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A project report
By
M.YESHWANTH RA1611002020107
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
SRM UNIVERSITY
2016-2020
1. INTRODUCTION
1.1 HISTORY
1.2 HISTORY OF KIPL
2. DUMP TRUCK
2.1 KOMATSU HD 465
2.2 KOMATSU HD 785
2.3 FABRICATION PROCESS
2.4 ASSEMBLING PROCESS
3. EXCAVATOR
3.1 PC 71
3.2 PC 130
3.3 PC 210
3.4 PC 300
3.5 PC 350
3.6 PC 450
3.7 FABRICATION PROCESS
3.8 ASSEMBLING PROCESS
1. INRODUCTION
1.1 HISTORY
Komatsu Iron Works was started by Takeuchi Mining Industry as a subsidiary to make
industrial tools for the parent company. Komatsu eventually became large enough to sell to the
public, and was spun off on May 13, 1921 as Komatsu Ltd.
Komatsu produced its first agricultural tractor prototype in 1931. Through the 1930s, Komatsu
also produced tractors for the Japanese military, as well as bulldozers, tanks and howitzers.
After World War II, under its new president Yoshinari Kawai, Komatsu added non-military
bulldozers and forklifts to its line of equipment. In 1949 it began production of its first diesel
engine. Its growth as a company was aided by the strong demand for its bulldozers during
Japan's post-war reconstruction in the 1950s. In August 1951 the corporate headquarters were
moved to Tokyo. By 1957 the company had advanced technologically to the point that all its
models were using Komatsu engines.
A dump truck (known in the UK as a dumper/tipper truck) is a truck used for transporting
loose material (such as sand, gravel, or demolition waste) for construction. A typical dump truck
is equipped with an open-box bed, which is hinged at the rear and equipped with hydraulic
rams to lift the front, allowing the material in the bed to be deposited ("dumped") on the ground
behind the truck at the site of delivery. In the UK, Australia and India the term applies to off-
road construction plant only, and the road vehicle is known as a tipper, tipper lorry (UK, India)
or tip truck (AU).
There are two types of dump trucks assembled in the plant . one is model 465 and the other is
785. The parts for the dump truck are imported from different countries and only the assembling
of dump truck is done in this plant 1.
Komatsu HD465
Standard Body
Type Rigid
Limestone Body
Type Rigid
Komatsu HD785
Type: Rigid
Max. Gross Vehicle Weight: 166000 kg
Engine
Power: Net 1178 HP
Engine speed: 1900 rpm
Max Payload: 91 tonnes
Heaped Capacity: 60 cu. m.
Max Travel Speed: 65 kmph
2.3 ASSEMBLING PLANT FOR DUMP TRUCK (PLANT 1)
The assembling plant is split into three lanes. The center lane has welding for main frame then
paint booth for painting the main frame, then the 5 stations for assembling the truck together
.Then the modification area. On the left side we have two sub stations , one is pressure
accumulator sub and the other is platform sub.
The right lane of the plant consists QA sub , hydraulic , radiator , cabin , transmission , engine ,
assembly rear axle, rear axle motoring sub.
1. WELDING AREA
The fabrication of the main frame is done in the welding area . the locally imported frame
is fabricated by tact and saw welding, then sent for the painting.
2. PAINT BOOTH
The fabricated main frame is painted here and is sent for assembling
3. MAIN LANE
The stations are split up into 5 . Each station assembles a part to the dump truck. The
radiator ,engine, wheels and the cabin of the dump trucks are assembled in this 5 stations.
4. QA
Parts of the main frame are checked here by the inspection crew.
6. RADIATOR SUB
The assembling of radiator into a fully finished part is done here.
7. CABIN SUB
The cabin for the dump truck is assembled and finished . the lining for the cabin is also
done here.
8. ENGINE SUB
The engine of the dump truck is checked here
9. REAR AXLE SUB
The rear axle is assembled in this sub
Usage
Excavators are used in many ways:
There are 5 types of excavators which are been facbricated and assembled in the komatsu plant
. the plant is spilt up into two . one is for the fabrication of excavators and the other for
assembling.
3.1 PC 71
The fabrications of revo frame and the track frame are done here. The plant is split up into three
column . One for track frame, the other for revo frame and the last one is for the boom and arm.
The fabrication is done by using different welding process .Each welding process is described
below. The products are also checked before and after the fabrications.
1. QA
This crew checks if the product has any minor defects or change in structure after the
fabrication is done.
2. FIXTURE AREA
The parts are fixed with in a fixture and are made to combine with a tack welding for a
support.
3. RAW
Raw is known as robotic arm welding , the welding is done by a robot. This welding is
done after the tact welding for a strong support. The robot welds the joints of the two
parts above the tact welding.
4. SAW
This is known as semi atomatic welding. The parts after the raw welding is made to
undergo semi atomatic welding for the left out edges which doesn’t get welded by raw.
5. SHORT BLASTING
Shot Blasting is also used for removing burrs, scale and rust that may interfere with
the part's integrity, appearance or definition. Shot blasting can also prepare the surface of a part
for coating by removing surface contaminants and provide a surface profile for increased
coating adhesion.
Shot Blasting is different than Shot Peening which is used to induce compressive
stresses on a part's surface for increased fatigue life, increasing the part strength or preventing
fretting.
6. PAINT BOOTH
Painting booth is used to paint the finished products . The finished material is made to go
inside a booth where the robot paints all the parts seperatly.
3.8 ASSEMBLY PLANT FOR EXCAVATOR (PLANT 3)
The fabricated boom ,arm ,track frame, revo frame are shifted to plant 3 which is
assembling plant. The assembly plant assembles all the parts together. The assembly
plant is divided into three columns. The first column assembles the track frame ,track
shoes and fills the grease and the places the engine .There are even small subs left side of
the plant. The small sub assembles the cabin , radiator and arm and the bucket. After the
fixture of these parts , the track frame is moved to the second column where the marriage
assembly takes place. This column fills the hydraulic oil and fuel . before that the swing
machine and the main valve is connected to the excavator.
The boom is then connected to the half finished excavator use using a crane to move the
boom from column 1 to 2. After fixing the boom the bucket is fixed .
Then the finished excavator is shifted to the third lane for flushing. After flushing the
vehicle an inspection is completed for any defects. Then the machine is sent for the repair
and painting . after the painting , once again the vehicle is going through an inspection.
After checking everything , the excavator gets ready for the shipment.
The rollers are fixed to the track frame . then the track frame is sent to track lane.
2. TRACK SHOE SUB
The track shoe is fixed in this area by placing the track frame above the stretched
track shoe.
3. GREASE FILLING SUB
The grease is filled for a smooth movement and for reducing the friction
4. CABIN SUB
The main valve for the excavator is fixed into the track frame and then the engine is
also placed in between the track frame for the rotation.
7. FLUID FILLING SUB
The hydraulic fluid is filled into the excavator. The fuel is also filled into the
excavator for the engine.
8. COUNTER WEIGHT ASSY
The counter weight for the excavator is fixed here. The counter weight helps the
excavator balance the weight correctly.
9. BOOM, ARM AND BUCKET ASSY
The three parts are assembled step by step in the excavator. The parts are lifted using a
crane and moved from one lane to another for fixing.
10. FLUSHING AREA
The finished excavator is water washed and sent for an inspection for checking any
defects. The excavator is operated and made to move into all the directions for
checking. The excavator is made to undergo several levels for testing.
11. REPAIR, PAINTING AND DECAL
The checked excavator is dent for painting. The painting for the excavator is fully
man powered. Once the painting is finished, The layer of the paints after checked for
a perfect paint coating using a lazer device.
12. SHIPMENT
After a long process of fabrication and assembling the excavator is ready for the
shipment at the shipment area.