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INDUSTRIAL

TRAINING

REPORT

KSRTC REGIONAL WORKSHOPALUVA

12/06/2013 to 17/06/2013

SUBMITTED BY FOURTH SEMESTER

STUDENTS B-TECH IN MECHANICAL ENGINEERING

RAJAGIRI SCHOOL OF ENGINEERING


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AND

TECHNOLOGY,KAKANAD, KOCHI

MEMBERS OF THE TEAM

1. Sebin Thomas

2. Kiran Jacob Johny

3. Eldho Samel

!. "ar#hese "in$. %eb & 'hili(

). *a+ham Saran#

,. Roshan F Koni--ara

. Ma+he/ Jose0. Abhilash An+ony


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%TRO&TO%

The fourth semester B-Tech in Mechanical

Engineering students of Rajagiri School of Engineering

And Technology , Kakkanad conducted an industrialtraining at the KSRTC Regional orksho!, Alu"a#

The !rime o$jecti"e of an engineering student is to

ac%uire kno&ledge and analysing skills on technical

su$jects #As Mechanical Engineering students it is "ery

much essential for us to ha"e hands on e'!erience on

"arious !ractical a!!lications of the su$jects &e study#(t is "ery hard to achie"e such !ractical e'!erience $y

only a"ailing the facilities and !ractical sessions of our

college#

So &e sa& an o!!ortunity to get this !ractical

e'!erience $y undergoing industrial training at KSRTC

Regional orksho!, Alu"a, &here re!air, maintenance,

and $uilding of KSRTC $uses of central Kerala is done#

This is the re!ort of our industrial training at KSRTC

Regional orksho!, Alu"a dated from )*-+-*+) to

).-+-*+)#


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A&K%O45E*EME%T

e take this o!!ortunity to e'!ress our sincere

gratitude to all those &ho hel!ed us to com!lete this

industrial training in an enlightening manner#

e thank /od and our !arents for guiding us through

the right !ath# e thank our 0rinci!al 1r# 2# (saac &ho

ga"e us the !ermission and confidence for this training

and our 341 51e!artment of Mechanical Engineering6

, 0rof# Manoj# /# Tharian &hose hel!, stimulating

suggestions and encouragement hel!ed us in all ourendea"ours#

e sincerely thank Mr# M#S# Rajendranath , orks

manager KSRTC R7, Alu"a for gi"ing us the

o!!ortunity to &ork as interns at the KSRTC R7# e

&ould also e'tend our &holehearted gratitude to

Assistant 1e!ot Engineer KSRTC R7 A$oo$ecker sirfor the "alua$le suggestions , guidance and o"erall

direction hel!ed us in com!letion of this industrial

training# e also e'!ress our gratitude to the &orking

staff of all the sections of KSRTC R7, Alu"a &ho in

s!ite of their hectic &ork schedule &ere "ery hel!ful in

clearing our dou$ts in a lucid and understanda$le


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manner and e'!laining a$out each of the different

!rocesses#

The different sections of the &orksho!

&here &e under&ent training are8

)# Engine 4"erhaul Section*# Small 9nit

# /ear$o' Section

:# 0ro!eller Shaft section

;# # Tyre Sho!?#


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1. En#ine O6erhal Sec+ion

The engine of a "ehicle is one of its most im!ortant

!arts and in the engine o"erhaul section &e &ere

introduced to ho& the engine &as disassem$led,cleaning and ins!ection of the engine !arts and

assem$ly of engine to its com!lete form# The

mechanics of this section e'!lained to us a$out the

different !arts of the engine# Engine o"erhauling means

the reconditioning of engines# An o"erhauled engine is

an engine that is remo"ed from the "ehicle,disassem$led, cleaned, ins!ected, re!aired &here"er

necessary and tested using suita$le methods in the

factory#

The "arious !rocedures in"ol"ed in o"erhauling include

honing, !lace ne& !iston rings 5oil and com!ression

rings6, $earings, gaskets, oil seals etc#

3oning !rocess is a method of !roducing !recision in

the engine cylinder $y means of ru$$ing &ith any

a$rasi"e# The diameter of the $ore of the engine $lock

is measured using "ernier cali!ers# (f the "ariation is

too much, then the &hole engine $lock is re!laced#1uring o"erhauling, the engine $lock after ins!ection


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and disassem$ly is !laced on a ta$le# The ne& crank

shaft is !laced inside the engine $lock &hich is

su!!orted $y $earings# The crank is designed such that

the !istons that &ill $e !laced in the cylinder &ill mo"e

&ith a !articular firing order#

This is follo&ed $y fitting of gaskets, cam shaft, gear

!um!, &ater !um! for cooling of engine and other

com!onents# The $ottom co"er is !laced and $olted in


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!lace after all the com!onents in the lo&er side of the

engine $lock are !laced# The engine is then side&ays to

fit the fuel !um!# Again the engine $lock is turned and

the !istons are fitted to the crank shaft through the

$ore# After !lacing the sealant, the to! co"er &ith the

fuel injectors are !laced and $olted tightly in !lace#

The !rocess of o"erhauling mentioned a$o"e is similar

to $oth =eyland as &ell as Tata engines# 3o&e"er,

some factors such as firing order, design of the engine$lock, the com!onents used etc "ary# The o"erhauling

&orks of these t&o engine $locks are done se!arately in

t&o different areas of the same sections#

The testing of the engines is done $y attaching them to

their test rigs &hich consists of "arious other

com!onents that make u! the &hole !o&er generationsystem in the $us so that they can $e started and run

under no load to check &hether they are &orking

!ro!erly#


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2. Small ni+

The small unit is section of the &orksho! &hich

undertakes the re!air and re!lacement of "arious

critical com!onents of a $us such as clutch, air $rake

system com!onents, &ater !um!s etc# The small unit

handles the re!air of almost :: different com!onents#

The com!onents &hich &e &orked u!on &ere8 1rying and 1istri$ution 9nit

System !rotection "al"e

9nloader @al"e

Air com!ressor !um!

1ual Brake "al"e

Clutch

1rying and distri$ution 9nit


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The drying and distri$ution unit is an integral !art of

the air $rake system# The 1rying and distri$ution unit

51196 com$ines the function of the Air dryer &ith an

unloader "al"e, a !urge tank and a System 0rotection

@al"e 5S0@6#

The s!ecial features of 119 are listed $elo&

Air 1rying Remo"es moisture com!letely from

the com!ressed air

9nloading Regulates system !ressure $y

e'hausting the air deli"ered to the com!ressor, to

the atmos!here &hen system !ressure is increases

and allo&s re-charging of the system &hen the

system !ressure reduces#

Safety @al"e (n case of any malfunctioning of

the unloader "al"e, it !rotects the com!ressor and

system $y $lo&ing off the e'cess !ressure# This

de"ice is integrated &ith the unloader "al"e

mechanism#


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System 0rotection @al"e 5S0@6 This function is

integrated into the 119, &hich !rotects the

healthy circuits of the air $rake system, in case of

failure in one of the circuits# The non-return "al"esin this !ortion !re"ents $ack flo& of stored

com!ressed air u!stream#

0urge tank This tank &hich is integrated &ith the

119 stores dry air for regeneration of the

desiccant $ed#

The dismantling and cleaning of the 119 &as done at

the &orksho! and the Assem$ly and re!air &as done at

ABC4 Technical Centre in the R7 cam!us#

Air Com!ressor !um!

Com!ressors are used to generate air !ressure in the air

$rake system# 0ressuried air is used for actuation of air


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$rake e%ui!ment for reducing s!eed, sto!!ing the

"ehicle and other a!!lications# The dismantling and

cleaning of the Air Com!ressor !um! &as done at the

&orksho! and the Assem$ly and re!air &as done atABC4 Technical Centre in the R7 cam!us#

1ual Brake "al"e

The 1ual $rake "al"e is either a floor-mounted, treadle-

o!erated ty!e or fire&all-mounted $rake "al"e &ith t&ose!arate su!!ly and deli"ery circuits for ser"ice and

secondary $raking, &hich !ro"ides the dri"er &ith a

graduated control for a!!lying and releasing the "ehicle

$rakes#The dismantling and cleaning of the 1ual Brake

@al"e &as done at the &orksho! and the Assem$ly and

re!air &as done at ABC4 Technical Centre in the


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R7 cam!us#

Clutch

To allo& smooth shifting from one gear to another, a

clutch is !ro"ided to disengage the engine from the

transmission# A clutch is a mechanism for transmitting

rotation, &hich can $e engaged and disengaged#Clutches are useful in de"ices that ha"e t&o rotating

shafts# (n these de"ices, one shaft is ty!ically dri"en $y

a motor, and the other shaft dri"es another de"ice# The

clutch connects the t&o shafts so that they can either $e

locked together and s!in at the same s!eed or $e

decou!led and s!in at different s!eeds#Clutch frictiondisc also called as friction lining is made u! of a s!lined

round metal !art !late co"ered &ith friction material

5lining6 #the S!lines in center of the clutch disc mash

&ith s!lines on the in!ut shaft of manual transmission#

This makes the in!ut shaft and disc turn together#

3o&e"er the disc is free to slide $ack and forth in the


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shaft#

3. *earbo7 Sec+ion


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to road s!eed, to a"oid noisy and damaging

clashing of the gears

Constant-mesh gear$o'es, &hich can include non-

synchronised, or synchronied7synchromeshsystems, &here ty!ically diagonal cut helical 5or

sometimes either straight-cut, or dou$le-helical6

gear sets are constantly DmeshedD together, and a

dog clutch is used for changing gears# 4n

synchromesh $o'es, friction cones or Dsynchro-

ringsD are used in addition to the dog clutch toclosely match the rotational s!eeds of the t&o sides

of the 5declutched6 transmission $efore making a

full mechanical engagement#

Re"erse gear is usually unsynchronised, as the dri"e is

only e'!ected to engage it &hen the "ehicle is at a

standstill, meaning it also could only $e used for

mo"ing a&ay from a sto! unless the dri"er $ecame
http://en.wikipedia.org/wiki/Double_helical_gearhttp://en.wikipedia.org/wiki/Dog_clutchhttp://en.wikipedia.org/wiki/Dog_clutchhttp://en.wikipedia.org/wiki/Double_helical_gear


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ade!t at dou$le-declutching and had a !articular need

to regularly do&nshift into the lo&est gear#

!. 'ro(eller sha8+ Sec+ion

The !ro!eller shaft transmits !o&er from the gear $o'

to the differential of the rear a'le# The gear its !o&er

from the engine &hich is in turn transmitted to the

!ro!eller shaft $y means of a uni"ersal joint#

A uni"ersal joint is em!loyed to accommodate the

angular changes that occur in the shaft# T&o uni"ersaljoints are used for the !ro!eller shaft# 4ne is used

$et&een the gear$o' out!ut and the !ro!eller shaft and

the second is used $et&een the !ro!eller shaft and the

differential of the rear a'le#


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$. Fron+ A7le Sec+ion


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The front a'le section deals &ith the dismantling and re!airof the front a'le of the $us chassis# The major re!air &ork on

the front a'le includes re!air and re!lacement of the king!in

&hich holds the &heel hu$ ,re!lacing old $earings &ith ne&

ones, re!lacement of old oil seals &ith ne& ones, re!lacement

of $rake liner, connecting rod etc#

). Rear a7le sec+ion


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The Rear a'le section deals &ith dismantling and re!air

of the rear differential, $rake cham$ers of the front and

rear a'les, slack adjusters etc#

The &orking of differential is that &hen any four

&heeler makes a turn, the rear &heels &ill ha"e

different s!eeds# This is due to the fact that one &heel

&ill ha"e to co"er more distance than the other

de!ending on the direction of turn#


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This "ariation in s!eed of the tyres is sol"ed $y using a

mechanical setu! called the differential# (t is a system

of gears and !i"ots that accomadate the s!inning of the

rear tyres &ith the same s!eed 5straight dri"e6 and or at

different s!eeds5during cornering6#

The &heels are connected to t&o se!arate a'les &hose

ends are attached &ith t&o gears# The gears are allo&ed


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to mesh &ith t&o other gears that are !i"oted so that

they can s!in freely# They are su!!orted $y connecting

them to the a'les of the &heels# The connection is such

that they can s!in around the a'is of the a'les# 0o&er is

transmitted to the a'les $y means of a large gear

attached to the a'le and a gear at the end of a !ro!eller

shaft#


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The lathe is used for different turning !rocesses and is

used for remo"ing the &eld of !ro!eller shaft, ta!er

turning, cutting, sanding, knurling, drilling, ordeformation, facing, turning, &ith tools that are a!!lied

to the &ork !iece#

The &elding section deals &ith &elding of different

machine !arts to !recision#
http://en.wikipedia.org/wiki/Sandinghttp://en.wikipedia.org/wiki/Knurlinghttp://en.wikipedia.org/wiki/Drillinghttp://en.wikipedia.org/wiki/Deformation_(engineering)http://en.wikipedia.org/wiki/Facing_(machining)http://en.wikipedia.org/wiki/Turninghttp://en.wikipedia.org/wiki/Sandinghttp://en.wikipedia.org/wiki/Knurlinghttp://en.wikipedia.org/wiki/Drillinghttp://en.wikipedia.org/wiki/Deformation_(engineering)http://en.wikipedia.org/wiki/Facing_(machining)http://en.wikipedia.org/wiki/Turning


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The drilling and other micellenous o!erations are

carried out#

. Tyre Sho(


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The !rocess that takes !lace in the tyre sho! is

Retreading# Retreading is a !rocess for tyres that

re!lace &orn out tyres# Retreading !rocess is a!!liedfor tyres that ha"e $een &orn so that they can $e reused

after !ro!er ins!ection# This hel!s in conser"ing of

resources used for !roduction of fresh tyres from

factories and sa"es material cost#

The first ste! in the !rocess is ins!ection# (ns!ection is

done on &orn tyres to find out &hether there are any

defects in them such as holes, !rojections etc# (f no

such defect is found, then they can !roceed for

retreading#

The ne't ste! is Buffing &hich in"ol"es remo"ing of

the &orn out treads from the tyres !eri!hery using a


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suita$le $uffing machine# Again, the Buffing !rocess is

different for ordinary K#S#R#T#C "ehicles and lo& floor

$uses#


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0. Fel n9ec+ion Sec+ion

(n section the dismantling, re!air and assem$ly of fuel

injection !um!, fuel feed !um! and the atomiser is

done# An (njection 0um! is the de"ice that !um!s fuel

into the cylinders of a diesel engine# Traditionally, the

injection !um! is dri"en indirectly from the crankshaft$y gears, chains or a toothed $elt 5often the timing $elt6

that also dri"es the camshaft# (t rotates at half

crankshaft s!eed in a con"entional four-stroke engine#

(ts timing is such that the fuel is injected only "ery

slightly $efore to! dead centre of that cylinderGs

com!ression stroke# (t is also common for the !um!


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$elt on gasoline engines to $e dri"en directly from the

camshaft# The !istons ha"e a constant stroke "olume,

and injection "olume 5i#e#, throttling6 is controlled $y

rotating the cylinders against a cut-off !ort that aligns

&ith a helical slot in the cylinder# hen all the

cylinders are rotated at once, they simultaneously "ary

their injection "olume to !roduce more or less !o&er

from the engine# All injection !um!s incor!orate ago"ernor to cut fuel su!!ly if the crank s!eed

endangers the engine - the hea"y mo"ing !arts of diesel

engines do not tolerate o"ers!eeding &ell, and

catastro!hic damage can occur if they are o"er-re""ed#

The fuel is raised to e'treme !ressures $y fuel injection

!um!s and is deli"ered to the com$ustion cham$er $y

!ressure-acti"ated injectors &ithout com!ressed air#ith direct injected diesels, injectors s!ray fuel

through : to )* small orifices in its nole#

The fuel feed !um! is used to dra& the diesel fuel from

the fuel tank#


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1:. &oach bildin# sec+ion

The coach $uilding section in K#S#R#T#C deals &ith

construction and re!air &orks of $uses# The $uilding

houses many $uses at a time and different &orks take

!lace inside#


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Before the $ody can $e $uilt using the sheets, there%uired sha!e of the coach is made $y using steel

skeleton structure !laced on the $ase# The sheets are

then !laced around this structure# The re%uired

finishing !rocesses such as !ainting and attaching of

other accessories are done after&ards#


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S**ESTO%S

4n account of the training session &e ha"e

undergone, &e &ould like to !ut forth a fe&

suggestions &hich might $e $eneficial for the

firm8

)# 0ro"ide $etter lighting conditions inside the

&orksho! !remises#

*# (ntroduction of integrated crane hoist facilities

in the &orksho!#

# (ntroduction of air tools for faster and easy

dismantling and assem$ly of machine !arts#

:# (nstallation of an emission testing facility to

cater the needs of stricter emission norms#


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&O%&5SO%

The (ndustrial Training at KSRTC R7, Alu"a

&as a "ery fruitful e'!erience as $udding

Mechanical Engineering students# The training

definitely ga"e us an o!!ortunity to $e a !art of a

/o"ernment institution &hich has "ast e'!erience

in re!air, maintenance and $uilding of KSRTC$uses# The training at the R(1 &orksho! &ill

definitely hel! us in our future endea"ours# e

take this moment to thank The orks Manager,

A1E, and all the em!loyees of KSRTC R7,

Alu"a for hel!ing us to com!lete this industrial

training in an enlightening manner#

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