ONE MONTH SUMMER TRAINING AT

ROKI MINDA CO. PVT. LTD. SURAJ COLLEGE OF ENGNEERING & TECHNOLOGY BUCHOLI (M/GARH)

SUMMER TRAINING REPORT

Submitted to: H.R. Deptt. ROKI MINDA CO. PVT. LTD , BAWAL MECHNICAL Submitted by:
SUNIL KUMAR

B.TECH. (8h Sem.)

TRAINING REPORT
In partial fulfillment of requirements of prescribed course Of The Award Of Bachelor Of Technology In MECHNICAL ENGINEERING Of Suraj College of Engneering & Technology Bucholi (M/Garh) At ROKI MINDA CO. PVT. LTD. Period of Training: 16 JAN. To 15 MAY

Submitted to:
H. R. Deptt.
ROKI MINDA CO. PVT. LTD , BAWAL

Submitted by:
SUNIL KUMAR B.TECH. (8th Sem.) MECHNICAL

ACKNOWLEDGEMENT I am very grateful to my supervisor Mr.YOGESH SINGH who has given me the chance to participate in several interesting industrial projects. He has supported me with his encouragement and many fruitful discussions. I would also like to express my sincere thanks to Mr. ANKUR JAISWAL for his invaluable experience and advice. The close cooperation with Mr. PAWAN TYAGI as well as many other industrial members was a great experience, which lead to many joint activities. The internship at learning centre was a unique experience and I would like to thank Human Resource Department, head of the training conductance, for this great opportunity.

COMPANY OVERVIEW

Group Profile

Starter Batteries Product Portfolio

Product ProductRange Range Segments Segments

CAR CAR

ORIGINAL ORIGINALEQUIPMENT EQUIPMENT Cars, trucks, motorcycle manufacturers and other OEMs (boats, tractors, etc.)

TRUCK TRUCK

MOTO MOTO

AFTERMARKET AFTERMARKET Wholesalers, accessory shops, garages, franchised dealers, fast-fit, auto-centres, etc.

MARINE MARINE

Acoustical Devices Product Portfolio

Electromagnetic Horns
Annual Prod. = 34 millions units

FIAMM's main product lines for OE are the following: Electromagnetic horns: the sound is produced through an electromagnetic circuit, that forces a membrane to vibrate at high frequency. Vibrations are amplified by a horn Main use: Major OE applications

Annual Prod. = 5.5 millions units

Resonating disc Horns

Resonating disc horns: the sound is produced using a diaphragm or resonating effect, by a metallic disc that touches another one Main use: OE applications (Japan and small cars) Electro pneumatic horns: the sound is produced using a trump effect, where air is forced to pass through a horn Main use: Aftermarket Electronic horns for emergency situations: the sound is modulated through an electronic system Main use: Emergency vehicles-ambulances, police, fire trucks, etc

Annual Prod. = 0.5 millions units

Air Horns-heavy trucks

Electronic resonating disc horns Main use: Industrial applications (forklift trucks)

MINDA Acoustical Device Technological Leadership

Disc Horns The largest Disc Horn range with the flexibility offered by the range of voltages, connectors & brackets. Electro-magnetic Horn Horn Sound Only Available in High SPL and electronic versions Multi-Sound Device The MSD is capable of complex sounds such as alarm, voice and chirps, in addition to horn sound Multi-Sound Horn Horn sound plus the flexibility offered by variable frequency driver to produce limited range of sounds.

Acoustical Devices Market Share by Country

FIAMM is Leader in the most important Markets: North America and Europe

FIAMM FIAMMMarket MarketShare Shareby byCountry Country

6% Oth.s % & % E % d % % % % % % 5% FIAM M

15% Oth.s

8% Oth.s 25% Oth.s

25% BOSCH

20% HELLA 15% MIAMOTO

14% HELLA

92% FIAMM 55% FIAMM 65% FIAMM

25% MITSUBA

25% DENSO

Pe`North

P
`South

:P`Asia

MINDA Acoustic Devices Global Manufacturing Footprint

Sales/Marketing and Technical Centers Montecchio, Italy Farmington Hills (MI)

Montecchio, Italy AM80s & LLH Surface: 13,000 m2 No. empl.: 170 Units: 16 million

China JV AM80s & LLH TBD

Japan & Korea Cadillac, MI - AM80s Surface: 14,000 m2 No. empl.: 190 Units: 16.5 million San Paolo, Brazil V3 & Disc Surface: 5,000 m2 No. Empl: 90 Units: 4 million
(Manufacturing Capacity)
technical/commercial support

New Delhi, India FIAMM/MINDA JV V3 & Disc No. empl.: 241 Units: 12.7 million Key: AM80s = global trumpet V3 = high SPL trumpet LLH = long life electronic horn

FIAMM Group - OEM Customers

CATERPILLAR FORD GM U.S.A. MAZDA MITSUBISHI NISSAN SATURN VOLVO
ITALY

APRILIA DUCATI-CAGIVA FERRARI-MASERATI FIAT-ALFA-LANCIA IVECO PIAGGIO SAME

UNITED KINGDOM

TOYOTA ASTON MARTIN FORD FORD TRUCK HONDA GM - IBC JAGUAR LOTUS PEUGEOT-TALBOT ROLLS ROYCE ROVER LAND ROVER FIAT POLAND

GERMANY

AUDI BMW FORD MAGIRUS MAN MERCEDES VW

TOYOTA
SOUTH AFRICA

FRANCE

PEUGEOT-CITROEN PEUGEOT M.T.C. RENAULT RVI TOYOTA

SPAIN

FORD IVECO PEUGEOT-CITROEN SEAT

POLAND

FORD SAAB VOLVO VOLVO-SCANIA TRUCK SKODA FORD NISSAN VW

MEXICO

BRASIL

AUSTRALI A

FIAT FORD VW TOYOTA GM RENAUL T TOYOTA

SWEDEN

FORD VOLVO FIAT FORD RENAULT PSA GM

CANADA

TURKEY

CZECH REP.

ARGENTINA

TOYOTA
VENEZUELA

MAZDA
JAPAN

Our Exports Customers: 4W

GM-USA
CATERPILLAR

FORD MEXCO

Volkswagen

GM
KOREA

TORICA JAPAN YANMAR KOBELCO

FORD CHINA GM Mexico

FORD VIETNAM

Mazda
FORD ARGENTINA

MINDA ACOUSTIC
Product Range
Excellent & Widest Range

Horn Range (After Market)

AC/DC Horn K-82 Twin

Air Horn-2 Pipe

K-82

SD-7

K-90 Twin

EC-120

MINDA Product Range

K-95 Twin Jericho-Air

TR99 V3 Grave K-95 Twin with Grill

MINDAs ACOSTIC Quality Policy

ity to r o i r hp g i h and d s s e e d ccor petitiven ctive a e to b et com effe t y t s i l o Qua re mark ply of c omers. t ensu able sup the cus to en ducts to d by e pro t c refle ctions, e b all h ts, a o our s n s e i h T mitm rvices t rs. e m o m c our cts & se al custo u rn ent prod nd exte m n o al a nvir ppliers n e r e n t in su te a & a ce. e s r n e c e l e l l l ploy or exce sha m e e w ive f his, e all our t r t r s o F and rag u s t o c c e to en vent def e to pr

Quality Control Facilities

Acoustic Tunnel & Spectrum Analyzer

Contour Measurement System

Resonance Frequency Tester

Water Tightness Test Rig

34

PRINCIPLE AND WORKING OF HORNS

PRODUCT OVERVIEW

Working of Disc Horn

Sealing of Breather Hole

HK-9 HORN

MAJOR PROJECT REPORT on Automation of pick & placing of Horn HK-9

Introduction of project:
To pick the horn from Fixture at conveyor and place it, on the indexing table. How to Manufacture a horn. To study about the Horns.

Content
PLC. Pneumatic cylinder. Pneumatic valve. Flow control valve. Proximity Sensors. Photo Electric Sensors. Reed switch. Push button. Emergency Switch.

INTRODUCTION OF P.L.C
P.L.C. is a programmable logic control device. It is a solid state device design to perform the logic function previously accomplished by components such as electrometrical relays, drum switches, mechanical timers and counters for the control and operation of manufacturing process equipment and machinery. Even though electromechanically relays control relays, numeric timer relay etc. P.L.C. has also a memory like computer for storing the user program or logic as well as memory for controlling the operation of process machine. P.L.C. is programmed in LADDER LOGIC. The P.L.C. is also design to operate in the industry environment with wide range of ambient temperature, temperature, vibration, and humidity.

PICTORIAL VIEW OF PLC

CPU PLC INPUTS PLC OUTPUTS

SIEMENS S5 PLC

INTRODUCTION TO PROGRAM
A program is a connected series of instructions written in a language that the PLC can understand. There are three forms of program format; instruction, ladder and SFC/STL. Not all programming tools can work in all programming forms. Generally hand held programming panels only work with instruction format while most graphic programming tools will work with both instruction and ladder format.

PROGRAM IN P.L.C

LEDDER LOGIC OF PICK & PLACE

CONTD

LEDDER LOGIC OF PICK & PLACE

CONTD.

LEDDER LOGIC OF PICK & PLACE

END

INPUT OUTPUT DETAILS

PARTS OF P.L.C A typical PLC has divided in to four main components. Processor unit. Power supply. Input &output section. Programming device.

PROCESSOR UNIT
Processor is the decision maker or brain of the system. The brain is a microprocessor based system that replace control relays, counters, timers, sequencers etc. and is design so that the user can enter the desirer program in LADDER LOGIC. The processor then makes all decisions necessary to carry out the user program based on status of input and output for control of machine. The dc power required for processor is provide separate power supply unit. It control the operation of the equipment to which it is connected .it is the brain of the PLC. It also control operation of output device that are connected to output module based on the status of input device. It control as few as 8 or as many as 40000 real world input & output . Processor scan the following: Determine the status of input device . Interpret logic of program. Up date ( turn on or off output devices) Communication with connected devices and house keeping. before any output device can be turned on or off the processor has to scan the enter program that is in user memory.

MEMORY
The most common type of volatile memory is RAM (random access memory). The information can be written in to or read from a RAM chip and refer to as read/write memory. Information can be retrieved or read. Write indicate that user can program or write information in to it. It refer to the ability of any location in memory to be used. It is used both for user memory and storage memory in many PLC. It must have battery back up to protect the stored program. It include CMOS and MOS. most common nonvolatile memory is ROM it do not require battery back up and retains information when power is off. It indicate the information can be read only cannot be changed. other types of memories are explained bellow: P-ROM : programmable read only memory. EP-ROM : Erasable programmable read only memory. UVP-ROM: Ultraviolet programmable only memory. EEP-ROM: Electrical erasable programmable read only memory. EA-ROM : Electrical alterable read only memory.

OUTPUT MODULES
Discrete output modules: These are used to control the current
flow to real world devices such as motor relay coils, lights, control relays, solenoids valves. This also works on digital or and off basis. This works like a remote control switch that is control by a processor for turning the output devices or on off. These are sized by the output devices connected to them. scr. When processor decide that output tuned to be on a signal is sent from the i/o rack and LED is on and the light cause the phototransistor to conduct. Which provide current for the gate of triac this portion optical isolate the logic section of processor from line voltage of output device. The triac is used as electronic device to turn the output device on and off.

Ac output module: They contain a triac. Some manufacturer used

Dc output modules: It is same as ac output modules. Difference is

that power transistor used instead of triac to control the output current. It has a quicker switch capability.

PNEUMATIC MOUNTINGS

ADVANTAGE OF USING PNEUMATICS

Weight Compare the weight of several valves and cylinders to that of the motors, gears, belts, and chains used on some lift mechanisms and you will find the weight comparable, if not much lighter. Adjustable Force To adjust the force of the cylinder, all you have to do is adjust the regulator in front of it. The force is equal to the area of the cylinder piston times the pressure. Remember that the valves need at a minimum of 15-30psi to work properly. Durable All of us have problems burning up motors from time to time. We can stall an air cylinder against a load indefinitely and turn off the compressor. These are industrial grade products. Last Minute Additions At the last minute, you can add a cylinder and valve very quickly.

COMPRESSOR
we have the same compressor provided by Thomas Industries that weve had for the last few years. The compressor will put out approximately 120psi before the Norgren relief valve opens (that would give you 376 pounds of output force on a 2.00 bore cylinder). Because the compressor can produce a significant amount of vibration, we have included vibration isolation mounts donated by the Lord Corporation. They can be screwed directly into the feet of the compressor as shown on the following picture. In order for these to isolate the vibration, they need to be mounted to a stiff piece of metal such as a 1/4 aluminum plate. The distance between the front feet is 3.5. The distance from the centerline of these feet to the rear foot is 5.19. A spike relay must be used to control the power to the compressor using a 20amp breaker, not a fuse. Ensure that the relay is programmed to provide forward power only to the compressor. Do not reverse the compressor! Norgren has supplied the pressure relief valve. It is shown installed on the compressor.

PRESSURE SWITCH
We have included a pressure switch manufactured by The Nason Company. These switches are normally closed. The switches will open at approximately 115psi and will not close again until the pressure drops to approximately 95psi. This will allow you to turn off the compressor once you are up to 115psi, saving power in the battery. It should be wired directly to the robot controller digital input bank with PWM type cable. No specific Digital Input Port is designated for the pressure switch. The Robot Controller must be programmed to react to the Input Port that is connected to the pressure switch The Robot Controller will activate the designated Spike Relay to turn the Compressor on and off.

REGULATOR
Norgren has donated the primary pressure regulator. These are relieving regulators. Assume that you extend the cylinder or the apparatus the cylinder is attached to against a wall. Then push against the wall with your robot. That would increase the pressure in the cylinder. The increased pressure will relieve out of the regulator and the cylinder will slowly retract. Please note: the specification states that the nominal output pressure range is 050psi. It also has an arrow on it to denote the outlet of the regulator. The opposite port is the inlet. A pressure gauge may be placed in either of the other ports.

ELECTRIC VALVES
SMC has provided two double solenoid valves and one single solenoid valve. For the double solenoid, if you energize one of the solenoids to make the cylinder extend, you must then energize the opposite solenoid to make it retract. Either solenoid may be left in the energized state or you may leave it un-energized and the valve will hold its position. This is a great valve to use to maintain position when the power is turned off at the end of the match. A double solenoid valve will maintain its position until you turn on the opposite solenoid. The orange buttons on the top of the valves are manual overrides. With a double solenoid valve you can depress the override and the valve will shift and stay in that position. The valve is pilot operated and requires a minimum pressure of 20 psi to work.

PNEUMATIC SYSTEM
Pneumatic systems use pressurised air to make things move (for example, pistons), to hold things up (for example, car tyres), or to move things (for example, air lines inside hopper feeder tubes). Dealing with pneumatic systems poses some dangers: if you puncture the balloon tyres on an earth mover they may rip open and injure you. If you puncture a high pressure air line, small particles of flying dust or metal may damage your eyes. Pneumatic systems are used mainly in the Mechanical systems in industry,

PNEUMATIC CYLINDER
One of the main uses for compressed air in industry is to make things move - from printing machines to advanced robotic assembly systems. The main component in these systems is the pneumatic cylinder. Cylinders work 'in reverse' to an average bike pump. Air is inject at one end or the other. This moves the piston inside the cylinder, and the rod connected to it. The power with which this takes place is proportional to the diameter of the piston - the greater the more power. Unlike hydraulic systems, where fluid is conserved, in pneumatic systems the compress air is always released. Whereas a hydraulic ram needs to be pushed in both directions.

PNEUMATIC VALVE
Pneumatics valve are used mainly inthe following situations: Mechanical systems in industry, mainly using piston/cylinders to move rods or levers, where heavy pressure is used. On automotive equipment air brakes are widely used where large amounts of energy need to be used quickly (e.g. braking systems for lorries and trains) Many hoppes and material storage systems use streams of air to move dust or small particles.

5/2 Solenoid valve

Connectors type QS, QST

FLOW CONTROL VALVE

Maintain constant flow with inlet pressure changes from 15 to 120 PSI (1 bar to 8 bar). Standard flow ranges from 1/4 GPM (see note) to 120 GPM (1.0 l/m - 454.2 l/m). Automatic in operation - no adjustments. These flow controls are designed for liquids similar in viscosity to water. All applications should be tested for flow characteristics and chemical compatability to insure desired results. The standard Series "FC" flow controls are constructed of TYPE 1, GRADE 1 PVC (Polyvinyl Chloride) with diaphragms controls are used to maintain a constant pre-determined flow in a system. They must be installed in the correct flow direction (indicated by label) to work properly.

INDUCTIVE PROXIMITY SENSOR

INDUCTIVE PROXIMITY SENSOR

A proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact. A proximity sensor often emits an electromagnetic or electrostatic field, or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal.Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target. The maximum distance that this sensor can detect is defined "nominal range". Some sensors have adjustments of the nominal range or means to report a graduated detection distance. Proximity sensors can have a high reliability and long functional life because of the absence of mechanical parts and lack of physical contact between sensor and the sensed object.

BASIC DESIGN OF PHOTOELECTRIC SENSOR

PHOTO ELECTRIC SENSORS

A PHOTOELECTRIC SENSOR, OR PHOTOEYE, IS A DEVICE USED TO DETECT THE DISTANCE, ABSENCE, OR PRESENCE OF AN OBJECT BY USING A LIGHT TRANSMITTER, OFTEN INFRARED, AND A PHOTOELECTRIC RECEIVER. THEY ARE USED EXTENSIVELY IN INDUSTRIAL MANUFACTURING. THERE ARE THREE DIFFERENT FUNCTIONAL TYPES: OPPOSED (A.K.A. THROUGH BEAM), RETROREFLECTIVE, AND PROXIMITY-SENSING (A.K.A. DIFFUSED). SOME PHOTOEYES HAVE TWO DIFFERENT OPERATIONAL TYPES, LIGHT OPERATE AND DARK OPERATE. LIGHT OPERATE PHOTOEYES BECOME OPERATIONAL WHEN THE RECEIVER "RECEIVES" THE TRANSMITTER SIGNAL. DARK OPERATE PHOTOEYES BECOME OPERATIONAL WHEN THE RECEIVER "DOES NOT RECEIVE" THE TRANSMITTER SIGNAL.

REED SWITCH
The basic reed switch consists of two identical flattened ferromagnetic reeds, sealed in a dry inert-gas atmosphere within a glass capsule, thereby protecting the contact from contamination. The reeds are sealed in the capsule in cantilever form so that their free ends overlap and are separated by a small air gap.

How does a reed switch work ? When a magnetic force is generated parallel to the reed switch, the reeds become flux carriers in the magnetic circuit. The overlapping ends of the reeds become opposite magnetic poles, which attract each other. If the magnetic force between the poles is strong enough to overcome the restoring force of the reeds, the reeds will be drawn together. What magnetic force is required to close a reed switch ? Minimum force - expressed in ampere-turns, will cause the reeds to close, and is called the just-operate force. Since the force between the poles increases as the gap decreases, a force of approximately half the just-operate force will maintain the operated state. Speed of operation of the reed switch is determined by the excess of operating force over the just-operate force. What are the advantages in using reed switches ? They are hermetically sealed in glass environment, free from contamination, and are safe to use in harsh industrial and explosive environments. Reed switches are immune to electrostatic discharge (ESD) and do not require any external ESD protection circuits. The isolation resistance between the contacts is as high as 1015 ohms, and contact resistance is as low as 50 milli-ohms. Reed switches can directly switch loads as low as a few micro-watts without needing external amplification circuits, to as high as 120W. When used in combination with magnets and coils.

PUSH BUTTON
Resistant to dust and frost . The IA seraies actuator consists of a polyurethane membrane which depresses when the switch is actuated. The sealed push button switch features include an IP67 front panel seal, a low profile soft feel actuator, a 16mm dia bushing and wire leads. IA Specification . 10 mm threaded bushing Single and double pole momentary configurations with solder lug terminals. Gold plated silver or coin silver contacts are available plus optional color caps. CECC approved.

EMERGENCY SWITCH
For Protection Against Accidental Actution Emergency switch guards are designed to work with APEMs IP and IS series sealed pushbutton switches. The switch guard mounts flush into the panel providing a distinct target for the pushbutton switch and protection against accidental actuation. The guards fit into a 22 mm round panel cut-out. Available in black and clear anodized finish.

New SD 7 Line from FIAMM

Coil winding

GVS Fixing

Washer Riveting

C/B Assy Riveting

Diaphragm Forming

Auto Contact Gap Setting

Auto Air Gap Correction

Resonator Riveting

Housing Closing