and A2 line only carried out the hemming and spot welding
operations. So our device is used in this area only. B and C are the testing area, i.e.
if there is any error occurred in line A1 or A2 the workers from these area will
inspect the error occurred and they will rectify these error.
This error information is given from the production department. Because,
our device is installed in production line. In quality area they will control only the
timing operation of the device. So, the wasting of time in quality is reduced by
improving defect less production of material in production area itself.
OPERATION DONE BY B AND C TESTING AREA
In production line, the shop test methods include the shear down test, the
destructive chisel test and the nondestructive chisel test. In the shear down test and
the destructive chisel test, the spot welds are subjected to stress until they break
using simple test means, without recording a measured value. Used as evaluation
criterion is the type of the breakage and the size of the ruptured nugget. The
quantity of test scrap cause considerable cost.
The advantage of the chisel test lies in the fact that it can also be used on a
finished component, e.g. on a shell. However, it is mostly used as a nondestructive
test in these cases, i.e. load is not applied all the way up to the breakage of the
welded joint. The costs for this test are comparably low, but so is also the value of
its test results. This applies in particular to the nondestructive chisel test. It can
only be used for detecting defective spot welds whose strength already lies far
below the permissible minimum value, e.g. so-called ―stick welds‖. Besides, due to
the relatively indefinite test conditions which cannot be kept constant, the test
results vary within wide limits.

36
5.2 DEPLOYMENT OF BSCD IN PRODUCTION LINE
FIGURE 5.2 BODY SEATING CONFORMATION DEVICES
When the car body reaches the area of spot welding, the conformation
device movies forward, and this movement is carried by using linear guiderail,
which is fixed at the base. During time when the body reaches to that area, the
horizontal sensor placed in the platform will give digital pulse to the plc controller,
and it gives signal to the automation system which is connected to the air
compressor. This air compressor supplies air to the single acting cylinder was that
is mounted in the base of the device at carriage on the guide rail. After the setup
moves forward near to the clamp area, the sensor which is placed in the l-block
structure will start to sense the variation, if there is positive result, the normal 0 and
1 signal is send to the controller and the production line moves normally.
If there is any defect or variation in the clamp seating area the sensor will
sense this variation and send reverse signal 1 and 0 to the controller, there the
controller circuit will lock the gate and stops the production line. Until this both

37
quality and production area will control the operation. After detecting the defect
the variation data will send to the production controller, here quality controller
doesn’t receive these data because, these defect is going to rectify in production
area itself.
After receiving these data, production department will send the service or
operating engineer to the line and they will rectify the variation and improper
seating condition.
FIGURE 5.3 PROPER SEATING CONDITION
Actual
seating
position
Car body

38
CHAPTER 6
CONCLUSION
 After implementing this device, 99% of the defects were founded and
rectified.
 The cycle time of the production rapidly reduced from 15sec to 7sec.
 There no separate team to control this device, so manual work stress is
reduced.
FIGURE 6.1 BEFORE INSTALLATION OF BSC DEVICE
FIGURE 6.2 RESULT AFTER INSTALLATION OF BSC DEVICE
Accurate spot
welding after
seating
inspection

39
REFERNCE
[1] Mirosh Y.M., Medushevsky L.S. Providing stability of production quality for
complex products. NDT world. 2001. № 4 (14). Pp. 19-20.
[2] Samokrutov A..A.; Bobrov V.T.; Shevaldykin V.G. and others EMA thickness
gauge for aerospace industry. – XVI Russian scientific-technical conference «Non-
Destructive Testing and Diagnostics», St.- Petersburg, 2002. Thesis of Conference,
abstract 4.5.38, pp. 48.
[3] Samokrutov A..A.; Bobrov V.T.; Shevaldykin V.G.; Kozlov V.N.; Alekhin
S.G.; Zhukov A..V.: Application of EMA thickness gauge A1270 for aluminium
alloy testing, NDT World 2002 № 4, pp. 24-27.
[4] Samokrutov A.A.; Bobrov V.T.; Shevaldykin V.G.; Kozlov V.N.; Alekhin
S.G.; Zhukov A..V.: Anisotropy researches of rolling and its influence on the
results of acoustic measurements, Testing. Diagnostics. 2003, № 11, pp. 6-8, 13-
19.
[5] Samokrutov A.; Alekhin S.; Ivchenko S.; Bobrov V.: The industrial wall
thickness testing of paneling body of ―PROTON‖ rocket. The 3rd International
Conference and Exhibition ―Non-destructive testing and technical diagnosis in
Industry‖(Moscow, 2004). Program and Thesis of Conference, p. 245.
[6] V. Roe Ultrasonic testing of spot welds in automobile industry.
http://www.geinspectiontechnologies.com/ProductLiterature/index.html

40
ANNEXTURE I
COMPANY PROFILE
TYPE Joint venture
INDUSTRY Automotive
FOUNDED May 2010
HEADQUARTERS
Chennai, Tamil Nadu,
India
KEY PEOPLE
Mr.Sano Toshikhio,
MD & CEO[1]
PRODUCTS Automobiles
PARENT Renault Nissan
SUBSIDIARIES
 Renault India
Private Limited
 Nissan Motor
India Private
Limited
WEBSITE
www.nissan.in
www.renault.co.in

41
HISTORY
In February 2008, Renault-Nissan Alliance signs Memorandum of Understanding
with Government of Tamil Nadu to set up a manufacturing plant in Oragadam near
Chennai.[2]
Work on the plant began in June later that year and was completed in a
record 21 months. Renault Design India, the first vehicle design studio set up by a
foreign manufacturer in India, was established in Mumbai in September 2008. The
design house is integral to Renault’s success in India as one of its functions is to
monitor customer trends and customise global products for India.
OPERATIONS
In September 2008, Renault India opened its fifth global vehicle design studio in
Mumbai.[3]
In March 2010, Renault India and Nissan India opened a production facility in
Chennai.[4]
Established with an initial investment of Rs 45 billion (US$750
million), the plant has a combined annual capacity to produce 480,000 vehicles.[5]
As of May 2014, Renault India has 130 dealerships in 16 cities across 9 states and
2 Union Territories.[6]
MODELS
Renault sales commenced in May 2011 with the Fluence sedan. This was followed
in September by the Koleos SUV.[4]
In 2012 Renault launched three further
models; the Pulse hatchback in January, the Duster in July 2012, and the Scala in
August 2012. In 2014, aside from the launch of the all-new Fluence and Koleos,
Renault also launched the Duster Adventure Edition.

42
MILESTONES
2008
 Renault-Nissan Alliance signs Memorandum of Understanding with
Government of Tamil Nadu to set up a manufacturing plant in Oragadam
near Chennai
 The Renault DeSign Studio opened in Mumbai. It is one of the 5 satellite
global design studios for Renault, monitoring customer trends and helping
customize global products for India.[7]
 Launch of International Logistics Network (ILN) in Pune handling
components sourced from Indian suppliers for all Renault-Nissan Alliance
production plants worldwide, in particular South Africa & Brazil.
2010
 Inauguration of the Renault-Nissan Alliance manufacturing facility in
Chennai (investment of Rs. 4500 crores with a capacity to produce 480,000
cars per year).
2011
 Renault launches its first car in India, the Fluence.
 Renault – Nissan Alliance manufacturing facility rolls out its 100,000th car.
 All new Koleos global launch in India.
 Announcement of localization of the Renault K9K diesel engine.
 K9K powered Renault Pulse unveiled at the 2011 Indian Grand Prix by
Formula1 drivers Mark Webber and Karun Chandok.[8]

43
2012
 Renault launches the Pulse and unveils the Duster at the New Delhi Auto
Expo 2012.[9]
 Renault Scala launched in New Delhi.
2013
 Inauguration of the new warehouse for the Renault Alliance International
Parts Center (IPC) in Pune.
 Renault launched the Gang Of Dusters, the official community for Duster
owners.[10]
 Since the launch of the brand in early 2011, Renault has won over 43 awards
till date. The Renault Duster alone receiving 29 awards.
 Inauguration of the new warehouse for the Renault Alliance International
Parts Center (IPC) in Chennai as a part of expansion.
MANUFACTURING FACILITIES
Renault Nissan Automotive India Private Limited have their manufacturing plant
in Oragadam near Chennai. The plant has a capacity of 400,000 vehicles per
annum. The capacity is divided equally between Renault India Private Limited and
Nissan Motor India Private Limited.[2]
Renault is constructing a small car powered
by an 800cc engine, to compete with Maruti Suzuki's Alto, Hyundai India's Eon
and Chevrolet's Spark, in the segment, that makes up for about 40-45% of India's
car market. RNAIPL has achieved production target of 5,00,000 lakhs vehicle in
the month of October 2013 in the short span of 40 months after start of production.
RNAIPL is one of the most profitable company which adopts Japanese
manufacturing policy of GENBA KANRI. The company works on the style of

44
maximum productivity with minimum resources. But, in due course this
manufacturing strategy sometimes frustrates its employees. The small car is likely
to be rolled out from the Renault Nissan Alliance plant in Chennai and to hit the
market in 2014-15.[3]
MODELS
RENAULT
1. Renault Fluence (Launched 2011)
2. Renault Koleos (Launched 2011)
3. Renault Pulse (Launched 2012)
4. Renault Duster (Launched July-2012)
5. Renault Scala (Launched 2012)
NISSAN
1. Nissan X-Trail (Launched 2005)
2. Nissan Teana (Launched 2007)
3. Nissan 370Z (Launched 2010)
4. Nissan Micra (Launched 2010)
5. Nissan Sunny (Launched 2011)

45
ANNEXURE II
1. LATEST LASER TECHNIQUES INSPECTION
FIGURE A.1 LASER TECHNIQUE METHOD
FIGURE A.2 CONCEPT ILLUSTRATION OF COMBINING LASER PROJECTOR-
BASED SAR AND HMD-BASED AR FOR COLLABORATIONS

46
FIGURE A.3 VIEW PONT INSPECTION
2. ULTRASONIC INSPECTION TECHNIQUES
FIGURE A.4 MANUAL ULTRASONIC TEST

47
FIGURE A.5 THE INTEGRATION OF DRAWINGS INTO UITRALOG
3. TECHICAL ABBREVATIONS
 BSCD - BODY SEATING CONFORMATION DEVICE
 SPA - SPATIAL AGUMENTED SENSOR
 PLC - PROGRAMMABLE LOGIC CIRCUITS
 CNC - COMPUTER NUMERICAL CONTROL
 LIM – LASER INSPECTION METHOD
4. BASIC PLC CODINGS USED
 M1266 Disable the external control signal input point of HHSC1 reset signal
point (R)
 M1267 Disable the external control signal input point of HHSC1 start signal
point (S)
point (R)
point (S)

48
point (R)
point (S)
 M1272 Internal control signal input point of HHSC0 reset signal point (R)
 M1273 Internal control signal input point of HHSC0 start signal point (S)
 M1289 High speed counter I010 interruption forbidden
 M1312 C235 Start input point control
 M1320 C235 Reset input point control

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