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project report - apurv

This document provides a summary of an industrial training project completed by Apurv Rathore at Tata Motors Ltd. in Pantnagar, India from June 8 to July 7, 2015. It includes an introduction to Tata Motors, certificates of completion signed by his project mentor Mr. Ravindra Joshi, acknowledgements thanking those who supported the project, and an outline of the project report contents which provide details about Tata Motors' facilities and a study of a tire inflator.

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PROJECT REPORT ON INDUSTRIAL TRAINING AT TATA MOTORS LTD., PANTNAGAR 2015-2016 Under guidance of: Submitted by: Mr. Ravindra Joshi APURV RATHORE Project mentor (CMS lab)
CERTIFICATE This is to certify that APURV RATHORE Studentof NATIONALINSTITUTEOFELECTRONICSAND INFORMATION TECHNOLOGY Has successfully completed his Industrial training at Tata Motors. He has submitted A report on “TYRE INFILATOR” “AT CMS LAB” During his training From 08 JUNE – 07JULY 2015 He was sincere & dedicated to his work. We wish him all the best for the future. DATE: PLACE: PANTNAGAR Mr. RavindraJoshi Project mentor (CMS LAB) TATA MOTORS PANTNAGAR, UTTRAKHAND
ACKNOWLEDGEMENT I take this opportunity with much pleasure to thank all the people who have helped me through the course of my journey towards producing this report. I have taken effort in this project. However, it would have not been possible without the kind support of many individuals and Tata Motors Ltd. I would like to acknowledge and extend my gratitude at heart to all of them. I sincerely thank my report supervisor, Mr. Prabhat Singh for his guidance, help and motivation. I would like to express my immense gratitude to Mr. RAVINDRA JOSHI . Apart from the subject of my project, I learned a lot from him, which I am sure, will be useful in different stage of my life. I would also like to thank Mr. Brijlal Arora for giving me the chance to work in this prestigious organization. I would like to express my gratitude towards my parents & people who have willingly helped me out with their abilities. This report could not have been written without the generous assistance of countless individuals who shared their knowledge and expertise. To you all, I extend my deep appreciation.
CONTENTS CHAPTER 1: INTRODUCTION 1.1 General introduction about the TATA GROUP 1.2 Company Profile 1.3 Milestone CHAPTER 2: PROFILEOF THEORGANIZATION 2.1 Pantnagar Plant 2.2 Functional departments of the organization 2.2.2 Welding Shop 2.2.3 EngineShop 2.2.4 PaintShop 2.3 CMS Lab 2.4 Trim Line
CHAPTER 3 SMPS CHAPTER 4 INTRODUCTIONOF PLC • Advantages of PLC • Need of PLC • Allen Bradley PLCs • Micrologix 1200 PLC CHAPTER 5 PROJECT: STUDYOF TYRE INFLATOR • Introduction of Project • Component used • Hard Wiring • Working • Flow chart • Program INTRODUCTION 1.1 THE TATA GROUP The Tata group comprises over 100 operating companies in seven business sectors: communications and information technology, engineering, materials, services, energy, consumer products and chemicals. The group has operations in more than
80 countries across six continents, and its companies export products and services to 85 countries. The total revenue of Tata companies, taken together, was $100.09 billion (around Rs475,721 crore) in 2011-12, with 58 percent of this coming from business outside India. Tata companies employ over 450,000 people worldwide. The Tata name has been respected in India for more than 140 years for its adherence to strong values and business ethics. Every Tata company or enterprise operates independently. Each of these companies has its own board of directors and shareholders, to whom it is answerable. There are 32 publicly listed Tata enterprises and they have a combined market capitalisation of about $85.42 billion (as on June 14, 2013), and a shareholder base of 3.8 million. The major Tata companies are Tata Steel, Tata Motors, Tata Consultancy Services (TCS), Tata Power, Tata Chemicals, Tata Global Beverages, Tata Teleservices, Titan, Tata Communications and Indian Hotels. Tata Steel is among the top ten steelmakers, and Tata Motors is among the top five commercial vehicle manufacturers, in the world. TCS is a leading global software company, with delivery centres in the US, UK, Hungary, Brazil, Uruguay and China, besides India. Tata Global Beverages is the second-largest player in tea in the world. Tata Chemicals is the world’s second-largest manufacturer of sodaash and Tata Communications is one of the world’s largest wholesale voice carriers. In tandem with the increasing international footprint of Tata companies, the Tata brand is also gaining international recognition. Brand Finance, a UK-based consultancy firm, valued the Tata brand at $18.16 billion and ranked it 39th among the top 500 most valuable global brands in their BrandFinance® Global 500 2013
report. In 2010, BusinessWeek magazine ranked Tata 17th among the '50 Most Innovative Companies' list. Founded by Jamsetji Tata in 1868, Tata’s early years were inspired by the spirit of nationalism. It pioneered several industries of national importance in India: steel, power, hospitality and airlines. In more recent times, its pioneering spirit has been showcased by companies such as TCS, India’s first software company, and Tata Motors, which made India’s first indigenously developed car, the Indica, in 1998 and recently unveiled the world’s most affordable car, the Tata Nano. 1.2 COMPANY PROFILE Tata Motors Limited is India's largest automobile company, with consolidated revenues of INR 1,88,818 crores (USD 34.7 billion) in 2012-13. It is the leader in commercial vehicles in each segment, and among the top in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. It is also the world's fourth largest truck and bus manufacturer. The Tata Motors Group's over 55,000 employees are guided by the mission "to be passionate in anticipating and providing the best vehicles and experiences that excite our customers globally." Established in 1945, Tata Motors' presence cuts across the length and breadth of India. Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company's manufacturing base in India is spread across Jamshedpur
(Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains. The company's dealership, sales, services and spare parts network comprises over 3,500 touch points. 1.3 MILESTONES • 1945 • Tata Engineering and Locomotive Co. Ltd. (TELCO) was established to manufacture locomotives and other engineering products • 1948 • Introduction of the Steam road roller, in collaboration with Marshall Sons (UK) • 1954 • Collaboration with Daimler Benz AG, West Germany, for manufacture of medium commercial vehicles. The first vehicle rolled out within 6 months of the contract • 1966 • Engineering Research Centre (ERC) set up at Pune, to provide impetus to automobile R&D • 1971 • Introduction of DI engines • 1977
• First commercial vehicle manufactured in Pune • 1983 • Manufacture of Heavy Commercial Vehicle commences • 1985 • First hydraulic excavator produced in collaboration with Hitachi • 1986 • Production of first, indigenously designed, light commercial vehicle (LCV) - Tata 407, followed by Tata 608 • 1989 • Introduction of the Tatamobile 206 - 3rd LCV model • 1991 • Launch of the first indigenous passenger vehicle - Tata Sierra • 1 millionth commercial vehicle sold • TAC 20 crane produced • Roll out of the 1 millionth vehicle • 1992 • Launch of the Tata Estate • 1993 • Joint venture agreement signed with Cummins Engine Co. Inc. for the manufacture of high horsepower and emission friendly diesel engines
• 1994 • Launch of Tata Sumo MUV • Launch of LPT 709 - a full forward control, LCV • Joint venture agreement signed with M/s Daimler - Benz / Mercedes - Benz for manufacture of Mercedes Benz Passenger cars in India • Joint venture agreement signed with Tata Holset Ltd. (UK) for manufacturing turbochargers to be used on Cummins engines • 1995 • Launch of Mercedes Benz car E220 • 1996 • Launch of Tata Sumo deluxe • 1997 • Launch of the Tata Sierra Turbo • 100,000th Tata Sumo rolled out • 1998 • Tata Safari - India's first sports utility vehicle launched • Roll out of the 2 millionth vehicle • Launch of India's first fully indigenous Passenger car - Tata Indica • 1999 • 115,000 bookings for Indica registered against full payment within a week • Commercial production of Indica commences in full swing • 2000 • First consignment of 160 Indicas shipped to Malta
• Indica with Bharat Stage 2 (Euro II) compliant diesel engine launched • Utility vehicles with Bharat 2 (Euro II) compliant engine launched • Indica 2000 (Euro II) with multi-point fuel injection petrol engine launched • Launch of CNG buses • Launch of the intermediate commercial vehicle – Tata 1109 • 2001 • Launch of 2nd generation Indica - Indica V2 • 2 millionth commercial vehicle sold • 100,000th Indica wheeled out • Launch of Tata Indica CNG • Launch of the Tata Safari EX • Indica V2 becomes India's number one car in its segment • Exits joint venture with Daimler Chrysler • 2002 • Unveiling of the Tata Sedan at Auto Expo 2002 • Petrol version of Indica V2 launched • Launch of the EX series in commercial vehicles • Launch of the Tata 207 DI • 200,000th Indica rolled out • 500,000th passenger car rolled out • Launch of the Tata Sumo+ series • The all-new Safari EX, with extra luxury features launched • Launch of the India’s first fully indigenous sedan - Tata Indigo • Productagreement with MG Rover (UK) for the Tata Indica in Europe • 2003 • Tata Indigo captures 27% markets share in its segment in the first month of its debut on Indian roads, in January 2003 • Limited edition of the Tata Safari launched • Unveiling of the Tata Indigo Station Wagon at the Geneva Motor Show
• Distribution agreement with Phoenix Venture Holdings for Safari & Loadbeta in UK and Ireland • Tata Spacio A1 with enhanced fuel economy and greater torque launched • On 29th July, J. R. D. Tata's birth anniversary, Tata Engineering becomes Tata Motors Limited • 3 millionth vehicle produced • Indigo clocks its highest ever sale in a month at 2,664 nos. and the highest ever in a month by any brand in the entry mid-size segment post1996 • First City Rover rolled out • 135 PS Tata Safari EXi Petrol launched • Tata Motors signs MOU for the acquisition of Daewoo Commercial Vehicle Co., Korea • Tata SFC 407 EX Turbo launched • 2004 • Tata Motors unveils new productrange at Auto Expo 2004 • New Tata Indica V2 launched • Unveiling of the Indigo Advent at the Geneva Motor Show • Acquired Daewoo Commercial Vehicle Company • Tata LPT 909 EX launched • Tata Daewoo Commercial Vehicle Co. Ltd. (TDCV) launches the heavy duty truck Novus in Korea • Sumo Victa launched • Launch of Indigo Marina • Listing on the NYSE • 50 years of automotive excellence • 2004 - Indica wins the CSIR (Council of Scientific and Industrial Research) Diamond Jubilee Technology award • 2005 • 500,000th Passenger car rolled out • Launch of the premium version of the Tata Spacio Gold - Tata Spacio A1 • Supply of the first batch of CNG buses to the Gujarat State Road Transport Corporation
• Unveiling of the Tata Xover at the Geneva Motor Show • Tata Indica launched in Turkey • Launch of branded buses and coaches - Starbus and Globus • Acquisition of 21% stake in Spanish bus manufacturing company - Hispano Carrocera SA, • Launch of the Tata Safari Dicor • Introduction of the luxury variant of Tata Indigo - Indigo SX series • Indica V2 Turbo diesel launched • Launch of India’s first mini-truck - Tata Ace • 1 millionth passenger car sold • Launch of Tata TL 4X4, India's first Sports Utility Truck (SUT) • Tata Daewoo Commercial Vehicle Company (TDCV) launches Novus range of medium trucks in Korea • 2006 • Unveiling of the new long wheel base premium Indigo & X-over conceptat the Auto Expo 2006 • Indica V2 Xeta launched • 3 millionth commercial vehicle sold • Passenger car sales in India crosses 1 million mark • Tata Motors and Marcopolo (Brazil) announce joint venture to manufacture fully built buses & coaches for India & markets abroad • Tata Motors first plant for small car to come up in West Bengal • CNG options extended to hatchback and Estate range • Tata Daewoo Commercial Vehicle Company develops South Korea's first LNG-powered tractor- Trailer • Three additional cooperationagreements with Fiat Group • Industrial joint venture with Fiat to producecars, engines, transmissions in India • Introduction of a new Indigo range • 4 million mark Tata vehicles sold • Half million vehicles sold in a year • 2007
• Construction of Small Car plant at Singur (West Bengal) begins on January 21 • Launch of the 2007 Tata Indica V2 range • Launch of the longwheel base Tata Indigo XL, India's first stretch limousine • Common rail diesel (DICOR) engine extended to the Indigo sedan and estate range • Joint venture with Thonburi Automotive Assembly Plant Co. (Thonburi) in Thailand to manufacture, assemble and market pickup trucks • Agreement with Fiat for pick-up production in Argentina • Signed MoU with Iveco to explore strategic alliance opportunities • Roll out of 100,000th Tata Ace • Inauguration of the Tata-Fiat plant at Ranjangaon • Launch of the upgraded Tata Spacio range • CRM-DMS initiative crosses the 1000th location milestone • Launch of Tata Magic • Launch of Tata Winger • Fiat Group and Tata Motors establish a Joint Venture in India • Launch of the Tata Sumo Victa Turbo DI and the upgraded range of the Tata Sumo Spacio • Tata Indica V2 Turbo with dual airbags and ABS launched • Launch of the Tata Safari DICOR 2.2 VTT range, powered by a new 2.2 L Direct Injection Common Rail (DICOR) engine • Roll-out of the 1 millionth passenger car of the Tata Indica platform • 2008 • The Tata Indica V2 DICOR launched • Launch of Tata Indigo CS (CompactSedan), world's first sub 4-metre sedan • Launch of the Tata Sumo Grande • Tata Motors unveils its People's Car, Tata Nano, at the 9th Auto Expo • Tata Xenon, 1-tonne pick-up truck, launched in Thailand • Tata Motors acquires Jaguar Land Rover from Ford Motor Company • Tata Motors introduces the Super Milo range of buses • Tata Ace plant at Pantnagar (Uttarakhand) commences production • Launch of the new generation Indica - Tata Indica Vista
• 2009 • Tata Marcopolo Motors’ Dharwad plant begins production • Launch of the Tata Xenon XT (Cross Terrain) • Launch of the Tata Nano • Jaguar Land Rover's first flagship showroom facility opened at Ceejay House in Mumbai • Introduction of new world standard truck range – Tata Prima • Launch of the Jaguar Land Rover range of premium luxury vehicles -- Jaguar XF, XFR & XKR and Land Rover Discovery 3, Range Rover Sport and Range Rover in India • Launch of the Tata 407 Pickup, Tata Super Ace and Tata Ace EX • Launch of Tata SK 407 Tipper • Launch of Tata Prima in South Korea • Launch of Freelander 2 in India • Launch of the next generation Tata Indigo Manza • Tata Motors acquired the remaining 79% shares in Hispano Carrocera S. A., Spain. • Launch of the Tata Sumo Grande MK II 2010 • Tata Motors Group unveils the Jaguar XJ; 4x4, 7-seater CrossoverTata Aria, Tata Venture and the Tata Magic Iris at the Auto Expo 2011 • Roll out of the 100,000th Tata Safari from the Pune Plant • Tata Motors sells its 4 millionth commercial vehicle • Inauguration of the Tata Nano plant in Sanand • Launch of the first Indian 4-wheel drive, Crossover, Tata Aria • Tata Nano receives the world's oldest and most coveted GOODDESIGN™ Award for 2010 • Tata Motors ranks as India's Most Valuable CorporateBrand in The Economic Times' 'India's Most Valuable Brands 2010' Study • 2011 • Tata Venture launched • Launch of Tata Divo Luxury Coach and Tata Starbus Ultra
• Launch of Tata Nano 2012 • Tata Sumo Gold introduced • Range Rover Evoque launched in India • New Tata Indica Vista launched • Tata Magic IRIS and Tata Ace Zip launched • Tata Indica eV2 introduced with 25 kmpl mileage • Tata Pixel, a city car conceptfor Europe, displayed at the Geneva Motor Show • Refreshed Tata Indigo Manza introduced • Tata Prima ConsTruckrange launched • Tata Motors unveiled assembly plant in South Africa • Tata Nano began international journey with Sri Lanka • Tata Motors completes 50 years of its International Business • Jaguar Land Rover inaugurated its vehicle assembly plant in Pune • Tata Nano launched in Nepal • HVTL amalgamates into HVAL renamed as TML Drivelines Ltd. • Tata Motors (Lucknow) produced & dispatched the first Hybrid Chassis to Spain • Tata Motors (Dharwad) rolled out the first Tata Ace Zip • Tata 407 celebrated its silver jubilee year • Jaguar celebrates 50 years of iconic E-Type • 2012 • Tata Motors enters Bangladesh’s new car market • Tata Ace races through the one-million mark in just 2,680 days • Tata Safari Storme, the Real SUV, hits the road • Launch of PT Tata Motors Indonesia • Tata Motors plant at Dharwad comes on stream • Tata Motors enters into distribution agreement in Myanmar • Launch of Tata Ace in South Africa • 2013
• Tata Nano becomes the first Auto Brand in India to cross 3 million fans on Facebook • The Tata Indigo ECS enters Limca Book of Records • Tata Motors' Jamshedpur plant rolls out its two millionth truck • Tata Nano offered industry first phenomenon - Swipe your credit card and drive home a Nano Tata Motors launches the world-class range of Tata PRIMA trucks in Sri Lanka PROFILE OF THE ORGANIZATION 2.1 PANTNAGAR PLANT The Company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based on the Ace platform) at Pantnagar in Uttarakhand. The plant began commercial production in August 2007. This is the company's fourth plant, after Jamshedpur (commercial vehicles), Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The plant is spread over 953 acres, of which 337 acres is occupied by the vendor park.
State-of-the-art facilities include weld shops, paint shops, engine and gear box shops and assembly lines. The Company has invested over Rs.1000 crores in the plant. Vendors for the vehicle have made additional investments to set up their plants in the vendor park adjoining the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among vendors and service providers in the area. 2.2 Functional Departments Tata Motors, Pantnagar Plant consists of mainly four shops namely- Assembly shop, Welding shop, Engine shop and Paint Shop. 2.2.1 Assembly Shop The Assembly Shop is where it all starts to come together. The frame truly becomes a chassis here, as the suspensionis built and added. In the Assembly Shop the bodies are fitted to the chassis, doors, hoods and trunk lids are hinged and fitted. Most of the accessories are also installed by craftsmen with many years of experience. 2.2.2 Welding Shop BIW Welding PE has a highly skilled team that can meet the expectations with innovative but simple solutions in BIW welding. The team has at its credit the experience of handling almost all vehicle projects in Tata
Motors Limited at turnkey level across all its plants through its in-house and supplier-based resources. PE takes utmost care during design and manufacturing of welding fixtures for safety aspects during BIW production. With use of modular bases and units and high quality standard items the fixtures are most reliable and consistent in performance. Main Line BIW Welding Fixture for a Tata Small Truck BIW Weld Line for a Tata Pick up Frames / Chassis Welding PE has a highly experienced team to design and manufacture welding fixtures for various types of chassis / frames. Frames of many Tata vehicles known for their reliable performance on rugged Indian road conditions have been tooled in PE.
Frame Welding Fixture meant for a Japanese OEM's MUV for India before dispatch Trunion Fixture Having Balanced Rotation for a Tata SUV Frame 2.2.3 Engine shop There are three broad operational areas here: • Engine machine shop — This is where the five most critical parts of the engine are made: cylinder block, cylinder head, crankshaft, camshaft and connecting rod. • Engine assembly— The five critical parts and outsourced components are brought together here. The place where this is done is among the cleanest in the plant, with the temperature maintained at 23oC to guard against any expansion of the engine-part metals. The cylinder-block and cylinder-head assemblies move in near parallel conveyor lines before being joined in a confluence zone. • Engine testing —Engines are checked separately in ‘testing cubicles’ and ‘test beds’ forpower, fuel efficiency, smoke, torque and leaks. After the
testing operations, the engines are moved to where they will be integrated with the gearbox. • Engine assembly shop, capable of supplying upto 1200 engines per day. 2.2.4 Paint shop Spread over 44,400 square meters, it’s the biggest block in the plant. But magnitude alone does not make the paint shop stand apart; it is the quality of its work that makes it special. The paint shop is a cut above the rest of the plant in the spic-and-spandepartment. This is a necessity in this facility because even the slightest bit of grime — in some areas of operations — can have telltale effects. The cleanliness in this block extends to unexpected areas. The paint shop operates at four levels to cater to the requirements of its processes. At 10 metres below ground level, everything, specially the paint that spills, is exhausted out. At five metres above ground level are the ovens that bake and dry the coating on the car. At 10 meters above ground level is an air supply plant that helps keep dust out of the shop’s environs. The atmosphere in parts of the paint shop is strictly controlled. Temperatures here are kept at 26oC and clean air is continuously filtered. The car itself, the end object of all this care, goes through a five-stage painting process beforeit can be sent to the final assembly block. The procedurebegins with a ‘dip treatment’ wherein the car body(the bodyin white from the weld shop)is dipped in14 tanks and gets a phosphatecoat. After this the bodyis baked. Then comes the ‘cathodic electrolytic deposits’ coat, following which the bodyis baked again.
The bodyis sealed before it gets a primer surface coat and is brushed clean with dusters made of ostrich feathers. The basecoat and a clear coatof lacquer follow the primer surface coat. The primer is a water-based coat, whereas the base coatis of the same color as that the car will sportwhen the painting operation is completed. The lacquer coat is the final flourish in the process. Quality audits follow before the car is transported, via an elevated and covered conveyor bridge, to the final assembly block. 2.3 CMS Central Maintenance Services provide central facilities and shop maintenance. Under central facilities activities such as purchasing, storing and maintaining of equipment’s under proper hygienic and temperature conditions. Each shops consists of its own maintenance department and their job is to immediately replace the parts that cause machine break-down and other concerned defects and thus helping in optimum output of the shop. In case, they fail then the CMS provide the requisite help and most importantly repair the parts causing the defects thus resulting in high optimum use of resources. Further, they undergo projects for upliftment of the shop and also improvement works to maximize the output of the shop. 2.4 Trim Chassis Fitment-1D Lay Out
2.4.1 Trim line-I There are four conveyor lines in the final assembly block. The trim line is the first of these and the action here begins with each car bodybeing allocated a chassis number. The Tata tags come on before the cabling and wiring of the car gets done. The doors ofthe car are detached at this point. This is to enable workers easy maneuverability as they swarm over and inside the vehicle fitting and fixing parts. Noise, vibration and harshness is minimized by a procedurecalled foaming (adding rubber fittings). The first wave of work happens here: the brake pipe and hand brake come on, the cabin and the floor are insulated, the floor is carpeted and the accelerator is fitted. Next come the air conditioner, dashboard, steering mechanism, steering pipeline, rooflining and the instrument cluster (indicators).
2.4.2 Trim line-II Robotics is a dominant feature on this conveyor line. A robotapplies a sealant on the front glass before it is manually fixed to the car. Then comes the air- conditioning controls, combination switches and seat belts. The rear lights are put on panels in the bullhorn design typical of the vehicle. The fuel neck, rear bumper, seats and steering wheel are fixed before the vehicle is taken to the next line. 2.4.3 Underbody line On this stretch the vehicle is lifted up to line which is around five feet high. Work is done on the vehicle from below. Given the critical nature of the components added here, the best operators in the block are deployed here. This is where the engine, exhaust and wheels are fitted, as also the radiator, the fuel tank, the condenser, the mudguard. 2.4.4 Mechanical line The mechanical line is the last stop before the vehicle comes into existence. Fuel, oil and gas (for the air conditioning) are filled before the vehicle gets a battery. The doors are fitted back, the wheels aligned and the headlights are adjusted. This is followed by a brake test and some serious roughing up over a jagged surface.
shower test to detect leaks is the final round Switched Mode Power Supply (SMPS) like a linear power supply, the switched mode power supply too converts the available unregulated ac or dc input voltage to a regulated dc output voltage. However in case of SMPS with input supply drawn from the ac mains, the input voltage is first rectified and filtered using a capacitor at the rectifier output. The unregulated dc voltage across the capacitor is then fed to a high frequency dc-to-dc converter. Most of the dc-to-dc converters used in SMPS circuits have an intermediate high frequency ac conversion stage to facilitate the use of a high frequency transformer for voltage scaling and isolation. In contrast, in linear power supplies with input voltage drawn from ac mains, the mains voltage is first stepped down (and isolated) to the desired magnitude using a mains frequency transformer, followed by rectification and filtering. The high frequency transformer used in a SMPS circuit is much smaller in size and weight compared to the low frequency transformer of the linear power supply circuit. The ‘Switched Mode Power Supply’ owes its name to the dc-to-dc switching converter for conversion from unregulated dc input voltage to regulated dc output voltage. The switch employed is turned ‘ON’ and ‘OFF’ (referred as switching) at a high frequency. During ‘ON’ mode the switch is in saturation mode with negligible voltage drop across the collector and emitter terminals of the switch where as in ‘OFF’ modethe switch is in cut- off mode with negligible current through the collector and emitter terminals. On the
contrary the voltage regulating switch, in a linear regulator circuit, always remains in the active region. Details of some popular SMPS circuits, with provisions for incorporating high frequency transformer for voltage scaling and isolation, have been discussed in next few lessons. In this lesson a simplified schematic switching arrangement is described that omits the transformer action. In fact there are several other switched mode dc-to-dc converter circuits that do not use a high frequency transformer. In such SMPS circuits the unregulated input dc voltage is fed to a high frequency voltage chopping circuit such that when the chopping circuit (often called dc to dc chopper)is in ON state, the unregulated voltage is applied to the output circuit that includes the load and some filtering circuit.
INTRODUCTIONOF PROJECT Tyre infliator is based upon solenoid valve’s principle and PLC programming. A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current through a solenoid : in case of a 2 port valve the flow is switched on or off ; in case of a 3 port valve the outflow is switched b/w the two outlet ports. Here we have 2 solenoidal valves of 3/2
means 3 ports and 2 positions. Valve 1 for filling the air in tyre and valve 2 for exhausting the air from tyre. • COMPONENTUSED • 2 LAMP • 2 PUSH BUTTON: For Start and Stop • 3 SELECTOR SWITCHES: Respectively for 30 PSI, 35 PSI and 40 PSI • 2 SOLENOIDAL VALVE: Valve 1 for filling Valve 2 for exhausting HARD WIRING OF TYRE INFLATOR
WORKING OF TYRE INFLATOR The 30 PSI push button helps to maintain the appropriate pressure in the following manner: • When we press the control switch and connect the air pipe to the tyre, now the pressure switch measures the pressure of the tyre. • Let the pressure of the tyre be X . • Now PLC checks the conditions i.e. Is X<30? Is X>30? or Is X=30? • Now PLC on a suitable output i.e. solenoidal valve, valve 1 for filling and valve 2 for exhausting. • If X<30, then PLC switches on valve 1.
• If valve 1 is on then the air flows in the tyre for 5 sec • After 5 sec PLC checks the condition if X<30 then again valve 1 is on for 5 sec. • This process will be continued until the pressure of the tyre is near about 30. • When the pressure of the tyre is near about 30 this process will be stopped. • If X>30 , then PLC switches on valve 2. • If valve 2 is on then the air exhausts from the tyre for 3 sec. • After 3 sec PLC checks the condition if X >30 then again valve 2 is on for 3 sec . • This process will be continued for 3 sec until the pressure of the tyre is near about 30. • When the pressure of the tyre is near about 30 this process will be stopped.
For 35 PSI and 40 PSI the working process is similar.
PROGRAMING OF TYRE INFLATOR
THANK YOU TATA MOTORS

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project report - apurv

  • 1.
    PROJECT REPORT ON INDUSTRIAL TRAINING AT TATAMOTORS LTD., PANTNAGAR 2015-2016 Under guidance of: Submitted by: Mr. Ravindra Joshi APURV RATHORE Project mentor (CMS lab)
  • 2.
    CERTIFICATE This is tocertify that APURV RATHORE Studentof NATIONALINSTITUTEOFELECTRONICSAND INFORMATION TECHNOLOGY Has successfully completed his Industrial training at Tata Motors. He has submitted A report on “TYRE INFILATOR” “AT CMS LAB” During his training From 08 JUNE – 07JULY 2015 He was sincere & dedicated to his work. We wish him all the best for the future. DATE: PLACE: PANTNAGAR Mr. RavindraJoshi Project mentor (CMS LAB) TATA MOTORS PANTNAGAR, UTTRAKHAND
  • 3.
    ACKNOWLEDGEMENT I take thisopportunity with much pleasure to thank all the people who have helped me through the course of my journey towards producing this report. I have taken effort in this project. However, it would have not been possible without the kind support of many individuals and Tata Motors Ltd. I would like to acknowledge and extend my gratitude at heart to all of them. I sincerely thank my report supervisor, Mr. Prabhat Singh for his guidance, help and motivation. I would like to express my immense gratitude to Mr. RAVINDRA JOSHI . Apart from the subject of my project, I learned a lot from him, which I am sure, will be useful in different stage of my life. I would also like to thank Mr. Brijlal Arora for giving me the chance to work in this prestigious organization. I would like to express my gratitude towards my parents & people who have willingly helped me out with their abilities. This report could not have been written without the generous assistance of countless individuals who shared their knowledge and expertise. To you all, I extend my deep appreciation.
  • 4.
    CONTENTS CHAPTER 1: INTRODUCTION 1.1General introduction about the TATA GROUP 1.2 Company Profile 1.3 Milestone CHAPTER 2: PROFILEOF THEORGANIZATION 2.1 Pantnagar Plant 2.2 Functional departments of the organization 2.2.2 Welding Shop 2.2.3 EngineShop 2.2.4 PaintShop 2.3 CMS Lab 2.4 Trim Line
  • 5.
    CHAPTER 3 SMPS CHAPTER4 INTRODUCTIONOF PLC • Advantages of PLC • Need of PLC • Allen Bradley PLCs • Micrologix 1200 PLC CHAPTER 5 PROJECT: STUDYOF TYRE INFLATOR • Introduction of Project • Component used • Hard Wiring • Working • Flow chart • Program INTRODUCTION 1.1 THE TATA GROUP The Tata group comprises over 100 operating companies in seven business sectors: communications and information technology, engineering, materials, services, energy, consumer products and chemicals. The group has operations in more than
  • 6.
    80 countries acrosssix continents, and its companies export products and services to 85 countries. The total revenue of Tata companies, taken together, was $100.09 billion (around Rs475,721 crore) in 2011-12, with 58 percent of this coming from business outside India. Tata companies employ over 450,000 people worldwide. The Tata name has been respected in India for more than 140 years for its adherence to strong values and business ethics. Every Tata company or enterprise operates independently. Each of these companies has its own board of directors and shareholders, to whom it is answerable. There are 32 publicly listed Tata enterprises and they have a combined market capitalisation of about $85.42 billion (as on June 14, 2013), and a shareholder base of 3.8 million. The major Tata companies are Tata Steel, Tata Motors, Tata Consultancy Services (TCS), Tata Power, Tata Chemicals, Tata Global Beverages, Tata Teleservices, Titan, Tata Communications and Indian Hotels. Tata Steel is among the top ten steelmakers, and Tata Motors is among the top five commercial vehicle manufacturers, in the world. TCS is a leading global software company, with delivery centres in the US, UK, Hungary, Brazil, Uruguay and China, besides India. Tata Global Beverages is the second-largest player in tea in the world. Tata Chemicals is the world’s second-largest manufacturer of sodaash and Tata Communications is one of the world’s largest wholesale voice carriers. In tandem with the increasing international footprint of Tata companies, the Tata brand is also gaining international recognition. Brand Finance, a UK-based consultancy firm, valued the Tata brand at $18.16 billion and ranked it 39th among the top 500 most valuable global brands in their BrandFinance® Global 500 2013
  • 7.
    report. In 2010,BusinessWeek magazine ranked Tata 17th among the '50 Most Innovative Companies' list. Founded by Jamsetji Tata in 1868, Tata’s early years were inspired by the spirit of nationalism. It pioneered several industries of national importance in India: steel, power, hospitality and airlines. In more recent times, its pioneering spirit has been showcased by companies such as TCS, India’s first software company, and Tata Motors, which made India’s first indigenously developed car, the Indica, in 1998 and recently unveiled the world’s most affordable car, the Tata Nano. 1.2 COMPANY PROFILE Tata Motors Limited is India's largest automobile company, with consolidated revenues of INR 1,88,818 crores (USD 34.7 billion) in 2012-13. It is the leader in commercial vehicles in each segment, and among the top in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. It is also the world's fourth largest truck and bus manufacturer. The Tata Motors Group's over 55,000 employees are guided by the mission "to be passionate in anticipating and providing the best vehicles and experiences that excite our customers globally." Established in 1945, Tata Motors' presence cuts across the length and breadth of India. Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company's manufacturing base in India is spread across Jamshedpur
  • 8.
    (Jharkhand), Pune (Maharashtra),Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains. The company's dealership, sales, services and spare parts network comprises over 3,500 touch points. 1.3 MILESTONES • 1945 • Tata Engineering and Locomotive Co. Ltd. (TELCO) was established to manufacture locomotives and other engineering products • 1948 • Introduction of the Steam road roller, in collaboration with Marshall Sons (UK) • 1954 • Collaboration with Daimler Benz AG, West Germany, for manufacture of medium commercial vehicles. The first vehicle rolled out within 6 months of the contract • 1966 • Engineering Research Centre (ERC) set up at Pune, to provide impetus to automobile R&D • 1971 • Introduction of DI engines • 1977
  • 9.
    • First commercialvehicle manufactured in Pune • 1983 • Manufacture of Heavy Commercial Vehicle commences • 1985 • First hydraulic excavator produced in collaboration with Hitachi • 1986 • Production of first, indigenously designed, light commercial vehicle (LCV) - Tata 407, followed by Tata 608 • 1989 • Introduction of the Tatamobile 206 - 3rd LCV model • 1991 • Launch of the first indigenous passenger vehicle - Tata Sierra • 1 millionth commercial vehicle sold • TAC 20 crane produced • Roll out of the 1 millionth vehicle • 1992 • Launch of the Tata Estate • 1993 • Joint venture agreement signed with Cummins Engine Co. Inc. for the manufacture of high horsepower and emission friendly diesel engines
  • 10.
    • 1994 • Launchof Tata Sumo MUV • Launch of LPT 709 - a full forward control, LCV • Joint venture agreement signed with M/s Daimler - Benz / Mercedes - Benz for manufacture of Mercedes Benz Passenger cars in India • Joint venture agreement signed with Tata Holset Ltd. (UK) for manufacturing turbochargers to be used on Cummins engines • 1995 • Launch of Mercedes Benz car E220 • 1996 • Launch of Tata Sumo deluxe • 1997 • Launch of the Tata Sierra Turbo • 100,000th Tata Sumo rolled out • 1998 • Tata Safari - India's first sports utility vehicle launched • Roll out of the 2 millionth vehicle • Launch of India's first fully indigenous Passenger car - Tata Indica • 1999 • 115,000 bookings for Indica registered against full payment within a week • Commercial production of Indica commences in full swing • 2000 • First consignment of 160 Indicas shipped to Malta
  • 11.
    • Indica withBharat Stage 2 (Euro II) compliant diesel engine launched • Utility vehicles with Bharat 2 (Euro II) compliant engine launched • Indica 2000 (Euro II) with multi-point fuel injection petrol engine launched • Launch of CNG buses • Launch of the intermediate commercial vehicle – Tata 1109 • 2001 • Launch of 2nd generation Indica - Indica V2 • 2 millionth commercial vehicle sold • 100,000th Indica wheeled out • Launch of Tata Indica CNG • Launch of the Tata Safari EX • Indica V2 becomes India's number one car in its segment • Exits joint venture with Daimler Chrysler • 2002 • Unveiling of the Tata Sedan at Auto Expo 2002 • Petrol version of Indica V2 launched • Launch of the EX series in commercial vehicles • Launch of the Tata 207 DI • 200,000th Indica rolled out • 500,000th passenger car rolled out • Launch of the Tata Sumo+ series • The all-new Safari EX, with extra luxury features launched • Launch of the India’s first fully indigenous sedan - Tata Indigo • Productagreement with MG Rover (UK) for the Tata Indica in Europe • 2003 • Tata Indigo captures 27% markets share in its segment in the first month of its debut on Indian roads, in January 2003 • Limited edition of the Tata Safari launched • Unveiling of the Tata Indigo Station Wagon at the Geneva Motor Show
  • 12.
    • Distribution agreementwith Phoenix Venture Holdings for Safari & Loadbeta in UK and Ireland • Tata Spacio A1 with enhanced fuel economy and greater torque launched • On 29th July, J. R. D. Tata's birth anniversary, Tata Engineering becomes Tata Motors Limited • 3 millionth vehicle produced • Indigo clocks its highest ever sale in a month at 2,664 nos. and the highest ever in a month by any brand in the entry mid-size segment post1996 • First City Rover rolled out • 135 PS Tata Safari EXi Petrol launched • Tata Motors signs MOU for the acquisition of Daewoo Commercial Vehicle Co., Korea • Tata SFC 407 EX Turbo launched • 2004 • Tata Motors unveils new productrange at Auto Expo 2004 • New Tata Indica V2 launched • Unveiling of the Indigo Advent at the Geneva Motor Show • Acquired Daewoo Commercial Vehicle Company • Tata LPT 909 EX launched • Tata Daewoo Commercial Vehicle Co. Ltd. (TDCV) launches the heavy duty truck Novus in Korea • Sumo Victa launched • Launch of Indigo Marina • Listing on the NYSE • 50 years of automotive excellence • 2004 - Indica wins the CSIR (Council of Scientific and Industrial Research) Diamond Jubilee Technology award • 2005 • 500,000th Passenger car rolled out • Launch of the premium version of the Tata Spacio Gold - Tata Spacio A1 • Supply of the first batch of CNG buses to the Gujarat State Road Transport Corporation
  • 13.
    • Unveiling ofthe Tata Xover at the Geneva Motor Show • Tata Indica launched in Turkey • Launch of branded buses and coaches - Starbus and Globus • Acquisition of 21% stake in Spanish bus manufacturing company - Hispano Carrocera SA, • Launch of the Tata Safari Dicor • Introduction of the luxury variant of Tata Indigo - Indigo SX series • Indica V2 Turbo diesel launched • Launch of India’s first mini-truck - Tata Ace • 1 millionth passenger car sold • Launch of Tata TL 4X4, India's first Sports Utility Truck (SUT) • Tata Daewoo Commercial Vehicle Company (TDCV) launches Novus range of medium trucks in Korea • 2006 • Unveiling of the new long wheel base premium Indigo & X-over conceptat the Auto Expo 2006 • Indica V2 Xeta launched • 3 millionth commercial vehicle sold • Passenger car sales in India crosses 1 million mark • Tata Motors and Marcopolo (Brazil) announce joint venture to manufacture fully built buses & coaches for India & markets abroad • Tata Motors first plant for small car to come up in West Bengal • CNG options extended to hatchback and Estate range • Tata Daewoo Commercial Vehicle Company develops South Korea's first LNG-powered tractor- Trailer • Three additional cooperationagreements with Fiat Group • Industrial joint venture with Fiat to producecars, engines, transmissions in India • Introduction of a new Indigo range • 4 million mark Tata vehicles sold • Half million vehicles sold in a year • 2007
  • 14.
    • Construction ofSmall Car plant at Singur (West Bengal) begins on January 21 • Launch of the 2007 Tata Indica V2 range • Launch of the longwheel base Tata Indigo XL, India's first stretch limousine • Common rail diesel (DICOR) engine extended to the Indigo sedan and estate range • Joint venture with Thonburi Automotive Assembly Plant Co. (Thonburi) in Thailand to manufacture, assemble and market pickup trucks • Agreement with Fiat for pick-up production in Argentina • Signed MoU with Iveco to explore strategic alliance opportunities • Roll out of 100,000th Tata Ace • Inauguration of the Tata-Fiat plant at Ranjangaon • Launch of the upgraded Tata Spacio range • CRM-DMS initiative crosses the 1000th location milestone • Launch of Tata Magic • Launch of Tata Winger • Fiat Group and Tata Motors establish a Joint Venture in India • Launch of the Tata Sumo Victa Turbo DI and the upgraded range of the Tata Sumo Spacio • Tata Indica V2 Turbo with dual airbags and ABS launched • Launch of the Tata Safari DICOR 2.2 VTT range, powered by a new 2.2 L Direct Injection Common Rail (DICOR) engine • Roll-out of the 1 millionth passenger car of the Tata Indica platform • 2008 • The Tata Indica V2 DICOR launched • Launch of Tata Indigo CS (CompactSedan), world's first sub 4-metre sedan • Launch of the Tata Sumo Grande • Tata Motors unveils its People's Car, Tata Nano, at the 9th Auto Expo • Tata Xenon, 1-tonne pick-up truck, launched in Thailand • Tata Motors acquires Jaguar Land Rover from Ford Motor Company • Tata Motors introduces the Super Milo range of buses • Tata Ace plant at Pantnagar (Uttarakhand) commences production • Launch of the new generation Indica - Tata Indica Vista
  • 15.
    • 2009 • TataMarcopolo Motors’ Dharwad plant begins production • Launch of the Tata Xenon XT (Cross Terrain) • Launch of the Tata Nano • Jaguar Land Rover's first flagship showroom facility opened at Ceejay House in Mumbai • Introduction of new world standard truck range – Tata Prima • Launch of the Jaguar Land Rover range of premium luxury vehicles -- Jaguar XF, XFR & XKR and Land Rover Discovery 3, Range Rover Sport and Range Rover in India • Launch of the Tata 407 Pickup, Tata Super Ace and Tata Ace EX • Launch of Tata SK 407 Tipper • Launch of Tata Prima in South Korea • Launch of Freelander 2 in India • Launch of the next generation Tata Indigo Manza • Tata Motors acquired the remaining 79% shares in Hispano Carrocera S. A., Spain. • Launch of the Tata Sumo Grande MK II 2010 • Tata Motors Group unveils the Jaguar XJ; 4x4, 7-seater CrossoverTata Aria, Tata Venture and the Tata Magic Iris at the Auto Expo 2011 • Roll out of the 100,000th Tata Safari from the Pune Plant • Tata Motors sells its 4 millionth commercial vehicle • Inauguration of the Tata Nano plant in Sanand • Launch of the first Indian 4-wheel drive, Crossover, Tata Aria • Tata Nano receives the world's oldest and most coveted GOODDESIGN™ Award for 2010 • Tata Motors ranks as India's Most Valuable CorporateBrand in The Economic Times' 'India's Most Valuable Brands 2010' Study • 2011 • Tata Venture launched • Launch of Tata Divo Luxury Coach and Tata Starbus Ultra
  • 16.
    • Launch ofTata Nano 2012 • Tata Sumo Gold introduced • Range Rover Evoque launched in India • New Tata Indica Vista launched • Tata Magic IRIS and Tata Ace Zip launched • Tata Indica eV2 introduced with 25 kmpl mileage • Tata Pixel, a city car conceptfor Europe, displayed at the Geneva Motor Show • Refreshed Tata Indigo Manza introduced • Tata Prima ConsTruckrange launched • Tata Motors unveiled assembly plant in South Africa • Tata Nano began international journey with Sri Lanka • Tata Motors completes 50 years of its International Business • Jaguar Land Rover inaugurated its vehicle assembly plant in Pune • Tata Nano launched in Nepal • HVTL amalgamates into HVAL renamed as TML Drivelines Ltd. • Tata Motors (Lucknow) produced & dispatched the first Hybrid Chassis to Spain • Tata Motors (Dharwad) rolled out the first Tata Ace Zip • Tata 407 celebrated its silver jubilee year • Jaguar celebrates 50 years of iconic E-Type • 2012 • Tata Motors enters Bangladesh’s new car market • Tata Ace races through the one-million mark in just 2,680 days • Tata Safari Storme, the Real SUV, hits the road • Launch of PT Tata Motors Indonesia • Tata Motors plant at Dharwad comes on stream • Tata Motors enters into distribution agreement in Myanmar • Launch of Tata Ace in South Africa • 2013
  • 17.
    • Tata Nanobecomes the first Auto Brand in India to cross 3 million fans on Facebook • The Tata Indigo ECS enters Limca Book of Records • Tata Motors' Jamshedpur plant rolls out its two millionth truck • Tata Nano offered industry first phenomenon - Swipe your credit card and drive home a Nano Tata Motors launches the world-class range of Tata PRIMA trucks in Sri Lanka PROFILE OF THE ORGANIZATION 2.1 PANTNAGAR PLANT The Company has set up a plant for its mini-truck Ace and the passenger carrier Magic (based on the Ace platform) at Pantnagar in Uttarakhand. The plant began commercial production in August 2007. This is the company's fourth plant, after Jamshedpur (commercial vehicles), Pune (commercial vehicles and passenger vehicles) and Lucknow (commercial vehicles). The plant is spread over 953 acres, of which 337 acres is occupied by the vendor park.
  • 18.
    State-of-the-art facilities includeweld shops, paint shops, engine and gear box shops and assembly lines. The Company has invested over Rs.1000 crores in the plant. Vendors for the vehicle have made additional investments to set up their plants in the vendor park adjoining the plant. The operation has generated about 7500 direct and indirect jobs in the plant, among vendors and service providers in the area. 2.2 Functional Departments Tata Motors, Pantnagar Plant consists of mainly four shops namely- Assembly shop, Welding shop, Engine shop and Paint Shop. 2.2.1 Assembly Shop The Assembly Shop is where it all starts to come together. The frame truly becomes a chassis here, as the suspensionis built and added. In the Assembly Shop the bodies are fitted to the chassis, doors, hoods and trunk lids are hinged and fitted. Most of the accessories are also installed by craftsmen with many years of experience. 2.2.2 Welding Shop BIW Welding PE has a highly skilled team that can meet the expectations with innovative but simple solutions in BIW welding. The team has at its credit the experience of handling almost all vehicle projects in Tata
  • 19.
    Motors Limited atturnkey level across all its plants through its in-house and supplier-based resources. PE takes utmost care during design and manufacturing of welding fixtures for safety aspects during BIW production. With use of modular bases and units and high quality standard items the fixtures are most reliable and consistent in performance. Main Line BIW Welding Fixture for a Tata Small Truck BIW Weld Line for a Tata Pick up Frames / Chassis Welding PE has a highly experienced team to design and manufacture welding fixtures for various types of chassis / frames. Frames of many Tata vehicles known for their reliable performance on rugged Indian road conditions have been tooled in PE.
  • 20.
    Frame Welding Fixturemeant for a Japanese OEM's MUV for India before dispatch Trunion Fixture Having Balanced Rotation for a Tata SUV Frame 2.2.3 Engine shop There are three broad operational areas here: • Engine machine shop — This is where the five most critical parts of the engine are made: cylinder block, cylinder head, crankshaft, camshaft and connecting rod. • Engine assembly— The five critical parts and outsourced components are brought together here. The place where this is done is among the cleanest in the plant, with the temperature maintained at 23oC to guard against any expansion of the engine-part metals. The cylinder-block and cylinder-head assemblies move in near parallel conveyor lines before being joined in a confluence zone. • Engine testing —Engines are checked separately in ‘testing cubicles’ and ‘test beds’ forpower, fuel efficiency, smoke, torque and leaks. After the
  • 21.
    testing operations, theengines are moved to where they will be integrated with the gearbox. • Engine assembly shop, capable of supplying upto 1200 engines per day. 2.2.4 Paint shop Spread over 44,400 square meters, it’s the biggest block in the plant. But magnitude alone does not make the paint shop stand apart; it is the quality of its work that makes it special. The paint shop is a cut above the rest of the plant in the spic-and-spandepartment. This is a necessity in this facility because even the slightest bit of grime — in some areas of operations — can have telltale effects. The cleanliness in this block extends to unexpected areas. The paint shop operates at four levels to cater to the requirements of its processes. At 10 metres below ground level, everything, specially the paint that spills, is exhausted out. At five metres above ground level are the ovens that bake and dry the coating on the car. At 10 meters above ground level is an air supply plant that helps keep dust out of the shop’s environs. The atmosphere in parts of the paint shop is strictly controlled. Temperatures here are kept at 26oC and clean air is continuously filtered. The car itself, the end object of all this care, goes through a five-stage painting process beforeit can be sent to the final assembly block. The procedurebegins with a ‘dip treatment’ wherein the car body(the bodyin white from the weld shop)is dipped in14 tanks and gets a phosphatecoat. After this the bodyis baked. Then comes the ‘cathodic electrolytic deposits’ coat, following which the bodyis baked again.
  • 22.
    The bodyis sealedbefore it gets a primer surface coat and is brushed clean with dusters made of ostrich feathers. The basecoat and a clear coatof lacquer follow the primer surface coat. The primer is a water-based coat, whereas the base coatis of the same color as that the car will sportwhen the painting operation is completed. The lacquer coat is the final flourish in the process. Quality audits follow before the car is transported, via an elevated and covered conveyor bridge, to the final assembly block. 2.3 CMS Central Maintenance Services provide central facilities and shop maintenance. Under central facilities activities such as purchasing, storing and maintaining of equipment’s under proper hygienic and temperature conditions. Each shops consists of its own maintenance department and their job is to immediately replace the parts that cause machine break-down and other concerned defects and thus helping in optimum output of the shop. In case, they fail then the CMS provide the requisite help and most importantly repair the parts causing the defects thus resulting in high optimum use of resources. Further, they undergo projects for upliftment of the shop and also improvement works to maximize the output of the shop. 2.4 Trim Chassis Fitment-1D Lay Out
  • 23.
    2.4.1 Trim line-I Thereare four conveyor lines in the final assembly block. The trim line is the first of these and the action here begins with each car bodybeing allocated a chassis number. The Tata tags come on before the cabling and wiring of the car gets done. The doors ofthe car are detached at this point. This is to enable workers easy maneuverability as they swarm over and inside the vehicle fitting and fixing parts. Noise, vibration and harshness is minimized by a procedurecalled foaming (adding rubber fittings). The first wave of work happens here: the brake pipe and hand brake come on, the cabin and the floor are insulated, the floor is carpeted and the accelerator is fitted. Next come the air conditioner, dashboard, steering mechanism, steering pipeline, rooflining and the instrument cluster (indicators).
  • 24.
    2.4.2 Trim line-II Roboticsis a dominant feature on this conveyor line. A robotapplies a sealant on the front glass before it is manually fixed to the car. Then comes the air- conditioning controls, combination switches and seat belts. The rear lights are put on panels in the bullhorn design typical of the vehicle. The fuel neck, rear bumper, seats and steering wheel are fixed before the vehicle is taken to the next line. 2.4.3 Underbody line On this stretch the vehicle is lifted up to line which is around five feet high. Work is done on the vehicle from below. Given the critical nature of the components added here, the best operators in the block are deployed here. This is where the engine, exhaust and wheels are fitted, as also the radiator, the fuel tank, the condenser, the mudguard. 2.4.4 Mechanical line The mechanical line is the last stop before the vehicle comes into existence. Fuel, oil and gas (for the air conditioning) are filled before the vehicle gets a battery. The doors are fitted back, the wheels aligned and the headlights are adjusted. This is followed by a brake test and some serious roughing up over a jagged surface.
  • 25.
    shower test todetect leaks is the final round Switched Mode Power Supply (SMPS) like a linear power supply, the switched mode power supply too converts the available unregulated ac or dc input voltage to a regulated dc output voltage. However in case of SMPS with input supply drawn from the ac mains, the input voltage is first rectified and filtered using a capacitor at the rectifier output. The unregulated dc voltage across the capacitor is then fed to a high frequency dc-to-dc converter. Most of the dc-to-dc converters used in SMPS circuits have an intermediate high frequency ac conversion stage to facilitate the use of a high frequency transformer for voltage scaling and isolation. In contrast, in linear power supplies with input voltage drawn from ac mains, the mains voltage is first stepped down (and isolated) to the desired magnitude using a mains frequency transformer, followed by rectification and filtering. The high frequency transformer used in a SMPS circuit is much smaller in size and weight compared to the low frequency transformer of the linear power supply circuit. The ‘Switched Mode Power Supply’ owes its name to the dc-to-dc switching converter for conversion from unregulated dc input voltage to regulated dc output voltage. The switch employed is turned ‘ON’ and ‘OFF’ (referred as switching) at a high frequency. During ‘ON’ mode the switch is in saturation mode with negligible voltage drop across the collector and emitter terminals of the switch where as in ‘OFF’ modethe switch is in cut- off mode with negligible current through the collector and emitter terminals. On the
  • 26.
    contrary the voltageregulating switch, in a linear regulator circuit, always remains in the active region. Details of some popular SMPS circuits, with provisions for incorporating high frequency transformer for voltage scaling and isolation, have been discussed in next few lessons. In this lesson a simplified schematic switching arrangement is described that omits the transformer action. In fact there are several other switched mode dc-to-dc converter circuits that do not use a high frequency transformer. In such SMPS circuits the unregulated input dc voltage is fed to a high frequency voltage chopping circuit such that when the chopping circuit (often called dc to dc chopper)is in ON state, the unregulated voltage is applied to the output circuit that includes the load and some filtering circuit.
  • 40.
    INTRODUCTIONOF PROJECT Tyre infliatoris based upon solenoid valve’s principle and PLC programming. A solenoid valve is an electromechanically operated valve. The valve is controlled by an electric current through a solenoid : in case of a 2 port valve the flow is switched on or off ; in case of a 3 port valve the outflow is switched b/w the two outlet ports. Here we have 2 solenoidal valves of 3/2
  • 41.
    means 3 portsand 2 positions. Valve 1 for filling the air in tyre and valve 2 for exhausting the air from tyre. • COMPONENTUSED • 2 LAMP • 2 PUSH BUTTON: For Start and Stop • 3 SELECTOR SWITCHES: Respectively for 30 PSI, 35 PSI and 40 PSI • 2 SOLENOIDAL VALVE: Valve 1 for filling Valve 2 for exhausting HARD WIRING OF TYRE INFLATOR
  • 43.
    WORKING OF TYREINFLATOR The 30 PSI push button helps to maintain the appropriate pressure in the following manner: • When we press the control switch and connect the air pipe to the tyre, now the pressure switch measures the pressure of the tyre. • Let the pressure of the tyre be X . • Now PLC checks the conditions i.e. Is X<30? Is X>30? or Is X=30? • Now PLC on a suitable output i.e. solenoidal valve, valve 1 for filling and valve 2 for exhausting. • If X<30, then PLC switches on valve 1.
  • 44.
    • If valve1 is on then the air flows in the tyre for 5 sec • After 5 sec PLC checks the condition if X<30 then again valve 1 is on for 5 sec. • This process will be continued until the pressure of the tyre is near about 30. • When the pressure of the tyre is near about 30 this process will be stopped. • If X>30 , then PLC switches on valve 2. • If valve 2 is on then the air exhausts from the tyre for 3 sec. • After 3 sec PLC checks the condition if X >30 then again valve 2 is on for 3 sec . • This process will be continued for 3 sec until the pressure of the tyre is near about 30. • When the pressure of the tyre is near about 30 this process will be stopped.
  • 45.
    For 35 PSIand 40 PSI the working process is similar.
  • 47.
  • 63.