24-09-2014, 02:42 PM
ABSTRACT Training is an investment and should be able to get due returns in terms of better quality of workmen and engineers for future. I underwent my training at the SWARAJ DIVISION of PTL which is a manufacturer of a wide range of quality products like Tractors, Harvester Combines and Fork lifters etc. The product brand of PTL is �SWARAJ� which is one of the best selling company of agricultural implements in the market and that is why I preferred to have my training at this unit. It helped me to enhance my knowledge. I learnt many technical and problem solving techniques there in the plant. I was allotted with the project named as �TO REDUCE THE PROBLEM OF CLUTCH ACTUATOR LEAKAGE � I have worked on it with full dedication. I am very thankful to the training faculty of our campus and technical operators of PTL for this cooperation, for providing this opportunity to carry out the six month industrial training at MAHINDRA &MAHINDRA LTD(SwarajDivision). I am extremely grateful to Mr. ASHUTOSH TRIPATHI as a Project Director wh
1. PROJECT REPORT
PROJECTS DONE AT
MAHINDRA & MAHINDRA SWARAJ TRACTORS
DURING 6 MONTHS INDUSTRIAL TRAINING
1.1 TO REDUCE THE PROBLEM OF CA GUIDE LEAK
1.2 CONCEPT OF CLUTCH ACTUATOR
The clutch actuation system transfers the force exerted by the driver’s foot on the pedal to the clutch, in order to disengage it. In acar\'sclutch, aflywheelconnects theengine, and aclutch plateconnects to thetransmission.When your foot is off the pedal, the springs push the pressure plate against the clutch disc, which in turn presses against the flywheel. This locks the engine to the transmission input shaft, causing them to spin at the same speed.
The amount of force the clutch can hold depends on the friction between the clutch plate and the flywheel, and how much force the spring puts on the pressure plate. The friction force in the clutch works just like the blocks described in the friction except that the spring presses on the clutch plate instead of weight pressing the block into the ground.
When the clutch pedal is pressed, a cable or hydraulic piston pushes on the release fork, which presses the throw-out bearing against the middle of the diaphragm spring. As the middle of the diaphragm spring is pushed in, a series of pins near the outside of the spring causes the spring to pull the pressure plate away from the clutch disc. This releases the clutch from the spinning engine.
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The clutch allows engine power to be applied gradually when vehicle is starting out, interrupts power to the transmission to avoid gear clashing when shifting and prevents engine stalling when bringing the vehicle to a stop. Engaging the clutch allows power to transfer from the engine to the transmission and drive wheels. Disengaging the clutch (clutch pedal fully depressed) stops the power transfer and allows the engine to continue turning without force to the drive wheels.
1.2.1 COMMON CLUTCH-RELATED COMPONENTS ARE:
Flywheel – mounts to the engine crankshaft
Clutch Disk – the friction material assembly that provides easy engagement and firm torque transference
Pressure Plate – also known as “Clutch Cover” – this is the spring-loaded surface that locks the clutch Throw-out
Bearing – also known as “Release Bearing”
Pilot bearing –centers and supports the transmission input shaft (many cars do not have this bearing)
Clutch Cable – mechanical release mechanism for some vehicles
Clutch Master Cylinder – force-multiplying cylinder for vehicles with hydraulic release mechanisms Clutch Slave Cylinder – used along with a Master Cylinder for hydraulic release mechanisms Misc. hoses, lines, brackets, linkages, etc. – varies from vehicle to vehicle
The flywheel is a large steel or aluminum disc. It acts as a balance weight for the engine, dampening engine vibrations caused by the firing of each cylinder and provides a surface that the clutch can contact.
The flywheel also has teeth around its circumference for the starter motor to engage and crank the engine.The clutch disc is a steel plate, covered with a frictional material that is sandwiched between the flywheel and the pressure plate. The center of the disc is the hub, which fits the spines of the transmission input shaft. When the clutch is engaged, the disc is "squeezed" between the flywheel and pressure plate, and power from the engine is transmitted by the disc\'s hub to the input shaft of the transmission.
A pressure plate is a metal spring-loaded friction surface that is bolted to the flywheel. It has a metal cover, heavy release springs, a metal pressure surface, and a thrust ring or fingers for the release bearing. The thrust ring or fingers release the clamping force of the springs when the clutch is disengaged.
When the clutch pedal is depressed, the "Throw-out bearing" pushes the pressure plate\'s release fingers. The pressure plate pulls away from the clutch disc, disengaging the clutch, thus interrupting power flow. When the clutch pedal is released and the clutch is fully engaged, the release bearing is normally stationary and does not rotate with the pressure plate.
Clutch operation is accomplished either mechanically or with a hydraulic pressure system.If a vehicle has a mechanically operated linkage, it will incorporate either a shaft-and-lever linkage arrangement or a cable.Systems that are made up of linkages, levers and pivot points are found primarily on older vehicles. These systems require regular lubrication and can only be designed to fit a limited range of configurations.
1.2.2 CA GUIDE OPERATION IN TRACTOR
In a tractor it is operated by the left-most pedal using hydraulics or a cable connection from the pedal to the clutch mechanism. Even though the clutch may physically be located very close to the pedal, such remote means of actuation are necessary to eliminate the effect of slight engine movement, engine mountings being flexible by design. With a rigid mechanical linkage, smooth engagement would be near-impossible, because engine movement inevitably occurs as the drive is "taken up". No pressure on the pedal means that the clutch plates are engaged (driving), while depressing the pedal will disengage the clutch plates, allowing the driver to shift gears.
A manual transmission contains cogs for selecting gears. These cogs have matching teeth, called dog teeth, which means that the rotation speeds of the two parts have to match for engagement. This speed matching is achieved by a secondary clutch called a synchronizer, a device that uses frictional contact to bring the two parts to the same speed, and a locking mechanism called a blocker ring to prevent engagement of the teeth (full movement of the shift lever into gear) until the speeds are synchronized.
1.3 PROBLEM IDENTIFICATION
1.3.1 TEAM FORMATION
1.3.2 ABOUT THE PROBLEM
1. C.A. guide seal leak after filling differential oil at QP4 lead to clutch slippage , which is Critical to Quality Customer requirement.
2. Considering this ,we calculated leakages in different Tractors at dismounting area .Total number of tractors are 70 and total amount of leakage was 12litres in 16 hours.
3. To calculate the amount of oil seepage =
(leakage /min ×16 hrs /day )
4. Major problem being observed in rework area is tractors with differential Oil Seepage from Drain plug. Leakage observed from CA guide assembly which leads to clutch slippage while driving. Clutch slippage may lead to accidents.
1.3.3 HISTORY OF THE PROBLEM
1. Based On Data From April2013 To July 2013
2. These problem observed in all models of SWARAJ TRACTORS - 735FE/XM,744FE/XM,855FE/XM (DATA TAKEN FROM April 2013 to July2013).
1.3.4 RESULTS OF C.A. GUIDE LEAKAGES
1.4 OBSERVATION
1.4.1 PROCESS FLOW FOR TRACTOR ASSEMBLY
We have observed that major problem of oil leak is taking place at rework area –(QUALITY POST4).
STANDARD OPERATING PROCEDURE OF GEAR BOX ASSEMBLY
1.4.2 PROCESS OBSERVATION
problem identification area source of leakages
1.4.3 OBSERVATION OF SYMPTOMS
GEAR BOX INSPECTION PLUG LEAK(PAST DATA)
S/N
GEAR BOX INSPECTION PLUG LEAK CAUSES
NO. OF CASES
(APRIL 12 TO DEC 12)
RESPONSIBLE
1.
COVER PLATE BOLT HAND LOOSE
9
ASSEMBLY
2.
COVER PLATE CRACK (cross tightening not done)
6
ASSEMBLY
3.
COVER PLATE MOUNTING HOLE NOT DRILLED
5
HMS
4.
C.A. GUIDE SEAL IN OPPOSITE DIRECTION
15
ASSEMBLY
5.
C.A. GUIDE SEAL DAMAGE
10
ASSEMBLY
6.
BIG SIZE BOLT FITTED
5
HMS
7.
STEP ON THE COVER PLATE MOUNTING FACE
9
ASSEMBLY
8.
C.A. GUIDE GASKET CUT
7
ASSEMBLY
9.
C.A. GUIDE BROKEN FROM MTG. HOLE
4
ASSEMBLY
10.
C.A. GUIDE GASKET FOLD
2
ASSEMBLY
11.
C.A. GUIDE BROKEN DUE TO FALLING OF GEAR BOX
1
ASSEMBLY
12.