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ASSIGNMENT 3. 3. ANALYSES AND RECTIFICATION OF LEAKAGES IN THE VEHICLE
3.1 AIM:
To analyse the LEAKAGES in vehicle ARIA and their RECTIFICATION
3.2 OBJECTIVE:
1. To collect collect data of of shower shower leakages leakages 2. Rectification Rectification of leakage leakage problems problems 3. Finding Finding the permanent permanent soluti solution on
3.3 IMPORTANCE OF PROJECT:
Various problems due to shower leakages: •
Water affects the electronic parts and may cause permanent damage.
•
Leakages inside the vehicle are due to improper joints which symbolises the quality of vehicle.
•
Water leakage inside the vehicle causes discomfort to the consumer.
3.4 INTRODUCTION TO SHOWER TESTING:
1. What is a shower shower test? Checking the leakage inside the cabinet 2. Why shower shower test test is is needed? needed? To check and ensure that there is no water leakage inside the cabinet 3. How is is the shower shower test test performed performed??
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Vehicle is kept under the shower for 3 minutes and VISUALLY CHECKED from INSIDE for a LEAKAGE from windshields, glass door pads, windows, firewall, tailgates etc.
3.5 EQUIPMENT:
1. Shower area 2. Supply pipe 3. Motor 4. Nozzles 5. Blower
3.6 SPECIFICATIONS 3.6.1 SHOWER TEST AREA SPECIFICATION:
Shower Test Indicruz TCF Tech Techni nica call Para Parame mete ters rs Riser Pitch Nozzle Pitch Nozzle Spray angle Flow rate per nozzle Water pressure at Nozzle Length of booth Test time
I.SI.S-11 1186 865 5 revi revisi sion on 2006 2006 400 mm 400 mm 60 deg 15 lpm +/- 15% 2 bar +/- 15% NA NA Additional Fitures
Equi Equipm pmen entt Spec Specif ific icat atio ion n 400 mm 400 mm 60 deg 15lpm +/- 10% 2 bar +/- 10% 5.4 m 3 min
( Rain And Light Sensor Testing)
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3.6.2 MOTOR SPECIFICATION ::-
Manufactured by- Kirloskar Brothers Ltd. Type- SP- IHM S no.- A0DAJF0366 Size mm- 40x40 mm IP kw- 1.75 Head m- 13.5 IMP.DIA.mm-134.0 HEAD RANGE m-9.0-18.0 Lps-4.5 RPM-2800 CAPACITY RANGE lps- 6.2-1.5
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kW/HP -1.5/2.0 OVERALL EFF. %-34.0 INS B 50Hz 3 Ph CONN S 415V A 3.9 DUTY S1 INDUCTION MOTOR
3.7 TEST PROCEDURE :
1. Close all the doors, windows and fold carpet in the cabinet. 2. Pull the shower test ON cord and start the shower. 3. Start Start wipers wipers 4. Enter the vehicle in the the shower shower testing testing booth. booth. 5. Stop vehicle vehicle in the shower shower for 3 minutes. minutes. 6. Visually Visually check check for leakag leakages es closely. closely. 7. Check whether the wiper blades are over shouting shouting on the wind shield. 8. If a leakage leakage is found mark on the history card for rework. 9. If no leakage is found allow vehicle to dry on platform.
3.8 PREPARATION OF VEHICLE FOR SHOWER TEST:
1. Ensure Door beading is fitted properly and no sealing gap gap in BIW. 2. Ensure doors and windows are fitted properly. 3. Ensure Sealant application as per specification.
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4. Check tailgate tailgate bidding. bidding. 5. Ensure that that AC air is not sucked from outside. 6. Ensure that parking lighjt switch is ON when vehicle is inside the shower area.
Leakage place D Pillar leakage T/G seal leakage f-lhs door sash Both f -door sash T/G panel joint f-lhs door sash r-lh r-lhss door quart uarter er glass lass T/G panel joint
Cause sealant not properly filled seal loose sash immature sash immature sealant not properly filled sash immature seala ealan nt not prop proper erly ly fill filled ed sealant not properly filled
r-lhs door sash f-rhs door sash f-lhs door sash A pill pillar ar (win (winds dshi hiel eld d glas glass) s) f&r-rhs door sash A pill pillar ar (win (winds dshi hiel eld d glas glass) s) f-rhs door sash D Pillar leakage D Pillar leakage A pill pillar ar (win (winds dshi hiel eld d glas glass) s) T/G seal leakage
sash immature sash immature sash immature seal sealan antt not not prop proper erly ly fill filled ed sash immature seal sealan antt not not prop proper erly ly fill filled ed sash immature sealant not properly filled sealant not properly filled seal sealan antt not not prop proper erly ly fill filled ed seal loose
3.10 PROBLEMS
3.10.1 THE COMMON PROBLEMS:
1. Water leakage through through TAILGATE TAILGATE OR SEATBELTS due to improper fitting of the TAILGATE BEADING. 2. Water leakage through inner BEADING of of the DOORS DOORS due to DOOR SASH SASH PROBLEM. 3. Water leakage through the INNER BEADING BEADING of the FRONT DOORS due to improper use of SEALANT for the ROOF. 4.
Water leakage through D-pillar due to improper sealant filling.
3.10.2 SEVERE UNCOMMON PROBLEMS:
1. Leakage Leakage due due to blow holes. holes. 2. Leakage Leakage due to dents dents on on tail tail gate.
3.10.3 ANALYSES OF PROBLEMS :
PROBLEM
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REASON
CAUSE
Leakage through the
Improper fitting of the
Tailgate and roof joint left
TAILGATE or SEATBELTS
tailgate BEADING
open hence loose tailgate beading
Leakage through Inner BELT
Impr Improp oper er seal sealan antt fill fillin ing g
Seal Sealan antt not not cont contin inuo uous usly ly
of the doors
applied on the roof No checking in the BIW shop for Sealant application Roof of the cab too high for the operators to apply sealant in a proper manner
Water leakage through door
Door sash is immature
sash Water leakage through
Improper SEALENT filling
Change in operators
TAILGATE glass Water leakage through
by the OPERATOR Improper SEALENT filling
Improper Inspection Change in operators
WINDSHIELD GLASS Leakage through QUARTER
by the OPERATOR Improper SEALENT filling
Change in operators
GLASS
by the OPERATOR
Front and Rear
BIW joints mismatch
3.11 SOLUTIONS:
PROBLEM
SOLUTION
Leakage through the TAILGATE or
PS-Beating of joints suggested to be done
SEATBELTS
regularly
TS-Proper pressing pressing of TAILGATE TAILGATE beading beading before fixing Leakage Leakage through through Inner BELT of the doors doors
PS-
Change Change in sealant sealant filling filling procedure procedure •
Proper Instructions given to the operator
•
Strict follow up in BIW shop advised
TS- White sealant filled
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Water leaka akage through door sash
No perma rmanent solution
TS- pulling the door inside PS- Instructions given to the operator Water leakage through TAILGATE glass
Follow up taken by supervisors
Water leakage through WINDSHIELD
TS- black sealant filled PS-Instructions given to the operator
GLASS
Follow up taken by supervisors
Leakage through QUARTER GLASS
TS- black sealant filled PS-Instructions given to the operator
Front and Rear
Follow up taken by supervisors
TS- black sealant filled Abbreviations used:TS- Temporary solution
PS- perma rmanent solution
3.12 CONCLUSION:
After analysing the leakages in the cars during shower testing and after giving appropriate suggestions, it was observed that •
Testing Procedure Time on the whole was reduced considerably
•
As the leakages reduced , the damage of the interior parts was reduced, hence reduction in losses
•
The quality of the vehicle to the accepted standard, was obtained.
