BWI Automation and Technology Summer Training Report YOGESH MITTAL

Acknowledgements The summer training was a very good experience for me and it give me great confidence. And I would like to express my gratitude to Mr. Chand Miglani to give me brief knowledge about machine and its installation. He share his experience and provide me full support. I would also like to thank Mr. Anshu Mehra HR Manager who allow me to complete my training in his organisation.

INTRODUCTION BWI is stand for Beijing West Industries. It was established in 1920 as manufacturing of shock absorber but now it makes many auto products. It is the international manufacturer of suspension , braking system etc. Plants are in Beijing, México, UK, Poland, and many other countries. First time it is in India. In India the plant for suspension was established in 2009 at Dharuhera. It is a shocks and struts making company. It makes shocks and struts of various models. Delphi Automotive System Noida have sold all machines and other assets to BWI Automation and Technology.

Products Shocks and Struts of various models 1.M-800 2.M-ZEN 3.M-SWIFT DZIRE 4.M-ALTO 5.M-WAGNOR

PRODUCTS Shocks and Struts

DAMPERS

Introduction Vehicle body is suspended on springs to reduce the vertical displacements and accelerations that are transmitted from the road to the occupants Springs decrease the intensity of the road inputs (i.e. displ., accel.) by storing and releasing the energy over time Damper convert this kinetic energy of the vehicle and spring into thermal energy and dissipates it to the atmosphere

Nomenclature The device name in common parlance is shock absorber or shocks. Technical name includes dampers or daspot.

Description Pneumatic and hydraulic shock absorbers commonly take the form of a cylinder with a sliding piston inside. The cylinder is filled with a fluid (such as hydraulic fluid) or air. This fluid-filled piston/cylinder combination is a dashpot Shock absorbers include cushions and springs.

Description/Major Components Shock Absorber -A hydraulic device which controls the sprung and unsparing masses of a vehicle by converting kinetic energy to thermal energy which is dissipated to the environment

Mounting Ring Cover Plate Dust Tube Bushing Seal Assembly Rod Guide Assembly

Major Parts Upper Mount Dust Tube Cover Plate Reservoir Tube Cylinder Tube Piston Rod Piston Compression valve assembly Major Parts Lower Mount

Position of Shocks in Car

Description/Major Components Strut-A structural member of an automotive suspension capable of withstanding the forces and bending moments resulting from braking, accelerations etc. Also serves as a shock absorber

\\ Seal assembly Spring Seat Piston Rod Bump Cup Rebound Stop Rod Guide Assembly Reservoir Tube Formed Rebound Bumper Insert Stabilizer Bar Bracket \\ Piston Assembly Mounting Bracket Cylinder Tube Compression Valve Assembly

Function The shock absorber's function is to absorb or dissipate energy. One design consideration, when designing or choosing a shock absorber, is where that energy will go. In most dashpots, energy is converted to heat inside the viscous fluid. In hydraulic cylinders, the hydraulic fluid heats up, while in air cylinders, the hot air is usually exhausted to the atmosphere. In general terms, shock absorbers help cushion vehicles on uneven roads.

Shock absorbers and struts do more than just provide a comfortable ride. Their most important function is to influence the control and handling characteristics of your vehicle. Without them, vehicle would continually bounce and bound down the road, making driving extremely difficult. Shocks and struts are designed to help keep your tires on the road. They control the action of the spring to resist bottoming out like when you hit a pothole and keep the movement of the springs under control when they rebound

How Shocks Works Shocks provide resistance by forcing hydraulic fluid (oil) through valves in the piston as it moves up and down. Because the oil cannot be compressed, only a certain amount of fluid can be forced through these valves, which creates resistance to the vehicle movement. Premium shocks and struts are superior to regular hydraulic shocks because air in the shock is replaced by pressurized nitrogen gas. This advancement in technology prevents bubbles from forming in the hydraulic fluid. These bubbles, called foaming, reduces the ability of shocks to provide resistance and prevent bounce. Gas shocks also quicken the response of a shock's movement thereby increasing comfort and control under all conditions.

Theory of Operation D A C B The twin tube damper can be divided into four distinct chambers The chamber above the piston (A) The chamber below the piston (B) The reservoir chamber below the fluid level (C) The air volume in the reservoir above the fluid level (D) D A C B

Theory of Operation in Rebound Motion of the piston away from the base valve builds pressure in chamber A The fluid in chamber A is forced into chamber B through the piston rebound valve The base valve intake opens, letting fluid from chamber C to go back into chamber B to compensate for the rod volume Rebound control is generated entirely through the piston rebound valve Air A D C oil B

Theory of Operation in Compression Motion of the piston toward the base valve builds pressure in chamber B The pressure forces fluid through the piston intake valve into chamber A Chamber A can’t hold all of the fluid from chamber B due to the piston rod volume The rod volume is forced through the base valve into chamber C The air in chamber D is compressed to compensate for the change in volume Therefore, compression damping is obtained through the piston and base valves Air D A Oil B C

Factor of Damaged Shocks A badly leaking shock or strut. The unit is losing fluid and can't provide the resistance it was originally designed for. Shiny Spots at the contact point of the safety bumper, and marks between the coils of the spring called "coil clash". They are the result of topping and bottoming caused by excessive suspension travel. Tire cupping around the circumference of the tire can be caused by worn or ineffective shocks & struts. Broken or loose shock or strut mount. The product is not solidly connected at both ends and cannot function properly.

Broken or damaged piston rod Broken or damaged piston rod. The product cannot function properly and should be replaced. Noise- When the upper mount nut is either loose or free then there will be noise while tightening the nut. Torque-The value of torque for the nut should be in limits in between 40-50 N-m

Dampers Types Twin-tube shocks or struts have a cylinder tube and a reservoir tube Mono-tube shocks have one tube that does both jobs with a gas cup to separate the gas and oil Struts are mainly twin-tube dampers with bigger rod diameter and stronger reservoir tube to attach knuckle, spring seat, ...

Machine Installation Content 1.Introduction 2.Features 3.Procedure

Introduction During my summer training period I have face the machine installation and various problems related about it. The machine were installing at Dharuhera plant of BWI group for production of shocks and struts of various model. When the machine was installed they were in very bad condition. The machine installation is the process of improving the condition of machine by changing damaged parts or by introducing new concept. I have studied the installation process of hydraulic spot welding machine, seam welding machine, hydraulic punching press, hydraulic shooting and crimping machine.

Silent Features Improve job handling process. Improve quality of product. Reduce the lead time. Increase the rate of production. Increase the overall efficiency of plant.

Procedure After improving the condition of machine it was checked weather it is working properly or not. For hydraulic spot welding machine certain parameter are checked. Parameter are 1.Welding on the required spot. 2.Welding current. 3.Welding pressure. 4.Temperature of chiller. (25˚C) 5.Viscosity of hydraulic oil. 6.Cycle time.

Working Principle In hydraulic machine hydraulic energy is converted into mechanical energy. Basically hydraulic machine operates on principle of compression and expansion of hydraulic oil in cylinder and piston arrangement. Hydraulic oil is of fixed viscosity is responsible for expansion and compression process. Viscosity of hydraulic oil is maintained by device named chiller. In which heat is exchanged with cooled water. Oil enter in cylinder from two ends i.e inlet and outlet.

Working of Hydraulic Machine In hydraulic machine a piston cylinder arrangement is there. In which it have two valve i.e. inlet and outlet valve. Inlet valve is just below the cylinder and outlet valve is at the top of cylinder. Hydraulic oil named sepsa oil is used. Viscosity of oil is maintained by device chiller. The hydraulic oil enter in cylinder at high pressure when piston is at bottom dead centre and this oil will force the piston to move toward top in between that near top dead centre there is a merging point at this point the entered oil will come in top region above the piston and now the oil will start fill in top region and push the piston to move toward bottom.Again when oil will enter piston move upward during that the oil above the piston comes into chiller through outlet valve

MACHINE TOOLing

INTRODUCTION The machine undergo continues wear and tear during operation which decrease the rate of production of machine. Hence it is essential to install tooling of suitable material and of suitable dimensions. Even a small error may cause a large damage or loss. Tooling of machine undergo certain process

Process of Machine Tooling 1. Tool drawing/design 2.Material selection 3.Process selection of tool 4.Tool installation in machine 5.Try out of tool

Material Selection For the long tool life material should be suitable as per requirement. The material defined its life. The selection of material depends upon the following factors It can withstand the conditions Easily available in market. Cost should be less. If material will be good then it will increase the rate of production and reduce machine setup time or in turn wear and tear. The quality of the product depends upon tool material.

Process selection for tool It includes following steps 1.Raw material 2.Cutting of material 3.Handling of job 4.Operation on machine 5.Unclamp the tool

Try out of Tool After installing tool in the machine it is tested for proper functioning of machine. Is the tool performing its job. Is it damage the product or not. The product produced is of good quality. For example piston rod holding fixture is clamping the piston rod so that pressure should be enough for performing welding. If the fixture will not clamp piston rod properly the spot welding will not takes place on the spot.

Seam Welding Machine Seam Welder /Welding Items Units Value Supply V 415 Phase Ph 2 Frequency Hz 50 Welding Current A 19000 Load KVA 100 Water supply L/m 30

Thank you An organisation cannot do today’s job with yesterdays methods & be in business tomorrow. Issue is not whether SS should be considered or not – but it is a question of When as continuous improvement is here to stay.