QUALITY CHECK MACHINE FOR OUTER DOOR MIRROR

Submitted to: Mr. SUMIT KUMAR MISHRA Submitted By: SHASHANK TIWARI

Asst. Professor Enrollment No. A12405411032

AMITY SCHOOL OF ENGINEERING Roll No: 11046

B.TECH (7MAE)

AMITY SCHOOL OF ENGINEERING

QUALITY CHECK MACHINE FOR

OUTER DOOR MIRROR

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ACKNOWLEDGMENT

The 49-days industrial training is indeed the most important and integral part of my curriculum at the Mechanical and Automation Engineering Department at Amity University, Noida.

The 49-days industrial training gave me ample opportunity to develop a veritable and first hand industrial experience not only towards technical but all round development also, being able to see and learn about the actual implementation of the subjects we study is indeed a valuable experience.

Training at SANDHAR Automotive HSCI Division LIMITED has been beneficial in the technical aspect, as it has given an unprecedented opportunity to exercise and put into practice some of the theoretical aspects of engineering.

I would like to thank my Head of institution Dr. (Prof.) Ajay Rana for his efforts in maintaining a good rapport with the industry and for keeping his faith and confidence in my performance and for being source of continuous encouragement.

I would like to thanks my mentor Mr. Arjun Singh (Deputy Manager/ Engineering processing, SANDHAR HSCI) for giving me an invaluable opportunity to do my project at SANDHAR Automotive HSCI Div. and for assigning me the Design and Development department, working at which, I gain firsthand knowledge on Designing and different Manufacturing processes.

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ABSTRACT

In these 49-days of my industrial training at SANDHAR Automotive HSCI Div. Gurgaon, I had to deal with a variety of tasks. Each activity presented a unique challenge as well as great learning opportunity. This was the perfect setting to further strengthen my understanding of the various technical processes by brushing up the theoretical knowledge gained in the university with practical observations. More often than not, I was entrusted with responsibilities and was expected to deliver the results within the stipulated time frame and of required quality.

At SANDHAR, I was involved in a number of activities, which were directly involved, with the daily functioning of the manufacturing process. This implies that the project assigned to me a live project, which was actually relevant and the results of which has important implications on the market as well. The project on which I was entrusted was” DESIGN DEVELOPMENT OF QUALITY CHECK MACHINE”.

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Certificate

This is to certify that Mr. SHASHANK S.TIWARI, student of B. Tech. in Mechanical and Automation

Engineering has carried out the work presented in the Industrial work report on ‘DESIGN AND

DEVELOPMENT OF QUALITY CHECK MACHINE FOR OUTER DOOR MIRROR’ as a part of

third year program of Bachelor of Technology in Mechanical and Automation Engineering from Amity

School of Engineering, Amity University, Noida, Uttar Pradesh under my supervision.

(Mr. SUMIT KUMAR MISHRA)

Asst. Professor

ASE, Noida.

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INDEX

S.No.

DESCRIPTION PAGE NO.

1 2 3 4 5 6 7 8 9

SCOPE SPECIFICATIONS BILL OF MATERIAL STRUCTURAL DESIGN OPERATING SEQUENCE IN-PUT/ OUT-PUT LIST ELECTRICAL CIRCUIT DIAGRAM MAINTANENCE CHECK POINTS TECHNICAL DRAWINGS

• DIMENSIONAL VIEW • ISOMETRIC VIEW

5 6 7 9

15

16

17

19

20

5

SCOPE

This manual covers operating instruction for O.K. Marking Machine of outer Door Mirror As per HSCI Div.

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SPECIFICATIONS

This machine will check mirror motor wiring connection by making the following SEQUENCE TEST: DOWN UP LEFT RIGHT The machine will take a decision on OK/NG depending upon the sequence of mirror plate movement. The OK sequence is shown above. After OK mirror testing, machine will put a punch mark on mirror coupler assy.

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OK MARK

MODEL: UH

OK MARK

BILL OF MATERIAL (BOM)

Door Mirror QC Checker M/c

BILL OF MATERIAL (MECHANICAL PARTS)

MECHANICAL PARTS: DATE: 06/6/14

SR. NO.

DESCRIPTION FINISH SIZE (in mm)

MATERIAL QTY.

1 DMQC_BASE PLATE 2CV 400X400X15 M.S 1

2 DMQC_2_BASE PLATE 2CV 160X100X10 MS 1

3 DMQC_PILLOR_HOLDER_2CV 160X50X55 EN-31/ MS 1

4 DMQC_HOLDER_SUPPORT_2CV 160X35X24 EN31/MS 1

5 DMQC_PILLOR_2CV Ø30X560 EN31 2

6 DMQC_MOUNTING_BLOCK_2CV 50X50X65 EN31 6

7 DMQC_BASE_SLIDE_UNIT_2CV 350X150X10 MS 1

8 DMQC_ANGLE_BRACKET_2CV 65X70X50 EN31 1

9 DMQC_GUIDE_BLOCK_STOPPER_2CV 45X50X50 EN31 1

10 DMQC_PANNEL_MOUNT_BLOCK_2CV 110X35X50 EN31 1

11 DMQC_PANEL_PILLOR_2CV Ø30X340 SS 1

12 DMQC_PANNEL_BLOCK2_2CV 120X50X50 MS/EN31 1

14 DMQC_MAIN_CYL_MOUNT_PLATE_2CV 100X45X25 MS/EN31 2

15 DMQC_PANNEL_MOUNT_PLATE_2CV 150X150X8 MS 1

16 DMQC_CARRIER_VERTICAL_PLATE_2CV 150X165X10 EN-31 1

17 DMQC_CARRIAGE_RIB_2CV 75X75X8 EN-31 2

18 DMQC_COUPLER_FORK_2CV 35X32X30 EN-31 1

19 DMQC_CARRIAGE_HOR_PLATE_2CV 250X180X12 EN-31/MS 1

20 DMQC_LMK_L_LM8_2CV Ø34X46 EN-31 4

21 DMQC_COULPER_PLATE_2CV 70X42X32.5 EN-31 1

22 DMQC_COUPLER_PIN_2CV Ø10X40 EN-31 1

23 DMQC_CONTROLPANEL_HMETR_2CV 210X150X3 SS 1

24 DMQC_CYL_CXSM_MOUNTING_2CV 150X23X20 MS/EN31 2

25 DMQC_CYL_CXSM_MOUNTING_L_2CV 150X23X20 MS/EN31 2

26 DMQC_LEVELING_ROD_HOLDER_2CV 40X56X23 MS/EN31 2

27 DMQC_ROD_LEVELING_2CV Ø8X145 EN31/HRC-45

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28 DMQC_JIG_SPACER_2CV 50X150X250 AL. 2

29 DMQC_S.MOTOR_SPACER_2CV 40X40X30 AL. 1

30 DMQC_LINER_TRANS_MOUNTING_2CV 70X50X30 NYLON 1

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31 DMQC_LINER_RAIL_SMALL_MOUNTING_2CV 90X70X15 EN-31 1

32 DMQC_LINER_RAIL_SMALL_M_ROUND_2CV Ø50X40 AL. 1

33 COUPLER CLAMP 150X18X25 MS 4

34 O K PUNCHING CYLINDER MOUNTING PLATE

60X25X10 MS 2

35 O K PUNCHING CYLINDER SPACER PLATE 25X25X12 MS 2

36 O K PUNCHING CYLINDER BASE PLATE 60X12X150 MS 2

37 COUPLER SUPPORT 25X25X12 ACCRALIC 2

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SWITCHMAIN ON

REGULATORPRESSURE

PANEL CONTROL

FIXTURE

SWITCHSTART

TABLE

UNIT ALIGNING

TRUCTURAL DESIGNS

CONTROL PANEL

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OK INDICATOR LEFT/RIGHT AUTO/MANUAL INDICATOR+ READY SWITCH NG BUZZER

DISPLAY UNITSWITCHMAIN ON

OK MARKING UNIT

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PUNCH

PUNCHING CYL.

UH -MODEL COUPLER

LK -L MODE COUPLER

ALIGNING UNIT

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CYLENDR ALIGNING

MOVEMENT PINS

CHECK SENSORS MOVEMENT

SENSORALIGNING

ALIGNING PINS

DISPLAY UNIT

PRODUCTION SCREEN TIMER SCREEN

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NUMERIC KEYS FUNCTION KEYS

MANUAL OPERATIONS SCREEN OK SCREEN

FIXTURES

LEFT (MODEL-UH) RIGHT (MODEL-UH)

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OPERATING SEQUENCE

MIRROR SETTING PROCEDURE:

OPERATING SEQUENCE: STEP 1: PUT ON MAIN SWITCH STEP 2: SELECT AUTO MODE & CHOSE MIRROR TYPE (LEFT / RIGHT) STEP 3: SET DOOR MIRROR ON FIXTURE STEP 4: INSERT MIRROR SWITCH INTO COUPLER (UH / LK) STEP 5: PRESS START SWITCH. STEP 6: MAIN CYL. GO DOWN & ALIGNING CYL. MAKE MIRROR PLATE TO ALIGN. STEP 7: NOW MOVEMENT PINS MAKE THE REQUIRED SEQUENCE TEST.

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STEP 8: MACHINE WILL MAKE DECISION ON OK/NG DEPENDING UPON SEQUENCE OF MIRROR PLATE MOVEMENT. OK SEQUENCE: DOWN UP LEFT RIGHT

IN PUT/ OUT PUT LIST

S.No. INPUT I/P No. OUTPUT O/P No.

1 START 0 OK 1000

2 1 FAULT 1001

3 LEFT/RIGHT MIRROR SELECTION 2 MAIN CYLENDERDOWN

1002

4 AUTO/MANUAL 3 ALIGNMENT CYL. 1003

5 RESET 4 DOWN MOVE 1004

6 MAIN CYLENDER DOWN SENSOR 5 UP MOVE 1005

7 ALIGNMENT CYLENDER DOWN SENSOR 6 LEFT MOVE 1006

8 DOWN MOVE CHECK SENSOR 7 RIGHT MOVE 1007

9 UP MOVE CHECK SENSOR 100 READY 1100

10 LEFT MOVE CHECK SENSOR 101

1101

11 RIGHT MOVE CHECK SENSOR 102 MAIN CYL. UP 1102

12 103 PUNCHING CYL. 1103

ELECTRICAL CIRUCIT DIAGRAM

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PLC WIRING

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POWER & DISPLAY UNIT CONNECTION

L: 220v N: Neutral P24v: +24v Z: -24v G: Ground CIF-01: Communication Unit b/w PLC & NT-11

MIRROR MOTOR CONNECTION

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R: Relay L: 220v N: Neutral P24v: +24v Z: -24v G: Ground

MAINTENANCE CHECK POINTS

S.No. CHECK POINTS FREQUENCY ACTION 1 2 3 4 5 6

MAIN AIR PRESSURE OILING ON GUIDE ROD CHECK FRL CHECKING OF SENSORS GUIDE ROD DUST CLEANING CHECK FIXTURE ADJUSTMENT

DAILY WEEKLY DAILY DAILY DAILY AT START

SET AIR PRESSURE AT 5 bar APPLY OIL IF REQUIRED REMOVE DRAIN IF REQUIRED TIGHT SENSORS IF REQUIRED REMOVE DUST IF REQUIRED MOVEMENT SENSORS SHOULD NOT COME WHILE MIRROR IS ALIGNED.

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