TRAINING REPORT OF SIX MONTHS INDUSTRIAL TRAINING, UNDERTAKEN AT ESCORTS LIMITED, FARIDABAD IN ENGINE APPLICATION BUSINESS ON ENGINE ASSEMBLY

AND TESTING SUBMITTED IN THE PARTIAL FULFILMENT OF THE DEGREE OF BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING

Under the Guidance of: Name: Arjit Gupta Designation: Assistant Manager Department: Engine Application Business

Submitted By: Name: Dhruv Talwar College Roll No.: E094028 University Roll No.: 90181124945

ACKNOWLEDGMENT
I have taken efforts in this training. However, it would not have been possible without the kind support and help of many individuals and organization. I would like to extend my sincere thanks to all of them.

I am highly indebted to Mr. Arjit Gupta for their guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project.

I would like to express my gratitude towards my parents & members of Escorts Limited, Engine Application Business Department, Faridabad for their kind cooperation and encouragement which help me in completion of this training.

I would like to express my special gratitude and thanks to industry persons for giving me such attention and time.

My thanks and appreciations also go to my colleague Amit in developing the project who has willingly helped me out with their abilities.

PREFACE
This project presents the research, findings and recommendations resulting from the project, towards effective utilization of resources supported by all corelated departments.

The objective was to design a solenoid bracket with a better thickness so that it wont break and the power supply will be continuous. In doing so, it lays the strong foundation for industries overall growth. The involvement of the Genset department and Engine Application Business department in this project reflect its long term success. This report has benefitted from the significant input and collaboration of numerous partners that comprises of a Total Productive Maintenance Machine, Engine Application Business department.

The findings and recommendations of this report address data and information gaps and needs, and provide valuable information for guiding the next steps in the process of developing a better fuel efficient diesel engine.

This report and the projects in this report provide a wealth of information about the process on the assembly line, engine testing and dress up of a diesel generator and practical application of Total Productive Maintenance. Report appendices, which include technical reports generated in the project, are attached in the CD-Rom.

CONTENTS Content 1. Company Profile 3. Cylinder block assembly 4. Crankshaft assembly 5. Fuel Injection Pump Assembly 7. Camshaft Assembly 8. Gear Assembly 9. Piston Assembly 10. Rocker arm Assembly 11. Flywheel Assembly 12. Engine Testing 14. Solenoid Plate failures (Project) 15. Practical Applications 16. Conclusion 17. Bibliography/References. Page Number 6 11 12 13 13 14 15 15 17 18 22 24 25 26

1. COMPANY PROFILE

ESCORTS AGRI MACHINERY GROUP

ESCORTS LIMITED

FARIDABAD

The genesis of Escorts goes back to 1944 when two brothers Mr. H.P Nanda and Mr. Yudi Nanda, launched a small agency house, Escorts Agents Ltd. in Lahore. Over the years, Escorts has surged ahead and evolved into one of Indias largest conglomerates.

Over six decades back two young men set out on a journey together armed with little beyond intelligence, business acumen and determination and dreams aplenty. They believed that India could only achieve total freedom with a breakthrough in the field of agriculture and mechanization would have to rule the fields. Their youthful enthusiasm had kindled the hope that one day they would make a mark of their own. They were in fact writing the first chapter of what has come to be widely recognized as one of the greatest success stories in Indian industry.

Escorts came into being with a vision. A vision that eschewed easy paths to profitability, and sought instead for ways to make a contribution. A vision that led two young brothers, Yudi and Hari Nanda, to branch out of their family's prospering transport business and institute ventures that were to become the foundations of Escorts Limited. On 17th October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi Nanda as Managing Director and Mr. Hari Nanda as Chairman. It was a trendsetting marketing house driven by the same business philosophy, which had given their family enterprise an unrivalled reputation: customer concern.

Not long afterwards, this driving ambition to go beyond the expected led Hari Nanda to the first of his many successful business insights -the discovery of the great business potential that lay in India's villages. This led to the launch, in 1948, of Escorts (Agriculture and Machines) Ltd., with Yudi Nanda as Director. Though separate business entities then, both companies had two great strengths in common: the dynamic Nanda brothers and the unifying force of the name they gave their companies; Escorts, literally 'escorting' their products and services to the customer while most other businessmen were just selling.

Tragically, Mr. Yudi Nanda died in an accident in 1952 -but his spirit remained embedded in the foundations of the company. Mr. H P Nanda then took on the mantle to realize the dreams which he had always seen with his brother.

Beyond the growth of the organization, these principles have ensured that Mr. H. P. Nanda's contribution to the cause of industry and the consumer will endure. He pioneered the revolutionary concept of 'interdependence' between ancillary and large industries, institutionalizing vendor development and in the process building Faridabad and the entire belt of townships in the region. He introduced the discipline of service going before marketing, reassuring the customer that Escorts would stay with them that they were here for the long run. He built lasting alliances with an array of the world's most respected names in tractors, industrial equipment, two-wheelers, construction equipment and telecommunications.

Going further, he created institutions devoted to value engineering and training, not only as investments in the company's future but also as catalysts for the enhancement of Indian industry as a whole Knowledge Management Centre and the unique Escorts Training and Development Centre (ETDC). His concern extended to the society in which he worked, and he manifested it by establishing the Escorts Medical Centre at Faridabad, Escorts Heart Institute and Research Centre at New Delhi, as well as numerous village development programs.

And

above

all,

heimbued

the

corporation

with

his own

pioneering,

entrepreneurial spirit, instilling both a conscience and a vision of leadership.

Escorts is testimony to the valor, vision and values of its Founder Mr. H P Nanda. He remains the inspiration for our courage, spirit of adventure and ability to Think Big. These qualities are his enduring legacy and have inspired and encouraged us down the decades and will continue doing so in all our endeavors Escorts have played a pivotal role in the agricultural growth of India for over six decades. Having pioneered farm mechanization in the country, Escorts have been developing solutions to enhance agricultural productivity and improve quality of life in rural India.

Escorts are laying greater emphasis on improvement, innovation and effective execution of its offerings. We are constantly evolving and creating new products to suit market demands. We are closely monitoring the quality of our products and re-gearing our strategies which are both customer and market focused. The launch of tractors fitted with 4 -Cylinder engines that are around 15% more fuel efficient than most other tractors in the market, or the entry segment tractor (Powertrac 429) to cater to the aspirations of small farmers and first time buyers, or the 'XTRA Torque' series of tractors that are meant specially for the emerging trends of using 'rotary' implements, or India's first-ever INVERTER TRACTOR have been all case in points where the farmers' 'cost of ownership', his overall operating economics and his need for enhancing productivity have been supreme considerations for Escorts.

At Escorts Agri Machinery, the catalyst for the next wave of farm mechanization has brought about two large customer centric initiatives-New products and Variants that are aligned with changing applications and the shift of Escorts from being a tractor manufacturer to being a complete Farm solution provider.

ENGINE ASSEMBBLY

2.1 CYLINDER BLOCK ASSEMBLY. Cylinder block is a block made of cast iron which is hanged to the housing and on which whole of the engine is the assembled. Cylindrical block is the main building block the engine. Block is tapped either by 215/273/312D for the assembly of crankshaft depending upon the model of crankshaft.

2.2 CRANKSHAFT ASSEMBLY. Crankshaft generates power. Crankshaft is a long cylindrical shaft, which has a crank gear on it which further is meshed with Idle Gear. Thrust washer is installed in the crankshaft and then, it is assembled on the main bearing.

The figure shows the crankshaft.

2.3 FUEL INJECTION PUMP ASSEMBLY. Fuel Injection Pump or Oil Pump is used to pump the fuel from oil tank o the injector with the help of pressure. From injector, oil goes to sliding piston and crankshaft of the engine.

2.4 CAMSHAFT ASSEMBLY Camshaft is used to open and close the inlet and outlet valve which is fitted over the cylindrical head.

2.5 GEAR ASSEMBLY Gear is a rotating machine part having cut teeth or cogs, which meshes with the teeth of other gears.

2.5.1 Gears are of three types: 1. Spur gear. 2. Helical gear. 3. Bevel gear. Gears are used for transmitting rotational motion and torque.

2.5.2 In the engine assembly of tractors at Escorts Limited, we have four gears. 4. Fuel injection pump gear 5. Crankshaft gear 6. Camshaft gear 7. Idle gear

2.6 PISTON ASSEMBLY Piston is a disc and it reciprocates inside the cylinder. The main function of the piston is to receive an impulse from the expanding gas and then transmit the energy to the crankshaft through the connecting rod.

2.7 ROCKER ARM ASSEMBLY Rocker arm is the part of an I.C engine. It is used over the cylinder head to open and close the inlet and outlet valve. Rocker arm is connected to camshaft.

Rocker arm assembly consists of Rocker Cover.

2.8 ROCKER COVER Rocker cover is used to cover the rocker arm. Under the rocker cover, an air filter is used to filter the air. Pressure of the air must be between 4-5 kg/cm2.

2.9 FLYWHEEL ASSEMBLY Flywheel is a rotating mechanical device used for storing rotational energy and provides it when it is required.The amount of energy stored in a flywheel is proportional to the square of its rotational speed.

ENGINE TESTING.

2.10 Testing procedure is as follows. 1. Once the pre testing is done, engine is brought to the testing bed at Total Productive Maintenance Machine. (TPM) 2. The flywheel is connected to the dynamometer through the shaft. 3. Oil filter is fixed at the bottom of the engine. 4. After fixing oil filter, thermostat sensor (during testing) is attached with the outlet water pump pipe. 5. Inlet pipe of the water is attached to the water tank. The water coming out of the outlet is measured by the digital meter on AVL machine.

6. After connecting water pump pipes (Inlet and Outlet), overflow pipes are connected. 2.13.2 There are two overflow pipes: . Fuel injection pump overflow pipe.

. Overflow pipe from the injector. 7. Further, after overflow connections, we will make oil connection and fuel connection.

8. Using TORQUE WRENCH set the torque of oil sump. Torque Wrench: It is a mechanical tool which is used to set the torque of the rocker arm for tappet clearance. 9. After the setting of torque is done, check the tappet clearance using filler gauge. 10. Since the tappet clearance is checked, diesel is feeded to fuel injection pump through feed pipe. 11. Start the engine and note down the observations.

ENGINE TESTING. ENGINE MODEL: E 3.215 3-Cylinder engine. Fuel Injection Pump Model NO: MICO (746)

2.11.1 The following parameters were needed to be observed: 1. Load(N-m) 2. Time(seconds) 3. Oil Temperature (degree Celsius) 4. Air Temperature (degree Celsius) 5. Water Outlet Temperature(degree Celsius) 6. Oil Pressure (bar)

2.12 GENSET Genset or Diesel Generator is used to provide electricity whenever there is power failure. 2.12.1 Escorts produce five different types of Genset. G-15. (2-cylinder)

G-20. (3-cylinder) G-25. (3-cylinder) G-30. (3-Cylinder) G-40. (4-cylinder)

PROJECT SOLENOID PLATE. Solenoid Bracket or Solenoid Plate is metallic plate which is connected to solenoid coil, so that whenever power goes, the solenoid plate sends a signal to the solenoid coil and then to the Fuel Injection Pump and the generator starts automatically supplying us the required power.

PROBLEM: The Problem that was occurring was that whenever there is failure in the power supply, the solenoid plate which is shown above in the figure couldnt take the require load and hence, the joint was broken, from the centre. Since, the solenoid plate was broken there was no forwarding of power to solenoid coil and further Fuel Injection Pump wont start and we wont receive the required power.

SOLUTION: Now, what we did was we changed the design of the solenoid. The material of it is aluminum. Also, we increased the thickness of it. The next figure shows the earlier design which failed several times as the one and only joint used to get broken.

The next figure shows us the new design. This new design has more thickness and hence more stability. Since, the time we implemented the new design there were no more Solenoid Plate failure.

PRACTICAL APPLICATIONS
1. This training helped me knowing about the different models of diesel engines and their differences. 2. Also, I learned about the assembly line which helped me in gaining my knowledge about the engine parts. 3. I went to the Engine Testing and thus tested engine at various loads, and helped me in knowing about different failures that might occur during testing. 4. I gained the knowledge about the Genset, its applications and its different models. 5. Also, this training improved my communication skill and gave me an outline of how a successful industry works. 6. This six months training helped me in developing professional relationships with people from other departments.

CONCLUSION The aim of this six months industrial training was to get as much knowledge as I can so that itd be beneficial for me as well as for the organization. I learned about engine assembly and testing procedure as engine was testing on Total Productive Maintenance Machine. I gained knowledge about the DG Sets and its dress up. All in all, the six months training was really beneficial for it increased my knowledge about a diesel engine which is now a days a major sector in Mechanical engineering. Id love to work in the organization again.

BIBLIOGRAPHY/REFRENCES 1. Escorts website: www.escortsgroup.com 2. Literature of the company. 3. Manual of the Diesel Genset. 4. Spare Parts Book of the Genset. 5. Machine Design by R.S Khurmi 6. Google: www.google.com