1. SUMMER TRAINING AT UCAL FUEL SYSTEM LIMITED, GURGAON 1

2. SUMMER TRAINING PRESENTATION BY Vikram singh 12328 2

3. ACKNOWLEDGEMENT I am very grateful to all under whom I completed my summer training. I would like to give my heartiest thank to Mr. Pramod Rana who give me opportunity (letter to join us trainee) to do training at UCAL FUEL SYSTEM LIMITED. I am very grateful to them for introducing me to the technicalities and process flow of the plant. 3

4. Products made in company 1. INTAKE MANIFOLD 2. DELIVERY PIPE 3. OIL PLATE 4. CHAIN COVER 5. THROTTLE BODY 6. THROTTLE BODY HOUSING 4

5. 5 STUDY OF ASSEMBLY OF THROTTLE BODY AND DELIVERY PIPE

6. VARIOUS MODELS OF DELIVERY PIPE 1. Y88 DPT-002E 2. F8B DPT-007C 3. YM1 DPQ-001E 4. YE2 DPQ-010 5. YJ9 DPQ-003E 6. YG4 DPQ-005 7. YV4 DPQ-013 8. YN4 UDP-2 OMNI MARUTI 800 WAGONR ESTEEM GYPSY ALTO RITZ SWIFT 6

7. Throttle body 7

8. It helps control the amount of air that goes into the engine. Inside the throttle body something called the throttle, which is normally a butterfly valve. Everytime this valve opens, air gets sucked into the engine.When it closes the suction slows down. The throttle body can normally be found in between the air filter and intake manifold. 8

9. There is normally an airflow sensor near the throttle body to measure the amount of air going into the engine. The car’s computer decides how much fuel to add into the air mixture into the air/fuel mixture based off theis measurement. 9

10. The throttle valve is controlled with a lever by a direct mechanical linkage from the accelerator, the more the accelerator is pressed down, more the valve opens up and lets more air in. There is something new called “drive-by-wire ” this is when wire is electronically controlled. 10

11. Instead of the accelerator being connected to the linkage directly, it is connected to a sensor. the sensor detects the throttle position and sends that information to the cars engine control unit(ECU). The ECU then determines how much the throttle valve should be opened. 11

12. 12

13. Range: Bore size from 32mm to 80mm Customers: Marurti suzuki, Hyundai,BOSCH,Continental. 13

14. PROCESS DESCRIPTION: 1.Marking:a)Customer part number b)Model no. c)date 2.Locate the bush in the punch and the 200 button. 14

15. PROCESS DESCRIPTION: P/M/TOOL Required. Pneumatic press 15

16. .05mm to. 5mm gap from cast surface Air pressure more than 5kg/cm^2. Inspection method filler gauge 16

17. Inspection frequency: 2 piece 4 times per day. 17 Inspection required 2 piece 4 times per day.

18. 1. Air pressure minimum 5kg/cm^2 2. Hydraullic pressure min. 16kg/cm^2. 18

19. Product process specification tool Clarity of marking Depth 5.5+.3 spring side Depth 3.5+.3 TPS (throttle position sensor. Inspection method: DIG caliper By hand. 19

20. INSPECTION FREQUENCY: TWO PIECE FOUR TIMES A DAY. 20

21. PROCESS DESCRIPTION: Tighten bracket with scrrew driver. PROCESS MACHINE TOOOL REQUIRED : Pneumatic screw driver 21

22. Torque 35+_10 kgf/cm^2. Inspection method: torque wrench Inspection frequency: 100% 22

23. ASSEMBLY PROCESS 23

24. ASSEMBLY OF THROTTLE VALVE: 24 APPLYING MOLYBDENIUM IN THROTTLE SHAFT AREA ASSEMBLY OF TPS

25. THROTTLE VALVE FIXING SCREW STAKING RACING EQUIPMENTS FULL CLOSE LEAKE TESTING & IDLE ADJUSTING 25

26. ASSEMBLY OF ISCV(Ideal speed control valve) LEAK CHECKING FINAL INSPECTION 26

27. IT ALLOWS THE CONSTANT FUEL SUPPLY THROYUG PRESSURE REGULATOR. 27

28. DELIVERY PIPE: 28

29. ASSEMBLY OF DELIVERY PIPE 1.BATCH CODE MARKING a).Model no. b).Year code c).month code d).date code PLUG PRESSING AND CAULKING OF DELIVERY PIPE ASSY. OF FUEL INLET PIPE & PRESSURE REGULATOR LEAK CHECKING OF DELIVERY PIPE. 29

30.  SENSOR PROVIDED WITH TORQUE SETTTLER(TORQUE CHECKING)  SENSOR AVAILABLE(FOR DETECTING BLOCKED PIECES)  AUTOMATICALLY DOT WILL BE PROVIDED WITH PUNCH(FOR O,K, COMPONENTS)  2 HAND PUSH BUTTONS (FOR SAFETY) 30

31. THANK YOU 31