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PROJECT REPORT
Development of Automatic ON-OFFSystem for various Electrical Equipmentsof Paint Touchup Zone
at
TATA MOTORS LIMITED, LUCKNOW
Submitted by
K AANCHAN K RISHNAB.Tech. 3 rd Year Electrical & Electronics Engineering
Northern India Engineering College, LucknowSummer Trainee
Cowl-Cx Assy
Under the Guidance of
Mr. Ritesh SrivastavaDiv. Manager [Cowl-Cx Assy]
Project Duration
13 th June 2012 11 th July 2012
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TABLE OF CONTENTS
S.No.
Content PageNo.
1 Declaration 32 Certificate 43 Acknowledgement 54 TATA MOTORS- An Introduction 65 TATA Journey-Year by year 76 TATA MOTORS (Lucknow Plant) 107 Organization Structure of Lucknow Plant 118
Organization Structure Of Trim cx12
9Divisions of Tata Motors Lucknow
13
10 My department Cowl Shop 1711 Process Flow for Manufacturing of Cowls 1812 Project: Development of Automatic ON-OFF System for
various Electrical Equipments of Paint Touchup Zone
21
13 Summary 35
DECLARATION
I KAANCHAN KRISHNA hereby declare that the project work
entitled Development of Automatic ON-OFF System for
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various Electrical Equipments of Paint Touchup Zone is an
authentic record of my own work carried out at TATA MOTORS,
LUCKNOW as requirements of 4 weeks project during trainingunder the guidance of MR. RITESH SRIVASTAVA DIV. MANAGER
(COWL-CX-TRIM ASSY ).
KAANCHAN KRISHNA
(SUMMER TRAINEE)
COWL-CX ASSY.
Date: 11 TH -JULY-2012
I certify that the above statement made by the student iscorrect to the best of our knowledge and belief.I wish him every success in life.
Mr. Ritesh Srivastava
(DIV.
Manager, COWL-CX ASSY) Tata Motor Ltd., Lucknow
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CERTIFICATE
I, RITESH SRIVASTAVA (Div. MANAGER TRIMLINE), HEREBY DECLARE THAT KAANCHAN
KRISHNA of B.Tech. 3 rd Year Electrical &
Electronics Engineering HAS COMPLETED HIS
PROJECT ON Development of Automatic ON-
OFF System for various Electrical Equipments
of Paint Touchup Zone DURING THE ACADEMIC YEAR 2012-13.THE INFORMATION SUBMITTED IS
TRUE AND ORIGINAL TO THE BEST OF MY
KNOWLEDGE.
Mr. RITESH SRIVASTAVA(Div. Manager,
COWL-CX ASSY.)
Ms. JASNEET RAKHRA(Manager, HR)
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ACKNOWLEDGEMENT
Industrial training is a crucial period in
engineering curriculum since it exposes a student to
the real world which he or she is going to enter afterthe completion of the Diploma. This is the period during
which an engineer actually becomes an engineer by
gaining the Industrial experience. I am extremely
happy that I was given the opportunity to get training
in TATA MOTORS, LUCKNOW one of the most
renowned organization of India.
I would like to take the opportunity to thank my
Project Head MR. RITESH SRIVASTAVA (Sr.
Manager, CX TRIM ASSY) for having provided me
with the wonderful & conductive environment to work
in. He has been ever helpful and supportive.
I would like to thank Ms. JASNEET RAKHRA
(Manager HR) for providing me the opportunity to adda new dimension to my personality. I will remain
indebted to her for her generous way of dealing with
industrial trainees.
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Kaanchan Krishna
(Summer Trainee)
Cowl-Cx Assy
AN INTRODUCTION
Type : Public (BSE: 500570 )
(NYSE: TTM)
Industry: Automotive
Founded: 1945
Founder(s): JRD Tata
Headquarters: Mumbai , Maharashtra ,
India
Key people: Ratan Tata , Chairman
Ravi Kant , Vice
Chairman
Carl Peter Forster , CEO
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http://en.wikipedia.org/wiki/Types_of_business_entityhttp://en.wikipedia.org/wiki/Public_companyhttp://en.wikipedia.org/wiki/Bombay_Stock_Exchangehttp://www.bseindia.com/bseplus/StockReach/AdvanceStockReach.aspx?scripcode=500570http://en.wikipedia.org/wiki/New_York_Stock_Exchangehttp://www.nyse.com/about/listed/quickquote.html?ticker=ttmhttp://en.wikipedia.org/wiki/Automotive_industryhttp://en.wikipedia.org/wiki/JRD_Tatahttp://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Maharashtrahttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Ratan_Tatahttp://en.wikipedia.org/wiki/Ravi_Kanthttp://en.wikipedia.org/wiki/Carl_Peter_Forsterhttp://en.wikipedia.org/wiki/Types_of_business_entityhttp://en.wikipedia.org/wiki/Public_companyhttp://en.wikipedia.org/wiki/Bombay_Stock_Exchangehttp://www.bseindia.com/bseplus/StockReach/AdvanceStockReach.aspx?scripcode=500570http://en.wikipedia.org/wiki/New_York_Stock_Exchangehttp://www.nyse.com/about/listed/quickquote.html?ticker=ttmhttp://en.wikipedia.org/wiki/Automotive_industryhttp://en.wikipedia.org/wiki/JRD_Tatahttp://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Maharashtrahttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Ratan_Tatahttp://en.wikipedia.org/wiki/Ravi_Kanthttp://en.wikipedia.org/wiki/Carl_Peter_Forster -
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Prakash Telang, MD
(India Operations)
Ravi Pisharody,President (CVBU)
Products: * Automobiles
* Engines
Services: Outsourced
Engineering and Design
Revenue: $20.572 billion (2010)
Net income : $844 million (2010)
Total assets : $20.192 billion (2010)
Total equity : $2.224 billion (2010)
Employees: 50,000 (2010)
Parent : Tata Group
TATA JOURNEY YEAR BY YEAR:
1868: Jamsetji Nusserwanji Tata starts a privatetrading firm, laying the foundation
Of the TATA group.
1874: The Central India Spinning, Weaving andManufacturing Company are set up,marking the Group's entry into textiles.
1902: The Indian Hotels Company is incorporated toset up the Taj Mahal Palace and Tower, India's firstluxury hotel, which opened in 1903.
1907: The Tata Iron and Steel Company (now TataSteel) is established to set up India's first iron and steel
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http://en.wikipedia.org/wiki/Automobileshttp://en.wikipedia.org/wiki/Engineshttp://en.wikipedia.org/wiki/Outsourcinghttp://en.wikipedia.org/wiki/Engineeringhttp://en.wikipedia.org/wiki/Designhttp://en.wikipedia.org/wiki/Net_incomehttp://en.wikipedia.org/wiki/Assethttp://en.wikipedia.org/wiki/Equity_(finance)http://en.wikipedia.org/wiki/Holding_companyhttp://en.wikipedia.org/wiki/Tata_Grouphttp://en.wikipedia.org/wiki/Automobileshttp://en.wikipedia.org/wiki/Engineshttp://en.wikipedia.org/wiki/Outsourcinghttp://en.wikipedia.org/wiki/Engineeringhttp://en.wikipedia.org/wiki/Designhttp://en.wikipedia.org/wiki/Net_incomehttp://en.wikipedia.org/wiki/Assethttp://en.wikipedia.org/wiki/Equity_(finance)http://en.wikipedia.org/wiki/Holding_companyhttp://en.wikipedia.org/wiki/Tata_Group -
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plant in Jamshedpur. The plant started production in1912.
1910: The first of the three Tata Electric Companies, The Tata Hydro-Electric Power Supply Company, and(now Tata Power) is set up.
1911: The Indian Institute of Science is established inBangalore to serve as a centre for advanced learning.
1912: Tata Steel introduces eight-hour working days,well before such a system was implemented by law inmuch of the West.
1917: The Tatas enter the consumer goods industry,with the Tata Oil Mills Company being established tomake soaps, detergents and cooking oils.
1932: Tata Airlines, a division of Tata Sons, isestablished, opening up the aviation sector in India.
1939: Tata Chemicals, now the largest producer of soda ash in the country, is established.
1945: Tata Engineering and Locomotive Company(renamed Tata Motors in 2003) is established tomanufacture locomotive and engineering products.
Tata Industries is created for the promotion anddevelopment of hi-tech industries.
1952: Jawaharlal Nehru, India's first Prime Minister,requests the Group to manufacture cosmetics in India,leading to the setting up of Lakme.
1954: India's major marketing, engineering andmanufacturing organization, Voltas, is established.
1962: Tata Finlay (now Tata Tea), one of the largesttea producers, is established. Tata Exports isestablished. Today the company, renamed TataInternational, is one of the leading export houses inIndia.
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1968: Tata Consultancy Services (TCS), India's firstsoftware services company, is established as a divisionof Tata Sons.
1970: Tata McGraw-Hill Publishing Company is createdto publish educational and technical books. TataEconomic Consultancy Services is set up to provideservices in the field of industrial, marketing, statisticaland techno-economic research and consultancy.
1984: Titan Industries - a joint venture between the Tata Group and the Tamil Nadu Industrial DevelopmentCorporation (TIDCO) - is set up to manufacture
watches.
1991: Tata Motors rolls out its millionth vehicle. (Thetwo-million mark was reached in 1998 and the thirdmillion in 2003.)
1995: Tata Quality Management Services institutes the JRD QV Award, modelled on the Malcolm BaldrigeNational Quality Value Award of the United States,laying the foundation of the Tata Business ExcellenceModel.
1996: Tata Tele services (TTSL) is established tospearhead the Group's foray into the telecom sector.
1998: Tata Indica - India's first indigenously designedand manufactured car is launched by Tata Motors,spearheading the Group's entry into the passenger carsegment.
1999: The new Tata Group corporate mark and logoare launched.
2000: Tata Tea acquires the Tetley Group, UK. This isthe first major acquisition of an international brand byan Indian business group.
2001: Tata-AIG - a joint venture between the TataGroup and American International Group Inc (AIG) -marks the Tata re-entry into insurance. (The Group's
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insurance company, New India Assurance, wasnationalized in 1956). The Tata Group ExecutiveOffice (GEO) is set up to design and implement change
in the Tata Group and to provide long-term direction.2002: The Tata Group acquires a controlling stake inVSNL; India's leading international telecommunicationsservice provider Tata Consultancy Services (TCS)becomes the first Indian software company to crossone billion dollars in revenues. Titan launches Edge, theslimmest watch in the world. Idea Cellular, the cellularservice born of a tie-up involving the Tata Group, theBirla Group and AT&T, is
Launched. Tata Indicom, the umbrella brand fortelecom services from the Tata Tele services stable,starts operations.
2003: Tata Motors launches City Rover Indicasfashioned for the European market. The first batch of City Rovers rolled out from the Tata Motors stable inPune on September 16, 2003.
2004: Tata Motors acquires the heavy vehicles unit of Daewoo Motors, South Korea. TCS goes public in July2004 in the largest private sector initial public offering(IPO) in the Indian market, raising nearly $1.2 billion.
2005: Tata Steel acquires Singapore-based steelcompany NatSteel by subscribing to 100 per centequity of its subsidiary, NatSteel Asia.
2009: Tata Motors launched Tata Nano, worldscheapest family car.
2010: Tata Ace becomes India's first 1-lakh brand in
goods commercial vehicles. Appointment of Mr. Carl-Peter Forster as
Managing Director of Tata Motors. Jaguar Land Rover announces opening of its
Dealership in New Delhi. Tata Motors to construct heavy truck plant in
Myanmar under Government of India's Line of Credit.
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Tata Motors declared as the Commercial VehicleMaker of the Year.
Chief Minister of Punjab inaugurates
Tata Motors supported State Instituteof Automotive and Driving Skills. Jaguar Land Rover announces
Dr. Ralf Speth as Chief Executive Officer. Tata Motors appoints Mr. Carl-Peter Forster as
GroupCEO. Tata Motors Group displays the widestrange of products and environment-friendlytechnologies at Auto Expo 2010.
Tata Motors launches Magic Iris. On 26th April
2010, Tata Motors soldits 4 millionth Commercial Vehicle. Tata Motors Passenger Car Division launches
Tata Motors Service Edge' for leading edgecustomer service.
Tata Motors displays Tata Nano EV atthe 80th Geneva Motor Show.
TATA MOTORS LTD. (LUCKNOW PLANT)
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Year of commencement: 1991
Plant Area: 600 acresNumber of employees 835
DivisionsBIW, Paint,
Assembly Training
TATA MOTORS Lucknow Works is a
third manufacturing unit of Tata Engineering and
Locomotive Company. This unit covers an area of 600 acres.In this unit the assembly of chassis and spare parts takes
place. On 14th January 1992 the recruitment of operators
started in Lucknow plant. On 25th June induction of
Engineers (first phase) started which also included ITI's and
Occupancy of administration office of assembly shop in
September 1992. First vehicle rolled out from Lucknow plant
on 20th October 1992 which was LP 1210 52. Constructionof MRS finished on 6th January 1993. It took approximately
9 years since the conception of the plan and to rollout the
first vehicle from this latest manufacturing facility of Tata
Motors.
ORGANIZATION STRUCTURE (Lucknow Plant)
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Organization Structure Of Trim cx
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Alok SaxenaPLANT HEAD
Umair TauheedA.G.M Trim
Assy/Weld Shop
S.N.VermaA.G.MManufacturing
Ritesh SrivastavaProcess Owner TrimCX-1
Mandar Puranik Process Owner CV-CX
Sunil KumarProcess Owner FramCX
Alok SaxenaPlant Head
Umair TauheedA.G.M Trim
Assy./Weld Shop
Ritesh SrivastavaProcess Owner
SHANTI SHAW/ N.L.Mishra
UMESH SHUKLAMANAGER
NARENDRAKUMAR/D.Chaudhary
NALIN KUMARASST..MANAGER
Navyug Navodaya Navshakti Navjeevan
1. Vijay Kumar2. Abraham K.G.
3. A.K.Shukla4. Anand Singh
5. ChandenSingh
6. G.D.Bhatt7. Rajendra
Singh8 B.N.Godwami
9. U.P.Singh10.Bagisg Prasad
1. A.K.Sahi2. Man Singh3. A.K.Srivastava4. V.S.Nagi5. Jai Kishor6. D.Vishwakarma7. M.S. Rawat8. P.K.Singh9. A. N. Dubey10.P.C. Ram
1. Nand Kishor2. Gauri Dutt3. D.Mathpal4. Chhabi Nath5. Mahesh Dutt6. Krishna Kumar7. B.S.Sajwan8. Moti Lal9. Rakesh10.VikashChandra11. Ram Taj
1.RameshChandra2.Balendra Singh3.M.K.Mishra4.M.K.Sharma5.Mukesh Katyer6. Budh Singh7. A.K.Tripathi8. R.K.Chaudhary9. Rajesh Kumar10. SanjayKumar
11. ArvindKumar12.J.C.Gupta
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Divisions of TATA Motors Lucknow:
Training division
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The Training Center at the Lucknow plant aims atproviding high quality Apprenticeship Training. In addition,
the Centre provides both internal and external training,
support to operators, supervisors and managers in areas
like special skills and technology, safety, personnel
practices etc.
The Lucknow plant, after a major restructuring
exercise, executed a smooth transition from function-based
to process-based structure. By this structure, process
owners are required to meet stretched targets, and in orderto do so, are required to encourage individual learning and
development of employees. A structured process is being
followed to establish and reinforce an environment that
encourages innovation.
Assembly division
Lucknow Plant started with the assembly of
Medium Commercial Vehicles (MCVs) to meet the demand
in the Northern Indian market. However, in 1995, the unit
started manufacturing bus chassis of Light Commercial
Vehicles (LCVs) and SUMOs. The facilities for manufacturing
the spare parts were set up and started supply of Crown
wheel & pinion (CWP) in 1994. Subsequently, G-16 & G-18
Gear Parts started in 1998. With the availability of G-16
gear parts manufacturing facility, the Plant also started
assembly of G-16 Gear Box to meet in-house requirement
for SUMO vehicles in the year 2000.Now TATA Motors
Lucknow has started assembling of CNG MCV`s to meet the
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consumers demand. TATA Motors is also producing Rear
Engine CV`s.
Manufacturing Division
In TATA Motors Lucknow Crown Wheel and Pinion are
manufactured by various gear cutting process. Machining
(grinding and heat treatment) of Gear Box parts is Aalso
done here. These gears are used in gear boxes or as spares.
Now TATA Motors is assembling Gear Box of ACE (Newly
launched small CV) in Lucknow itself. The Manufacturing
unit of Tata Motors at Lucknow is the latest manufacturing
facility of Tata motors and is located towards East of Lucknow plant.
There are five factories in Tata Motors, Lucknow:
- CV-CX (Commercial Vehicle) Factory
- Transmission Factory
- TATA MARKOPOLO MOTORS Limited
- Integral Bus Factory (IBF)- RECON Factory
Departments in TATA Motors Lucknow are:
Planning
Technical services
Central tool room
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Central procurement
Dispatch
Central logistics
Factory logistics group-CV
Factory logistics gear-transmission
Factory logistics Gr-sumo
SQIG
Engineering services
Central maintenance
FPIG - CV factory
FPIG-transmission factory
Central quality (CQ)
Area office, Lucknow
Regional sales office (Lucknow)
Service deptt., Lucknow works
Plant head office
Manufacturing head office
Human resources
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Business excellence
Finance
Internal audit
ERC Lucknow
Administration
Construction
COMMERCIAL VEHCILES CENTER OF
EXCELLENCE
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Over the last fifty years, Tata Engineering has built up
an impressive line up of commercial vehicles that can
match international benchmarks. Today Telco is Indias
largest and among the worlds top ten commercial vehicles
manufactures. They have over 130 models and variants of
vehicles designed to transport almost anything. Their
commercial vehicles can haul loads ranging from 0.75 tones
to 49 tones. They have mini buses that can seat 12 people
and buses that can accommodate as many as 60.Tippers,
tractors trailers, and 4x4off road vehicles.
ABOUT VEHICLE CLASSIFICATION
In the Commercial Vehicle Business Unit, the models are
classified on the basis of GVW as under:
HCV: Heavy Commercial Vehicles
MCV: Medium Commercial Vehicles.
LCV: Light Commercial Vehicles.
The HCV segment can be further classified into three
segments based on gross vehicle weight as follows: ICV : Intermediate Commercial Vehicle with GVW
of 8 to 10 ton. MCV : Medium Commercial Vehicle with GVW of 10
to 15 ton. HCV : Heavy Commercial Vehicle with GVW of 16
ton and above.
MCV & HCVs can also be classified into two categories
depending on their usage as Trucks and Buses . Buses are
passenger carriers. Trucks include goods carriers along with
specialized vehicles like dumpers, tractor-trailers etc. the
ICVs fall in the load category of 8 to 10 ton GVW and are
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often substituted for medium or heavy commercial vehicles
in trunk routes or cities. EICHER Motors and SWARAJ
MAZDA are two manufacturers operating in this segment.
About Cowl CX
Cowl is the front portion of the Chassis, which has driving
seat, engine hood, lights, blinkers, dashboard, different
meters, indicators and other electrical connections toregulate the vehicle. Bare Cowls are being received from
Tata Motors, Jamshedpur as well as from Eastern Complex
and are assembled here.
Bare Cowls are put on the trolley with the help of 0.5 ton
(JIB) hoist and different fitments are made. Cowls trimmed
on the floor slat conveyor. Cowls of all the vehicles are
firstly assembled at Cowl CX and then it is finally bolted tothe Chassis at the Chassis assembly line (cowl dropping
station).
The Cowl CX is divided into two areas:
1. Bare Cowl Rectification Area
2. Trim CX Assembly Area
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Process Flow for Manufacturing of Cowls
Whole process of manufacturing cowls is divided into
19 stages as under after which the cowl is transferred
to main assembly line where it is assembled with the
Chassis:
Stage 0 (bare line): Unloading, tapping, washing, inspection and
welding (if required) Filling of sealant at open joint
Denting cowl where dents are observed
Grinding, emery paper sanding and application of
putty Centre panel alignment and knob fitting and
stopper fitting
Stage 1 : Dropping of the cowl
Model determination by facing mascot
Fitment of the L bracket/Maxi Fuse bracket
Stay rod and sleeve attachment
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Pasting of the inspection card
Stage 2 : DTV mounting and fitment
Fitment of the rubber bellow
Fitment of accelerator paddle
Acc pedal stopper bolt
Fitment of retaining plate
Stage 3 : Hand brake fitment
Connection of hand brake with W/H main cable
Placing clutch container with pipe above the
rubber grommet Fitment of the wiper motor
Fitment of the high temperature buzzerStage 4 :
Insulation and fitment of elbow in flange tube
Fitment of flange pipe and service indicator
Fitment of the footrest in LHD vehicles
Stage 5 : Assembly of jaali
Engine hood beading
Fitment of the stay rod
Pasting of BS2, BS3 and caution stickers
Stage 6 :
Fitment of the letter TATA
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Fitment of the T-emblem
Fitment of reflector triangle bracket
Fitment of Auxiliary water tankStage 7 :
Harness layout and routing, placing grommets
over the holes Horn fitment & connection
Stage 8 :
Routing of bottom harness Place speed cable inside clamps and holes
provided
Stage 9 : Placing of W/H cable wire inside hole of dome and
tighten screws of dome Fitment of the head lamp
Tighten blinker with screw
Stage 10 : Fitment of power steering tank
Fitment of combi switch
Stage 11 : Panel wiring
Instrument cluster connection
Stage 12 : Fitment of beeper
Driver seat stand fitment
Thrust rod fitment
Stage 13 :
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Mounting of air filter assembly on the bracket with
straps
Fitment of air filter bracket Mount and connect air intake pipe assembly to
flange pipe
Stage 14 : Mounting of driver seat
Tightening of wiper motor
Stage 15 : Instrument cluster fitment
Ammeter fitment
Stage 16 : Mounting of steering column assembly on the
bracket Steering wheel fitment
Hydraulic Jack fitment
Stage 17 : Electrical testing
Stick OK marked
Stage 18 : Inspection of the cowl and its parts
Remove the cowl from the conveyor with the help
of tackle Finished cowl palletizing on empty pallet
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PROJECTDevelopment of Automatic ON-
OFF System for various
Electrical Equipments of Paint
Touchup Zone
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Development of Automatic ON-OFF
System for various ElectricalEquipments of Paint Touchup Zone
OBJECTIVE : To reduce wastage of electricity in Paint Touchup Zone in Bare Line by designing automatic shut
down system for blowers and other electrical equipments.
APPROACH OF THE PROJECT: -
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PROBLEM IDENTIFICATION:
The Paint Touchup Zone in the Bare line section is used to
touch up the paint of cowls whenever necessary. The Paint
Touchup Zone has many electrical equipment necessary for
painting such as Blowers, Exhaust, Halogen Lamps and
Tube lights etc. These equipments are kept ON in the whole
shift of 8 Hrs. but it is used occasionally according to need.
So a large amount of energy is being wasted. This is not
suitable on financial ground as well as for company policy of
eco-friendliness. This is the problem.
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Problem Identification
Current State
Proposed Ideas
Selection of best alternative
Solution Development
Plan Implementation
Benefits
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CURRENT STATE:
The layout of Paint Touchup Zone and current energyconsumption study is as following:
The Paint Touchup Zone in Bare Line in Cowl Cx. Contains
following electrical equipments-
1. Blowers - 4
2. Halogen Lamps - 2
3. Industrial Tube Lights - 16
The arrangement of these equipments is shown in the
following plan layout of Paint Touchup Zone.
Layout of Paint Touchup Zone:
The following figure shows the top view of Paint Touchup
Zone
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Energy Consumption Study of Paint Touchup Zone:
The following table shows the energy consumption of the
Paint Zone-
S.
No.
Equipme
nt
Power
Rating
No. of
Units
Used
Working
Hours
Power
Consumed
1 Blower 7.5 hp =
5.6 KW
4 8 179.2 kWh
2 Halogen
Lamp
400 W 2 8 6.4 kWh
3 Industrial
Tube Light
40 W 16 8 5.12 kWh
Total 190.72 kWh
Proposed Ideas:
For the above said problem following solutions are
proposed-1. Off Delay Timer Circuit
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Limiting Switch Delay Timer Circuit
Relay
Contactor coilPower Equipments
2. Sensor Based System
3. Manual System
These solutions are explained in detail as following-
1. Off Delay Timer Circuit:
In this system an Off Delay Timer is made using IC-555 and
this is used to control a relay which in turn controls the
various electrical equipments.
The following Flow chart shows the plan.
Block Diagram :
Working:
According to this plan a limiting switch senses the entry of
cowl in the paint booth and sends a trigger signal to the off
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delay timer circuit. Limiting switch is of Pushbutton type so
after the entry of cowl the off delay timer starts its count
down. After a predetermined time the timer goes off which
is controlling a relay so relay turns off which turn off the
equipments connected to it through contactor coil. Thus the
equipments of Paint touchup Zone are turned off after a
predefined time after cowl entry. This circuit keeps off until
another cowl comes in the zone.
Merits: Simple and Cheap construction of system
Large saving of power
Fully automatic System
Demerits: Installation is Difficult
Timing not very accurate
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Entry Sensor Switching Circuit
Relay
Contactor coilPower Equipments
Exit Sensor
2. Sensor Based System:
In this system sensors are employed at entry and exit of the
paint zone which gives triggering signal to a switchingcircuit which turns on and off a relay on receiving trigger
signals from sensors which in turn controls the various
electrical equipments.
The following Flow chart shows the plan.
Block Diagram:
Working:
According to this plan input and output sensors are used.
When a cowl comes in the booth the input sensor sends
signal to switching circuit which turns on a relay and on exit
the exit sensor senses the cowl exit and sends trigger to
switch off relays. Thus power is on only for the period when
it is being used to paint.
Merits: Large saving of power
Fully automatic System
Demerits:
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Costly system
On busy days frequent ON-Off can cause
breakdown of equipments Interference due to workers passing through
booth
3. Manual Operation:
A very simple and basic solution of our problem is that the
worker manually switches off the equipments from electrical
panel but this is not very suitable because its notautomated and increases strain on workers.
Merits: Large saving of power
No additional cost
Demerits: Not automatic
Increased burden on workers
Safety Threat
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Selection of best alternative:
In above explained proposals the Selection of bestalternative is done on the basis of effectiveness of system
and applicability. The most suitable alternative is selectedto be the Delay Timer based system because- Its cheap and simple to construct Helps to save considerable amount of power
Solution Development:
According to our need an OFF Delay Timer Controlled Relaybased system is developed. The entry of cowl in booth issensed by an pushbutton limiting switch and the triggersignal is sent to an off delay timer circuit which starts itscountdown as soon as cowl enters the booth. After apredetermined time the timer goes off and turns off allequipments. The suitable delay time is selected to bearound 5 minutes by interaction with workers andtechnicians as well as considering fatigue to equipments.
Thus following circuit is developed .
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Circuit Diagram:
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The above circuit shows the developed system forAutomatic ON-OFF for various Electrical Equipments of Paint
Touchup Zone.
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The circuit uses an IC-555 with various other components to
make an off delay timer circuit. The circuit containsfollowing components-
S.
No.
Part Rating
1 IC- 5552 Resistor 100 Kohm, watt, 12 v3 Resistor 2 Mohm, watt, 12 v4 Capacitor 100 F, watt, 12 v
5 Diode- 1N1004 watt, 12 v6 Relay 12V DC, 230V AC,7 Battery 12V8 Push Button Switch 12V, watts
Working:
The circuit is triggered by a switch between pin 1 and pin 8.
In actual case we use an limiting switch. When this switch is
pressed and released the circuit turns ON which energizes arelay coil which inturn turns on all equipments. After a pre
calculated time delay of around 250-300 seconds the circuit
turns off automatically.
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Plan Implementation:
The above discussed plan is made and implemented. Thecircuit is made on a matrix PCB. The images of actual circuit
are following-
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Circuit Developed
Back View
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Closer View
Benefits Achieved:
The plan for automation of Equipments of Paint TouchupZone has the sole purpose of saving electricity being
wasted. The following study shows how much energy could
be saved by this project-
Average number of cowls in an fair day = 40
System on Time per cowl through our system = 5 mins.
Total ON time per shift = 200
mins. 3.5 hrs.Energy consumed per shift with our system = 3.5 x
190.72 = 667.52 kWh
Energy consumed per shift without our system = 0 8 x
190.72 = 1525.76 kWh
Total energy saving per shift = 1525.76
667.52 = 858.24 kWh
Thus our system offers a energy saving upto56% which is very good for company as well
as environment.
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SUMMARY
The sole motive of this four weeks projecttraining is to give an idea what a real industry is all
about and getting training in such an esteemed
organization is definitely a thing to be proud of. I got
the chance to learn much more than I expected before I
came here.
In my training I learnt how to plan the
activities regarding different work and develop the
techniques to solve the problem. I also learnt the power
of team work that how onerous tasks can be
accomplished easily with the help of team work.
By working in the Cowl shop, I learnt about the
different processes which are being carried out in the
Cowl line and more specifically about the Electrical and
Electronic Systems used in industry, sensors and
controllers, safety systems, automation etc.
During training I was given a project to
develop an Automatic ON-OFF System for various
electrical equipments of Paint Touchup Zone
which were kept ON continuously during whole shift
causing lots of wastage of energy. I have designed,
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developed and built an Auto On-OFF system for the
Paint Zone. The system designed by me saves upto
56% of energy .Apart from the allotted project, I also learnt
a lot about Organizational Culture. Working with people
from different areas taught me a lot of managerial as
well as personal skills that are definitely very helpful for
my future.
My experience in TATA motors has been really enriching
and has provided me a stepping stone for a prospective
bright future in the industrial Sector. I wish that every
engineer should get a chance to get associated with
such a giant and reputed group.