1
BABA BANDA SINGH BAHADUR ENGINEERING COLLEGE FATEHGARH SAHIB, PUNJAB. INDUSTRIAL TRAINING FINAL PROJECT REPORT UNDERGONE AT
PREET AGRO INDUSTRIES PVT. LTD. NABHA(PB)
FROM: JULY 1, 2008
TO: DECEMBER 31,2008
FOR THE REQUIREMENT OF PARTIAL FULFILLMENT OF THE AWARD OF DEGREE OF B.TECH IN
MECHANICAL ENGINEERING
NAME
:
RAMANDEEP SINGH GILL
COLG. ROLL NO
:
246/05
UNI. ROLL NO.
:
5121111065
BRANCH
:
MECHANICAL ENGINEERING
SEMESTER
:
7TH
BATCH
:
2005-2009
2
CONTENTS S. No.
Text
1.
Certificate
3
2.
Declaration
4
3.
Acknowledgment
5
4.
Abstract
6
5.
Company Profile
6.
5.1 5.2 5.3 5.4 5.5 6.1
6.2 6.3 6.4 6.5 6.6 6.7 7.
8.
7.1 7.2 7.3 7.4 7.5 7.6 7.7 8.1 8.2 8.3 8.4
Objectives Marketing Infrastructure Awards/Achievement Products
Tractor
Introduction Constructional Parts Applications Design Product Range Differential Gear Box
Combine Harvester
Introduction History BriefDescription and working Cutter Bar Conveyors Gear Box and Reduction Box Hydraulic System
Quality Department
Need Benefits
Testing Procedure Quality Improvement System
Page No
7
9 10 10 11 12 25
25 26 27 27 27 28
29 30
30 30 31 33 34 34 34 35
37
38 40 43
3 8.5 8.6
Hardware Section List of Instruments 8.7 Flow chart of Quality check system
44 47 51
9.
PPC Department
52
10.
Purchase Department
53
11.
Projects
56
References
75
12.
11.1 To make Hardness chart of various parts of57 tractor so that ease in checking the incoming quality of various components 11.2 To implement power steering on the tractor 62to make the steering simpler and easier.
4
DECLARATION
I, Ramandeep Singh Gill do hereby solemnly affirm that the project work has been undertaken by me at the” Preet Agro Industries Pvt. Ltd. ", is an original work and that it is not a duplicate or a copy of any other work. I was guided in this project by Gurpreet singh, and have performed all the required tasks on my own.
Date: January 5, 2009
Ramandeep Singh Gill
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ACKNOWLEGMENT
I attribute my Honors in showing my feelings of indebtedness and tha Mr. B.S. Bhullar(Head of Training and Placement cell at Baba Banda Singh Ba Engineering college,FatehGarh Sahib(Punjab),S. Hari Singh (M.D.) and Mr. Rajiv Kaushal(Head of Training and accounts manager of Preet Agro Industries
Pvt.
Ltd.)
I am extremely grateful to all the supervisors and workers who offe valuable guidance, assistance, cooperation, and suggestion.
In the last but not the least I express my thanks to all, who directly or in encourage me to work at shop floor and discussed with me the trick’s to ac goal.
So I thanks to all mighty God who gave me chance to work with suc personalities. Ramandeep Singh Gill Mechanical Engineering.
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ABSTRACT
My industrial training in Preet Agro Industries Pvt. Ltd for six mon fourth year, 7th semester is highly learning experience for me. During th
done two projects, from which I learnt how to apply the knowledge of th academics of the engineering in practical application.
Secondly an exposure to the general behavior and the attitud industry an added gains. The various communication levels in the indus
first hand. The projects also give me an idea of the practical work, a importance and flow of documentation. Projects helped me to know that what type of expectations the industry from an engineer.
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COMPANY PROFILE
HISTORY OF THE FIRM
In 1980, when the nation needed one type of machine which could
harvest and thresh the crop simultaneously, to reduce the losses bearded by farmers, S. Hari Singh (M.D. of Preet Agro Industries Pvt. Ltd) was working project in his tractor repair workshop. After three years of hardship, he wa establish a small scale unit for manufacturing harvesting reapers, Threshe
Agriculture parts. Later, his brother S.Gurcharan Singh (Director) joined hi and they were able to make a tractor driven combine in 1986. The name Preet was established in 1987. In 1996, they manage
approval certificates from Machinery Training and Testing Institute, Minist agriculture, Govt. of India. In 1999, they converted their firm into a Pvt. Lt
Company. Today, they are the largest manufacturers of Self propelled combi harvesters in India.
Today, Preet Agro Industries Pvt. Ltd. has finally reached on this s when they are known in the farmer’s community nationwide.
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Plant Location :-
PREET TRACTORS PVT. LTD. P.O. Box No.28, Patiala Road, Nabha - 147201 (Pb.) INDIA Phone: 01765-220400, 222609, 309649 Fax: 91-1765-221619, 505649 Email:
[email protected] Website: www.preetagro.com
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OBJECTIVES PRIMARY OBJECTIVES:
The company has laid down for itself goal of improving the value to the c through maintaining leadership in following categories. •
•
•
•
•
•
Market share: To maintain for combines and tractors.
its
status
as
brand
leaders
in
th
Product Development: To develop tractors and combines for all ne as identified. Technology modernization and up gradation of technology to improvements to meet customers requirements.
Customer satisfaction it shall strive to achieve customer satisfaction than 90%. Quality: To improve quality consistently through quality assurance control. Delivery to strive to achieve 100% on time.
SECONDARY OBJECTIVES: •
Protection & security to its workers.
•
Safety for its workers.
•
Economy of operation by lowering cost.
•
Ensure a good quality system.
•
Training & development of existing work force.
•
To satisfy customer.
•
Better management
•
Better human relation.
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MARKETING
The Company is having very good marketing network all over India with 28
authorized dealers of tractor as well as combine harvesters. And having 35 % share in Self-propelled combine harvester and 10 % of tractor mounted co
harvester. Aim is take up 60 % of the market share. The company has sold m 3200 combine harvesters. INFRASTRUCTURE: PREET
is one of the India's leading manufacturers of agricultural tractors
combine harvesters. PREET is market leader in self propelled combine har
India. The company is controlling 35% market share of self-propelled comb harvesters. Present scenario of plant: -
1. ISO 9001: 2000 certified company. 2. Combine harvesters are manufactured on organized assem production line.
3. Plant is equipped with latest CNC turning machines for machin components and others computerized machines i.e. shearing machines, bending press, power press, lathe, shapers and rad machines etc.
4. Company is having one another fully computerized Turret punc
machine to enhance production capacity and to maintain the qu of product.
11 Future Plans: -
1. Company has installed Laser oscillator machine from MAZ Japan.
2. We will be first to install Robots for all type of welding jobs i plant in next financial year. 3. Dip Painting of sheet metal will be install soon. AWARDS / ACHIEVEMENTS:
The company participated in KISSAN MELA organized by Punja University Ludhiana in September 2003 and September 2005 with ex
our tractors and harvester combine. In the fair all the established ma
and international giants participated we were adjudged the best perfor awarded the first prize by the organizing authorities.
The company has participated in International Farm Equipme Toronto Canada in Feb’06. Mr. Ron Bollman from Government of Canada Invites “Preet to setup their plant in Ontario Canada.
The company has also participated in international trade exhib Lanka & South Africa. The company has also attended the multi-trade visit, in diffe United States of America & Canada.
Participated, adjudged the best performer and awarded the fir Mela 2006 held in University of Agricultural Sciences, Dharwad Karnat
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PRODUCTS
Today, Preet Agro Industries is the largest manufacturer of self propelled c harvesters in India. The company produces a wide range of tractors and co which are given below: 1. Tractors
a) Preet-6049 b) Preet-5049 c) Preet-4549 d) Preet-4049 e) Preet-3549 2. Combines a) Preet-987 Dominator (Multicrop combine harvester) b) Preet-987 (Maize Special Combine Harvester ) c) Preet-949 (Track type combine Harvester) d) Preet-649 (Tractor operated combine Harvester )
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1.PRODUCT RANGE FOR TRACTORS
14
15
Technical Specifications of Tractors DESCRIPTIO
PREET
PREET
PREET
PREET
N
3549-I
4049-I
4549-I
5049-I
PREET 6049-I
ENGINE
Model / Make
PREET 3549 PREET 4049
Power (PS) Type
34
39
Four Stroke DI Four Stroke DI
PREET 4549
PREET 5049
PREET 6049
45
47
57
Four StrokeFour Stroke Four Stroke DI DI DI
No. of Cylinders
3. Vertical Inline
3. Vertical Inline
Max. Torque
136Nm @ 1300 rpm
150Nm @ 1300 rpm
Bore / Stroke (mm)
95/110
97/110
102/110
95/110
100/110
Rated Engine rpm
2100
2100
2100
2100
2200
Displaceme nt (cc)
2340
2438
2697
3119
3456
Fuel Pump
Air Cleaner Cooling System
3. Vertical Inline
4. Vertical Inline
175.5%Nm 136Nm @ @ 1300 rpm 1300 rpm
Inline Inline PlungerInline Plunger Plunger (MICO (MICO Bush) (MICO Bush) Bush)
4. Vertical Inline 183Nm @ 1300 rpm
Inline Plunger Inline Plunger (MICO Bush) (MICO Bush)
Oil Bath with Oil Bath with pre cleaner pre cleaner
Oil Bath with pre cleaner
Oil Bath withOil Bath with pre pre cleaner cleaner
Water Cooled Water Cooled
Water Cooled
Water Cooled
TRANSMISSION
Water Cooled
16 Gear Box
8 + 2 Sliding 8 + 2 Sliding8 + 2 Sliding8 + 2 Sliding 8 + 2 Sliding Mesh Mesh Mesh Mesh Mesh
Clutch
Heavy Duty Heavy Duty Heavy Duty Heavy Duty Heavy Duty Dry Dry Single 280Dry Single 280 Dry Single Dry Single Single 280 mm mm mm 280 mm 280 mm
Breaks
Multi Disc Multi Disc DryMulti Disc Dry Multi Disc Dry Multi Disc Dry Dry Type Type Mech. Type Mech. Type Mech. Type Mech. Mech.
ROAD SPEED Km/Hr
Gear
LOW
HIGH LOW
LO HIGH LOW HIGH LOW W
9.87
2.51 9.87
2.57
10.1
2.37 10.88
2.51
HIGH
1
2.51
2
3.30
12.98 3.30
12.98
3.30 12.98
3.38
13.28
3.64 14.30
3
5.12
20.13 5.12
20.13
5.12 20.13
5.24
20.6
5.64 22.18
4
8.08
31.8
8.08
31.8
8.08 31.8
8.27
32.54
8.90 35.04
3.51
13.8
3.51
13.8
3.51 13.8
3.59
14.12
3.87 15.21
Reverse
9.87
HIGH
STEERING
2 Lever, ADDC
2 Lever, ADDC
2 Lever, ADDC
Hydraulic Pump
Gear Type
Gear Type
Gear Type
Linkage
3 Point Linkage - II
3 Point 3 Point 3 Point Linkage - II Linkage - II Linkage - II
Type
2 Lever, ADDC Gear Type
2 Lever, ADDC Gear Type 3 Point Linkage - II
POWER TAKE OFF
Splines
21
21
21
21
21
P.T.O. Speed
1000
1000
1000
1000
1000
48
48
56
56
56
8
8
8
10
10
CAPACITIES (Liters)
Fuel Tank Engine Sump
17 Cooling Systems
8.5
8.5
8.5
9.5
9.5
Air Cleaner
0.75
0.75
0.75
1
1
Transmissio n& Hydraulic
55
55
55
55
55
Steering
0.5
0.5
0.5
0.5
0.5
Front
6.00x16
6.00x16
6.00x16
6.00x16
7.50x16
Rear
13.6x28
13.6x28
13.6x28
14.9x28
16.9x28
1945
1945
1945
1945
2170
TYRE SIZE
Weight (Kgs)
18
1. PRODUCT RANGE OF COMBINES
19
20
SPECIFICATIONS OF PREET 987 DESCRIPTION ENGINE
Model Power No. of Cylinder Air Cleaner Cooling System
CLUTCH
Type of Clutch Dia (mm)
TRANSMISSION
No. of Gears Gear Speeds (Km/hr) Forward 1st Gear 2nd gear 3rd gear Reverse CUTTER BAR
Width Cutting Height (mm) No. of Blades No. of Guards Stroke (mm) Reel (rpm) Dia (mm) THRESHING DRUM
Width (mm) Diameter (mm) Speed (rpm)
MODEL - PREET 987
ASHOKA LEYLAND / KIRLOSKAR ALU-400 / 6 R-1080 105 BHP at 2200 rpm Six Combination of Dry & Wet Type Water Cooled Single, Heavy Duty Dry Clutch 310 3 Forward, 1 Reverse 2-4 4-8 8-20 4-8 14 feet (4.3 m) 55-1250 58 56 89 20-60 1064 W P Rasp Bar Peg Tooth 1250 1265 606 605 540 to 1200
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Speed Adjustment)
By Means of Mechanical Variator
CONCAVE
Clearance Front (mm) Rear (mm) Adjustment
STRAW WALKER
No of Straw Walker/Steps Length (mm) Width (mm)
17 to 30 13 to 35 7.5 to 11 9 to 12 Mechanical 5/5 3770 234
CLEANING SIEVES
Area (m2) Upper Sieve Lower Sieve F. CAPACITIES Grain Tank (m3) Fuel Tank (It)
BATTERY
No. of Batteries Capacity & Rating of each H. TYRE Front Rear
2.30 1.30 3.24 380 2 12 V, 88 Ah Size Ply Rating 18.4/15x30 14 PR 7.5x16 12 PR
MAIN DIMENSIONS
In Working: Length (mm) Width (mm) Height (mm) In Transport: Length (mm) Width (mm) Height (mm)
WEIGHT (Kg)
8130 4610 3855 11900 2950 3855 8200
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FLOWCHART OF MANUFACTURING PROCESS
Production Planning & Control (PPC)
Purchase Department
Quality Control Department
Stores
Machine Shop
Assembly Shop
Paint Shop
Pre Delivery Inspection (PDI)
SALES DEPARTMENT
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PROCESS OF MANUFACTURING
The process of manufacturing is rather a complex one though it seems simple. Every part to be manufactured undergoes through tests and is use
the approval of quality department. The entire manufacturing process is pre and is guided by the recommendations and suggestions of Production Plan
Control Department (PPC). During manufacturing process, the manufactur follow the industry standards being established by the industry. After qual
department o.k. & rejected component send to store. From store o.k. compo send to the assembly line no.1 and after assembling, the machines are sen
shop for painting. After paint shop all the electrical work, mirror’s work & se
is done in the assembly line no.2 or/final assembly. Thus, the manufacturing
complete after assembly line no.2. Then machines are sent to PDI (Pre Deliv Inspection) where they are checked for the faults if any. Now, the machine to be send to the sales department for sale.
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INTRODUCTION TO TRACTOR
The word tractor has been define fi d from an English word ‘traction’ which me
‘pulling force’. In other words it may be define fi d as the machine, which can d
work with the help of pulling force. The back tyres of tractor experience this
force.A tractor is a vehicle specifically designed to deliver a high tractive e
slow speeds, for the purposes of hauling a trailer or machinery used in agric construction. Most commonly, the term is used to describe the distinctive farm
vehicle: agricultu ral imp lements may be towed behind or mounted on the t the tractor may also provide a source of power if the implement is mechan
Another common use of the term is for the power unit of a semi- trailer tru
The word tr ac tor was taken from Latin, being the agent noun of tr aher e "to pu first recorded use of the word meaning "an engine or vehicle for pulling wa ploughs" occurred in 1901, from the earlier term traction engine (1859).
The first tractors were steam-powered ploughing engines. They were used in pa
either side of a field to haul a plough back and forth between them using a w CUGNOT STEAM TRACTOR
The Cugnot tractor is believed to be the first self-propelled road vehicle, an earliest automobile. Powered by steam, the three-wheeled tractor was inve by Nicolas-Joseph Cugnot. It was designed to carry artillery, but similar ve found many other uses in industry.
25
CONSTRUCTIONAL PARTS OF TRACTOR
26
TRACTOR APPLICATIONS
Tractors are mainly used for the following major applications: a) Farming b) Material handling and c) Transportation A tractor is a critical tool in farm mechanization. A 20 HP tractor can repla 200 laborers. Tractor is also for material handling in industries and a trac
combination is also used as a passenger / commercial vehicle in rural and se areas. Studies done in Punjab shows that an average farmer runs his tractor for a
hours in a year. Out of this, 278 hours is spent on farming while the remainin divided between marketing of produce and purchase of inputs (61 hours), c hiring (32 hours) and other social engagements (26 hours). TRACTOR DESIGN
A tractor is an automotive vehicle driven by an internal combustion engine. generated by the diesel engine is transmitted to the drive wheels through a
The tractor design is different from other commercial vehicles as it has a diff i.e. a gear assembly on the drive axle, which allows the two wheels to rotat
different speed. A tractor is normally equipped with power take off shaft, wh auxiliary equipment such as pumps and compressors. Tractors are normal with high power air cleaners, which ensure smooth working even in dusty c PRODUCT RANGE
Tractors are normally distinguished on the basis of power of the engine m horse power (HP) as follows: Less than 20HP (Small size) 20 - 40HP (Medium size)
27
30 – 60HP (Large size)
Above 60HP (Very large size)
In India popular range of tractors is 20 – 40HP compared to 60HP in Europe in U.S.A. In India, most of the farms are small and fragmented. Tractors av developed countries have advanced features and accessories.
DIFFERENTIAL
If a tractor travels in a straight line, the two rear wheels turn on the road e
same speed. There is no relative movement between the rear wheels. But wh
tractor takes a turn, the outer wheel travels on a longer radius than the inne
The outer wheel turns faster than the inner wheel, that is, there is a relative b/w the two rear wheels. If the two rear wheels are rigidly fixed to a rear ax
wheel will slip which will cause rapid tyre wear, steering difficulties and poo holding. Therefore, there must be some devices to provide relative movem
two rear wheels when the tractor is taking a turn. The differential serves thi
28
Differential is a part of the inner rear axle housing assy., which includes the differential, rear axles, wheels and bearings. The differential consists of a system of gears arranged in such a way that connects the intermittent shaft with the rear axles. The purpose of the differential is to provide the relative movement to the two rear wheels when the tractor is taking a turn. The torque transmitted to each wheel is, however, always equal.
GEAR BOX
The main functions which are performed by the gearbox are: -
The torque or the tractive effort ff produced by the engine va within narrow limits. But the practical consideration for the running o
under different conditions demands a large variation of torque availa wheels. The main purpose of the gearbox is to provide a means to var
leverage or torque ratio between the engine and the road wheels as re
Gearbox also provides a neutral position so that the engin wheels are disconnected even with the clutch in the engaged position.
The third function of the gearbox is to reverse the rotation shaft so as to drive the tractor in reverse direction.
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COMBINE HARVESTERS The
combine harvester,
or simply c ombine, also known as a thr es he r is a machine
that co mb in es the tasks of harves ting, threshing, and cleaning grain crops objective is to complete these three processes, which used to be distinct the machine over a particular part of the field. Among the crops harveste
combine are wheat, oats, rye, barley, corn (maize), soybea ns, and flax (lins waste s traw left behind on the field is the remaining dried stems and lea with limited n u trients which is either chopped and spread on the field or and bedding for livestock. HISTORY:-
The first combine was invented by Hiram Moore in 1838. It took many de
combine to become popular. Early combines often took more than 16 hors them. Later combines were pulled by steam engines. George Stockton B combine into a single machine using straw to heat the boiler. The heade forty feet long, cutting over one hundred acres per day. Early combines, some of them quite large, were drawn by horse or mule te
used a bull wheel to provide power. In 1902, a combine could harvest enoug
one hour to make 10 loaves of bread. Tractor-drawn, combines were used fo
Tractor drawn combines evolved to have separate gas or diesel engines to p grain separation. Newer kinds of combines are self-propelled and use dies
for power. A significant advance in the design of combines was the rotary de Straw and grain were separated by use of a powerful fan. "Axial-Flow" rota
combines were introduced by International Harvester "IH" in 1977. In abou on-board electronics were introduced to measure threshing effic ff iency. This
30
instrumentation allowed operators to get better grain yields by optimizi speed and other operating parameters.
31
32
WORKING OF COMBINE HARVESTERS
Combine harvester has been mainly divided into two parts:A. Cutter bar & conveyor unit B. Thresher, cleaner & Storage unit A. Cutter bar & conveyor unit:
Cutter bar assembly is mounted on the machine with
the feeder conveyor &can be lifted up or down with the help of hydraulic the following sub units 1. Reel 2. Knife and its drive 3. Auger 4. Feeder conveyor The function of the reel (1) is to hold the standing crop (2) until it has be knives and lay it over the pan of the cutter bar (3) and the rest of the sta the field to be slightly pushed apart so that it is not damaged by the mac entire length of the cutter bar there are blades guards in which knife bla
blades are riveted o the knife strip and have a reciprocating motion. The c
on the auger (4). Due to spiral movement, the crop is bought to the cente
In the center of auger, the prongs (5) handle the crop and push it to the c
of the feeder assembly. Feeder chain (6) conveys the crop from auger to t drum. B Thresher, Cleaner & Storage Unit:
cut crop is threshed in the threshing unit
consisting of moving drum (7) and stationary concave basket (8). To suit va
and their threshing characteristics, drum speed is and can be adjusted from th
33
operator’s platform. The gap between concave and drum which can be inc be increased or decreased by adjusting nuts on both side of the machine
The stone trap (9) is provided in front of the threshing drum and concave
catch the stone. the threshed straw is brought to the straw walkers to gui baffle ffl plate (12) is placed above the straw walkers (11) to control the gra
allowing the grains to fall at the front of the straw walkers and straw to b at the rear end of the machine at traveling complete length of straw wal
mixture of the grains and the straw drops from grate of concave above th
(13. due to vibrating action of the straw walkers the straw is carried to th the blower blows (15) blows the chaff ff and short straw and grains are se
hinged screw(14). Inclination and size of opening can be adjusted accordi nature and size of grains. Air from speed blower (15) is arranged in such passes under chaffe ff r racks (16) as well under both the sieves. The air cu light weight dust particles, short straws and other impurities out of the c A slide is mounted at the end of cleaning box to trap the grain if any be
away by current. The clean grains are drooped from the lower sieve (17) t
inclined lead (18) and are carried out by the grain elevator (19). At the to elevator is fixed another screw conveyor to convey the clean grain to the
(21). The un-threshed ear which had fallen at the rear of chaffe ff r rack find
inclined bed and are carried by screw conveyor (23) into the threshing dr compartment for re threshing.
34
CUTTER BAR
Cutter bar is one of the most important parts of the Combine Harvesters. Its cut the crop and then feed into feeder convener which then passes the crop
Cutter bar is placed on a Trailor assembly when it is taken from one place to
The main parts of cutter bar are Reel,Knife and its Drive,Auger. Power is sup these parts from engine with the help of various pullies.
KNIVES
While its construction,first of all the main base plate is constructed with the sheets and by various process like welding and grinding. Then side plates a Then the knives and knife drive and other pullies are installed. Then the au called as conveyor worm is fitted. Hydraulic cylinders are also placed at the lift the reel up and down. The function of the reel is to hold the crop and the by knives and then by the help of the auger,it is passed to Feeder. Usually the specifications of cutter Bar are:CUTTER BAR
Width Cutting Height (mm) No. of Blades No. of Guards Stroke (mm) Reel (rpm)
14 feet (4.3 m) 55-1250 58 56 89 20-60
35
Dia (mm)
1064 GEAR BOX AND REDUCTION BOX
Power from engine is supplied to Clutch with the help of pulleys. Clutch with gear box. The function of gear box is to get different speeds at same engine Gear box is designed to have 4 different ratios.(3 forward and 1
reverse).Reduction box is used to decrease the speed of the tyres as not v
speed is desired. Reduction box has only two gears,bull gear and small ge TYPES OF CONVEYORS & FUNCTION
GRAINCONVEYOR :-
It is an endless chain used to take only grain at the top of the combine in gra
tank. From Tank grains can be discharged to any tractor or other machine th discharge arm. It has total 38 links. EARCONVEYOR ;-
It is an endless chain used to take grain mixed with straws at front of Drum
Thresher,where it is again threshed to get grains,and straw is then thrown o combine from the back through straw walkers. It has 40 links. HYDRAULIC SYSTEM
Hydraulic fuel is put into the tank placed at the top near the Engine. From th
fuel goes to Pump. There are two pumps assembled at both sides of the engi get power from the Engine with the help of the belt and pulley arrangem
From the left pump fuel goes to the Armedeol which is used for the steering the right pump fuel goes to Distributer used for 3 purposes
36
Distributer used for 3 purposes 1) For lifting the reel of the cutter bar up and down. 2) For lifting up the cutter bar. 3) For the high low arrangement of the combine. Exit is through the right side to the reservoir, and then circle is repeated.
37
QUALITY DEPARTMENT Preet Agro Industries. is making a wide variety of Harvestor combines an which are being sent to National & International market .Quality is the ma important thing of this industry to sell there machines. Quality department at Preet. checks the quality of the componen
purchased from the different vendors, which are used in the assembly of the
and combines. These components are checked with very close quality contr parameter with the help of state-of-the-art quality control and inspection e MEANING OF QUALITY AND QUALITY CONTROL
Quality is one of the important factors which influences the purchaser of pro helps to capture market. It plays an important role in customer‘s decision a
why control of quality during manufacture of a product is very necessary. Qu simple words is define fi d as the fitness for use. An equally good definition fi is conformance to requirements. In both the above definitions, quality is defined relat
to use, rather than as a general characteristic that may be intangible. By thi
practical definition, fi if a product or service lives up to expectations, it is of hi
quality. On the other hand, extra fine finish or using materials that are far str required does NOT add quality to an item unless it somehow causes the ite conform to its requirement better. Quality of product depends upon the application of materials, men, ma
manufacturing conditions. The systematic control of these factors is the qu control. The quality of a product differs greatly due to these factors. For e
skilled worker will produce products of better quality and a less skilled wor produce poor quality products. Similarly better machines and better mate
38
satisfactory manufacturing conditions produce a better quality product. T
that to control the quality of product; the various factors which are responsi quality are required to be controlled properly.
In the words of Alford and Beauty quality control may be define fi d as “Indu
management technique by means of which products of uniform acceptable q manufactured”. It is concerned with making things right rather than disco rejecting those made wrong. It is something of the sort” a stitch in time sav but nine hundred in industry”. It may also be define fi d as “Quality control is an effe ff cting system for integ quality development, quality maintenance and quality improvement efforts ff
groups in an organisation so as to enable production and service, at the mos levels which allow for full customer satisfaction”. In other words, quality is everybody’s business and not only the duty of the persons in the Inspection Department.
NEED: - The quality control is needed due to the following reasons:
a)
CUSTOMER’S SATISFACTION
: - While purchasing a product, the customer
expects that the quality of the product should be accordance with the d
standard. If the manufacturer fails to achieve quality control, the custo be dissatisfied and the firm will lose its reputation in the market. b)
E C O N O M :Y
- one of the major aims of manufacturer is to make a product as
cheap as possible. The quality control activities can achieve setting a
adjustment of machinery in an economical way. This reduces the cost o production while retaining the desired quality. c)
REDUCTION IN SCRAP
: - Quality control ensures the best utilization of
material by locating and rectifying process faults and product defects. the amount of scrap is reduced to considerable extent.
39 d)
FEASIBILITY OF USING SPARE PARTS
: - It is often desired to replace
certain component parts in a machine. The manufacturers produce spa supply customers as and when needed. The quality control of product the interchangeability of spare parts. BENEFITS OF QUALITY CONTROL
There are many advantages by controlling the product quality. Some of them below: a) Improvement in quality. b) Increased production under same set up. c) Reduction in cost due to lower rejection and reworking. d) Reduction in scrap. e) Reduction in production bottlenecks. f) Reduction in inspection in terms manpower and equipment cost.
g) Evaluation of quality tolerance with an idea of avoiding uncalled for q build-up. h) Maintenance of operating efficiency. i) Less customer complaints. j) Quality consciousness. k) Obtain feed back from customers.
In IQC Department Incoming Raw Material are inspected in order to:
Eliminate those material which do not meet specification and like cause trouble during processing. Evaluate vendor’s quality and ability to supply acceptable materia
40
Inspection of raw material may involve a visuals check up only, a
dimensional check, a test of physical properties and chemicals comp etc. Raw materials depending upon their characteristics and may req sampling inspection
After inspection, the right quality parts are sent either to stock ro Assembly lines.
Hence Incoming Quality Control department helps to maintain the standa tractors being assembled in International tractor Ltd.
QUALITY RESPONSIBILITIES:-
AS A USER:-
Transmit needs to supplier.
Provide feed back to supplier
Obtain feed back from supplier
AS A PROCESSOR:-
Plan process to meet customers need. Control process to meet customers need. Improve process based on customers feed back. AS A SUPPLIER:-
41
Know who are customers Understand the needs of customers. Avoid creating problems for customers
TEST I N G PRO CEDUR E OF TH E COMP ON EN TS
The components are tested by the following procedure:1) APPEARANCE 2) DIMENSIONS 3) WEIGHT 4) FITMENT 5) FUNCTION/PERFORMANCE 6) MATERIAL 7) PROCESS 8) CHEMICAL COMPOSITION 9) WELDING CHECKING 1)
APPE RANCE :-
It is the first step to checking appearance of the components means how t
component looks like. Whether its surface is smooth or not? Whether its sha are chamfered or not? In this step component welding, surface treatment a machining is also checked. 2)
DIMENSIONS
:-
It is the most important step of the quality testing of the various compon
dimensioning means the checking of the dimensions of the component, whe
42
are correct or not? The dimensioning is done by certain instruments like the CALLIPER, MICROMETER, BEVEL PROTECTOR, HEIGHT GAUGE etc. B these measuring instruments the measurement of the dimensions of the co become very easy. These dimensions are checked with respect to the dime in the drawing i.e. the required dimensions.
3)
WE IGHT :-
The material of component is also necessary because it gives idea of the m
required for manufacture the component. The weight of the component is m weighing machine. This machine can measure the weight from 500gram to 50000gram. There is scale on the measuring machine, which shows the re weight. 4)
FIT ME NT :-
Fitment means fitting of the component actually in the vehicle. The comp then checked whether it fit properly in the relevant position or not. If the c fitted properly and then component get accepted otherwise it rejected. So
acceptation or rejection of the component is also based upon the fitment of t component. 5)
FUNCT IONAL PE RFORMANCE
:-
The functional performance of the component is measured after the fitme
component. Functional performance means how well the component is func
the vehicle. Stresses produced in the component, fatigue strength, reliabilit checked during functional performance process. 6)
MAT E RIAL :-
The material of the component should be able to absorb the stresses prod that component. The material may be brittle, hard or tensile as per req
43
Hardness of the material is generally checked by Rockwell hardness testing m poldi type hardness tester and shore hardness tester. 7)
PROCE SS :-
In this step of the quality control of the components the processes of the components are checked. For making a certain component there are certa
by which a component should go through. These processes are made in seria the component should follow these processes in serial wise. If the processe
wise then component is made exactly according to our requirement. These p can be checked only at the production site i.e. where the component is man
So in case of our industry the processes can only be checked on the vendor s
the component is manufactured. The processes can be drilling, punching, ta lathing, heat treatment, machining etc. 8)
:-
CHE MIAL COMPOSIT ION
There are standard materials, which can be used to make certain compon specific component there is specific material, by only which that compone manufactured. For the certain component, the material is selected as its re
like the stresses produced in the component, its working climate, working ti
it is very necessary to make the component with the required and reliable m
Material checking is done by the certain instruments and required lots of re
PREET TRACTORS PVT. LTD the material checking for chemical compositio not done. 9)
WE L DING CHE CKING
:-
Welding checking is also an important process in the quality testing of the
components. Welding checking means checking of the strength of the weldi components are made of different parts, which are welded with each other suitable and complete component. So it is very necessary to check the stre
44
welding, in order to maintain strength and quality of the component. Here m holes, porosity, welding appearance etc. of the welded component is checked
QUALITY IMPROVEMENT SYSTEMS
1.
COMPONENT DRAWINGS.
2.
PROCESS SHEET WITH SUMMERY SHEET. (REF. SCD PROCESS SHEETS).
3.
FIRST PC. SETTING OK RECORD
4.
RUN CHART FILLING BY OPERATOR & AUDIT BY QE ON RUN CHART.
5.
CHECKLIST ON FRONT SIDE & PDI ON THE BACKSIDE OF THE SHEET.
6.
IN PLANT REJECTION & THERE DEFECT ANALYSIS.
7.
PERIODIC INSPECTION AND MAINTENANCE OF TOOLS/GAUGES & MACHINES.
8.
MASTER SAMPLE SHOULD BE AVAILABLE FOR EACH SHEET.
9.
MATERIAL SHOULD BE PROPERLY STACKED IN BINS .(NO MATERIAL SHOULD BE ON SHOP FLOOR)
10.
TOOLS & GAUGES SHOULD BE KEPT PROPERLY AT THEIR ENMARKED PLACE.
11.
WORKSTATION SHOULD BE ACCORDING TO LAYOUT PLAN.
12.
MATERIAL SHOULD BE TRANSPORTED TO PTL IN BINS & ARRANGEMENT SHOULD BE AVAILABLE FOR LODING BINS INTO LCVs.
45
13.
THE RESPONSIBILITY OF IMPLEMENTING AND MAINTAINING VERIOUS RECORDS SHOULD BE CLEARLY DEFINED AND THE NAME OF THE PERSON TO BE INTIMATED TO VDC AND BUY.
14.
SUBMISSION OF SELF-APPRAISAL FORM.
HARDWARE SECTION
Hardware is one of the main sections of the Incoming Quality Control De
All the hardware items which are used in the tractor assembly are checke
thoroughly in this section of IQC department. There are more than 900 di
components which are checked on regular basis, for this purpose Quality Inspectors are provided with the entire measuring Instrument require
For the convenience these components are further categorized under di groups .Name of such groups is as follows:-
There are 96 types of different WASHERS whic checked under this group. All these are used in different tra
WASHERS:-
assemblies. There are 75 types of different SHIMS which a under this group. All these are used in different tractor assemblie
SHIMS: -
There are 60 types of different BOL SCREWS which are checked under this group. All these are use
BOLTS
&
SCREWS:
-
different tractor assemblies
46
There are 80 types of different RUBBER which are checked under this group. All these are used in diffe
RUBBER ITEMS: -
tractor assemblies.
There are 50 types of different SPRINGS wh checked under this group. All these are used in different tra
SPRINGS:
-
assemblies.
There are 54 types of differe DELIVERY & FUEL PIPES which are checked under this group. A
DELIVERY
&
FUEL
PIPES:
-
these are used in different tractor assemblies.
There are 54 types of different SUCTION which are checked under this group. All these are used in diffe
SUCTION PIPES: -
tractor assemblies. There are 21 types of different KNOBS which a under this group. All these are used in different tractor assemblie
KNOBS: -
There are 21 types of different PLUGS which a under this group. All these are used in different tractor assemblie
PLUGS: -
There are 20types of different RINGS &SEALING RINGS which are checked under this group. A
O-RINGS
&SEALING
RINGS:
-
these are used in different tractor assemblies. There are 23 types of different CLAMPS which a under this group. All these are used in different tractor assemblie
CLAMPS: -
47
There are 18 types of different HOSE PIPES checked under this group. All these are used in different tra
HOSE PIPES: -
assemblies. There are20 types of different DUST PTO COVER which are checked under this group. All these are us
DUST CAP PTO COVER: -
different tractor assemblies. There are58 types of different BUSHES which a under this group. All these are used in different tractor assemblie
BUSHES: -
There are 23 types of different WIRE & which are checked under this group. All these are used in diffe
WIRE & CABLES: -
tractor assemblies.
There are 120types of different PINS WASHERS checked under this group. All these are used in different tra
PINS: -
assemblies. There are 14 types of different NUTS which are this group. All these are used in different tractor assemblies.
NUTS: -
There are 13 types of different ADOPTERS wh checked under this group. All these are used in different tra
ADOPTERS: -
assemblies.
There are 65 types of different SPACERS whi checked under this group. All these are used in different tra
SPACERS:
-
assemblies.
48
There are 66 types of different GASKETS whi checked under this group. All these are used in different tra
GASKETS:
-
assemblies.
There are 6 types of different FUEL OFF ROD which are checked under this group. All these are use
FUEL CUT OFF RODS: -
different tractor assemblies. LIST OF INSTRUMENTS USED IN QUALITY DEPARTMENT S.NO . 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24
NAME OF INSTRUMENT
RANGE
MAKE
VERNIER CALLIPER 0 - 600mm MITUTOYO VERNIER CALLIPER 0 - 300mm MITUTOYO VERNIER CALLIPER 0 - 150mm MITUTOYO DIAL INDICATOR 0 - 11mm MITUTOYO DIAL INDICATOR MITUTOYO MICROMETER 0 - 25mm MITUTOYO MICROMETER 25 - 50mm MITUTOYO MICROMETER 50 - 75mm MITUTOYO MICROMETER 75 - 100mm MITUTOYO MICROMETER 100 - 125mm MITUTOYO MICROMETER 125 - 150mm MITUTOYO MICROMETER 150 - 175mm MITUTOYO FLANGE MICROMETER 0 - 25mm MITUTOYO FLANGE MICROMETER 25 - 50mm MITUTOYO FLANGE MICROMETER 50 - 75mm MITUTOYO FLANGE MICROMETER 75 - 100mm MITUTOYO FLANGE MICROMETER 100 - 125mm MITUTOYO FLANGE MICROMETER 125 - 150mm MITUTOYO SLIP GAUGE BOX 83PC. PECOCK RADIUS GAUGE 1 - 7mm MITUTOYO RADIUS GAUGE 7.5 - 15mm MITUTOYO RADIUS GAUGE 15 - 25mm MITUTOYO FEELER GAUGE 0.05 - 1.00 ATUL HEIGHT GAUGE(DIGITAL)
0 - 600
MITUTOYO
QTY.
1 2 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
49 ROCKWELL HARDNES 25
TESTER SHORE HARDNESS
-
FINE
1
26 27 28 29 30 31 32 33 34 35
TESTER DIAL BORE GAUGE DIAL BORE GAUGE DIAL BORE GAUGE DIAL BORE GAUGE MEGNETIC STAND MICROMETER STAND MAGNETIC V - BLOCK MAGNETIC V - BLOCK THREAD PITCH GAUGE
0 - 100 10 - 18.5 18 - 35 35 - 60 50 - 150 MS - 1 102X96X72 152X98X74 B.S.W.
MITUTOYO MITUTOYO MITUTOYO MITUTOYO MITUTOYO SAMRT SAMRT MITUTOYO BHAL
1 1 1 1 1 1 1 1 1 1
36 37 38 39
SPECIAL DEAD CENTRE SCREW JACK (BIG) SCREW JACK (SMALL) BED CENTRE SURFACE PLATE
1000X260
ENGG. LUTHRA
1 4 4 1
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
(GRANITE) CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS CYLINDRICAL PINS THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD RING GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE
1000X1000 ø 3.1 ø 3.2 ø 4.5 ø 5.00 ø 5.50 ø 6.00 ø 7.00 ø 8.00 ø 8.10 M24X1.5 M22X1.5 M20X1.5 M18X1.5 M16X1.5 M16X2 M14X1.5 M12X1.75 M10X1.5 M8X1.25 M8X1 M6X1 M24X1.5 M22X1.5
LUTHRA HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP
1 5 5 5 5 5 5 5 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1
50 64 65 66 67 68 69 70 71 72 73
THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE THREAD PLUG GAUGE CALCULTOR
74 75
SCIENTIFIC GEAR PROFILE TEATER
M20X1.5 M18X1.5 M16X1.5 M16X2 M14X1.5 M12X1.75 M10X1.5 M8X1.25 M8X1 M6X1
HIP HIP HIP HIP HIP HIP HIP HIP HIP HIP
1 1 1 1 1 1 1 1 1 1
-
CASIO MITUTOYO
1 1
PHOTOGRAPHS OF INSTRUMENTS VERNIER CALLIPER
51
MICROMETER
RO CKWEL L HA RDN ESS T ESTI N G M AC HI N E
52
MATERIAL REJECTED / O.K. Material unload by store helpers in Q.C. d e p a r t m e n t
Store give material received report (M.R.R.) to Q.C. d e p a r t m e n t
Enter the M.R.R. no. & material detail in daily register by Q.C. department for re Inspect the material in Q.C. If O.K.
d e p t.
If Reject
Send one copy of Send one copy of M.R.R. to Purchase M.R.R. to store So department that material may transfer to store
Send one copy of clear M.R.R. to Purchase To inform the store deptt. with inspection port of rej. material so department, to pick re the rejected material from that feed back may transfer to vendor. Q.C. department
53
PPC DEPARTMENT
PROD UCTI O N PLAN N I N G AN D CON T ROL
When a product is to be manufactured, the product must be carefully p ensure that proper methods are used and every work center is assigned the
work acc to the capacity. While the product is being manufactured, the prod must be controlled to ensure that the planned output is constantly maintai production planning and control consists of two diff and distinct function PRODUCTION PLANNING + PRODUCTION CONTROL.
Production planning involves management decisions relating to much to produce, what materials, parts and tools will be needed, what step
followed in the production process, within what time limit, the production is completed and how much work to be done by each work station. Production control involves implementation of production pla
schedules by coordinating different activities. It seeks to ensure that produc
operations and actual performance occur according to planned operations a
performance production operations are constantly evaluated, guided and di the plans formulated by the planning department. The specific objectives of PPC are as follows:-
1. 2. 3. 4. 5. 6.
To establish production targets and requirements. To ensure smooth production by removing problems and bottle-necks in the production process. To coordinate machine and labour for optimum utilization of resourc To guide purchase and supply of materials to suit production rate. To minimize the cost of production and to maintain quality of output. To ensure that jobs are completed in time and the delivery schedule maintained.
54
PURCHA SE DEPARTMENT I N TR ODUCT I ON TO PU RCH ASE DEPART MEN T
:-
As the name indicate the purchase department is mainly concerned with the of component & analysts of various parts that are provided by vendors. The work done by purchase department is:a) Costing & analysis b) Enrolment of new vendors c) Sample inspection report d) Monitoring the working of vendor e) To get submitted the corrective & preventive action report. f) To cancel the order of defaulter vendor g) To issue & order to fresh vendor
First have all the costing & professional in this field does analysis of compon
exact cost is measured by calculating the cost of material & cost of operation
the component. The purchase department bargain with the vendor to get th minimized. In the bargaining the profit is kept fixed. Either the cost of tran bared by the vendor or by the company.
To enroll the new vendor the vendor is to fill the enrollment form, which ma of following clauses: 1) Name & personal address of vendor 2) Telephone no. 3) Fax no. etc.
For new vendors first of all drawing is provided & he is asked to submit the s
within a time frame the sample is checked by quality control department & t report is filled & send to vendor.
55
If the sample is up to standard & compile with a drawing then vendor is
registered for the order. The vendor is made to sign the bond & cost price pa which is bound legally to supply the component stock. The payment is mad
according to agreement. The material from vendor is first of all checked by Q Department. TERM S USED I N TH E PU RCHASE DEPARTME N T
There are some terms which are commonly used in purchase departme are given below: ERN (Engineering Release Note): -
When a new drawing is released from the R & D department it is rele a number called the engineering change note. To every drawing there is c no. ECN (Engineering Change Note): -
When ever some changes are made in the drawings then the changed
released with the ECN number. It is done so because of the feedback from th
production side. This change is shown by an alphabetic letter, like a, b, c e I.O.M. (Inter Office Memo): -
It is a document that is issued with in the different department of the from purchase department to tell them to do the needful work as desired per company requirements. PURCHASE ORDER: -
The purchase order is given to the vendor which includes the details a prices of the components which are to be purchased from the vendor.
56
VENDOR REGISTRATION FORM: -
Vendor registration form (VRF) is a pre-printed document containing
standard list of questions which are required to be filled by the prospective v
The filled in VRF are preserved by the Purchase Department for future re SAMPLE INSPECTION REPORT:-
Sample inspection report (SIR) is an inspection report listing the qua parameters and specifications that are required to be checked by the qual The actual result of Q.C. is mentioned on the SIR against each quality para Based on the result the sample is either accepted or rejected.
57
58
PROJECT NO.1 AIM: - To make Hardness chart of various parts of tractor so that ease in che
the incoming quality of various components. REQUIREMENT OF HARDNESS CHART
If any component which is come under line rejection in qu mainly hardness then there is no need to open the control plan of that components, simply see the hardness of that component from hardne and check it again with suitable instrument.
It is easy to locate the component control plan from the component part no. from the hardness chart. It is benefic fi ial for trainee students and for trainee engineers hardness of various components of tractors. CONTROL PLANS USED FOR MAKING HARDNESS CHART
Rear Cover Front Axle Differential Gear and Shafts Gear Box Hardware
59
HARDNESS CHART FOR DIFFERENTCOMPONENTS S.NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
S.NO.
1 2 3 4 5 6 7 8 9
PART NO.
401004 401007 401010 401011 401013 401017 401020 402008 402010 405009 405016 403007 402018 104005 403006 104006 403002 104004 401023 4010106 402021 402016 405023 405013 405007
PART NO.
P0103005 P0406001 401019 407023 M0805007 301005 301006 407025 407026
REAR COVER DESCRIPTION
POSITION ACTUATOR ASSY. POSITION LINK ASSY. DRAFT LINK ASSY. SENSOR LEVER HINGE PIN SENSOR (L-42) SENSOR ROD PIN ROCKER LINK CONNECTING ROD LIFT ARM ASSY. POSITION CRANK ASSY. RETAINING PIN (BIG) RESPONE VALVE LINEAR LINK PIN BALL SHEET LINCH PIN PLUG PIN PIN SWIVEL PIN INSERT ROCK SHAFT DRAFT LEVER ASSY. POSITION LEVER ASSY. DRFT CRANK ASSY.
DIFFERENTIAL DESCRIPTION
P.T.O. COVER PLATE ( L ) P.T.O. COVER PLATE ( R ) ROCKER LINK ASSY. DRAW BAR WITHDRAWL NUT (PINION42X1.5) PLATE ASSY. ( L ) PLATE ASSY. ( R ) LOWER LINK BRACKET ( L ) LOWER LINK BRACKET ( R )
HARDNESS
58-63HRC 30-35HRC 35-40HRC 25-30HRC 40-45HRC 30-36HRC 25-30HRC 40-45HRC 58-62HRC 20-24HRC 20-25HRC 25-30HRC 50-60HRC 25-30HRC 50-60HRC 25-30HRC 20-25HRC 25-30HRC 25-30HRC 25-30HRC 40-45HRC 50-55HRC 35-40HRC 35-40HRC 20-40HRC
HARDNESS
180-230BHN 180-230BHN 40-45HRC 25-30HRC 25-30HRC 25-28HRC 25-28HRC 25-30HRC 25-30HRC
60
FRONT AXLE S.NO.
1 2 3 4 5 6 7 8 9
PART NO.
502013 502009 502007 501021 502008 501003 502002 502015 501010
DECRIPTION
STEERING ARM ( L ) STEERING ARM ( R ) HUB CAP DOWEL LEEVE O-RING HOLDER PIN ( TOE HOOK ) WEAR RING ( STUB AXLE ) KING PIN PIVOT PIN
HARDNESS
210-240BHN 210-240BHN 130-180BHN 20-25BHN 20-25BHN 35-42BHN 45-50BHN 45-50HRC 25-35HRC
HARDWARE S.NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16
PART NO.
P0609002 301002 301003 M0806001 P0301007 104007 1003009 402025 M0811000 406034 406031 106020 401022 406025 402012
DESCRIPTION
RUBBER PAD ( FLY WHEEL ) WHEEL BOLT ( REAR AXLE ) WHEEL NUT ( REAR AXLE ) STUD ( M16X1.5 ) RUBBER PAD ( FENDER ) DRAIN PLUG ( M24X1.5 ) HOSE PIPE O RING COPPER WASHER SPECIAL STUD SEALING WASHER O RING (B.P.S.) O RING (SENSOR) SEALING RING SEAL RING (ROCK SHAFT)
HARDNESS
SH 65 ±5 20 - 25HRC 20 - 25HRC 20 - 25HRC SH 80 ±5 20 - 25HRC SH 60 - 65 SH 65 ±5 40 -45HRC 20 - 25HRC SH 65 ±5 SH 65 ±5 SH 65 ±5 SH 65 ±5 SH 65 ±5
GEAR BOX S.NO.
1 2 3 4 5 6 7
PART NO.
P0204009 P0210004 P0210005 P0203017 207024 203010 207015
DESCRIPTION
INNER BUSH SHIFTER LEVER SHIFTER LEVER (HI - LOW) BOTTOM COVER PLATE IDLER CLUSTER PIN LOCKING PIN WITHDRAWL NUT (C.S.)
HARDNESS
180-230BHN 50-60HRC 55-60HRC 180-230BHN 58-63HRC 38-43 HRC 25-30HRC
61
S. NO.
PART NO.
GEAR AND SHAFTS DESCRIPTION
1
P0105001 BULL GEAR
2
P0105005 BULL PINION SHAFT ( L )
3
P0105016 BULL PINION SHAFT ( R )
4
P0207020 C. M. GEAR Z-43 DUAL
5
P0102002 CONNECTING SHAFT SMALL
6
P0207023 CONNECTING SHAFT BIG
7
P0207005 CONSTNT MESH GEAR Z-45
8
P0105009 CROWN WHEEL Z-42
9
P0207019 DRIVE SHAFT Z-21
10
P0207002 FIXED GEAR Z-25
11
P0207003 FIXED GEAR Z-30
12
P0207004 FIXED GEAR Z-36
13
P0207015 IDLER CLUSTER GEAR Z-15, Z-21
14
P0205001 INPUT SHAFT Z-19
15
P0206001 INTERMEDIATE SHAFT
16
P0206008 INTERNAL GEAR (4+1)
17
P0206009 OUTPUT SHAFT
18 19 20
208009
PLANET GEAR
P0102006 PTO SHAFT (21 SPLINES) 206020
SLEEVE HI/LOW
21
P0206002 SLIDING GEAR 34/12
22
P0206003 SLIDING GEAR Z-31
23
P0206004 SLIDING GEAR Z-24
HARDNESS
58-63HRC 58-63HRC 58-63HRC 58-63HRC 58-63HRC 58-63HRC 58-62HRC 58-62HRC 58-62HRC 58-62HRC 58-62HRC 58-62HRC 58-63HRC 58-60HRC 58-63HRC 58-63HRC 58-63HRC 60-62HRC 52-60HRC 50-55HRC 58-63HRC 58-63HRC 58-63HRC
62 24
101001
TAIL PINION
25
105006
CROSS
26
105007
BEVEL GEAR ( L )
27
105008
BEVEL GEAR ( R )
28
105011
BEVEL PINION
58-63HRC 58-63HRC 58-63HRC 58-63HRC 58-63HRC
63
Project No. 2
AIM: - To implement power steering on the tractor to make the steering simpl
easier. REQUIREMENT OF THIS PROJECT
1. Larger amount of torque is required to be applied by the driver for s medium and heavy vehicles
2. Heavy vehicles such as Off-road trucks, fork lifts, earth moving machine tractors demands high steering forces.
3. Mechanical linkage between the steering wheel and the steered wheels w more difficult and expensive in compact design vehicles. APPLICATIONS
• Agriculture • Construction • Forklift trucks • Lawn and garden • Mini tractors •
Municipal vehicles
64
COMPONENTS OF POWER STEERING 1. STEERING WHEEL:
- its diameter is 350mm [14 inch.], 3 spoke steering
wheel with knob standard and optional horn button.
2. STEERING COLUMN
Steering columns connect the steering wheel to the steering unit.
The steering column must be supported when its length exceeds 150 m The mounting of the steering column must be properly aligned so tha unit can return to neutral position automatically after a steering action completed.
The construction of the steering column must ensure that no are transferred to the steering unit input shaft.
65
3) STEERING UNIT
It has four ports, one is connected to tank or reservoir, one and remaining two is connected to steering cylinder. It controls the flow of oil in different ports. It is rigidly fixed with steering column. 4) PUMP
It provides the oil to the pump.
66
It has two ports one is connected to steering column and oth pump. The oil used must be filtered for better working of the system
A magnetic insert is recommended when using filters larger tha
5. STEERING CYLINDERS:-
The steering cylinder used in this power steering is
double
cylinder.
Balanced cylinders are compact and eliminate differences be wheel turns and steering forces because of equal volumes.
6. PUMP:-
The hydraulic power for the steering is provided by a below).
Gear Pump
67
This pump is driven by the tractor's engine via a belt and pulle Correct pump sizing is important in avoiding unnecessary energy slow response to steering demand. It supplies the required pressure to oil.
PUMP
68
LAYOUT OF HYDROSTATIC POWER STEERING
69
HOW TO SIZE THE CORRECT STEERING SYSTEM STEP 1. TOTAL STEERING TORQUE:-
Total steering torque, T = C.f (√B2/8 + E2 ) kgmm Where C = Load on the steered axle (in kgmm) E = King pin offset (in m) B = Tyre breadth (in m) LOAD ON THE STEERED AXLE, C = 1030 (LOAD ON FRONT STEERING) +2000 (Load of the loader)
C = 3030 kg
E/B = 60/190 = .316
70
(WHERE B=190,E=60)
F = 0.4
(from above graph )
Where F= coeffic ff ient of friction(dimensionless).Based on 0.7 As maximum. T = 3030X0.4 √(190)2/8+(60)2 kgmm = 3030X0.4X90.07 kgmm T = 109164.13 kgmm
STEP 2. FORCE REQUIRED FOR AXLE :-
F= Mr/Rmin. Where F = Required piston rod force (in kg), Rmin. = Minimum effective radius arm (mm) F= 109164.13/100 kg F = 1091.64 kg
A = F/P cm2
71
Where A = Pushing cylinder area (mm2), P = Steering max. pressure in bar For vehicle with a steered axle that can never be overloaded use 80% of the circuit relief valve setting. For moderately loaded vehicles use 60%. For ve can be severely overloaded use 30%. A = 1091.64/90 = 12.13 cm2 A = 1213 mm2
STEP 3. SELECTING STEERING UNIT DISPLACEMENT:-
Before proceeding further, a decision must be made as to the number of st revolutions desired for the application to steer the axle from full one side to Depending on vehicle usage, this will vary, normally
2
1/2
to 5
1/2
with 4 be
good typical value. Area of cylinder, A = Π/4[(D)2-(d)2] = Π/4[(60)2-(36)2] A= 1808 mm2
As 1808 > 1213 Therefore it is acceptable. Stroke length,
S = 175 mm
Volume, V = 1808X175mm3 = 316400mm3 V = 316.4 cm3 ,The volume of oil required to move cylinder rod(s) through the stroke. Total wheel turns, N = 3 Therefore, steering unit displacement, Cu = V/N = 316/3 cm3/rev. Cu = 105 cm3/rev.
As the calculations are complete, we select the closest standard steering displacement (i.e. 100 cc unit) from catalog information.
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STEP 4. CALCULATING REQUIRED PUMP FLOW :-
We select Dowty pump IP 30 28,which has discharge of 12.7 liter at 1500 rpm At 1000 rpm its discharge will be = 12.7X1000/1500 = 8.5 liter/min. Hence at 1000 engine rpm, we shall be able to get 8.5 liter./min. which me steer wheel = 8.5X1000/100 =
85 rpm which is fairly ok and at 2000 rpm of engine
we shall be able to steer wheel by 170 rpm.
STEERING TROUBLE SHOOTING
The most probable cause of this trouble is the slackness in the steering linkage due to wear of be
EXCESSIVE BACKLASH IN STEERING :-
steering. When the vehicle is being driven straight, it turns side and when the driver turns the steering to bring it back to the stra
WANDER :-
ahead, it turns slightly to the other side, thus the driver has to adjust s constantly to keep the vehicle direction straight, the effe ff ct is called PULLING
TO
ONE
towards one side.
SIDE
:-
Sometimes the vehicle constantly
The oscillation of the front wheels at low speeds is called wobble.
WHEEL WOBBLE(LOW SPEED SHIMMY) :-
The oscillation of the front wheels at high is called high speed shimmy.
HIGH SPEED SHIMMY :-
Sometimes the front wheels of vehicle at high vibrate so violently that an almost uncontrollable motion of the ve
WHEEL TRAMP :-
caused that is called wheel tramp.
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This is normally due to incorrect tyre pressure, excessive toe-in or toe-out.
EXCESSIVE TYRE WEAR :-
When the effort ff required for steering is mo the normal steering force.
HARD STEERING :-
Poor return of the steering wheel to may be due incorrect tyre pressure, tight or frozen steering shaft be
POOR RETURNABILITY :-
incorrect front wheel alignment.
BENEFITS
Minimizes steering linkage-reduces cost, provides flexibility in Provides complete operator comfort.
isolation
of
load
forces
from
control
sta
Provides continuous, unlimited control action with very low inpu
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REFERENCES
Information Brochure of the company. Websites of the company i.e. www.preetagro.com
www.preetcombines.com www.preettractors.com Other internet websites like google,wikipedia,howstuffworks,etc Text books used as reference for the study, especially A utomobile Engineering (Vol 1 and 2) by Dr. Kirpal Singh.