Training Report on Standard Tractors
-
Upload
heritagebnl -
Category
Documents
-
view
326 -
download
9
Transcript of Training Report on Standard Tractors
TRAINING REPORT
OF
INDUSTRIAL TRAINING
AT
STANDARD COMBINES PVT. LTD
(TRACTOR DIVISION)
Barnala
Submitted to:
Sh. Sachin Garg
Mechanical Department
B.G.I.E.T., Sangrur
Submitted by:
Maninderjeet Singh
B. Tech (4th Sem) Mechanical Engg)
Roll No. 100111195628
CONTENTS
S. No. Particular Page No.
1. Acknowledgement
2. Company Profile
3. Location
4. Technical Specifications f Tractors
5. Quality Policy
6. Name of Different Departments
7. Research and Development mechanism
8. Personnel Department
9. Material Handling Mechanism
10. Account Department
11. Purchase Department
12. Maintenance Department
13. Store
14. Machine Shop
15. Engine Assembly
16. Engine Testing
17. Tractor Assembly
18. Engg. Department
19. Single Cylinder Engine
ACKNOWLEDGEMENT
First of all I would like to convey thanks to Dr. S.K. Sharma (Principal
R.B.I.E.B.T. Mohali) and Prof. U.S. Koonar Training Incharge of Mech. Engg.
Department in our college.
I am highly thankful to Mr. Nachhatar ingh (Managing Director), Mr. Nirmal
Singh (GM HR&A) and Mr. B.K. Sharma (HR&A Manager) for permitting me to
join the industry & to get useful in information about the plant.
For full completion of my Industrial Training, Training Report and the help during
the Training Period, I Express my sincere thanks to Mr. Balkaran Sinqh (Engg.
Deptt.)
It is also my pleasure to express my gratitude towards the staff of parts inspection
Department for their full Co-operation and giving me the knowledge of instrument
and project to their best.
To sum up a heavy thanks to all those who through formal and informal way
guided me throughout my project work, I will cherish their support for the years to
come.
Finally I would like to convey thanks to all the workers.
Ravinder Singh
COMPANY PROFILE
STANDARAD is a well known name in the field of automobile industries. It was
established in year 1973 by S. Nachhatar Singh.
His hard working efforts and continues improvement in the company has now
made it the number one manufacturer in the field of combine manufacture. In
1999, S. Nachhatar Singh started anew project named by manufacturing of tractor.
Now this company has five improved models of tractor.
1. SE-335 (35HP ENGINE POWER)
2. SE-345 (45HP ENGINE POWER)
3. SE-450 (SOHP ENGINE POWER)
4. SE-460 (60HP ENGINE POWER)
5. 5E-475 (75HP ENGINE POWER)
6. 5E-124 (24HP ENGINE POWER)
STANDARAD is the first Indian company, which has designed 75HP engine.
Company's growth is 150% as compare to the last year. The Daily production is 15
tractors now days. The demand of this tractor is in Uttar Pradesh, Rajasthan, Bihar,
Haryana, Karnataka, and Tamilnadu etc. from the New Year production of the two
new models of tractors is starting. Models are of 30HP and 24 HP
Turnover of the company during the last year was of Rs. 400 crore. Market image
of this company is increasing day by day. Recently Standard Tractors has got the
second position in All India Tractor Competition held at GB Agriculture
University Pant Nagar organized by All India Tractors Association. Standard has
joined hands with a tractor-manufacturing unit of Italy for the manufacture of
tractor by compromise between the two.
LOCATION
The factory is located at Barnala a district of Punjab.
STANDARAD TRACTORS is situated on Sangrur Bathinda Road about 3 KM
from Barnala city at Handiaya Chowk hardly fifteen minutes drive from the main
Bus stand of Barnala. Standard Combine is a private concern of India Particularly
in state of Punjab. This factory was among first to be set up in this industrial town.
TECHNICAL SPECIFICATOINS OF STANDARD TRACTOR
ENGINE 335 345
POWER / CYLINDER 35 H.P. /3 45 H.P. /3
BORE/STROKE 95/110 102/110
MODEL/MAKE SE/STANDARD SE/STANDARD
ENGINE (RPM) 2100(RATED) 2200(RATED)
CAPACITY 2340 CC 2696 CC
TRANSMISSION
CLUCH DRY SINGLE CLUCH DRY DUAL CLUCH
BRAKES DRY DISC MECH DRY DISC MECH
STEERING WORM & SCREW WORM & SCREW
LIFT SYSTEM HYDRAULIC HYDRAULIC
LIFT CAPACITY 1200 Kgs 1200 Kgs
POWER TAKE OFF
SPLINES SPEED 6 6
PTO, ENGINE 540, 1764 540, 1764
TYRE SIZE
FRONT 6/8 PLY 6/8 PLY
REAR 12 PLY 12 PLY
WEIGHT 2096 Kgs 2120 Kgs
DIMENSIONS (MM)
LENGTH 3450 3500
WIDTH 1675 1760
GROUND CLEARANCE 400 435
CAPACITY
DIESEL TANK 68 Ltrs 68 Ltrs
ENGINE 8 Ltrs 8 Ltrs
COOLING SYSTEM 8.5 Ltrs 8.5 Ltrs
TRANSMISSION 47 Ltrs 47 Ltrs
Standard 335DI Standard 345DI
TECHNICAL SPECIFICATOINS OF STANDARD TRACTOR
ENGINE 450 460
POWER / CYLINDER 50 H.P. /4 60 H.P. /4
BORE/STROKE 95/110 100/110
MODEL/MAKE SE/STANDARD SE/STANDARD
ENGINE (RPM) 2200(RATED) 2250(RA'I ED)
CAPACITY 3120 CC 3454 CC
TRANSMISSION
CLUCH DRY DUAL CLUCH DRY DUAL CLUCH
BRAKES DRY DISC MECH DRY DISC MECH
STEERING WORM & SCREW WORM & SCREW
LIFT SYSTEM HYDRAULIC HYDRAULIC
LIFT CAPACITY 1200 Kgs 1200 Kgs
POWER TAKE OFF
SPLINES SPEED 6 6
PTO, ENGINE 540, 1764 540, 1764
TYRE SIZE
FRONT 6/8 PLY 6/8 PLY
REAR 12 PLY 12 PLY
WEIGHT 2158 Kgs 2325 Kgs
DIMENSIONS (MM)
LENGTH 3640 3640
WIDTH 1760 1930
GROUND CLEARANCE 435 490
CAPACITY
DIESEL TANK 68 Ltrs 68 Ltrs
ENGINE 12.5 Ltrs 12.5 Ltrs
COOLING SYSTEM 10 Ltrs 12Ltrs
TRANSMISSION 47 Ltrs 47 Ltrs
Standard 450 DI Standard 460DI
TECHNICAL SPECIFICATOINS OF STANDARD TRACTOR
ENGINE 475
POWER / CYLINDER 70 H.P. /4
BORE/STROKE 105/120
MODEL/MAKE SE/STANDARD
ENGINE (RPM) 2200(RATED)
CAPACITY 4156 CC
TRANSMISSION
CLLJCH DRY DUAL CLUCH
BRAKES DRY DISC MECH
STEERING WORM & SCREW
LIFT SYSTEM HYDRAULIC
LIFT CAPACITY 1500 Kgs
POWER TAKE OFF
SPLINES SPEED 6
PTO, ENGINE 540, 1764
TYRE SIZE
FRONT 6/8 PLY
REAR 12 PLY
WEIGHT 2450 Kgs
DIMENSIONS (MM)
LENGTH 3640
WIDTH 1930
GROUND CLEARANCE 475
CAPACITY
DIESEL TANK 68 Ltrs
ENGINE 11.5 Ltrs
COOLING SYSTEM 12.5 Ltrs
TRANSMISSION 47 Ltrs
Standard 475DI
QUALITY POLICY
We at Standard Tractors Ltd. are committed to the total customer delight by:
1. Providing consistent quality of tractors of combines through the best
utilization of the people and technology.
2. Involving all employees in an environment of learning and continuous
improvement.
3. Maintaining a safe and satisfying work culture.
4. Developing committed suppliers.
5. Adhering to Quality management systems based on ISO 9001: 2001 QMS.
DIFFERENT DEPARTMENTS
1. Research and Development Department
2. Personel Department
3. Tool Room
4. Accounts Department
5. Purchase Department
6. Maintenance Department
7. Store
8. Machine Shop
9. Engine Testing
10. Tractor Assembly Shop
11. Marketing Department
12. Servicing Department
13. Engineering Department
RESEARCH AND DEVELOPMENT DEPARTMENT
Research and Development is an integral and sustaining department of any
organization which want to sustain its place in the ever- developing industrial
environment. The emphasis on research and development in the Standard Group
proved by a long list of new products that have been introduced and established in
the years ever since the establishment of the Standard Group. Research work is
carried out in this unit and design work is accomplished presently, the research and
development is going on with various new products.
The organization of standard tractor division operates functionally, through a series
of shops and departments. Standard Tractor Division (STD) is undergoing
expansion on large scale. STANDARAD establishes well advanced testing shop
for testing of engines produced in order to maintain strict control. A full fledge
administrative block is produced for effective management and improved work
place. The production of engine is being planned to raise engine per day.
PERSONAL DEPARTMENT
Any industry depends upon human being it has acquired workers and creates an
acceptable environment and rule of practice to encourage the greatest degree of
participation from its employee The Depot. Concerned with this called personnel
Dept. a small concern the owner it self carries on the personnel function where as
in large organization, it is given a maximum individual development; desirable
working conditions and desirable working relationship between employees and
effective molding of human resources for the purpose of contributing to the
organization goals.
AIM OBJECTIVE AND FUNCTION
1. Procurement and maintenance of adequate workforce as regards to both
number and quality of personnel.
2. Education and training of present employees.
3. Maintaining satisfactory personnel contacts &employees relationships.
4. Maintaining satisfactory group relationships by contacting employer's
groups.
5. Maintaining employee’s health.
6. Maintaining employee’s safety.
7. Maintaining employees service activities and employees welfare.
MAINTAINING HANDLING MECHANISM
Material handling involves the movement of material manually or mechanically in
batches or one item with in plant. The movement may be horizontal, vertical or the
combination of both.
The various material handling equipments used in the machine shop of STD;
1. Roller Conveyer
2. Wheel conveyer
3. Screw conveyer
4. Haulage Conveyor
5. Power hoists
6. Trolleys
7. Block and Tackle type hoist
TOOL ROOM
Tool room is essential part of any industry. Tool room takes care of jigs and fixture
makes new ones reshape tool etc. The various function of tool room is
MAKING AND REPAIR OFTOOLING
Tool room makes different tool as per the design given by IE dept. the different
tool include insert setting fixture tendons bushes & many more items Repair of
worn out tool is also done.
ACCOUNTS DEPARTMENT
The main objective if account dept. is to determine, classify and analyze the cost
and income of business enterprise. The account dept has following dept. has
following functions:
1. Sales Accounting
2. Purchase Accounting
3. Labors Accounting
4. Financial Accounting
PURCHASE DEPARTMENT
The department is responsible for purchasing all type material in correct qualities
and at the most economical prices the purchase department occupies a vital and
unique sit-in-a concern because purchasing is one the main nation in the success of
a modern manufacturing concern the purchase function liaison agency which
operates between the factory out side vendors on all matters of procurement the
various objective and function of purchase department are;
1. To procure right material
2. To procure material in right quantity and quality.
3. To procure material economically.
4. Maintain records of reliable sources of supply.
5. Making controls with right sources of supply
6. Revives material specification with an idea of simplifying and standardizing.
7. procure and analyzer quotations.
8. Place and follow up purpose orders.
9. Maintains records of all purchases
10.To prepare purchasing budget.
11.To keep an uninteresting supply of materials
12.To endure that prompt payments are made to the vendors in the interests of
good public relations.
13.To sell material and scrap.
MAINTENANCE DEPARTMENT
In the modern industry, Equipment and machinery are very important part of the
total productive effort. Lot of capital is invested in the plant equipment and
machinery. These are deteriorated by their exposure to environment and working
condition. lf their damage is not checked at proper time, these make the equipment
non-usable. Thus it is very important to maintain, repair and recondition these to
increase their life and make them available for maximum number of operation
hours.
The various objective of maintenance department are:
1. To achieve minimum breakdown.
2. To keep the plant in good working condition at the lowest possible cost.
3. To prevent loss in production services.
4. To maintain the various plant services.
5. To provide plant protection including fire protection.
6. To establish and maintain a suitable state of maintenance of material.
Insurance administration.
7. Overhauling of plant equipment and, machinery.
8. Generation and distribution of power and other facilities.
9. To carry out corrective repairs to alleviate unsatisfactory conditions found
during preventive maintenance inspection.
SOTRE
1. Material and supplies constitutes the most important assets in the majority of
business enterprises The success of the business beside other factor depends
to a large extent on the efficient storage and material control.
2. Material pilferage, deterioration of material and careless handling of stores
leads to produce losses.
STORE MANAGEMENT TAKES CARE
1. That material is never out of stock.
2. That no material is available in much excess than required.
3. There is adequate procedure of receipts and issue of material
4. That there us proper method of keeping store records.
5. Proper storing of materials done.
VARIOUS FUNCTIONS
1. To receive material, goods and equipment's and to check them for
identification.
2. To receive pats and components which have been processed in the factory?
3. To record the receipts of goods.
4. To correct positioning of all materials and supplies in the stores.
5. To maintain stock safety in good condition by taking all precautions to
ensure that they don’t suffer from damage, pilfering deterioration.
6. To initiate purchasing cycle at the appropriate time.
INTRODUCTION TO MACHINE SHOP
The machine shop is major part of any factory all the machining operations which
are to be done on any component is performed in machine shop.
There are two types of machine shops depending on the work to be performed. As:
1. Light Machine Shop
2. Heavy Machine Shop
LIGHT MACHINE SHOP
Introduction
L.M.S. is shop for manufacturing small components of the tractor in Standard
Tractor division this is small shop where light operations on components are
performed on different components for production work.
Main operation performed in L.M.S. is as follows:
1. Drilling
2. Tapping
3. Reaming
4. Milling
5. Facing
6. Turning
7. Boring
8. Grinding
Major machines used in light machine shop are as follows:
LATHE
Lathe is the mother of entire machines & probably the oldest machine tool finds its
great application at STANDARD TRACTORS.
Here in this industry lathes of sizes 6 feet & 8 feet are installed owing to there use.
Lathe removes the undesirable material from the rotating work piece held between
two lathes centers of tail & head stock. The lathes are installed here are centre
lathes.
Major performed on lathes are:
1. Turning
2. Facing
3. Grooving
4. Drilling
5. Boring
6. Reaming
7. Knurling
8. Cutting
Milling Machine:
Milling is the process of removing metal by feeding the work past a rotating multi
point cutter. In milling operation the metal removing rate is high because cutter
rotates at high speed and has many cutting edges. The surface finish is also better
due to multi cutting edges column & knee types milling machine has been installed
in machine shop. In this type of machines three types of motion are possible.
1. Vertical (Up & Down) movement
2. Transverse (In & Out) movement of saddle
3. Longitudinal (Back & Front) movement of table
Shapers
The shapers makes use of the single point tool that transverse the work and feeds
over at the end of each stroke. In body agro industries vertical shapes has been
installed owing to the reason that is used in the formation of the key ways in round
pulleys.
Vertical shaper is proffered over the horizontal type because the thrust acts directly
on table bed, so there is no possibility of deflection of table. Only simple fixtures
needed.
POWER HACKSAW
For cutting of the large sized job reciprocally power hacksaw has been kept in
machine shop Although it is a slow and expensive method of cutting but owing to
its advantage, it is widely suitable. Several bars may be cut at same time and
continuous attention is not needed, since the saw stops automatically when cut is
finished. A lubricant is often used for easier cutting action and longer life of blade.
A crank mechanism is provided to raise the blade on each return stroke, to protect
the teeth of blade while it dragged backward. Average cut is of 3 mm.
GRINDER
It is one of the simple and useful machine required in the industry Grinding is a
process of removing metal by rotating abrasive wheel. Abrasive particles acts as
cutting tool tips.
GRINDER IS USED FOR
1. To remove a very small amount of metal from work space and to achieve
small tolerances.
2. To obtain better surface finish.
3. To sharpen the cutting tools
4. To cut hardened steel.
5. To machine tough surfaces, which are not easy to machine by H.S.S tool or
carbide tool.
HEAVY MACHINE SHOP
Introduction
The heavy machine shop (HMS) is one of the most important shops in the industry
It plays a very important role in the production of the tractor As the name suggests
all the heavy components namely the differential housing, the gearbox housing, the
cage and trumpet are machined here. The shop is called the backbone of the
industry. The Heavuy machine shop is divided into five sections.
1. Differential housing line
2. Trumpet Line
3. Rear Cover Line
4. Crankcase Housing Line
5. Tool Room
All the sections are highly equipped with modern machinery and equipment Each
section has a layout i.e. tile raw material is received at one ends and the finished
component is dispatched from the other. The material received is in form of casting
The machining process is carried out under strict quality norms. There is in the
process inspection at each workstation. The component is made to go through final
inspection before it dispatched for assembly.
The material handling system in the H.M.S shop consists of hydraulic life trucks,
power hoists; roller conveyors, overhead crane, and fork lift trucks. Bins etc. The
shop has well designed network of roller conveyers.
ENGINE ASSEMBLY
DETAILS OF ENGINE ASSEMBLY
STAGE l:
Three lines are present at STANDARD
a) A Grade tolerance +12 micron.
b) B Grade tolerance +24 micron.
c) C Grade tolerance +36 micron.
The cylinder has two seats: -
1. For water.
2. For oil.
The Grade sign of the liner should be kept toward the camshaft.
Crankshaft Fitting:
First of all bush type liners are inserted into the bearing holes. The liner is provided
with recess to store a minimum amount of oil, which wets as the crankshaft during
storing engine. The bearing cup is opened and crankshaft assembly placed into it.
The bearing cup is tightened again with 10-12 Kg-m torque rod and crankshaft is
checked that it is revolving easily or not
Stage 2:
Timing Gear Fitting: -
The idle shaft is pushed into the crankcase and roller type bearing with lock is
inserted into the shaft. The idle timing gear is then pressed into the bearing. The
timing gear is punched at two places and punched sign has to be matched with
punched mark of [on] crankshaft.
Timing Gear Fitting
Piston Assembly Fitting: -
The piston assembly is filled into the liner and big end is tightened to crankshaft
Line is filled with A grade piston assembly. The grade mark should towards
camshaft. The piston ring cuts should be so adjusted that there should not be in
same line
Piston
Stage 3:
Lubrication Oil Pump Mounting: -
The lubrication oil pumps connected to crankshaft gear by an idle gear of 2-3
degree. The crankshaft and pump gear has 22 teeth each. The pump is provided
with relief valve [through], which opens at kgf.
In the case of are loading or something injected in main gallery then pressure is
released from their valves.
Rear Cover & Front Cover Mounting: -
The rear cover and front cover are cleaned perfectly with air and filled to engine
with seals in between [mounted].
Stage 4
Cam Shaft Fitting: -
The camshaft is inserted into the camshaft hole with bearing and bolt ends are
locked by circle. The camshaft is forged from alloy steel or cast iron and is case
hardened.
The one end of the camshaft is provided with gear, which is locked, gear z-50 for
exact timing of the camshaft gear mark is matched with the mark on idle gear.
Another gear pump is attached with idle gear, which serves the purpose of driving
the fuel injection pump.
FLYWHEEL MOUNTING
The flywheel is mounted the crankshaft and bolts are tightened with 11-12 kg-m
force. The F.LP is connected to F.LP gear through the F.LP drive shaft.
The F.LP. drive shaft is specifically designed to advance the time of injection. The
both ends of F.1.P. drive shaft is provided with spline, one side a key is provided
which is locked to timing gear and recess on their side is pushed in to F.LP. slots.
The angle between the key and recess of 18°', thus the fuel injection is advanced by
18° degree.
Flywheel
Stage 5:
Cylinder Head mounting:
The cylinder head assembly is placed on the piston and studs are passed through it.
If the height of the piston at TDC from the surface is more then 0.1 mm than the
gaskets of given thickness are used. If it is 0.1 to 0.5 mm then 1.2mm thick gasket
is used. If it is 0.5 to 0.8 mm then 1.5 mm thick ,gasket is used. The cylinder nuts
are tightened by 17-18 Kg-m forces.
Cylinder Head
Stage 6:
Water Body and Pulley Mounting: -
The water body is mounted with thermostat control valve opens at 70° C. the
pulley is mounted on camshaft.
Stage .7:
The assembly is removed from the trolley, is placed on the stationary frame.
Stage 8:
Fuel Injection Pump Mounting and Setting of Fuel Injection Pump
The gear of F.I.P. is first of all meshed with F.LP. drive shaft and is loosely
tightened to set the timing of gear first of all pointer is tightened on the crankcase
and flywheel us rotated which is meshed for 16 , 18 , 20, 24 angles. The pointer at
set at 18 of flywheel and then the pump is rotated clockwise till one from first
nozzle stop out blowing. At this position a cut mark is made on both the pump and
crankcase for further setting. The pump is tightened properly and pipes are
tightened over nozzle and injectors. The head of position is covered with covers
and the complete engines are sending to engine testing shop. The whole of engine
shop is air-cooled.
Fuel Injection Pump
ENGINE TESTING
INTRODUCTION
Engine testing is done for checking the performance of newly assembled engine to
found out any assembled fault, their HP, leakage and other fault. Engine testing
shop of the STD is equipped with latest digital control equipment. The engine
testing is done with the help of turbine (Water) or hydro dynamometer is four in
number so that engine is tested at a time. The shop is equipped with heavy-duty oil
filter, which is used to clean the oil from dust or other large particle. The shop has
bush pump tester is measured on the based of S.A.E ratings. The society of
automobile engineer's USA has specified die method of measuring the power
output of the engine for standardized purpose. The engine is run without generator.
TRACTOR TESTING
Tractor testing is done under the international organization for standardization
(ISO). The first tractor with an internal combustion engine was introduced in
American agriculture in the year 1889. The tractor-testing act was passed in U.S.A
in 1920. In India tractor-testing station was finally establish at Budani in 1959 for
tractor testing atmospheric pressure shall not be less than 96.6 Kpa.
The basic task in the design and development of engines is to reduce the cost and
improve the efficiency and the power output. In the order to achieve the above task
the development engineer has to compare the developed engine with the other
engines in terms of its output and efficiency. Towards the end engineer has to test
the engine and mal<e measurements of relevant parameters that reflect the
performance of the engine.
ENGINE TESTING AT STANDARD TRACTORS
PURPOSE OF TESTING A TRACTOR ENGINE:
In general purpose of testing an I.C. engine is to determine the following:
1. To determine the rated power output with respect to the fuel combustion in
Kg per Kw hr brake power output.
2. To determine the mechanical and thermal efficiencies of the engine.
3. To see the performance of the engine at different loads.
4. To determine the quantity of lubricating oil required per B.P. Kw-hr. e) To
determine the quantity of cooling water required per B.P. Kw-hr. f) To
determine the overload carrying capacity of the engine.
5. To prepare the heat balance sheet of the engine.
Engine Testing
SOME IMPORTANT TERMS AS ISI STANDARD
TERMINOLOGY
Speed:
The speed of a engine is the mean speed of its crankshaft in RPM. Except in the
case of free piston engines where the speed is the number of cycles per minute of
the reciprocating components.
Steady Load Speed Band:
It is the maximum total variation in speed expressed as a percentage of the mean
speed, which may occur while there is no change in the external load conditions.
Continuous Power
The power which engine is capable of delivering continuously between the normal
maintenance intervals stated by the manufacturer at the stated speed and under
stated operating conditions.
Indicated Power:
It is the total power developed in the working cylinder by the gases on the
combustion side of the working pistons.
Friction Power:
It is the power consumed in the frictional resistance.
Brake Power:
It is the total power consumed in frictional resistance.
Fuel Consumption:
It is the quantity of fuel consumed per unit of power per unit of time. It is generally
expressed in grams of fuel consumed per B.H.P.
Mechanical Efficiency:
It may be defined as the ratio of the power obtained at the crank shaft i.e. Brake
power to the Indicated power.
Thus Mechanical Efficiency = Brake power (B.P.) /Indicated power (Z P.)
Thermal Efficiency:
Indicated Thermal Efficiency:
It may be defined as the ratio of heat converted into indicated work to the heat
energy supplied by the fuel, during a specified period of time.
So, Indicated Thermal Efficiency
= Heat equivalent to LP per min. / heat energy supplied by fuel per min. = LP.
* 60 / Mf *CV
Brake Thermal Efficiency:
It may be defined as the ratio of the heat equivalent to Brake power (B.P.) to the
heat energy supplied by the fuel during a specific time.
So, Brake Power Efficiency
=Heat equivalent to B.P. per min. /Heat supplied by fuel per min. =B.P.
*60/Mf*CV
Preparation for Test:
Test runs shall be made on an engine as being offered to the consumers. Before
starting the engine tests, the engine shall have been thoroughly run in the fuel and
lubricating oil used during the test shall be specified by the engine manufacture.
In general the engine operating temperatures and the lubricating oil pressure during
the test shall be maintained at the values recommended by the manufacturer. In
engine testing we note down the following data:
1. Revolution per minute (R.P.M)
2. Fuel Time
3. Engine Lub. Oil pressure
4. Water outlet temp.
5. Lubricating oil temp.
6. Torque (N-M).
7. Smoke reading with the help of Bosch smoke meter.
8. In case of silencer a noise meter & U-tube manometer for measuring
backpressure.
With the help of the data we calculate following parameters:
1) B.HP = R.P.M *N-Ml Dynamometer Constant Per B.KP per hour. .
(Which are 7023.746 for Dynamometers used at STANDARAD)
2) In kilowatts = R.P.M *N-M/9549.305
3) Specific fuel consumption (S.F.C) =297000/B.KP*fuel time
Gram per B.H.P per hour
Where 297000= 0.825 * 100 *3600
4) Torque Brake up (T.B. U)
= Max. Torque -Rated Torque / Rated Torque
Dynamometer is the instrument used at STANDARD to measure the engine power
and it must include at least four essential elements:
1. A means for controlling torque.
2. A means for measuring torque.
3. A means for measuring speed.
4. A means for dissipating the power.
Dynamometers are of mainly two types:
Absorption type:
a) Mechanical b) Hydraulic
Now mechanical absorption type dynamometers are of further two types:
1. Prony Brake.
2. Rope Brake.
3. Band Brake.
Transmission type:
a) Mechanical b) Electrical
In STANDARD TRACTORS Hydraulic type dynamometer are used for readings
TRACTOR ENGINE TESTING:
TRACTOR ASSEMBLY SHOP
Type of PTO Tractor
There are three types of PTO Tractor:
1. Multi PTO Tractor
2. Ground PTO Tractor
3. Simple PTO Tractor
Multi PTO Tractor:
it can be work in gear at stop position as in at well which help in achieving the
move speed as compare with other tractor. Multi PTO tractor is work at six high
speed & six low speed gears.
Ground PTO Tractor:
It is work in PTO in gear is only when tractor going as thoster and reaper. It can be
given only turo speed.
One directly to PTO and other throw the gear when tractor is going on. It cannot
work in gear when tractor is sleep gear is put through the idle gear.
Simple PTO Tractor:
It is the PTO which can be work at 540 R.P.Iv1 in one speed when the tractor is
stop and going on. Tractor is work in only one speed.
INTRODUCTION TO ASSEMBLY SHOP
Tractor assembly shop is main shop of standard tractor division. In this shop the
different machining parts, housing and other component, which are machined on
the other department or purchased, from outside are assembled here.
Then assembled components like differential housing, gearbox rear cover, trumpet
housing and other housing are sending to in main line for tractor assembly. In main
tractor assembly line tractors are said to paint shop through overhead endless chain
rotating conveyor.
Following are main phase of assembly.
1. Differential Housing Assembly
2. Rear Cover Assembly
3. Gear Box Assembly
4. Main line Assembly Phase
5. Paint Phase
6. Assembly of accessories and inspection
Deferential Housing Assembly Phase
It is rear part of the tractor cheesy. The main function of differential in tractor is to
reduce the final and also to turn the drive round at 90 degree. The reduction of the
speed is done in two staged. First stage reduction in tail pinion and crown wheel
meshing and second stage reduction in bull gear meshing with left and rights BP
shaft.
Assy. Of Differential
It is also consisting the PTO shaft (Power take off shaft), which is used to run the
thrashers, pumps and other accessory components with the help of pulley attached
on it.
Following are the main Parts of Differential Housing: -
Crown Wheel.
Tail Pinion.
Cage assembly with Sun & Planet gears.
P.T.O Shaft.
B.P. Shaft Left & right.
Bull Gears.
Bevel Gear.
Bearings.
Brakes Housing Assembly
Oil Seals,
Gaskets etc.
Assembly of Crown Wheel:
First of all components are washed with oil to remove the dirty particles. Cage
having two holes in these holes dowels are tight fitted for accurate fitting of crown
so that a11 other holes of the cage and crown are in same line. The crown wheel is
pressed on case with hydraulic press and then tightened by bolts with lock washer,
and then the right bevel gear is placed on their cage seat. The four plant gears are
put on across with washer and then assembly is placed in the cage. Then left bevel
gear is placed. Operator checks the motion of the gear by manual inspection
Tail Pinion Assembly:
In tail pinion assembly the cone for taper roller bearing is pressed with hydraulic
press. The bearing is heated before the tight fit, the tail pinion is inserted inside
bearing. The different size shims are also placed before tightening of rear cover of
cage. Whole assembly is tightened by nuts and bolts.
Rear Axle Assembly:
In rear axle assembly bolts are tight fitted in the holes of hub. Where the rear tire is
tightened with bolts to the whole assembly. Two bearing on either side of the
trumpet housing are tightened at gang drill
Brake Assembly:
Standard Tractors are provided with heavy self energizing water sealed disc brakes
with ventilation pipe, which gives better cooling.
The ventilated results in reduction of about 30% in pad temperature. Brake housing
cover contains to disc made of asbestos base. The max temp resistance is about 300
degree C. below this is two disc plate a cast iron plate is fixed which is held by
springs. Whenever brakes are applied plate tends to expand. During expanding of
C.I plate the discs strongly mounted on BY left and BY right shaft stops the
movement of differential.
P.T.O Shaft Assembly:
Two bearings, which tight it fit on P.T.O shaft, are firstly places with help of
circles then P.T.O shaft assembly is passed through rear PTO hope of differential
housing.
Following Three Tests are done:
1. Back Lash Testing
2. %Age of contact
3. Pattern Test
BACK LASH TESTING
This test is performed with the help of plunger dial gauge. Back lash in crown
wheel is not more then 20 to 30 micron if it is deviated from this value then
packing is changed on either side (left or side) of cage of bearing housing. But
never change the number of shim. If Backlash is more than 30 micron then shims
from right side is removed and shifted in to left side. IF it is less then 20 micron
then vice versa. Also require run out for crown wheel is OS-l mm.
%AGE OF CONTACT TEST AND PATTERN TEST
Pattern test and %age contact test is done with the help of yellow paint applied on
teethes of crown wheel. Then rotat8ing crown wheel with hand %age of contact
and pattern of tail pinion is impressed on the teeth of wheel. The %age of contact is
60 % to 70% require. IT can be increase or decrease by using the shims by
fastening it on tail pinion carrier. When increase in number of shims the pattern
goes increase and vice versa.
The bull gear are tighten to trumpet housing assembly by lock nut and the whole
assembly of trumpet housing is also tighten by nut and studs on outer side of
differential housing then PTO shaft head cover is tightened to protect its outer
teeth. The sliding gear and PTO shifter rod assembly is mounted on differential
housing. Two filters are places are inside diff. housing and then whole assembly of
dif£ Housing is sending to the main line.
REAR COVER ASEEMBLY:
Rear cover assembly is used to cover the differential housing. It contains lift
control system, which is hydraulically operated. Driver seat is fitted on the upper
side of rear cover. The response valve housing (R.V), control valve, ram cylinder
and other component assembly fitted inner and outer side of rear covers assembly.
The main components fitted on rear cover assembly are: -
a) Control valve assembly
b) RN. housing assembly
c) Ram cylinder and piston assembly
d) Operating sector assembly,
e) Sensor tube assembly
f) Gaskets, bolts, nuts
g) Other Components
Ram Cylinder Assembly: -
It contains cylinder with piston inserted inside it. The relief valve assembly is
mounted at top front of cylinder. The connecting rod is placed in piston rear side
and one side is locked with ram arm assembly. Rock arm, spacer and seals are
placed. At the end of rock arm assembly, lift arm assembly is placed & then locked
with bolts on both sides.
RV. Housing Assembly: -
It contains one response valve, check valve and release valve. It is also connected
with control valve through pipe housing. The Knob is placed at top of response,
valve to close or open the response valve as per requirements.
Control Sector Assembly: -
It contains the draft control assembly, and position control assembly. Both these
assemblies are connected to their lever. The position control assembly is connected
to black mark level and draft control assembly is connected to red mark lever.
First of all rear cover is mounted on the moving trolley and tightened with bolts.
The control sector assembly is placed at there respecting place. A sensor tube is
placed at rear side of rear cover. The ram cylinder assembly is placed inside rear
cover R.V. housing is placed outside rear cover, which is connected to control
valve through pipes.
Control valve contains three valves i.e. back measure valve and scroll valve. Oil
from pump goes into R.V. housing through pipes, which is further connected, to
the check valve through inner hole of R.V. housing and back presser valve of
control valves. The opening pressure of check valve is 9-12 Kgs and operating
pressure of back pressure is 3-6 Khs. During un-operated position the oil flow is
continues through the backpressure valve of control valve.
During operation of position arm the unloading valve close the gallery of oil to
backpressure valve. Thus the pressure R.V. housing builds up which open the
check valve at 9-12 Kgs. At this position the oil goes in the Ram cylinder, which
further operates the lift arm. For requirement of any position of lift knob of
response valve of R.V. housing is rotated which cut the supply of oil and Ram arm
achieved. Sensor tube works in field during plaughing of soil with harrow. When
harrow deeply dug in soil, draft it set at position through sensor tube.
The rocker arm attached sensor and harrow link, which push the sensor tube inside
and automatically control value control oil supply.
ENGINEERING DEPARTMENT
In Engineering Department at Standard Tractors the main works are done of
making catalogue, dealing with ISO and project regarding testing of tractor from
Central Farm Machinery Testing & Training Institute (CFMT&TI), Budni (M.P.)
and Automotive Research Association of India (ARAI), Pune.
This department takes responsibility of implementation of system given by ISO. It
also helps to perform Audits.
In this department, making of service operator of service Manual, Price list and
giving part No. according to requirement of company is being done.
It also takes responsibility to update the Bill of Materials (BOM) for Analyzing the
Cost.
PROJECT STUDY OF SINGLE CYLINDER DIESEL
ENGINE
Single cylinder diesel engine is that engine which only one cylinder is there. It is
air cooled engine.
Specifications:
Dia of Piston : 114.88
Dia of Liner : 115mm
Stroke : 150mm
Displacement : 1539cc
Type : Single Cylinder Diesel Engine Air Cooled
H.P. : 24
R.P.M. : 1700 rated
No. of fins : 21
Weight of fly wheel : 111Kg
Governor Type : Centrifugal
Diesel Pump : Plunger Type
Lubricating Type : Gear Pump Type
Angle of Fuel injection : 11 degrees before TDC
Air Cleaner : Dry Type
The single cylinder engine which is developed by STANDARD is air cooled. In
this radiator is required, only air fan is used which spread the air in the fins for
cooling the crank case.
There are only two companies who made the single cylinder engine namely
Mahindra and Eicher, Standard is the third company and first in Punjab.
Main advantage is that it is easy to handle. Fewer accessories are required for
cooling, high efficiency.
Setting of Engine:
The setting of engine is done from the pulley. The angle is 11 degrees before TDC.
It means the fuel inject in the cylinder 11 degrees before TDC (before Top Dead
Centre) in power strike. It is done with help of cam gear.
Lubrication System:
For lubrication system 4 liters oil is used. The lubrication is done with the help of
gear pump system, with the gear pump system the oil is put on the crank.
Air Clean System:
It has an Air Cleaner System. First of all Air is passed through the filter.
Crank Case:
Crankcase is made from cast iron. The cylinder is mounted on the crankcase. Shaft
is there, connecting rod is there, cam shaft is fitted to crankcase. On the backside
of crank case Lubrication gear system is fitted. The filter is fitted outside the
crankcase. Crankcase, is placed on the roller bearing because the weight of
crankcase is more.
Single Cylinder Diesel Engine
Inlet Valve:
Length : 149 +.1
Surface Hardness : 600HVM
Tuff tidal depth : 0.01min
Tensile Strength : 90-105 Kg/min
Cam Shaft
Splines
Type : Involute
Pressure Angle : 20 degrees
Module : 2
Material : Mn = 20, Cr = 5
Exhaust cam dia : 31.5
Inlet cam dia : 31