1. TURBO CHARGER:-
A turbocharger is an air compressor bused for forced induction on an ICE. Like a SUPER
CHARGER its purpose is to increase the mass of an air entering the engine to create power.
How ever it differs in that the compressor is powered by turbine driven by engine own exhaust
gases.
NOMENCLATURE:-
Early manufacture of turbo charger referred to them as turbo supercharger. It is an air
compressor used for forced induction of an engine. Logically then adding a turbine to turbo
charger. This is now the source of confusion as the term turbo super charged. It is some time
used to refer to an engine that used both a crank shaft driven super charger and an exhaust
driven turbo charger.
LUBRICATION OF TURBOCHARGER:
Its rotor assembly is supported by 2 fully floating bearing bushes in the bearing housing. These
bearing bushes are lubricated with finally filtered engine oil from lubricating system of the
engine
VARIABLE GEOMETRY TURBOCHARGER (DICOR)
Your TATA indigo XL DICOR version is fitted with reliable geometry turbocharger which is
controlled by ECU. It is an efficient supercharging device used in our engine. The geometry of
turbocharger is controlled by ECU for optimum performance from engine at all speeds
B.TECH MECH. ENGG
2. LAYOUT DETAILS
1) M.E. - MAIN ENTERENCE GATE
2) S.C. - SECURITY OFFICE
3) S.R. - SHOW ROOM
4) G. - WOREKSHOP GATE
5) R. - RECEPTION
6) ST. - STORE ROOM
7) O1. -OFFICE (G.M.SERVICE)
8) O2. - OFFICE (W.M.SERVICE)
9) W/S. -WORK SHOP
10) DR. -DRESSING ROOM
11) O3. -OFICE (GUARANTEE)
12) TC. - TRAINING CELL
13) WS. - WELLDING SHOP
14) DS. - DENTING SHOP
15) WR - WASHING ROOM
16) PB. - PAINT BOOTH
B.TECH MECH. ENGG
3. FUEL INJECTION PUMP.
The function of this is to deliver accurately metered quantity of fuel under high pressure at the
correct time &in correct sequence to injector fitted on each engine cylinder. The injection
pressure is employed in case of automotive fuel injection range from7-30 mpa. As the volume
of fuel to metered for each injection is very small & freq. of injection is quite high the pump
has to determine to very precession. The fuel pumps are of jerk pump type. How ever in many
cases distributed type pump is used.
JERK TYPE
The constt. Of this type is very simple & consists if delivery valves the plunger the control
sleeve& the control rack. The plunger contains a helix at upper end which serve to control the
quantity of fuel to be injected. The plunger is operated by means of cam & tapped.
DISTRIBUTER TYPE.
The constt. Of this is very simple. The fuel comes from suction port in a metered quantity
through metering port is delivered to distributor port. The pressure of fuel is increased in this
time. There is a central passage to which distribution is connected to rotor.
B.TECH MECH. ENGG
4. CLUTCH
It is a mechanism which enables the rotary motion of one shaft to another of which is
coincident with that of first.
REQUIREMENT
1 TORQUE TRANSMITTED: the clutch should be able to transmit torque of engine under all
condition. It is designed to transmit 125 to 150% of max. engine torque.
2 GRADUAL ENGAGEMENT: the clutch positively takes drive without occurrence of
sudden jerks.
3 VIBRATION DAMPING: suitable mechanism should be in cooperated with in clutch to
eliminate noise produced in transmission.
4 DYNAMIC BALANCING: this is necessary in high speed clutches.
5 SIZE: its size must be smaller possible so that it should occupy min. amount of space.
6 INERTIA: the clutch rotating part should have minimum inertia.
7 EASE OF OPERATION: for high torque transmission the operation if disengaging the
clutch not be tire some to drive.
B.TECH MECH. ENGG
6. MASTER CYLINDER
This can be named as heart of hydraulic breaking system.there is 2 main types i.e. fluid
reservoir &compression chamber in which piston operates. The fluid in reservoir components
for any leakage in pipe line due to temp. Variations & to some extent due to leakage. To reduce
dia. Region of piston is always surrounded by fluid. Towards brake lines side of compression
chamber there is fluid check valve with rubber cup inside.
More over drum brake disk brake should not have any residual pressure in pipe lines. In a
vehicle having either disk brake or both disk as well as drum brake a special fuel check valve is
used in master cylinder.
B.TECH MECH. ENGG
7. INTER COOLER
Hot air coming out of turbo charger flows through the inter cooler &gets cooled before end in
the intake manifold. The inter cooler is mounted on top of cylinder head.
MAINTENANCE RECOMMENDATION:-
1) Check the boast pressure pipe for its proper fitment.
2) Check oil feed pipe, return pipe air intake and exhaust piping for leakage.
3) Check the engine breathing system and oil separator.
4) Fill the oil inlet hole of turbo charger with clean engine oil when engine is stored after long
storage.
B.TECH MECH. ENGG
8. CONNECTING ROD
Its function is to convert the reciprocating motion of piston to rotary motion of crank shaft.
To reduce the obliquity of rod with the cylinder axis, its length should be kept as possible.
Reduced obliquity decreases oscillating angular motion of rod, about the end, there by
decreases piston side-thrust&improving reciprocating balance of engine.
The connecting rod is made by drop forging of steel. The connecting rods these days are cast
from malleable spheroid graphite cast iron.
B.TECH MECH. ENGG
9. RADIATOR
The function of radiator is to ensure close contact of hot coolant out of with outside air, so as to
ensure high rates of heat transfer from coolant to air. Beside, an overflow pipe in header tank&
drop in lower tank are provided. The coolant collets in collector tank from where it is pimped
to engine for cooling.
There are 2 types of radiator cores of i.e. tubular& cellular type. It is the coolant that flows
through tubes &air passed around them, while in cellular air passes through tubes &coolant
flows in spaces in b/w them.
Out of these, tubular core are most commonly used where further classified depend upon shape
of the fins around the tubes.
Both core tubes as well as fins are made from thinnest material. Tubes are made from 0.1 to 0.3
mm sheets, where as fins are made about 0.1 thick material.
B.TECH MECH. ENGG
10. CAM SHAFT
Cam shaft is a shaft with a cam for each intake& exhaust valve. Each cam has a high spot
called cam bobe which controls valve opening. The cam shaft provides a means of actuating
the opening & controlling the opening & closing intervals of inlet & exhaust valve relative to
each position along its stroke. It provide a drive for ignition distributor &mech. fuel pump
A cam is rotating member which imparts reciprocating motion to another member,
called follower in a rt. angle to cam axis. It is approx. shaped to provide a smooth rise & fall
for predicted motion of follower, which is then transmit to individual valves.
B.TECH MECH. ENGG
11. CRANK SHAFT
It is the engine component from which power is taken. It receives the power from the
connecting rod in designated sequence for onward transmission to clutch & to the wheels.
The crank shaft assembly includes crank shaft& bearings, the fly wheel sprocket or
gear to drive cam shaft & oil seal at the front & rear.
It consists of major parts;
1) main journals
2) crank fins
3) crank webs counter weights
4) oil holes
5) crank webs
B.TECH MECH. ENGG
12. OIL COOLERS
In all heavy duty engines the engine temp. & hence the temp. Of oil become quite high. As the
viscosity of lubricating oil decreases with temp. Rise, at high temp. The oil film in bearing
might break& conditions of boundary lubrication may create instead of fluid lubrication which
is desired.
Oil coolers are nothing but simple heat exchanger. Either the cold water from
radiator or the air steam is used to cool the oil.
B.TECH MECH. ENGG
13. BELT TENSION (DICOR)
Check the conditions of belt on engine. Examine the edge of the belt for cracks
Check the tension of following belts by pushing it with your thumb midway b/w pulley.
1) The alternate belt.
2) Power steering pump &A.C. compressor belt.
BELT TENSION ADJUSTMENT
A. Alternator belt adjustment.
1) Adjust the belt tension by turning tensional bolt.
2) Alternator belt tension is correct, if it can be depressed by X=5-6MM with thumb
pressure applied in middle of its length
B. Compressor belt adjustment
1) Adjust the belt tension by turning tensional screw.
2) Alternator belt tension is correct, if it can be depressed by Y = 5 - 6MM with thumb
pressure applied in middle of its length.
B.TECH MECH. ENGG
14. SPARK PLUG
Spark plug - MICRO
Spark plug no. - FR6 DC4
Spark plug gap - 0.7 to 0.8 mm
Spark plug replacement
1) Clean up any dirt or oil that we collected around the spark plug caps.
2) Pull out the spark plug cables by gripping at connector.
3) Remove the spark plug with the help of a special socket.
4) Check & adjust the gap, it should be 0.7 to 0.9 mm.
5) Replace spark plug if gap is more than 1.2 mm
B.TECH MECH. ENGG
15. EGR VALVE:
The exhaust gas re circulation valve is used to send some of exhaust gas in cylinder to reduce
combustion temperature
Nitrous oxides from when the combustion temperature gets above 2500 degree F. This
happens, because at such temperature, the N2 in air mixes with oxygen to create nitrous
oxide.Thats when EGR valve comes in handy by recirculation some of exhaust gases back
through the intake manifold to the cylinder. Lowering the combustion temperature lowers the
amount of N2 oxide produced.
There are 2 types of EGR valve. One operates through the use of vacuum, & other operates
through the use of pressure.
B.TECH MECH. ENGG
16. CATALYTIC CONVERTER
To reduce exhaust pollution the vehicle is fitted with diesel oxidation catalytic converter. The 2
way catalytic converter has coating if precious metal which enables conversion of pollutants.
OXIDATION CATALYTIC CONVERTER (DIESEL) DICOR:
2 numbers of oxidation catalytic converter are fitted on your vehicle to reduce exhaust
pollution. The 2 way catalytic converter is having coating of precious metals which enables
conversion of pollution.
CARE OF CATALYTIC CONVERTER:
It does not require any special maintenance however; following precaution should be taken for
effective functioning of converter &to avoid damage to the converter.
It is mandatory to use diesel fuel with sulphur content less than 0.035% use any other diesel
fuel can increase the pollutants.
B.TECH MECH. ENGG
17. TIE INSPECTION & ADJUSTMENT-
1) Vehicle should be in unloaded condition while checking & adjustment.
2) Steering wheel should be straight ahead condition.
3) Check that no suspension part has undergone any from damage.
4) Measure tie should be with in specifications.
5) Loosen both the lock on left & rt. Rear transverse links.
6) Tightening torque=5 kg m
B.TECH MECH. ENGG
18. HOW DOES DICOR TECHNOLOGY WORK?
1) The dicor engine uses a high pressure pump & common rail for supplying all cylinders with
high pressure diesel through the electronically controlled fuel injector. The high pressure
results in better atomization which had to complete combustion.
2) common rails is a key to better diesel engine performance, since more accurate high
pressure injection result in more efficient fuel combustion. It also injects fuel only when it is
required there by increase fuel efficiency.
3) The brain of dicor engine is the ECU which keeps dicor engine functioning at optional
capacity. It continuously receive signals from sensors.
4) In addition tie the other sensors ECU also receive continuous inputs from the rail
5) The ECU determines the load required by engine to meet the driven demand.
6) The fuel is injected in the combustion chamber at the specified time& pressure. As a result it
increases the power output & enhanced fuel efficiency.
7) In addition the ECU commands the injectors to inject a small amount of fuel in the cylinder
before the main injection happens. as a consequence there is far less noise , vibration &
harshness i.e. associated with diesel engine.
B.TECH MECH. ENGG
19. DRUM BRAKES
So if disk brakes are so great, how come we still have cars with drum brakes? The reason is
while all vehicles produced for many years have disk brake on the front, drum brakes are
cheaper to produce for rare wheel. In some cases a complete mechanical drum brake assembly
inside the brake rotor. It must be totally mechanical, but more on parking brake.
It consists of a backing plate, brake shoes, brake drum, and wheel cylinder return spring. When
you apply brakes, it is forced under pressure into wheel cylinder which inturn pushes the brake
shoes in contact with mechanical surfaces on the inside of the drum. As the brake linings wear,
the shoes must travel a greater distance to reach the drum.
Return spring pull the brake shoe back to their rest position after the pressure released from
wheel cylinder. If spring are weak & do not return the shoe the way. Good techian will
examine the springs during a brake job recommend their replacement if they show signs of
fatigue. On some vehicles techian may recommend replacing them even if they look good as
inexperience insurance
B.TECH MECH. ENGG
20. SIX WEEKS INDUSTRIAL TRANING
HELD AT
TATA MOTORS
FROM 15 /06/2009 TO 25/07/2009
TRANING REPORT IS SUBIMITTED IN PARTIAL FULLFILLMENT THE REQUIREMENT
FOR THE
AWARD OF DEGREE IN
BECHLOR OF TECHNOLOGY
UNDER THE SUPERVISION OF
SUBMITTED BY SUBMITTED TO
ISHAN KUDYAR DINESH KUMAR
7291114677 HOD
MECH.ENGG. DEPTT.
DEPARTMENT OF
MECHANICAL ENGINEERING
S.S.C.E.T (BADHANI / PUNJAB)
H.O.D
MECH. ENGG. DEPTT.
B.TECH MECH. ENGG
21. POWER STEERING
Larger amount of torque is reqd. to be applied by the driver fear steering of medium & heavy
vehicles .The power steering system provides automatic hydraulic assistance to the turning
effort applied to the manual steering system. The power system is always so designed that in
the event of failure of the power system, the driver is able to steer the vehicle manually at
through with increasing effort.
It has distinct advantages over manual steering
1) The steering effort is considerably reduced. Due to this the driver remains alert at
the end of the day
2) The vehicle can be steered lock to lock with one & half steering wheel turn on
either side compared to more than 3 turns on either side in case of manual gears with this high
degree of steering response, the driver gets excellent man even in high congested traffic.
3) The hydraulics of power steering system absorbs the road shocks where as in case
of manual steering, the shock due to pot hobs& humps are transmitted to the steering wheel.
Thus in power steering, there is less driver fatigue.
B.TECH MECH. ENGG
22. CONCLUSION
An industrial training /practice based project is a vital exp. For students of engg. .It add a lot
of knowledge to the vocabulary of student. In industry students learns a lot how to deal with
tech. as well as practical aspect , during industrial training student deal with both the aspect.
There are a lot of things which I come to know during this time.At last with a perennial
gratitude. I would like to thanks my parents, teacher & all the concerns who helped me with a
gracious & indulging effort
ISHAN KUDYAR
ROLL NO.7291114677
Mechanical Engineering
B.TECH MECH. ENGG
