BWI Automation and Technology

Summer Training Report

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YOGESH MITTAL

AcknowledgementsThe 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. 2

INTRODUCTIONBWI 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.

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ProductsShocks and Struts of various models1.M-8002.M-ZEN3.M-SWIFT DZIRE4.M-ALTO5.M-WAGNOR

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PRODUCTS

Shocks and Struts5

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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 7

NomenclatureThe device name in common parlance is

shock absorber or shocks.Technical name includes dampers or daspot.

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DescriptionPneumatic 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.

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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

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Mounting Ring

Bushing

Seal Assembly

Rod Guide Assembly

Cover Plate

Dust Tube

Major Parts 12

Cylinder Tube

Piston Rod

Reservoir Tube

Compression valve assembly

Lower Mount

Dust Tube

Cover Plate

Piston

Position of Shocks in Car

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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

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Piston Rod

Bump Cup

Rod Guide Assembly

Stabilizer Bar Bracket

Piston Assembly

Mounting Bracket

Compression Valve Assembly

Seal assembly

Spring Seat

Cylinder Tube

Rebound Bumper

Rebound Stop

Reservoir Tube Formed

Insert

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. 16

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

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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. 18

Theory of OperationThe 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)

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A

BC

D

Theory of Operation in ReboundMotion of the piston away from the base valve builds pressure in chamber AThe fluid in chamber A is forced into chamber B through the piston rebound valveThe base valve intake opens, letting fluid from chamber C to go back into chamber B to compensate for the rod volumeRebound control is generated entirely through the piston rebound valve

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AAir

oil

B

C

D

Theory of Operation in Compression

Motion of the piston toward the base valve builds pressure in chamber BThe pressure forces fluid through the piston intake valve into chamber AChamber A can’t hold all of the fluid from chamber B due to the piston rod volumeThe rod volume is forced through the base valve into chamber CThe air in chamber D is compressed to compensate for the change in volumeTherefore, compression damping is obtained through the piston and base valves

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Air D A

Oil BC

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.

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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

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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, ...

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Machine Installation Content1.Introduction2.Features3.Procedure

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IntroductionDuring 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.

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

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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.

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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.

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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

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MACHINE TOOLing

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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

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Process of Machine Tooling1. Tool drawing/design 2.Material selection3.Process selection of tool4.Tool installation in machine 5.Try out of tool

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Material SelectionFor 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 conditionsEasily 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.

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Process selection for tool It includes following steps 1.Raw material2.Cutting of material3.Handling of job 4.Operation on machine 5.Unclamp the tool

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Try out of ToolAfter 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.

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Seam Welding Machine

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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

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Thank you