Emmision System

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INTRODUCTION

Emission control equipments play a great role in the smoothfunctioning of a vehicle engine. It is an important part in vehicle which usespetroleum products as fuel. It controls the toxic gas emitted from the enginedue to the internal fuel combustion.

Mainly emission control involves two steps.First is the conversion of toxic gases like carbon monoxide into less toxiccarbon dioxide. Next function is to reduce the noise coming from engine dueto the expansion and compression in engine.

The part which converts the emission gas is called catalytic converterand noise reduction is done by muffler box. These are connected to theengine through metal boxes of suitable material. All these parts togethermake the emission control system of a vehicle.

The emission control system can be divided widely into two. Hot endand cold end parts. The Parts which carry gas just emitted from the engine iscalled hot end. Catalytic converter comes under this section. Parts whichcomes at the outlet end is called cold end. Muffler comes in this end.

When the gas is emitted it is transferred to the catalytic converter.Then the converted gas is passed through perforated tubes inside the mufflerbox. After the conversion and noise suppression the smoke is emitted outsidethrough the tail pipe.

DIPLOMA IN MECHATRONICS Page 1


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PROJECT BRIEF

Aim

To make Muffler Boxes for various vehicles as part of my IndustrialTraining.

Objective

To get the industrial experience by doing a real time project in anindustry.

To have basic idea about the production and functioning of vehicleexhaust system..

To get familiarized with different industrial management techniques likeKanban, kaizen etc.

To have a basic idea about quality control and product developmentmethods in an industry.

To have a basic idea about loading, operation and unloading in different

machines.



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PROJECT TARGET

Target

Muffler boxes are used to reduce the noise from vehicles by absorbingthe noise coming from engine. Sound of engine may vary according to thefuel used and engine design and output.



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PROJECT DETAILS

Project Relevance

Today the motor vehicles population is increasing day by day. Theenvironmental sound pollution created by vehicles will be the greatestpollution if it is having no mufflers.

By the sudden expansion and compression strokes inside the engine,the air outside the piston rod also expands and converges suddenly. Itcreates a continuous sound of low and high frequencies.

Low frequency high amplitude sound is created by cylinder strokes

also have high frequency low amplitude noises also by the friction and smallvibrations in the engine.

By using a suitable muffler box both low and high frequency noisescan be reduced to a considerable range. The designing of muffler is doneaccording to the noise created by the engine.

Customers Requirements

Sound coming from the engine should be within the range given by

the government of the country where the mufflers are using.Moreover it should be acceptable for the customer.The size and shape of the muffler should be designed in such a way that itshould fit correctly inside the vehicle.The material used for muffler should be resistant to corrosion and should notget broken by impact.



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The Emission Control System

Before going to the detailed study about the production of emission controldevices we should have some basic idea about the emission control system.

Three main parts of an emission control system are;

1. Catalytic converter2. Muffler box3. Boxes


Catalytic Converter

Pipe


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1.Catalytic Converter

A catalytic converter is a device used to reduce the toxicity ofemissions from an internal combustion engine.

A catalytic converter provides an environment for a chemical reactionwherein toxic combustion by-products are converted to less-toxic substances

http://en.wikipedia.org/wiki/File:DodgeCatCon.jpghttp://en.wikipedia.org/wiki/File:Pot_catalytique_vue_de_la_structure.jpghttp://en.wikipedia.org/wiki/File:DodgeCatCon.jpg


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Construction

The catalytic converter consists of several components:

1. The core or substrate.

The core is often a ceramic honeycomb in modern catalytic converters.The honey-comb surface increases the amount of surface area availableto support the catalyst.

2. The washcoat.

A washcoat is used to make converters more efficient, often as amixture of silica and alumina. The washcoat, when added to the core,forms a rough, irregular surface, which has a far greater surface areathan the flat core surfaces do, which then gives the converter core alarger surface area

3. The catalyst

Platinum is the most active catalyst and is widely used. Palladium and

rhodium are two other precious metals used. Platinum and rhodium areused as a reduction catalyst, while platinum and palladium are used asan oxidization catalyst.



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Muffler Box

Mufflers are used to reduce the noise coming from the engine.Sound of the vehicle is a pressure wave formed from pulses of alternatinghigh and low air pressure. These pulses make their way through the air assound.

In an engine, pulses are created when an exhaust valve opens and aburst of high-pressure gas suddenly enters the exhaust system. Themolecules in this gas collide with the lower-pressure molecules in the pipe,

causing a sound wave to generate.

Mufflers are a set of specially designed tubes and perforated plateswhich cancels the sound. The tubes and plates inside the mufflers arecollectively called as gut.

Parts of muffler are;

1. Case skin2. Perforated tubes3. Baffle plate4. End plate


END PLATES

BAFFLE PLATES

PERFORATED TUBE

INLET

OUTLET

CASE SKIN


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1. Case skin

It is the outer casing of muffler. Most of the vehicle uses stainlesssteel for case. Some company uses titanium or aluminum alloys of iron.

Its function is to protect the gut from external environment andimpacts which cause destruction of muffler.

2. Perforated tubes

These are the steel tubes inside the muffler which absorbs the

low frequency sound and functions as a passage for emission gases tomove in and out of the muffler.

3. Baffle plates

It is a perforated stainless steel plates in which tubes are weldedto form the gut. Perforations are made in according to the rate of soundcoming from engine. It also increases the strength of case skin.

4. End platesIt is used to close the two ends of muffler case. It is providedwith hole to connect the tubes inside muffler with outer boxes.



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How mufflers work

We know main part of a muffler is a simple set of tubes with someholes in them. These tubes and chambers are actually as finely tuned as amusical instrument. They are designed to reflect the sound waves producedby the engine in such a way that they partially cancel themselves out.

The tubes enclosed by the case skin makes the resonating chamber. Inthis chamber the sound waves undergoes reflection. The chamber is tuned tocause destructive interference, where opposite sound waves cancel eachother out.



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PRODUCT MATRICS

In muffler box cell we are making muffler boxes for

1. Ford India Ltd.2. Toyota Kirloskar Motor Ltd.3. Land Rover Britain.4. International Tractors Ltd.

1. FORD

VEHICLE MODELS DESIGNATION

Petrol DieselFigo 1.19 AE 1.19 DV4 BC

Fiesta 1.4 BF 1.4 DV4 CE

Icon C195 BA C195 AJ

2. TOYOTA

VEHICLE MODELS DESIGNATIONPetrol Diesel

Innova 10L02

New Innova 10L03 942L

Corolla 188W 186W

Corolla Altis 10C03 10N02

Qualis

3. LANDROVER

Land rover Diesel

4. ITL

ITL Diesel and Petrol



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CELL LAYOUT


SINGLE SPOT

WELDER 2

FLANGER

WIP

STAND

GUT 1

TROLLEY 2GUT 2

INSERTER

BAFFLE

CHUTE

GUT 1

INSERTER

GUT 1TROLLEY 1MULTI SPOT

WELDING

F.G.

TROLLEY

LEAK TESTERCASE SKIN

TROLLEY

CASE MAKER

END SPINNER

END PLATE

CHUTE

SINGLE SPOT

WELDER 1

WIP

STAND


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CELL ALLOCATION


W

IP

SINGLE

SPOT

WELDER 2

FLANGER

WIP

CHUTE

GUT 2

INSERTER

CHUTE

GUT 1

INSERTER

CHUTE

MULTI

SPOTWELDER

CASE

MAKER

SINGLE

SPOT

WELDER 1

W

IP

5

4

3

2


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CELL LAY-OUT EXPLANATION

CASE MAKER

Case maker is the first machine in box assembly line. It is used tomake the metallic case for the muffler box. It folds and lock the two oppositeends of sheet metal to form the case. It is driven by a hydraulic motor andelectro pneumatic cylinders for clamping. It is controlled by push buttons andsensors.

It uses a set of rollers to lock the two edges of sheet metal.


F.G.TROLLEY

LEAK

TESTER

CASE SKINTROLLEY

END

SPINNER

CHUTE

1WALK WITH PART

WALK W/O PART


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.

SINGLE SPOT WELDER

It is used to do spot welding on the lock seam of the muffler case. Ituses a 10mm dia spot welding tip. It uses a foot lever operated pneumatic

cylinder for pressing the welding head.



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The welding head is actuated by the pneumatic double actingcylinder. It uses a foot pedal operated switch to activate the pneumatic valve.

It is given with an air supply of 4 to 6 bar.


PNEUMATIC CYLINDER

WELDING TIP

WORK HOLDING RODE

FOOT PEDAL SWITCH

WELDING HEAD


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A small fluctuation in the pneumatic air pressure from theallowable tolerance can change the welding strength. A low pressure createsa weak welding and a high pressure makes over penetration of welding tip onwork which cause leak in spot weld. So a pressure switch is connected tothe pneumatic supply. If there is a change in pressure from given range thepressure switch will open and stops the welding operation.

It is a resistance spot welding machine. The welding process neednot requires any filler materials flux or gas. In this two layer of similarmaterial are joined by melting and pressing the melted point. The spot ismelted by the temperature created by the resistance of sheet metal to passelectricity from one electrode to other.

The electrodes are the welding tip and the work holding rode. Toavoid welding of electrode with the sheet metal copper is selected aselectrode; which is having less resistance. Heating of copper is prevented bycirculating water through the electrode. A laser torch is fixed on the machinewhich is used as a pointer for spot welding.

FLANGER

It is used for make a particular profile on the case skin for joining theeend plate with the case skin. Flanger make a small folding on the edge of

muffler box for spinning the muffler box edge with the end plate. End plate isa metal plate with a hole on it. It closes the two end of muffler box. The pipeis connected with the muffler through the hole in end plate.



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It is done by vertically pressing the case skin with a flanging tool drivenby a hydraulic press.It uses a electrical push button controlled hydraulic cylinder with a pressureof 15 Bar. It uses a limit switch to sense the cylinder forward motion and tomake the press to stop at exact position and to retract back after pressing.


PANEL BOARD

PUSH BUTTON

ACTUATORS

FLANGER

TOOL

TOP TOOL BOTTOM TOOL


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Flanger is a fully hydraulics operated press tool. It is given with anhydraulic supply from the hydraulic tank and pump kept near the machine.The flanger is operated by two serial pushbuttons. Two buttons are providedto ensure operator safety. As two buttons has to press, there is no chance ofgetting the hand inside the press while operating.

The cylinders are operated by electro hydraulic valves. It is havingmanual and auto mode of operation. In auto mode, by pressing thepushbutton the cylinder will extends and it will press the work. After pressing,the cylinder will go back to the home position.

In manual mode, there are separate switches for moving the cylinderto forward and backward. The top plate and bottom plate are stopped bymechanical stoppers to avoid the accident or damage to part if the limitswitches or sensors are failed to operate.

FLANGER HYDRAULIC PUMP



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THE HYDRAULIC PUMP

Hydraulic cylinders are used to actuate the double acting hydrauliccylinders in the flanger. The hydraulic pump is mounted at the back side ofthe flanger. The hydraulic fluid is supplied from a centralized hydraulic fluid

to the small hydraulic tank in the machine. It helps to keep the fluid level inthe small tank in same level.

A hydraulic pump is fitted on the tank. It pumps the hydraulic fluid toactuate the cylinder. It is rotated by a 230V induction motor.

A pressure gauge is used to monitor the pressure level of hydraulicfluid. The oil level in the hydraulic tank is monitored by a fluid level indicator

fitted on the hydraulic tank.

The pressure range for flanger is from 80 to 110 kg/cm2. The motorused is a single phase induction motor having 2 HP power working by a 230Vac supply.

OPTICAL SAFETY GUARD


ELECTRIC MOTOR

HYDRAULIC

PUMP

PRESSURE

GUAGE

FLUID LEVEL

INDICATOR

TANK


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The press is connected with an optical safety guard module. It is kepton both sides of the press. It consists of a transmitter and receiver module.It uses an IR transmitter array in the transmitter section. Parallel to thetransmitter module the receiver is mounted on the opposite side. The receiverwill always sense the signal if there is no barrier in between.

When the press is coming down the safety guard is on. If anythingcame in between the field of safety guard, the cylinder will stop at that

position. The cylinder will continue the operation, if the barrier is removed.


RECIEVER

MODULE

TRANSMITTER

MODULE

RECIEVER MODULETRANSMITTERER MODULE


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The fluid gets heated due to the continuous motion of cylinder andhydraulic pump. So the fluid is passed through a cooling tower before goingback to hydraulic tank after operation. Inside the cooling tower water iscirculated to cool the fluid. The hot water is collected in a cooling plantoutside the cell.

Same specification hydraulic power supply is used for gut inserterpressing machines also.

GUT INSERTER



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It is a hydraulic press which is used to insert the gut inside the case skin. Ituses two hydraulic cylinders actuated by push buttons. The cylinderexpansion and retracted end is sensed by using limit switches. The gut isloaded on the top tool. The case skin is loaded on the bottom tool. It uses 15Bar pressured hydraulic fluid power.

For Ford and Land Rover models whole part of the gut is inserted at atime. So it uses only one gut inserter machine. For Toyota the gut is insertedby two stages so it uses both Gut 1 and Gut 2 Inserter machines.

Gut 1 Inserter

Gut 2 Inserter



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Gut inserter 2 is not used inserting in all models. In Toyota it is usedfor inserting a third baffle into the case skin, in which already the gut isinserted.

But in land rover only gut 1inserter 2 only is used to insert ythe gut. Ithave no secondary gut insertion.

The hydraulic pump and cylinder used in it is similar to that of gutinserter 1.

MULTI SPOT WELDER



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It consists of an array of eight pneumatic cylinder operated spotwelding heads. By pressing one push button it make spot eight spot weld oncase skin. One cycle consists of four steps in which each step consists ofsimultaneous actuation of two cylinders.

The spot welding tip and work holding fixture is made of copper. Ituses resistance welding. The diameter of spot weld is 4mm. The cylinder isactuated by a 5 bar pressure pneumatic DAC.

The controller for multisport welder is a PLC which actuates thesolenoid operated pneumatic valves. Retraction and expansion is sensed byoptical proximity switches.

This machine is used only for Corolla and Innova models of ToyotaKirloskar Motor Limited.



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It is having two stations. Station 1 is for corolla and station 2 is forInnova.

PLC PANEL BOARD


CYLINDER

WORK HOLDING FIXTURE

WELDING TIP

OPTICAL PROXIMITY SWITCH


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All operations in the multisport welder is controlled by a PLC based

control system.It takes the inputs from various input devices in the machines. It

includes input push buttons and different sensors for various purposes. In thissome sensors are optical proximity switches which acknowledges the cylinderextracted and retracted end positions which is used to actuate the weldingheads.

Other sensor input devices are some limit switches which senses theposition of work to check whether work is clamped at the correct position ornot. The photo guard for operator safety is also connected to the PLC.

Other devices connected to the PLC are the output of pneumaticpressure switch and external timers. The pressure switch produces a signalwhen the input air pressure is out of the given range.

External timers are used for changing the time delay given forvarious processes to start or stop. Even PLC can provide timer operation, butexternal timer is used so that without going to plc programming any operatorcan change the time delay easily.


TIMER ARRAY

RELAY ARRAY

CONNECTOR

ARRAYS

TRANSFORMER

POWER SUPPLY

PLC MODULE


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Relay array are used to connected many devices with PLC input andoutput. It helps to provide electrical isolation between external devices andplc input/output modules.

Connecter arrays are a set of parallel connectors. All wires to, andfrom the PLC panel board is connected to a connector. Each connecter is a

given with a tag which shows which contact the wire is connected. So forchanging a connection in PLC there is no need to disturb the panel boardwiring and PLC module connections

CONTROL PANEL BOARD

The control panel board consists of switches and indicator lamps andan LCD display and a job counter.

Switches includes machine ON / OFF switches Job counter ON / OFF switch and SET/RESET button. Welding ON/OFF switch. Welding parameters changing switches. Fault reset switch. Machine home position switch.



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SWITCHES AND INDICATORS ON MULTISPOT WELDER

1. Power Lamp

It indicates whether the machine has switched on and ready for

operation. If any interrupts are present then power lamp goes off.

2. Home position Lamp

The home position lamp indicates whether the machine in home

position and ready for operation.

3. Program Error Lamp

The error lamp indicates whether any error occurs in PLC or any

parameter. If the error lamp is glows then we have to wait until it goes off.

Sometimes we have to manually correct the error or bring the machine tohome position.

4. Cycle ON indicator Lamp

It as a lamp which indicates whether the Welding cycle is ON or OFF. It

will be ON when the machine starts the welding cycle is going on.

5. Power ON/OFF switch

The power ON/OFF switch is used to switch on the power supply to the

machine

6. Master start switch

The master start switch is used to start and initialize PLC. After pressing

the switch we have to wait until lamp glows.

7. PLC Program reset switch

This switch is used to reset the PLC after some error occurs. If the

program execution is stopped due to an interrupt from the safety guard,

the cycle can be restarted by this switch,

8. Fault reset switch

It is used to continue a stopped program from where it is stopped; when

the program execution is interrupted by the error in loading or an

interrupt signal from safety guard.

9. Job selector switch

The job selector switch is used to select the type of operation. The multi

spot welder is having two type operations. One for petrol and other fordiesel boxes



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10. Manual / Auto selector switch

The manual/auto selector switch is used to select manual mode or

automatic mode of operation. In auto mode, by pressing one push button all

spot welding in that raw is done and the part is ejected. In manual mode

only one operation is done and it will not continue to next operation. For

checking machine and for doing a partial cycle, manual mode is used.

11.Emergency stop switch

This button is used to stop the machine in its last position if any

problem occurs for operator or part.

12.Welding parameter controller module.

It is a microprocessor based controller which is used to control the

different parameters for multisport welding like welding temperature,weld head on time, etc. It is having a 16x2 alphanumeric LCD matrix

keypad which displays the parameters.

13.Weld ON/OFF switch

The weld on off button is used to on and off the welding. It is kept in

off position when testing is going on.



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END SPINNER

It is a machine used to join the two end slate with the case skin. The

end plate is joined with the case skin should be a leak proof permanent jointIt has a pair of two different type rollers. One roller for spinning the edges ofcase and end plate, and the other is for flattening the spanned joint.

Spinning roller makes the two sheets of metal o get joined tightly byinterlocking of the sheets.

Flattening roller increase the strength of joint by pressing the spannedjoint. It helps to make the joint fully leak proof, so that the high pressure

emission gases will not get leaked through the jointed end.

Both top tool and bottom tool is doing the end spinning operation. It ishaving one flattening roller and one spinning roller on both top and bottomtool.

In this machine the box is loaded vertically. A hydraulic motor rotatesthe box slowly. At the same time the spinning rollers is pressed against theedges of case and end plate .The rollers are mounted on a shaft with abearing so that it can rotate over the box end freely.

The box shape will be different for different model. The top tool can bemoved up and down so that the tool can be adjusted for different height by alock nut. The rollers should move according to the cross sectional shapeof box. It is done by specially designed cam on each vehicle models spinningtool.

After each operation the top tool will go up so that loading and unloading ofpart can be done. When next part is loaded the top tool will come down andclamp the box and spinning is done. The up and down motion of top tool isdone by a hydraulic cylinder.



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END SPINNER


TOP TOOL

ROLLER

BOTTOM TOOL


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END SPINNER BOTTOM TOOL

The rollers are made of carbide. The rollers are rotating over case skincontinuously, and this will cause the roller to get worn out. The wear andtear to roller cause a considerable change in the desired profile to beachieved by spinning. The spinning tool for different models changesaccording to the cross sectional shape and size of each muffler models.


SPINNING ROLLER

FLATTENING ROLLER


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LEAK TESTER

It is a machine which is used for the final checking of muffler. In thisthe leak value for each box is measured. It passes air of a given pressure into

the muffler box through its inlet pipe by closing the outlet opening. Then thepressure inside the box is measured.

For each box a particular leak value range is given by the customer. Ifthe leak value is matching to this range a green indicator will glow. Then theleak value is written on the box and the box is sent for further assembly.

If the actual leak value is more than the given range , a siren is blownand the box should be checked for any crack or damage. If it cannot becorrected, the box will be rejected. Some boxes can be corrected by closing

the leaked area without affecting its quality requirements.

While testing the leak value the box is immersed in water so that theleaking place can be seen visually by the inspecting person.


WATER TANK

MUFFLER

HOLDING

FIXTURE

AIRSUPPLYINGBUNK AND


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Material Rack

The material rack is used to place the row materials for production. Theraw materials which are kept in small bin are kept on this stand for loadinginto the machine. In box cell, baffle plates end plates etc. are keeping on this

stand.

It is having three platforms. Two platforms on the topside are used tokeep the filled bin. The lower platform is used to keep the empty bins.



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WIP stand

The WIP (work in process) tables are used to keep the parts undergoing

process before loading to the machine. In our cell we are using around 3 WIP

stands. The number of WIP stands will be changed according to the parts

which is manufactured.

The WIP stand is a small table in which the part can be keep safely

while it awaits machining.

`

In box cell, first WIP stand is used to keep the flanged case skin which

has to be loaded to the gut inserter 1.

Second WIP stand is used to keep the box after finishing the multisport

welding. From this WIP stand the next person will load it to he gut inserter

two.

Third WIP stand is used to keep the boxes which are waiting for endspinning operation; after unloading from the gut inserter two.



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GUT TROLLEY

It is used to carry the gut from the gut assembly cell to the box cell.The gut for all models will be made and kept in the finished goods area of gutassembly cell is kept inside this trolley. The trolley containing the required gut

will be brought near the gut inserter in this trolley. It is having a kanban slotto put the kanban card for the corresponding model. The number of gut insidetrolley will be different according to the size of gut.



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FINISHED GOODS AREA

It is the place to keep the finished boxes coming from the box cell. Theboxes are collected in the box cell FG trolley and it is moved to this area.Each model will be having specific columns to keep the boxes, which ismarked by lines.

In this further assembly of ford model is done in the same company.For Toyota it is done at Bangalore plant. Land Rover is done at UK. The boxeswhich are going out for further assembly is checked thoroughly at here toavoid the quality problems.



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PROCEDURE OF WORKING

From starting of the shift to the end there is a prior planning and

procedure for every activity happening in the cell in a shift. Before startingthe work in a shift the operator has to verify that all machines and safety

devices are functioning properly. For ensuring that all the procedure are done

correctly, there are certain check list for all activities. It includes the work

standards, OPM sheets etc.

For ensuring proper daily preventive maintenance we are following a

method which is called as OPM. OPM means Operator Preventive

Maintenance. In each and every machine there will be a check sheet which is

mentioning the check points of that particular machine. This sheet is called asOPM sheet.

It is compulsory that before starting the work the operator should

have to fill the OPM sheet. One of the important things is that, the operator

should wear the goggles, safety shoes, ear plug, cotton gloves and over coat

to work safely in every cell.

Before starting the work the team should plan that which all the

products are today going to make. The supervisor will be giving the sheetwhich contains the customer requirements for the particular shift of 8 hours.

So, as per the plan the operator have to place the KANBAN cards in the TAKT

time shelf. TAKT time is the time given for the operator to manufacture one

trolley of finished goods. Each and every model will be having its own cycle

time. As per the cycle time operator has to produce the boxes. Each and

every model there is a separate trolley, and the number of boxes can placed

over it can be varies.

The standard trolley size varies and also number of boxes per trolleyvaries according to the size of model. Each products FG trolley has its own

standard capacity that how much it can carry. As per this we have to place

the KANBAN card. One KANBAN card is only for one FG trolley. We must not

put more than the number of part specified in the KANBAN card for every

model. A KANBAN can be put if the trolley contains the correct amount of part

as per the KANBAN.

After completing one trolley the operator has to put accepted tag as

well as KANBAN card for the FG trolley and move the trolley into FG storage

area. If some boxes are need any rework means, that boxes we can keep in a



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separate trolley and we have to keep aside. In that trolley we have put the

hold tag which is mentioning what rework has to do for that boxes.

KANBAN card

This is a KANBAN card of the pipe bending cell. By looking the card we can be

able to know all details about the material in that trolley. The background

color given in the PART NAME is the color code for that model vehicle. Each

card has its own serial number. It is given on the card above as CARD # 2

Accepted card

It is kept with the finished parts coming from each cell if the part is checked OK

Hold card



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It is kept in the trolley where parts to be reworked are kept.

Rejected Card

It is kept in the trolley where rejectedpart are kept.



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CONCLUSION

By this industrial training I got a direct exposure to an industry and thedifferent methods and techniques adopted in production and management ofan industry.

I also got familiarized with the production steps of the exhaust systemof a vehicle; especially the production of different muffler boxes in the mufflerbox assembly cell.

Documents

Emmision System