Summer Internship Report

Tata Motors Limited

Jamshedpur Plant

27th June - 23rd July 2016

Project Guide: Mr. Anil SinghDivisional Manager (Assembly)

Submitted by: Karthik ChakilamFourth year B. Tech Mechanical Engineering

GITAM University, Visakhapatnam

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ACKNOWLEDGEMENT

The internship opportunity I had with Tata Motors was a great chance for learning and professional development. Therefore, I consider myself as a lucky individual as I was provided with an opportunity to be a part of it. I’ve learned a lot about the office environment and my interpersonal skill have been improved significantly.

At this juncture I feel deeply honored in expressing my sincere thanks to Mr. Anil Singh (Divisional Manager-assembly line) for his good approach and outstanding supervision by which it has been possible for me to make a good practical and theoretical knowledge in preparing this report and under whom I have learned a lot of practical knowledge about vehicle assembly and and as well as truck manufacturing also.

I’m also thankful to other employees of Tata Motors Ltd. of Jamshedpur plant.

I am very grateful to the HR Department, especially Mr. Johnson Mathews, Asst. Manager - HR (MTC) for providing me to work in this prestigious organization.

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Index

Sr no: Title Page no

1 About the company 4

2 Tata Motors – Jamshedpur plant 6

3 Introduction 7

4 Engine Type 10

5 Clutch 11

6 Gearbox 12

7 Axles 14

8 Steering 16

9 Suspension 17

10 Chassis 19

11 Brakes 20

12 Wheelbase 21

13 GVW 22

14 Gradeability 22

15 Conclusion 23

About the company

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TATA Group

The Tata group’s core purpose is to improve the quality of life of the communities it serves globally, through long-term stakeholder value creation based on leadership with trust.

Type Private

Founded 1868; 148 years ago

Founder Jamshedji Tata

Headquarters Mumbai, Maharashtra, India

Area served India

Products Airlines, Automotive, Consumer goods, Defense & aerospace, Electrical distribution, Engineering services, Financial services, Information technology, Steel, Telecommunication

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Tata Motors Limited 

Tata Motors Limited is an Indian multinational automotive manufacturing company and a subsidiary of the Tata Group. Its products include passenger cars, trucks, vans, coaches, buses, construction equipment and military vehicles.

It is the world’s 17th largest motor vehicle manufacturing company, fourth-largest truck manufacturer and second largest bus manufacturer.

Type Public

Industry Automotive

Founded 1945

Headquarters Mumbai, Maharashtra, India

Area served Worldwide

Products AutomobilesCommercial vehiclesCoachesBusesConstruction equipmentMilitary vehiclesAutomotive parts

Services Automotive design, engineering and outsourcing servicesVehicle leasing

Jamshedpur Plant

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World-class facility equipped with: State-of-the-art equipment and assembly lines to produce a truck every 5 minutes Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers, mixers

and special application vehicles, catering to civilian and defence requirements 3D visualisation of new models Engine assembly shop, capable of supplying upto 200 engines per day Modern testing facilities

Tata Motors’ Jamshedpur plant today marked a milestone with the roll-out of the 2 million trucks from this world-class manufacturing facility. The plant manufactures Tata Motors’ entire range of medium and heavy commercial vehicles, including the Tata Prima, both for civilian and defence applications.

Modern World Class Manufacturing FacilityThe plant houses a world class Design and Engineering Center. The center is responsible for the conceptualization and integration of Tata Motors’ current and future truck range. The center undertakes complex digital design through 3D visualization of new truck models, including that of its features and electrical systems. It also houses a comprehensive facility for bench-marking, prototype planning, vehicle assembly, chassis fabrication and a customization unit. The testing unit also includes engine performance testing, indoor and outdoor vehicle testing, NVH (Noise, Vibration, Harshness) testing, durability testing and other performance related developments.

Introduction

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Tata LPK 3118 9S Truck

Tata LPK (Long Performance Kipper) 3118 9S Truck is a powerful truck comes with Tata Cummins Engine and Bigger 380 mm Clutch. The truck have a Stronger and Heavy Duty Chassis Frame for Higher Gradeability. It can offer you Best in Class Warranty and Safe & Strong Fixed Cabin. The Tata LPK 3118 9S Truck have Heavy Duty Single Reduction Rear Axle and engine mated with Heavy Duty 9 Speed Gearbox. The truck have wide applications in Surface movement of Coal, Aggregate, Sand etc.

Tata LPK 3118 9S Truck Features

Tata Cummins B 5.9 BSIII engine type 183 Hp @ 2400 rpm power output 680 Nm @ 1300 -1500 rpm torque Single plate Dry friction Push type : 380 mm Diameter 70 Kmph top speed 33% @ Crawler Gear, 23% @ 1st Gear gradeability Tata G 1150 9 Speed Gear Box With Crawler Gear All Steel Full Forward Control Cabin 5580 mm wheelbase Hydraulic assisted Power Steering Semi Elliptical Leaf Spring suspension Full Air S Cam Brake System brakes.

Engine Performance and Mileage

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Tata LPK 3118 9S Truck powered by the Tata Cummins B 5.9 BSIII engine type. The engine can churns out 183 Hp @ 2400 rpm power output and 680 Nm @ 1300 -1500 rpm torque. The truck features Single plate Dry friction Push type: 380 mm Diameter. The TATA LPK 3118 9S Truck can attain 70 Kmph top speed on ride.  The truck is highly power to give you 33% @ Crawler Gear, 23% @ 1st Gear gradeability. The engine mated with Tata G 1150 9 Speed Gear Box with Crawler Gear.

Safety and Mileage

The interior of LPK 3118 is equipped with All Steel Full Forward Control Cabin. The dimension of truck includes 5580 mm wheelbase, 31000 Kgs GVW, Best in Class 9.5 meters turning radius etc.

For safety LPK 3118 is equipped with Hydraulic assisted Power Steering, The suspension used is Semi Elliptical Leaf Spring suspension and fitted with Full Air S Cam Brake System brakes too.

Tata LPK 3118 9S Truck Full Technical Specifications

Technical specifications LPK 3118 9S

Engine Type Tata Cummins B 5.9 BSIII

Displacement NA

Max Power 183 Hp @ 2400 rpm

Max Torque 680 Nm @ 1300 -1500 rpm

Clutch

Single plate Dry friction Push type : 380 mm

Diameter

Max speed 70 Kmph

Gradeability 33% @ Crawler Gear, 23% @ 1st Gear

Gears Tata G 1150 9 Speed Gear Box With Crawler Gear

No of gears 9 Forward (including CRAWLER) + 1 Reverse

Cabin All Steel Full Forward Control Cabin

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Axle Type

Heavy Duty Single reduction Tandem Axle: Front

Heavy Duty Forged I Beam, Reverse Elliot Type: Rear

Tyre 10.00 x 20 – 16 PR Bias Ply

Gross Vehicle Weight (GVW) 31000 Kgs

FAW 12000 Kgs

RAW 19000 Kgs

Min Turning Circle Radius Best in Class 9.5 mtrs

Wheel base 5580 mm

Fuel Tank 300 Liters

Steering Hydraulic assisted Power Steering

Front Suspension Semi Elliptical Leaf Spring

Rear suspension Semi Elliptical Leaf Spring

Chassis

Best in Class Ladder type Heavy Duty Frame with

riveted/bolted cross members

Brakes Full Air S Cam Brake System

EngineCummins B5.9 180 BSIII

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Tata LPK 3118 is installed with B5.9 Mechanical engine which is a 5.9 liter engine designed for providing lower acquisition and operating cost solutions for its customers to meet BS-III emission standards. Mechanical fuel system products continue to be the right technology for developing countries like India because of their excellent reputation for performance and ease of service. This engine has been benefitting the operators of LPK 3118.

Based on the experience of our Indian customers with B5.9 Mechanical (BS II), the BS-III engine is highly service friendly and reliable. B5.9 Mechanical BS III engine provides equipment manufacturers with cost effective solution that has a better power and torque against BS II engines. The running cost for this engine will be even lower than BS-II, with increased reliability and reduced maintenance. The engine for every load.The 5.9 liters (360.0 cu in) ISB (Interact System B) is one of the largest straight-six engines used for light truck vehicles.

FEATURES AND BENEFITS of CUMMINS B5.9 180 BSIII

- Vertical injectors produce a balanced spray pattern for optimum combustion resulting in improved performance, improved fuel economy and reduced emissions 

- Rotary fuel pump is highly dependable, durable and delivers a steady stem of pressurized fuel for strong performance in every environmental condition. 

- Waste-gated turbocharger developed by Cummins Turbo Technologies provides excellent performance across the torque curve with improved response. 

- Improved cylinder block is structurally designed for reduced noise and increased durability 

TECHNICAL SPECIFICATIONS 

Engine Model

No. of Cylinder

Displacement Fuel System Bore x Stroke

Rated Power

Peak Torque

Emission Norms

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(HP) (Nm /

RPM)B5.9 180

6 5.9 Litre Bosch Mechanical

102 x 120

180 @ 2500

675 @ 1500

BS-III

Clutch

Single plate type clutch is used in LPK 3118 as it is used in heavy duty vehicles and the advantages of using it in this particular truck is,

As the name suggests, single plate clutch consists of a clutch plate whose both sides are coated with a frictional material.

Torque transmitting capacity is less. Heat generation is less, so there is no need of a cooling medium. It is called “dry

clutches.” The coefficient of friction is high. Faster response; Clutch engagement is almost instantaneous. Single plate clutch used where large radial space available as in LPK 3118

LPK 3118 uses Friction clutches for better performance

The vast majority of clutches used in trucks ultimately rely on frictional forces for their operation. The purpose of friction clutches in LPK 3118 is to connect a moving member to another that is moving at a different speed or stationary, often to synchronize the speeds, and/or to transmit power. Usually, as little slippage (difference in speeds) as possible between the two members is desired.

Organic Clutches in LPK 3118 Organic Clutches tend to be used more for standard driving conditions as they

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provide long life and smooth engagement.

Organic refers to the materials that the clutch disc is made from; that is metal fiber interwoven with organic materials. 

Organic clutches are suited to a range of driving conditions, and perform well in city traffic. Exedy organic clutches provide both good durability and smooth clutch engagement.

They are best used where the demand has been increased, such as towing or carrying a significant amount of weight all the time. This is achieved by increasing the clamp load from the pressure plate onto the clutch plate & increasing the quality of the friction material on the clutch plate itself.

Gearbox

G1150 gear box is a very robust, proven and updated to meet the market requirements of TATA LPK 3118. G1150 gear box is specially designed to cater to the Indian operating conditions. Optimally designed gear ratio offers best in class fuel economy along with good drivability. State-of-the-art synchronizers enable driver to shift in the various gears smoothly. 9 Forward (including CRAWLER) + 1 Reverse.

Benefits of G1150-9 SPEED GEAR BOX that is installed in LPK 3118

Indigenously developed 9 speed gear box Crawler Gear with deep ratio for Heavy haulage and Deep mining operation High Durability - Ground high strength gear provide durability in heavy

haulage application Over-Drive Version - Lesser turnaround time for on-highway trucks due to

higher achievable speeds and for better Fuel economy. Internal Lubrication pump - Better Gear and bearing lubrication even while

operating in hilly terrains

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Oil Cooler compatibility - Oil cooler can be installed based on requirement PTO compatibility - Standard PTO's can be installed for Mining and Tip

Trailer operation Double – H Shift Pattern - Ease in shifting, with minimal driver training Suitability up to 430mm dia. Clutch The first gear ratio is deeper than 6 speed gearbox, hence higher gradeability,

ability to start on grades The wider range with optimal ratio steps results in smooth gear shifting The increased durability of gears to separate planetary range gear box allows

higher input torques Durable performance with fast, easy and smooth shifting. Pneumatic power assistance adaptability. Over Drive Option for better Fuel

economy.

Crawler gear

You'll typically find crawler gears on heavy duty off road equipment as well as some heavy haul on road equipment where a larger than average gear ratio is used to maximize an engine's horsepower as quickly as possible to initiate the movement of a heavier than average load as in LPK 3118.

LPK 3118 engine produce maximum horsepower on the upper end of its rpm range. Using a vehicle's crawler gears, also known as granny gears, will allow the vehicle's engine to rev high producing maximum horsepower while the vehicle itself crawls along slowly.

To describe the highest gear ratio that a truck (LPK 3118) is capable of a term called crawl ratio is used. Since crawl ratio of a vehicle represents the total reduction of the engine speed until the road wheels, it is determined by combining the contributions of different elements on the entire drive train, including transmission and differential, both of which typically introduce a certain amount of speed reduction.

Since a lower crawl ratio (higher gear ratio) implies a larger output torque on the road wheels, it is desirable for vehicles that need to pull large loads, climb steep inclines, or drive over obstacles on the road or terrain, such as rocks, which is sometimes referred to as crawling over the rocks. Therefore, crawl ratios are most often discussed for trucks and off-road vehicles. And thus, it is discussed in LPK 3118 which is 12.9.

Axles

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Rear Axle

Heavy Duty Single reduction Tandem Axle is used in Tata LPK 3118 and it is used due to the following consideration.

Broad ratio coverage allows maximum performance across a variety of vocations.

Extra-wide, face-width gearing increases strength for added durability. High-capacity gearing and bearing system for durability and reliability with

higher horsepower/torque engines. Reduces driveline torsional for less vibration and wear. Carrier integrated retarder provides optimal strength, while reducing

complexity. Added strength and eliminates a leak path. Greater strength for added

durability Maximum strength, higher power density. Patented axle breather design allow unrestricted air flow – a no-maintenance

feature.

Front axle

Heavy Duty Forged I Beam, Revese Elliot Type is used as a front axle in LPK 3118.

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The reason behind using this type of axle in LPK 3118 is mainly due to,

The principal advantage of the beam axle is its simplicity. This simplicity makes it very space-efficient and relatively cheap to manufacture. They are nearly universally used in heavy-duty trucks and thus, it is used in Tata LPK 3118.

Beam axles fitted to LPK 3118 have an important advantage for off-road applications, as they provide better vehicle articulation and durability in a high load environment. This simplicity also makes it relatively easy to lift a vehicle.

A beam axle, is a dependent suspension design, in which a set of wheels is connected laterally by a single beam or shaft. Beam axles were once commonly used at the rear wheels of a vehicle, but historically they have also been used as front axles in rear-wheel-drive vehicles. In Tata motors, beam axles have been replaced by front and rear independent suspensions

Dead axle is also used in Tata LPK 3118 as used in many of the high performance trucks.

A dead axle is not part of the drivetrain but is instead free-rotating. The rear axle of a front-wheel drive car is usually a dead axle. LKP 3118 use dead axles for strictly load-bearing purposes. A dead axle located immediately in front of a drive axle is called a pusher axle. Dead axles are used in LKP 3118 as it is a heavy construction machinery.

Steering

In LPK 3118, power steering (also power assisted steering (PAS) helps drivers steer by augmenting steering effort of the steering wheel and for comfortable driving purpose.

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Purpose of using Hydraulic power steering in LPK 3118 is:

Hydraulic or electric actuators add controlled energy to the steering mechanism, so the driver can provide less effort to turn the steered wheels when driving at typical speeds, and reduce considerably the physical effort necessary to turn the wheels when a vehicle is stopped or moving slowly. Hydraulic power steering systems for LPK 3118 augment steering effort via an actuator, a hydraulic cylinder that is part of a servo system. These systems have a direct mechanical connection between the steering wheel and the linkage that steers the wheels. This means that power-steering system failure (to augment effort) still permits the vehicle to be steered using manual effort alone.

 

Suspension

A leaf spring is a simple form of spring commonly used for the suspension in wheeled vehicles as of commercial vehicles and so it is also used in LPK 3118.

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Semi Elliptical Leaf springs which are used in TATA LPK 3118 have found a niche that will keep them around for years to come, if not decades.

A leaf spring takes the form of a slender arc-shaped length of spring steel of rectangular cross-section. For LPK 3118, semi - elliptical leaf spring is made from several leaves stacked on top of each other in several layers, often with progressively shorter leaves. A leaf spring in LPK 3118 attached directly at one end, usually the front, with the other end attached through a shackle, a short swinging arm. The shackle takes up the tendency of the leaf spring to elongate when compressed and thus makes for softer springiness.

Semi Elliptical Leaf Springs are used in LKP 3118 because of the following reasons,

This leaf spring acts as a linkage for holding the axle in position and thus separate linkages are not necessary. It makes the construction of the suspension simple and strong.

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Semi elliptical leaf springs also help to maintain the position of the rear axle,

which simplifies the suspension system, in turn driving down both weight and cost.

This leaf-spring suspension is also sturdier than a coil spring setup, again reinforcing their use in LPK 3118 that are based around utility.

Therefore, this type of suspension does provide good riding comfort.

Anti – Roll bars

An anti-roll bar (stabilizer bar) is a part of LPK 3118 suspensions that helps reduce the body roll of the vehicle during fast cornering or over road irregularities. It connects opposite (left/right) wheels together through short lever arms linked by a torsion spring. A sway bar increases the suspension's roll stiffness—its resistance to roll in turns, independent of its spring rate in the vertical direction.

Main reasons why anti – roll bars is used in LPK 3118 is as mentioned below

Anti-roll is used in the reduction of body lean.

The reduction of body lean is dependent on the total roll stiffness of the vehicle.

Increasing the total roll stiffness of a vehicle does not change the steady state total load (weight) transfer from the inside wheels to the outside wheels, it only reduces body lean.

Chassis Frame

A vehicle frame, also known as its chassis, is the main supporting structure of a LPK 3118 to which all other components are attached.

The main functions of a frame in LPK 3118 are

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1. To support the vehicle's mechanical components and body2. To deal with static and dynamic loads, without undue deflection or distortion.

These include:

Weight of the body, passengers, and cargo loads. Vertical and torsional twisting transmitted by going over uneven surfaces. Transverse lateral forces caused by road conditions, side wind, and

steering the vehicle. Torque from the engine and transmission. Longitudinal tensile forces from starting and acceleration, as well as

compression from braking. Sudden impacts from collisions.

Ladder type Heavy Duty frame with riveted/bolted cross members type of frame is used in LPK 3118 which is the main part of the vehicle.

So named for its resemblance to a ladder, the ladder frame is one of the simplest and oldest of all designs. It consists of two symmetrical beams, rails, or channels running the length of the vehicle, and several transverse cross-members connecting them.

This design offers good beam resistance because of its continuous rails from front to rear, Also, the vehicle's overall height will be greater due to the floor pan sitting above the frame instead of inside it.

Ladder type frame in Tata LPK 3118 is used for the following reasons

This frames are incredibly tough. In off-road conditions the body of the vehicle is forced into

different orientations, often at the same time, as the vehicle navigates the uneven terrain.

The frame takes most of the punishment. A ladder type will require a fair bit of engineering to deal with the stresses the body will be subjected to.

A ladder frame can support a lot of different body types, allowing more variations with reduced costs.

It is easier to repair ladder frame vehicle as parts are replaced as needed.

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It is typically safer because the whole frame is designed to

absorb the forces of impact, but that means more extensive damage and in some cases the integrity is compromised.

Brakes

Brakes are one of the most important component of any vehicle LPK 3118 is a high performance commercial vehicle, S-Cam Air Brakes are used

The air brake systems used in LPK 3118 is an effective, very durable braking system for use in this truck due to high mileage and extreme operating conditions. This is outfitted with ABS (anti-lock brake systems) for accurate braking system for normal and off-road performance purpose.

S-Cams

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The S-cams rotate from the torque applied by the slack adjusters, resulting in spreading the brake shoes which applies the braking force to the drum. The S-cams are supported by two nylon, grease lubricated bushings. Due to the high forces exerted on the cam bushings, periodic inspection, lubrication and maintenance is required to achieve proper braking performance.

Wheelbase

In both road and rail vehicles, the wheelbase is the distance between the centers of the front and rear wheels. For road vehicles with more than two axles (e.g. some trucks), the wheelbase is defined as the distance between the steering (front) axle and the CenterPoint of the driving axle group. In the case of LPK 3118, the wheelbase is the distance between the steering axle and a point midway between the two rear axles, i.e. 5580mm in the this case.

GVW

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The gross vehicle weight rating (GVWR), or gross vehicle mass (GVM) is the maximum operating weight/mass of a vehicle as specified by the manufacturer including the vehicle's chassis, body, engine, engine fluids, fuel, accessories, driver, passengers and cargo but excluding that of any trailers.

The GVW of LPK 3118 is 31 tons, according to the thumb rule the weight on the each of the front axle is 6 tons, and on the rear axle is in between 9 and 10 tons.

In LPK 3118 we have 2 front axles i.e. 6 tons on each wheel it gives a total of 12 tons on the front axles. We have 2 rear axles this carries a total of 19 tons i.e. 9.5 ton on each of the rear wheel. This gives a total of 31 tons, this includes weight of the vehicle.

Gradeability

Gradeability is defined as the highest grade a vehicle can ascend maintaining a particular speed. When designing an automobile, various performance targets are kept in view, the major ones being weight, fuel economy, power, torque, speed, and acceleration, gradeability is given a lesser significance unless a special purpose vehicle is being designed like a heavy duty vehicle like LPK 3118. Gradeability is measured in multiple ways, mainly: As an angle of inclination to the horizontal (20˚, 30˚, 45˚, etc.).

As a percentage of rise over run. As a ratio of one part run to some particular number of parts (1 in 20 meters, 1 in 50 feet, etc.).

Gradeability of LPK 3118 is 33% at Crawler Gear and 23% at 1st Gear.

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CONCLUSION

The report indicates the procedure on how "TATA LPK 3118" is assembled in the assembly line.

All the details of the assembling procedure were precisely drafted to the best of our knowledge.

As you might have noticed, we drafted the report following a step-by-step approach, beginning from the chassis to the completion of the Truck. Through series of interventions between linkages of various parts, we consolidated the report with utmost importance and fine-tuning of the content we were able to produce.

The report in particular was focused from a singular point, which explains the assembling of the "Truck." All the specifications of the truck are explained in detail. But, to get this done, the report was referenced using various findings on the global internet platform to draw idealistic conclusions throughout the report.

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