Académique Documents
Professionnel Documents
Culture Documents
TABLE OF CONTENTS
TITLE PAGE NO.
1.
Preface
7 8 9 16 20 23 30 37 42 43 45 67 73 76
2. Acknowledgement 3. Introduction to Sona Koyo Steering System 4. Introduction to Steering System 5. Manual Steering System 6. Recirculating Ball Steering 7. Axle And DIfferential 8. Steering Column And Its Type 9. Steering System Testing 10. Project Work 9. Hydraulic Power Steering 10. Subparts Of Project 11. Kaizen And Kanban System 12. How this Training was helpful to Me
LIST OF FIGURES
FIGURE NO. 1.1 1.2 2.1 2.2 3.1 3.2 4.1 4.2 4.3 5.1 5.2 5.3 5.4 6.1 6.2 6.3
TITLE View of company Plant locations Basic steering system Ackermann Steering Geometry How car steering works Assy. of rack and pinion R.B.S. Parts Working of R.B.S. Final Assy. of R.B.S. Differential Assembly Working of Differential Axle assembly Universal Joint Steering Column Steering wheel with column Collapsible Steering
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FIGURE NO.
TITLE
PAGE
7.1 7.2 8.1 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15
Track for steering testing Endurance Testing Actuater Basic steering system Assembled view of power steering Power rack and pinion steering Rotary vane pump Rotary Valve Process of centerless grinding Flat milling machine Broaching tool Induction hardening Induction tempering process Process of stone lapping Process of paper lapping Centering and facing on pinion Pinion rod Turning process Serration rolling
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FIGURE NO.
TITLE
PAGE
9.16 9.17 9.18 9.19 10.1 10.2 10.3 10.4 10.5 10.6
Grinding process Hobbing done on pinion Leakage testing machine Complete H.P. Steering Leakage testing machine Outer ball joint Collet Gun and Collet Chuck Forward and reverse input testing Honning machine Pinion
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PREFACE
As a student of Netaji Subhas Institute of Technology, I have attended six weeks Industrial
Training after my second year from 4th June,12 to 10th July,12 to get a better knowledge of industrial atmosphere and floor work. As a part of it, I went for the six week Industrial training at SONA KOYO STEERING SYSTEM at Gurgaon to gain some practical and shop floor experience. These give me the opportunity to have an exposure to experience and to interact with engineers, supervisors and workers. During the training, I went for that discipline, sense of responsibility, orderliness, proper communication, leadership guidance are necessary to convert company or organization objectives into products/services through channel called production. The changing industrial scenario and environment needs trained and experienced engineers who can affectively handle the manpower without many grievances and ensure the effective utilization of machines and materials to achieve the objectives laid down by the organization. Accordingly engineers find placement in respective field such as Research and development, Designing, Production, Inspection, Quality control, Marketing, Maintenance, Material handling etc.
I might not have understood all the procedures and process of industry but I have tried my best to gain practical knowledge from this training. I think that this training has proved to be beneficial in upcoming life.
ACKNOWLEDGEMENT
It brings me immense pleasure for an opportunity to have undergone training at Sona Koyo Steering Systems Limited. I would like to thank my training supervisor Mr. Vijay Sethi for his valuable guidance throughout my training. I would also like to thank the entire Quality Assurance Department especially Process Quality Department in which I have undergone my training for the help extended to me through the course of my training. I would also like to thank Mr. Rakesh Bansal and Mr. Krishan Rohilla for their invaluable support. There is always a sense of gratitude which one expresses to others for their helpful and needy services, which they render during all phases of life. I would like to do the same as I really wish to express my gratitude towards all those who have been helpful to me during different stages of my Industrial training and encouraged me with their ideas and views, which were guiding and motivating factors in completion of mighty and tedious tasks of project report writing to be a success. In presenting this Report I would like to convey my deep and profound gratitude towards all Engineers and Operators at Sona Koyo Steering Systems Limited for their co-operation and guidance.
INTRODUCTION TO SONA
Hydraulic Power Steering Systems Manual Rack & Pinion Steering Systems Recirculating Ball Steering, propeller shaft, Differential Assy. Collapsible, Axle Assy., Tilt and Rigid Steering Columns for Passenger Vans and MUVs.
PLANT LOCATION
PLANT-1
PLANT- 2
PLANT-3
PLANT-4
56970 m2
2933 m2 5363 m2 1265 m2 2213 m2 1330 m2
Certification
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CUSTOMERS
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PRODUCTS
PLANT-1
1) 2) 3) 4) 5) 6) RPS Assembly Manual (TOYOTA) RPS Assembly Manual (MARUTI 800) Collapsible Column (SAFARI) Collapsible Column (YE-2R) Collapsible Column (MODEL-A) Collapsible Column (SCORPIO)
PLANT-2
1) 2) 3) 4) 5) 6) 7) Shaft Propeller Assembly RBS Assembly (OMNI,GYPSY) Case Differential Assembly (TELCO) Case Differential Assembly (OMNI) Case Differential Assembly (YE-2R) Axle Assembly (OMNI,GYPSY) Sector Shaft Assembly
PLANT-3
1) Hydraulic Power Steering(all models)
PLANT-4
1) 2) 3) 4) 5) 6) Case Differential (SWIFT) Collapsible Column (MARUTI 800) Column Assembly (ALTO) IMV Column (INNOVA) Column Assembly (OMNI) Column Assembly (SCORPIO)
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SONA KOYO endeavors to provide equal opportunity to all and one in the matter of internal promotion. Only the right person for the right job however, shall be promoted.
SONA KOYO is conscious of fact that the growth an d progress of its employees and the company is inter dependent, hence the concept of all round development of its team members shall be of prime importance.
SONA KOYO encourages meaningful participation of its team members to achieve the organizational goals and objectives.
SONA KOYO constantly endeavors to establish and promotes clean and safe working environment where it team members may work happily and drive joy and pleasure.
SONA KOYO shall encourage and promote sports and such other cultural activities, which may be useful in building the moral values and national character of honest, discipline and integrity among its team member.
SONA KOYO as a good cooperate citizen shall like to participate in the community development and welfare programs in its surroundings areas so as to develop understanding and generate goodwill amongst the inhabitancy of local society.
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INTRODUCTION TO STEERING
Steering is the term applied to the collection of components, linkages, etc. which will allow a vessel(ship, boat) or vehicle (car, motorcycle, bicycle) to follow the desired course. An exception is the case of rail transport by which rail tracks combined together with railroad switches (and also known as 'points' in British English) provide the steering function.
The most conventional steering arrangement is to turn the front wheels using a hand operated steering wheel which is positioned in front of the driver, via the steering column, which may contain universal joints (which may also be part of the collapsible steering column design), to allow it to deviate somewhat from a straight line. Other arrangements are sometimes found on different types of vehicles, for example, a tiller rearwheel steering. Tracked vehicles such as bulldozers and tanks usually employ differential steering that is, the tracks are made to move at different speeds or even in opposite directions, using clutches and brakes, to bring about a change of course or direction.
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The purpose of the steering system is to allow the driver to control the direction of the vehicle by turning the front wheels. Together with the suspension system, it plays an important role in ensuring easy, comfortable driving all the way from the low speed range to the high-speed ranges. A good and efficient steering system has to ensure the following: 1. Excellent Maneuverability: When the car is cornering on a narrow, twisting road, the steering system must be able to turn the front wheels sharply yet easily and smoothly. 2. Proper Steering Effort: If nothing is done to prevent it, steering effort will be greater when the car is stopped and will decrease as the speed of the car increases. Therefore, in order to obtain easier steering and better feel of the road, the steering should be made lighter at low speeds and heavier at high speeds. 3. Smooth Recovery: While the car is turning, the driver must hole the steering wheel firmly. After the turn is completed, however, recovery- that is, the return of the wheels to the straight-ahead position- should occur smoothly as the driver relaxes the force with which he is turning the steering wheel. 4. Minimum transmission of Shock from Road Surface: Loss of steering wheel control and transmission of kickback due to road surface must not occur.
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BASIC GEOMETRY
The basic aim of steering is to ensure that the wheels are pointing in the desired directions. This is typically achieved by a series of linkages, rods, pivots and gears. One of the fundamental concepts is that of caster angle - each wheel is steered with a pivot point ahead of the wheel; this makes the steering tend to be self-centering towards the direction of travel. The steering linkages connecting the steering box and the wheels usually conforms to a variation of Ackermann steering geometry, to account for the fact that in a turn, the inner wheel is actually traveling a path of smaller radius than the outer wheel, so that the degree of toe suitable for driving in a straight path is not suitable for turns. The angle the wheels make with the vertical plane also influences steering dynamics (see camber angle) as do the tires.
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RACK-AND-PINION STEERING:
Rack-and-pinion steering is quickly becoming the most common type of steering on cars, small trucks and SUVs. It is actually a pretty simple mechanism. A rack-and-pinion gear set is enclosed in a metal tube, with each end of the rack protruding from the tube. A rod, called a tie rod, connects to each end of the rack.
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Recirculating ball steering is used on many trucks and SUVs today. The linkage that turns the wheels is slightly different than on a rack-and-pinion system.
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Instead of the bolt directly engaging the threads in the block, all of the threads are filled with ball bearing that recirculate through the gear as it turns. The balls actually serve two purposes: First, they reduce friction and wear in the gear; second, they reduce slop in the gear. Slop would be felt when you change the direction of the steering wheel without the balls in the steering gear, the teeth would come out of contact with each other for a moment, making the steering wheel feel loose.
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STEER BY WIRE
The aim of steer-by-wire technology is to completely do away with as many mechanical components (steering shaft, column, gear reduction mechanism, etc.) as possible. Completely replacing conventional steering system with steer-by-wire holds several advantages, such as:
The absence of steering column simplifies the car interior design. The absence of steering shaft, column and gear reduction mechanism allows much better space utilization in the engine compartment. The steering mechanism can be designed and installed as a modular unit. Without mechanical connection between the steering wheel and the road wheel, it is less likely that the impact of a frontal crash will force the steering wheel to intrude into the driver's survival space. Steering system characteristics can easily and infinitely be adjusted to optimize the steering response and feel.
As of 2007 there are no production cars available that rely solely on steer-by-wire technology due to safety, reliability and economic concerns, but this technology has been demonstrated in numerous concept cars and the similar fly-by-wire technology is in use in both military and civilian aviation applications. Removing the mechanical steering linkage in road going vehicles would require new legislation in most countries.
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ARTICULATED STEERING
Articulated steering is a system by which a four-wheel drive vehicle is split into front and rear halves which are connected by a vertical hinge. The front and rear halves are connected with one or more hydraulic cylinders that change the angle between the halves, including the front and rear axles and wheels, thus steering the vehicle. This system does not use steering arms, king pins, tie rods, etc. as does four-wheel steering. If the vertical hinge is placed equidistant between the two axles, it also eliminates the need for a central differential, as both front and rear axles will follow the same path, and thus rotate at the same speed. Long road trains, articulated buses, and internal transport trolley trains use articulated steering to achieve smaller turning circles, comparable to those of shorter conventional vehicles. Articulated haulers have very good offroad performance.
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Rear Axle
DIFFERENTIAL OPERATION:
The differential is the thing that works both drive axles at the same time, but lets them rotate at different speeds so that the car can make turns. When a car makes a turn, the outer wheel has to turn faster than the inner wheel, due to the difference in the length of the paths they take. The differential is located between the two wheels, and is attached to each wheel by a half-shaft rotated through a bevel gear. Four-wheel drive cars have a separate differential for each pair of wheels.
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Differential Fluids
For lubrication fluid, very heavy oil must be used in rear axle housings. Special hypoid oils are used in the differential case. Even another type of fluid or oil must be used in a posit action type differential. The oil is circulated by the ring gear, and flung all over all the parts. Special troughs or gullies are used to bring the oil back to certain spots, like the ring and pinion area and the piston bearings. The fluid is kept in with gaskets and oil seals. The bottom of the housing has a drain plug, and another filler plug is located part way up the housing. The housing must never be filled above this plug. The housing fluid lubricates some of the outer bearings, but others have lubrication fittings for the injection of wheel bearing grease. A handgun, not a pressure grease gun must be used to grease these bearings (sparingly). A pressure grease gun could inject grease into the brakes-greasy brakes are inefficient at best! Finally, some bearings are filled with grease at the factory and are sealed. These never require attention unless they are defective.
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The drive shaft, or propeller shaft, connects the transmission output shaft to the differential pinion shaft. Since all roads are not perfectly smooth, and the transmission is fixed, the drive shaft has to be flexible to absorb the shock of bumps in the road. Universal, or "U-joints" allow the drive shaft to flex (and stop it from breaking) when the drive angle changes. Drive shafts are usually hollow in order to weigh less, but of a large diameter so that they are strong. High quality steel, and sometimes aluminum are used in the manufacture of the drive shaft. The shaft must be quite straight and balanced to avoid vibrating. Since it usually turns at engine speeds, a lot of damage can be caused if the shaft is unbalanced, or bent. Damage can also be caused if the U-joints are worn out.
There are two types of drive shafts, the Hotchkiss drive and the Torque Tube Drive. The Hotchkiss drive is made up of a drive shaft connected to the transmission output shaft and the differential pinion gear shaft. U-joints are used in the front and rear. The Hotchkiss drive transfers the torque of the output shaft to the differential. No wheel drive thrust is sent to the drive shaft. Sometimes this drive comes in two pieces to reduce vibration and make it easier to install (in this case, three U-joints are needed). The two-piece types need ball bearings in a dustproof housing as center support for the shafts. Rubber is added into this arrangement for noise and vibration reduction.
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PROBLEMS
Incomplete Bearing Press Stacking Out
CAUSES
Misalignment of Fixture Slipping of Yoke From Fixture, Due to BOP Bearing Needle Fall, Rusty spider, More staking force Spider Tolerance, Excess Widening of Claws Incomplete Bearing Press, Slipping of Yoke Increase/Decrease in Widening Distance of Claws Misalignment of Fixture
COUNTERMEASURES
Fixture alignment to be done properly. Yoke to be placed properly in the fixture. Avoid use of Rusty Spider, Stacking force should be less. Spiders of equal tolerance should be made available. Application of correct stacking force, Place Yoke properly. To be done manually by the operating the Joint Assembly Machine. Fixture alignment to be done properly.
Leg Bend
PROBLEMS
Loosening of Side Wedge Breakage of Union Pipe Connected with Pneumatic Cylinder Stuck-up of Bearings Falling of Bearings during Inversion of Cassettes
COUNTERMEASURES
To be done manually Replacement of New Union Pipe Apply Air Pressure Replacement of Cassette of suitable size
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COLLAPSIBLE COLUMN
In recent times with increase in automobile accidents, the progress of research into how far the life of the driver can be protected has resulted in the development of a new product called collapsible column (Impact absorbing type column), In case of an automobile accident where the chart of the driver strike the handle and due to the collapsing nature of the handle the shock of the impact is reduced thereby preventing a death in the accident. In our country from 1st Oct1973 a rule was implemented which specifies that all the automobiles sold in the domestic market must have the above mentioned impact absorbing handle. In other words its a contraption, which has been made as a product because of safety regulations. Our company developed a product, which matched well with the impact features of the vehicle under special license from G.M. for the 1st makers of the automobile in the World. Our company started using it on 1200cc Honda in 1972 and as such the history of the product is very. But our companys R&D has brought up the product as a high technology, high safety and presently due to the independent development of collapsible column by our company, it is being used in Mitsubishi Debonair, Diamate, Sherio, GTO and Suzuki Alto. (1) Functions, which a collapsible column must have :In case of an accident a collapsible column must have the ability to abort the shock due to the impact on the handle when the driver strikes. Along side being a product when protects the drivers it must have the function of normal steering. Legally it should satisfy safety regulations (FMVSS-203). In the experimentation rooms the column must satisfy and collapse at force of 1135 Kgf due to the burst portion of the dummy body strike. (2)Structure:The collapsible column is an apparatus, which absorbs the impact to the body from the handle at the time of collision and the structural parts, are column, Jacket, steering shaft column bracket etc.
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A steering column performs the following functions: The automotive steering column is a device intended primarily for connecting the steering wheel to the steering mechanism or transferring the driver's input torque from the steering wheel. (2) The energy dissipation management in the event of a frontal collision; (3) It provide mounting for: the multi-function switch, column lock, column wiring, column shroud(s), transmission gear selector, gauges or other instruments as well as the electro motor. (4) It offer (height and/or length) adjustment to suit driver preference.
(1)
Steering Wheel
Steering Column
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1.
Energy absorbing collapsible steering columns: They are designed for mass production and best suitable for stabilized Load at time of impact absorption. These types of columns break when load of more than 170 to 190 kgf are applied on it.
2.
Rigid steering columns: This type of steering columns is used with or without universal joints. It transmits torque from the steering wheel to the steering gear. These columns are used in MARUTI and OMNI.
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Paint Shop
SKSSL has a paint shop for catering to its in-house demand of painting of various components. The shop is located in Plant II and paints about 100 pieces per hour, working one shift a day. The cycle time for painting each component is about 2 hours and 45 minutes. The main components that are painted in the shop are propeller shaft, RBS Assy, I-Shaft Assy, lower shaft and collapsible column. The main activities that are carried on in the paint shop in the order of taking place are: 1. Degreasing: Degreasing is the process of removing rust, chemicals etc. from the surface of the component by washing it in alkaline powder solution (pH 12) in the degreasing tank. The solution is changed once a month. 2. Water rinsing: It is the process of washing off the degreasing solution from the surface of the component. This is basically washing the piece in water of pH between 7 and 8. This water is replaced daily. 3. Activation: This is a prerequisite to the phosphatising process. Here the component is treated with a solution of Ultra Act-C (of pH 8-9) 4. Phosphatising: This process is important because it makes sure that the paint sticks to the component and does not remove easily. Here the component is sprayed with a solution of Ultra-Bond 5P and accelerator. The solution is changed once a month. 5. Washing: Here the component is washed in DM water. 6. Drying: After washing, the component passes through a furnace (oven) where the moisture and water on the surface is dried. 7. Painting: The components are spray painted one-by-one manually by the operator. 8. Drying: The paint is then dried by passing it again inside the oven. The time spent by the component in the oven this time is twice that of the time spent before painting.
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Project: To Study and Solve the Problems occurs in Hydraulic Power Steering
Assembly Lines and To Increase Production.
STEERING SYSTEM
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Bellows
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PUMP
The hydraulic power for the steering is provided by a rotary-vane pump.
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The amount of flow provided by the pump depends on the car's engine speed. The pump must be designed to provide adequate flow when the engine is idling. As a result, the pump moves much more fluid than necessary when the engine is running at faster speeds. The pump contains a pressure-relief valve to make sure that the pressure does not get too high, especially at high engine speeds when so much fluid is being pumped.
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ROTARY VALVE
A power-steering system should assist the driver only when he is exerting force on the steering wheel (such as when starting a turn). When the driver is not exerting force (such as when driving in a straight line), the system shouldn't provide any assist. The device that senses the force on the steering wheel is called the rotary valve.
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The input from the steering shaft forms the inner part of a spool-valve assembly. It also connects to the top end of the torsion bar. The bottom of the torsion bar connects to the outer part of the spool valve. The torsion bar also turns the output of the steering gear, connecting to either the pinion gear or the worm gear depending on which type of steering the car has. As the bar twists, it rotates the inside of the spool valve relative to the outside. Since the inner part of the spool valve is also connected to the steering shaft (and therefore to the steering wheel), the amount of rotation between the inner and outer parts of the spool valve depends on how much torque the driver applies to the steering wheel. When the steering wheel is not being turned, both hydraulic lines provide the same amount of pressure to the steering gear. But if the spool valve is turned one way or the other, ports open up to provide high-pressure fluid to the appropriate line. It turns out that this type of power-steering system is pretty inefficient. Let's take a look at some advances we'll see in coming years that will help improve efficiency
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(1)POWER RACK BAR ASSEMBLY LINE (2) HYDRAULIC CYLINDER LINE (3)POWER PINION LINE (4)FINAL H.P.S. ASSEMBLY LINE
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(2) FLAT MILLING:- A milling machine is a machine tool used to machine solid materials.
Milling machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the mainspindle. Both types range in size from small, bench-mounted devices to room-sized machines. Unlike a drill press, which holds the workpiece stationary as the drill moves axially to penetrate the material, milling machines also move the workpiece radially against the rotating milling cutter, which cuts on its sides as well as its tip. Workpiece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and lead screws or analogous technology. Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control. Milling machines can perform a vast number of operations, from simple (e.g., slot and keyway cutting, planing, drilling) to complex (e.g., contouring, diesinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.
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(3) RACK TEETH BROACHING:- Broaching is a machining process that uses a toothed tool, called a broach, to remove material. There are two main types of broaching: linear and rotary. In linear broaching, which is the more common process, the broach is run linearly against a surface of the workpiece to effect the cut. Linear broaches are used in a broaching machine, which is also sometimes shortened tobroach. In rotary broaching, the broach is rotated and pressed into the workpiece to cut an axis symmetric shape. A rotary broach is used in a lathe or screw machine. In both processes the cut is performed in one pass of the broach, which makes it very efficient.
Broaching is used when precision machining is required, especially for odd shapes. Commonly machined surfaces include circular and non-circular holes, splines, keyways, and flat surfaces. Typical workpieces include small to medium sized castings, forgings, screw machine parts, and stampings. Even though broaches can be expensive, broaching is usually favored over other processes when used for high-quantity production runs.[1] Broaches are shaped similar to a saw, except the teeth height increases over the length of the tool. Moreover, the broach contains three distinct sections: one for roughing, another for semifinishing, and the final one for finishing. Broaching is an unusual machining process because it has the feed built into the tool. The profile of the machined surface is always the inverse of the profile of the broach. The rise per tooth (RPT), also known as the step or feed per tooth, determines the amount of material removed and the size of the chip. The broach can be moved relative to the workpiece or vice-versa. Because all of the features are built into the broach no complex motion or skilled labor is required to use it.[2] A broach is effectively a collection of single-point cutting tools arrayed in sequence, cutting one after the other; its cut is analogous to multiple passes of a shape.
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(6)INDUCTION TEMPERING:- Untempered martensitic steel, while very hard, is too brittle to be useful for most applications. A method for alleviating this problem is called tempering. Most applications require that quenched parts be tempered. Tempering consists of heating a steel below the lower critical temperature, (often from 400 to 1105 F or 205 to 595 C, depending on the desired results), to impart some toughness. Higher tempering temperatures, (may be up to 1,300 F or 700 C, depending on the alloy and application), are sometimes used to impart further ductility, although some yield strength is lost. Tempering may also be performed on normalized steels. Other methods of tempering consist of quenching to a specific temperature, which is above the martensite start temperature, and then holding it there until pure bainite can form or internal stresses can be relieved. These include austempering and martempering.
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(7)BATCH CODE PUNCHING:- In this a code is punched on the rack bar. It specifies the
date, month, year and shift of manufacturing. The size of letters should be 2mm.
(8)STRAIGHTNING:-In this the straightness of rack bar is checked. While checking it must
be ensure that rack teeth should be parallel to ram after runout correction before pressing start button again. Reverse bend are not allowed. The max bend must not exceed 0.1mm.
(9)CRACK DETECTION: - There should be checking of cracks in the rack bar (10) RUST PREVENTION OIL APPLICATION:-After checking rack bar is put in the
oil drum so that no rust will be present.
(11)CENTERLESS STONE LAPPING:-After stone lapping the surface finish will be 0.2
Ra. tone pressure during finishing must be 0.16 MPa.
Figure 9.10: Process of stone lapping (12) PISTON CRIMPING ON THE RACK BAR:-Piston crimping is done in one grove
and in other a circlip is fixed which is used to stop the piston movement beyond a limited distance.
(13)REVERSE SIDE BUFFING:- After this operation the surface finish will be 0.4 Ra. The coolant is used in this process is soluble oil 24/91.
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(14)PAPER LAPPING:-The condition of the surface will be free from scratches and burrs.
Figure 9.11: Process of paper lapping (15) WASHING:-Washing liquid is WS 500 NR and washing liquid temperature is 30C to
40C . Air drying after washing is required. Gundrilling side of the rack bar must be on top side.
(16) RACK BAR INSPECTION:-Clean the piston crimping area by brush and there should not present any chips in gun drill. (17)ANTI RUST OIL APPLICATION:-The coolant used is NISSEKIP-1600. There
should be presence of oil film on complete area of rack bar.
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(1)CENTERING AND FACING:- In this centering and facing of pinion rod is done.
Figure 9.12: Centering and facing on pinion (2) LENGTH OF PINION ROD CHECK:-In this length of pinion rod is checked.
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Figure 9.14: Turning process (4)SERRATION ROLLING:- Thread rolling machine is a special designed for serration
type working pieces, UM-35H thread rolling machine is setting up with horizontal movable center-seat to roll the serration type working pieces . To ensure steady teeth shape, concentricity of work-piece and vertical degree.
(5)FINISHED TURNING GEAR SIDE:- In this again turning of pinion is done. (6)COLLECT DIA GRINDING:-grinding is used to finish work pieces which must show
high surface quality (e.g., low surface roughness) and high accuracy of shape and dimension.
(7)HOBBING:- Hobbing is a machining process for making gears, splines, and sprockets on
a hobbing machine, which is a special type of milling machine. The teeth or splines are progressively cut into the workpiece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities.
(9)GRINDING:- Grinding is used to finish workpieces which must show high surface quality
(e.g., low surface roughness) and high accuracy of shape and dimension.
(10)CRACK CHECK:- There should be checking of cracks in the PINION. (11)BEARING PRESS:- In the end a bearing is pressed in the pinion. A bearing is any of
various machine elements that constrain the relative motion between two or more parts to only the desired type of motion.
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(1)FLARING:- It is an expansion on the end of hydraulic cylinder. (2)TURNING:-Turning is the process whereby a single point cutting tool is parallel to the
surface. When turning, a piece of material (wood, metal, plastic, or stone) is rotated and a cutting tool is traversed along 2 axes of motion to produce precise diameters and depths. Turning can be either on the outside of the cylinder or on the inside (also known as boring) to produce tubular components to various geometries.
(3)WASHING:-In this washing of hydraulic cylinder is done after turning process. (4)PART HOLE PUNCHING: In this two holes are punched in the hydraulic cylinder
through which flow is occur.
(5)DEBURING:- There are many deburring processes, but the most common are massfinishing, spindle finishing, blasting, sanding, grinding, wire brushing, abrasive flow machining, electrochemical deburring, electro polishing, thermal energy method, machining, and manual deburring.
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(8)LEAKAGE TESTING: - Here I have to take the reading of this leakage machine and see
the bubble formation from its two ends. The leakage is checked at 15 bar. But after checking and machine say GO the same pieces will found showing leakage at final testing.
Figure 9.18: Leakage testing machine (9)HONING: After leakage testing honing process occurs. (10)ANTI RUST OIL APPLICATION: - In the end cylinder is put in the oil tank. There
should be presence of oil film on complete area of hydraulic cylinder.
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(1) TO TAKE THE READING OF LEAKAGE TESTING MACHINE AND ALSO SEE THE BUBBLE FORMATION FROM ITS TWO DIFFERENT SIDES OF HYDRAULIC CYLINDER.
SOLUTION: Here I have to take the reading of this leakage machine and see the bubble formation from its two ends. The leakage is checked at 15 bar. But after checking and machine say GO the same pieces will found showing leakage at final testing. So I have to work on this machine to check the problems.
Hydraulic cylinder
Air pipe
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(2) TO INCREASE THE PRODUCTION OF HYDRAULIC POWER STEERING ASSEMBLY LINE IN WHICH AFTER EVERY 100 SEC ASSEMBLY OF ONE STEERING DISPATCH i.e. THE PRODUCTION PER HOUR IS 36.
SOLUTION: In this it is observed that if we place a table at outer ball joint so that one outer ball joint is assembled at one table and for second outer ball joint is assembled at second new table so the work load one first table worker decreased and idle time is consumed. Now after every 90 sec assembly of a hydraulic power steering dispatch for customers.
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(3) TO MAINTAIN THE QUALITY OF RACK BAR AND ITS PISTON POSITION. SOLUTION: If we observed the piston crimping machine the run out was more i.e. holding of rack bar for piston fitting shows the eccentricity from actual center. The problem for this may be old jaws in which some teeth was broken and loose holding of jaw chuck. So in this machine the collet chuck is used which has bought from Germany. Now the workload of worker also reduced and it becomes easy to work on that machine.
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(4) TO CHECK THE FITTING PROBLEM OF IMV MODEL (TOYOTA INNOVA) STEERING ASSEMBLY FROM THE PINION SIDE WITH THE MACHINE COLOUMN IN FORWARD REVERESE INPUT TESTING.
SOLUTION: In this I have to check all fixtures and note the reading. Then I have select I master piece whose fitting is correct and compare the entire v blocks mounted on fixture with the master piece v block. Then the undesired dimensions are removed using grinding machine.
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KAIZEN
KAIZEN means improvement and continuing improvement in personal life, social life, home life, and working life. When applied to the workplace KAIZEN means continuing improvement involving everyone managers and workers alike. KAIZEN is a Japanese word meaning gradual and orderly, continuous improvement. The KAIZEN business strategy involves everyone in an organization working together to make improvements without large capital investments. KAIZEN is a culture of sustained continuous improvement focusing on eliminating waste in all systems and process of an organization. The KAIZEN strategy begins and ends with people. With KAIZEN, an involved leadership guides people to continuously improve their ability to meet expectations of high quality, low cost, and on time delivery. KAIZEN transforms companies into Superior Global Competitors
There are two elements that construct KAIZEN, improvement/change for the better and ongoing/continuity. Lacking one of these elements would not be considered KAIZEN. For instance, the expression of business as usual contains the element of continuity without improvement. On the other hand, the expression of breakthrough contains the element of change or improvement without continuity. KAIZEN should contain both elements.
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Discarding conventional fixed ideas. Thinking of how to do it, not why it cannot be done. No place for excuses. Starting by questioning current practices. Less emphasis on seeking perfection. Doing things right away even if for achieving only 50% of target. Correcting it right away, if some mistake is made. Using wisdom, not money for KAIZEN Wisdom is brought out when faced with hardship.
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KANBAN SYSTEM
Many people think the Toyota production system a Kanban system: this is incorrect. The Toyota production system is a way to make products, whereas the Kanban system is the way to manage the Justintime production method. In short, the Kanban system is an information system to harmoniously control the production quantities in every process. It is a tool to achieve Just-intime production. In this system what kind of units and how many units needed are written on a tag like card called Kanban. The Kanban is sent to the people of the preceding process from the subsequent process. As a result, many processes in a plant are connected with each other. This connecting of processes in a factory allows for better control of necessary quantities for various products.
The following supports the Kanban system: Smoothing of production Reduction of set up time design of machine layout Standardization of jobs Improvement activities Automation
A Kanban is usually a card put in a rectangular vinyl envelope. Two kinds are mainly used: Withdrawal Kanban and Production-ordering Kanban.
A Withdrawal Kanban details the kind and quantity of product, which the subsequent process should withdraw from the preceding process, while a Production ordering Kanban specifies the kind and quantity of the product, which the preceding process must produce.
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I am thankful to entire SONA family for providing me this golden opportunity, which made me to learn a lot of valuable things. In our college, we are taught theoretical knowledge which is not sufficient to cope up in the industry. So, here in SONA I learnt how production activities are carried and various activities are coordinated. Here, I learnt the organizational behavior, which is a very important part of engineering education. I saw the various production activities, which were just taught in the classroom to us. Practical knowledge is entirely different from theoretical knowledge, so it is very necessary to gain practical aspect of technical knowledge. Here in SONA I learnt this thing i.e., practical knowledge. Here, I saw how objectives could be achieved by the hard work of a group. It is the hard work of the SONA family, which made them the market leader in their field. It was a pleasure to see the SONA family members working with such devotion. So, again, I thank the entire SONA group for making me familiar with the practical aspect of knowledge.
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