Delphi Noida PVT. LTD .Machine core bulder

PROJECT REPORT

ON

“MATRIX CORE BUILDER”

Undertaken at:

Automotive Systems, Greater Noida

Under the guidance of: Submitted by: Mr. Sanjay Grover Manoj Kumar

P C & L Department B. Tech 2nd Year

Delphi, Greater Noida PMCE, Sonepat

(Haryana)

ACKNOWLEDGEMENTS

The satisfaction and euphoria that accompany the development of any task would be incomplete without mentioning the people who made it possible and whose constant guidance and encouragement crowned my efforts with success. I take this opportunity to acknowledge the help I received from different individuals and place on record my appreciation and thanks to those who lent me a helping hand in bringing out this project work.

I would like to express my sincere thanks to Mr. Sanjay Grover for helping me conceptualize and realize this project. This project would not have been possible had it not been for his continual guidance and profound assistance. I am also indebted to the various team leaders and other members of the P C&L department for their valuable time and being extremely cooperative during my interactions with them. Lastly I would like to express my gratitude to the faculty of PMCE, (Sonepat) who have been a constant inspiration in my quest for knowledge and excellence.

Manoj Kumar B. Tech 2nd Year Mechanical Engineering. PMCE, Sonepat (Haryana).

CERTIFICATE

This is to certify that the Project Report titled “Matrix Core

Builder” is the bonafide work of Manoj Kumar, PMCE Sonepat

(Haryana) carried out at “Delphi, Automotive System Private

Limited, Greater Noida” in the year 2012-2013; and this has not

been submitted to any other University or Institution for the award

of any Degree or Diploma.

“Matrix Core Builder”

Project Guide:

Mr. Sanjay Grover Manoj Kumar

P C & L Department B. Tech 2nd Year

Delphi Automotive Systems PMCE, Sonepat

Greater Noida . Haryana.

CONTENTS

Acknowledgements

Certificate

Contents

Abstract

Company Profile

P C & L Department

Brief Overview of Center Machine and Matrix Core Builder

Matrix Core Builder Specification and its Process for making condenser

Matrix core Builder YE3 Condenser

ABSTRACT

This project was carried out under the guidance of various members of the Production Department at Delphi Automotive Systems, Greater Noida. The purpose of my project was to how “Matrix Core builder” use for making condenser in Delphi and save time and effort of workers. Matrix core builder fully automatic machine which connected with Central Machine which provides centers to machine for making condenser. Matrix core builder is use for making condenser of YE3 car (codename) for Maruti Suzuki. Its biggest machine in Delphi.

COMPANY PROFILE

Delphi India

In India, Delphi Automotive Systems Private Limited has been operating as a wholly owned subsidiary of the parent company since 1995. The Delphi employees in India are exposed to a diverse culture and rich history as they help drive tomorrow's technology. Delphi has four QS 9000 certified manufacturing facilities in the country, located in Bangalore, Noida and Gurgaon. Delphi„s key customers in India include Maruti Udyog Limited, General Motors India, Daewoo Motors, Fiat, Hindustan Motors, Volvo and Telco. Delphi facilities boast the conveniences and tools necessary to safely and efficiently produce the high-quality products that help make Delphi a world leader in automobiles. Delphi India facilities are steadily increasing product engineering capabilities to keep pace with the increasing prevalence of electronics in automobiles. Delphi Automotive Systems is the world„s most diversified automotive systems and components supplier. Earlier known as the Automotive Component Group Worldwide (ACG Worldwide) of General Motors, its operations were restructured and unified into a single identity called Delphi Automotive Systems in February 1995. Multi-national Delphi conducts its business operations through various subsidiaries and has headquarters in Troy, Mich., USA, Paris, Tokyo and São Paulo, Brazil.

Evolution of Delphi :

1988: ACG (Automotive Components Group) Worldwide Group structure created

1994: General motors established ACG Worldwide as a separate business sector 1995: ACG Worldwide became Delphi Automotive Systems 1998: Delphi incorporated as a subsidiary 1999: Delphi becomes a fully independent publically held corporation. 2002: Delphi Automotive Systems become ―Delphi

Milestones :

In 2003-2004, Delphi India has been honored by Maruti Suzuki with three quality awards, one for "Excellence in Quality," "Cost Reduction" and the prestigious "Outstanding Overall Performance" award.

In 2002, Delphi won the Vendor Performance Award for "Low PPM Rejections of Incoming Suppliers

In 2001,Delphi Gurgaon earned the Vendor Performance Award for "Overall Quality."

Products:

Delphi produces a wide range of products at its various facilities in India:

Brazed Aluminum Heat Exchangers

Catalytic Converters

Evap Containers

Front Corner Modules

Half SHAFTS

Heating, Ventilating, and Air conditioning (HAVC) Systems

Oil- Filters

Shock Absorbers and Struts

Steering Columns

Electrical/electronic distribution systems

Wire harness

Energy & Chassis Systems Diesel Engine Management Systems Gasoline Engine Management Systems Systems Fuel Handling & Evaporative Systems Automotive Batteries Fuel Cells Valve train Sensors & Actuators Chassis Systems & Module Fuel Cell Controlled Braking Systems Complete Brake Systems Wheel Brake Components Brake Apply Components Gen III Wheel Bearings Suspension Dampers & Modules Steering Systems Vehicle Control Systems

o Steering Columns

o Power Steering Pumps and Hoses

o Steering Gear

o Half Shafts, CV Joints

Electric Steering Systems

o Electric power steering

Interior Systems Instrument Panels Airbag Systems Door Modules, Trim & Related Hardware

Thermal Systems Climate Control Systems HVAC Modules Condensers, Compressors, Thermal Management Systems Engine/Transmission Cooling Systems Radiators, Oil Coolers, Engine Cooling Modules Product and Service Solutions Vehicle Electronics Consumer Electronics Service Technologies Diesel Products Electronics and Safety Sensors & Power Modules Body & Chassis Electronics Power train Controllers Audio & Communications Driver Information & Controls

About my Project:

I had undertaken to work in the production department. Thus I was assigned a project on Tooling Management. The project comes under the P C & L Department. A brief overview of the department is given in the next unit.

PC & L Department (Production, Control and Logistics) P C & L stands for

Production

Control (Stores)

Logistics (Dispatch)

Production Planning and Control

Production is a process whereby raw material is converted into semi-finished products and thereby adds to the value of utility of products, which can be measured as the difference between the value of inputs and value of outputs. The main objective of production function is to produce the goods and services demanded by the customers in the most efficient and economical way. Objectives:

o Define production management

o Analyze various factors, which are crucial for designing the production.

o Explain the design of production system and manufacturing processes.

o List out the factors influencing the choice of production process.

o Having properly designed production planning, and control system.

Production Management: Production system is a system whose function is to convert a set of inputs into asset of desired outputs Production management involves the managerial decisions regarding design of the product and design of the

production system i.e. determination of production processes and production planning and control.

Steps of Production Planning and Control - Planning

- Routing

- Scheduling

- Loading

- Dispatching

- Following up

- Inspection

- Corrective action

The most important role in production planning and control is played by Materials Requirements Planning (MRP). An MRP system is intended to simultaneously meet three objectives:

- Ensure materials and products are available for production and delivery to customers.

- Maintain the lowest possible level of inventory.

- Plan manufacturing activities, delivery schedules and purchasing activities.

Tooling management also has an important role to play in the planning process in the Production department. Tooling management and its advantages in manufacturing processes has been discussed in detail in the later unit of this project report.

Another important term we ought to know about is product specification. Product specification refers to anything which describes how a product will be manufactured. Advantages of product specification

- Raw material suppliers know exactly what they need to deliver.

- Production department knows exactly what it needs to produce.

- Raw materials can be controlled, ensuring a quality product.

- Customers can expect a certain standard.

- Testing for quality control is easier.

Logistics

Logistics is basically a business planning framework. It involves the management of material, capital flows, service and information. All the increasingly complex information, communication and control systems which are required in today's business environment are included in it. Logistics is not the transportation itself, but to streamline and control the flow through the value adding processes and eliminates non-value adding ones. Production logistics provides the means to achieve customer response and capital efficiency. Production logistics is getting more and more important with the decreasing batch sizes. In industries such as the cell phone industry, batch size one is the short term aim. This way even a single customer demand can be fulfilled in an efficient way. Track and tracing, which is an essential part of production logistics - due to product safety and product reliability issues - is also gaining importance especially in the automotive and the medical industry. Logistics management is that part of the supply chain which plans, implements and controls the efficient, effective forward and reverse flow and storage of goods, services and related information between the point of origin and the point of consumption in order to meet customers' requirements. A professional working in the field of logistics management is called a logistician.

Brief Overview of Center Machine And Matrix Core BuilderThere are various machines in Delphi which are used to perform different operations during the manufacturing processes. These machines have various types of tooling’s. In this unit, I have documented about the Matrix Core Builder machine and Center Machine which important machine in Delphi for making condenser of CodenameYE3.

CENTER MACHINE BASIC TERMINOLOGIES INVOLVED Air Centre The air center is a medium between the outside ambient air and the fluid that is carried in the tubes. It is a primary part of the heat exchanger and draws heat from the fluid flowing through the tube with which it is in contact and loses it to the air flow as it passes through the louvers. Convolution Combination of two consecutive fins is called convolution. Constant The distance between two consecutive tip radiuses is called constant. Margins Margins are the non-louvered material which is present in center turnaround and outside edges. Fin Fin is one half of a convolution. Center Length Center Length = Number of Convolutions X center constant Height Height is the distance between the top and bottom tip radius. Tip Radius It is the material that connects two consecutive convolution legs.

Louver Panel The combination of the louver banks on a single fin. Louver Bank The bank of louvers between the outside margins and middle margin is known as the louver bank. Louver Twist The difference in the measured angle between the louver angles at top and bottom tip radius and compared to nominal louver angle. Bulk Transmission Bulk transmission percentage is the amount of actual light that passes through the louver slit openings in a panel compared to the theoretical maximum you could receive. Raised Outside Margin Raised outside margin is used to avoid drop centers by holding the air center in position next to the tube during braze. Reduced Middle Margin The reduced middle margin is designed to minimize the barrel shape of the air center. Dog Leg Dog leg refers to the curve in the center over the length of the center. Rollovers Crushed convolutions exiting the pullout rolls are termed as rollovers. Lock Up Lock up is basically the amount of tooth engagement between the upper and lower form rolls.

Louver Angle Louver angle is the degree of angle of the louver slit relative to the flat surface face of the convolution panel. The spring back ie the elastic recovery of a metal after stressing is greater if the aluminum material is harder. Greater spring back results in a lower louver angle as the material attempts to bring the louver slit back to the natural flat state. Thus 40 degrees may be placed on the cutting edge of the form discs but the actual measured louver angle is 35 degrees.

Louver angle decreases due to disc wear, aluminum debris in the form rolls and minimizing the lubrication of the aluminum strip.

Automatic High volume Core Builder(YE3)

The YE3 is a high volume core builder that can produce a range of radiator and condenser cores. The machine uses servo-based controls to ensure precise core assembly dimensions. The YE3 can be configured with varying levels of automation. The standard machine (shown below) includes automatic header and tube loading into the machine from component storage carts that loaded into the machine. Other optional configurations can include automatic side support and braze bar loading, as well as automatic braze clip loading/core unloading.

ABOUT THE MACHINEThe front side of the center machine is basically the operator side of the center machine. The center machine pulls in the individual aluminum strips from the stock uncoiler by the rotation of form rolls. The center machine tooling creates all part characteristics in the air center but the overall quality will be influenced by the condition of the incoming material from the stock uncoiler. The center machine design concept for each different product family is identical and only differs on what the height, louver angle, and what the constant is to be. The sequence of operations for each system is the same.

YE3 Condensor for Maruti Suzuki Alto 800

Machine Matrix Core Builder

Steps for making YE3

1) Matrix core builder

2) Brazing

3) Separator leak test

4) Cosmetic test

5) DBA Assembly

6) End cap press

7) End cap flame Braze

8) Proof test

9) Mass Spectrometer

10) Under water SLT

11) Underwater test (mass spec)

12) Appearance

13) Final alignment gauge

Test On Condensor--------------------------------------------

Leak testing equipment is a type of nondestructive testing equipment used to measure the escape of liquids, vacuum or gases from sealed components or systems. Some configurations require a separate leak detector or sensor as an input. They are often equipped with various other components such as pumps, calibrators, gages and cases. A leak is a hole or porosity in an enclosure capable of passing a fluid from the higher pressure side to the lower pressure side.

There are many basic leak test methods and a few variations. The most familiar are dunk testing, pressure decay, mass flow, mass spectometer and ultrasonics. Dunk testing is still the most popular method, with pressure decay and mass flow rapidly gaining in use. Mass flow is the de facto test method of choice in automotive applications. An exception is pressure decay testing on a brazing fixture.

If there is a situation where a no leak application is required, there is only one choice— mass spectrometer—regardless of cost. This application uses helium and hydrogen gases as part of its inspection process. The good news is the leakage may be so microscopic it is rarely detrimental to product performance.

DunkTesting 

Dunk testing, sometimes called bubble testing, is used for applications that do not require high sensitivity. With dunk testing, the part under test is pressurized, submerged in a liquid—typically water—while the operator looks for bubbles. Bubbles form at the source of the leak as a result of air pressure, and the amount of bubbles per minute can signify the size of the leak. Automotive radiators often are checked for leaks this way. If a leak is present, the bubbles indicate where and the leak can be repaired. Leak testing works best when speed is not a factor. On a production line where test time is critical, leak testing is not the best choice.

While the initial cost of a dunk tank is low, in production it is expensive primarily because the water becomes contaminated, thus producing a hazardous toxic waste requiring special disposal. Tramp oil on the parts, as well as residual brazing flux are the main problems. Tramp and brazing flux from the parts leech into the water causing water contamination and costly special disposal. In one plant, aluminum condensers—AC radiators—are tested on four lines, six tanks total. Each operator has 19 seconds to determine if the bubbles represent air trapped in the fins or an actual leak. The operator is solely responsible for quality control prior to final mass spec testing. Failure of the operator to find a leak of 3.5 standard cubic centimeters per minute (sccm) or greater can shut the mass spec line down for hours. In addition to disposal, maintenance of the water for pH, bacteria and skimming the surface to control skin rashes is a big factor—possibly $30,000 per year for maintenance of each tank. In the above mentioned condenser plant, each 3- by 3- by 12-feet tank is said to cost $30,000 per year to maintain.

This is an example of a familiar process for low-volume applications and repairs but an inappropriate use in high-volume applications. High-speed leak testing in a production line situation hampers the operator’s ability to accurately identify bubbles. However, dunk testing can be used on fuel tank filler assemblies and fuel tanks themselves.

One advantage of water dunking is temperature stability. The large volume does not change temperature, which affects most of the more sophisticated testers.

Pressure Decay 

The pressure decay testing method measures the decrease in pressure in an object. A test object is initially inflated and then a reference pressure is established. After a designated amount of time, the pressure is monitored again, and the initial and final measurements are compared. The change in pressure can be used to calculate the leak rate given the internal volume of the device. Pressure decay is able to detect minute changes in pressure. A drop in pressure signifies a leak; the greater the pressure drop, the larger the leak. This method is convenient in that it is easily automated and dry.

Years ago, the operator drew a grease pencil mark on a gage and came back a while later to see if the gage pointer had moved. If it had, this meant that pressure decayed. Today, electronics monitor to 0.00001 psi and the test is fast—the fastest on small-volume parts. During the past 20 years, electronics have progressed from a 12-bit analog to digital converters, which provided a resolution of 0.0012 to 5 psi. This reduced to 0.0244 psi at 100 psi, far too coarse to be practical.

One way around this problem was the differential pressure tester. Two sensors, having a 5-0-5 psi range, could be set up at 100 psi and provide a resolution of 0.0012, which was usable. Presently, 24-bit resolution is available which provides 16,777,215 steps or 0.0000002 psi at 5 psi and 0.000059 psi at 250 psi. Consequently, differential testing has practically been phased out.

The pressure decay method can be used to test small parts at high speeds. A 0.3-inch diameter by 1.2-inch long medical filter can be tested to see if the filter is in place, if it is plugged and if it allows for correct air flow. Test time from clamp to next clamp is 0.85 second at 15 psi.

Also, a molded vacuum tube connection for the automotive industry is 12 inches of 0.2-inch inner diameter tube with circular molded fitting can be tested. Its test time is 3.5 seconds, clamp-to-clamp at 15 to 30 psi, depending on part. Each test result is permanently recorded and traceable if required.

Communication has become a significant quality tool. Sometimes, only a permanent record of key test parameters and results are sufficient. Other times, a label is printed out and permanently affixed to the part. Still others apply a permanent paint spot or stamp a mark. On certain safety-critical parts, a guillotine destroys a bad part.

Temperature variation is a concern. It is widely believed that pressure testing a gas tank filler assembly while red hot on the braze fixture is impossible. The part in the brazing fixture is approximately 1200 F in the brazing area. Room temperature air fills the part to test pressure, then the fill valve closes. A 30 psi test would normally be considered incorrect at 29.9 psi. However, the pressure is

Dry testing a radiator, this pressure decay tester inspects with a test cycle time of 16 seconds at 95 psi. This is the same tester that tested the brazing fixture. Source: Stewart Ergonomics Inc.

rising, not decaying. The pressure will climb to 34 to 35 psi before starting to decay. It will require at least 15 minutes to reach 29.9 psi and will not be repeatable enough to be practical. The required test time is 20 seconds maximum.

MassFlow 

With the mass flow method, the part is pressurized throughout the test. Any pressure change measured by a pressure sensor is compensated for by inputting air into the test part, therefore exact pressure control is critical. The amount of air entering a part is measured by a flow sensor, directly determining the leak rate of the part. Leakage flow is directed across a heating element. The temperature change across a temperature transducer bridge results in an output voltage proportional to mass flow.

If there is a leak, air will flow into the part. This flow is monitored electronically and processed directly in sccm. Because the flow of air into the part is equal to the leak loss, large-volume parts may be tested with relative ease. The problem with testing large parts is long settle or stabilize time. Because precise pressure control is critical, any oscillation during testing will compromise the test.

Several types of electronic sensors are available. One has a fine tube through which air flows to the part. An electric heater at the input heats the air slightly and that temperature is precisely measured just beyond the heater. The change in temperature is proportional to the flow of air.

Another application measures the milliampere (mA) of current needed to maintain temperature. Ambient incoming air temperature will affect the test. Most production systems are recalibrated every morning, noon and late afternoon. Large parts, such as truck radiators, are commonly placed in a wooden “coffin” to protect against air currents from fans and open doors. The slow test with long-settling time requires protection from thermal changes for repeatability. Mass flow is the process of choice in many automotive applications such as air conditioning condensers, radiators and some fuel lines.

Mass Spectrometer 

The mass spectrometer method involves pressurizing the test object with a helium mixture and placing it in a snug-fitting vacuum chamber. The air is then evacuated from the chamber, creating a pressure gradient between the internal volume of the part and the vacuum. The helium molecules move out of the part through any porosity, holes and cracks.

A wand testing system, while not as accurate as placing the part in a vacuum chamber, is superior to any other kind of test, and substantially less expensive than the vacuum chamber system. Source: Galileo TP Inc.

A mass spectrometer then samples the air inside the chamber and finds individual atoms of helium.

This is the most sensitive test presently available. These testers are capable of detecting a leak of R600a refrigerant as small as 0.0028 ounce per year. In use, the helium is usually a disposable item adding cost, although recovery systems are now available. Electronic parts often are tested by placing them in a chamber and pressurizing with helium, then placed in the vacuum chamber of the mass spectrometer to see if helium is drawn out. This method also will find porosity.

The initial cost of a snug-fitting chamber is high, requiring precise machining and extremely tight seals, limiting the practical part size. A basic operation limitation is that a large leak—more than 4 sccm—will saturate the vacuum container with helium. This requires several hours of flushing to lower the helium background to a workable level. A pre-test can be employed to weed out the gross leakers. As with dunk testing, a 19-second inspection has proven troublesome and is slowly giving way to pressure decay testing, with or without permanent recording. Even a condenser 16- to 18-inches high, and 24-inches long can be easily tested to 3 sccm in 12 to 15 seconds at 200 psi. Many air conditioner condensers (radiators) are quite large, but they still must not leak for 8 to 10 years. For these applications, a wand testing system has been developed which, while not as accurate as placing the part in a vacuum chamber, is superior to any other kind of test, and substantially less expensive than the vacuum chamber system.

Ultrasonics 

Ultrasonic leak testers, sometimes called sonic, choked flow or turbulent flow, analyze the turbulent flow of a fluid across a pressure boundary that creates acoustic waves. These waves can be transmitted through the medium of the fluid itself, through the containment structure or through the air surrounding the containment structure.

Because gas escaping through small holes generates ultrasonic sound, an array of ultrasonic sensors can be placed around the part. Computer control permits leak detection and, in certain circumstances, exact leak position may also be obtained, similar to dunk testing. Ultrasonic testing has become so widely used to test bearings, gearboxes and general mechanical inspection wear trends over time that it is often overlooked in leak detection. Part size is usually not a problem, nor is thermal variation. Arrays of sensors are used to pinpoint a leak. In some instances, pressure decay testing and mass flow testers have been integrated with ultrasonics to provide increased sensitivity. While this method has not been widely used, it has potential for larger parts.

In the future, leak testing will experience faster cycle times, improved reliability and validation. Leak testing will continue to be integrated into the assembly process and its accuracy and sensitivity will become higher. NDT

Brazing On Furnace

When condenser completed on matrix core builder its goes for brazing on furnace on High Temperature. Furnace is divided in four parts

Flexor

Dryer

Brazer

Cooling chamber and Final cool

Separator Leak Test

Parameters

Test Pressure—25to26psi (pressure sqr inch)

Reject level – 1.13 psi

Test Time—5 sec

Dump time – 0.0 sec

Cosmetic Inspection

Fitting Rubber caps in the core Or condenser.

DBA Assembly (Desiccant Bags assembly)

At this , desiccant bags insert in RD tank . An adsorbent package is provided for use within the sealed canister of a fluid flow tube of an air conditioning system. The adsorbent package includes a desiccant bag formed of a pouch having a sealed first end and a substantially cylindrical second end. A filter cap is slidably and sealingly received within the second end of the pouch. The cap includes a resilient sealing ring formed proximate a porous end wall. The sealing ring slidably and sealingly engages an inner surface of the canister. The package is constructed of a non-woven spun bonded nylon and can therefore be snugly received within the tight confines of fluid flow tube or canister sections of an integrated condenser receiver.

End cap pressure

Air pressure – 2 to4 bar

End cap flame braze

Down heater—550±25 centi sec.

Up heater -- 1200±50 centi sec.

Soft heater -- 500±40 centi sec.

Air cooling – 2500±125 centi sec.

Air pressure – 4-6 kg/cm2

LPG pressure – 1-2 kg/cm2

Chillet temp. – 10-12 def.c

Air Flow – 0.9 LPM

LPG – 0.22 LPM

Proof Test

Apply nitrogen gas pressure at 500 -550 psi. for 5 second.

Mass spectrometer test

Air pressure – 75-85 psi

Helium tank pressure – 120psi

NOTE____:

Under water SLT and Under water test performed after rejection of condenser at mass spectrometer Test. If Part not reject at mass spectrometer . Its will go to next test appearance and Final Alignment Gauge Test.

Quality Parameters For YE3 condenser

No. of convolution -- 114±2

Center Height – 6.90±0.08mm

Lower angle – Avg. 24+5°/-2°

Bulk transmission – Min. 65%

No. of lowers – should not be less than 6

Center length – 325 to 335 mm

Note –

Gap btw RD tank and Header HDR should be uniform and not exceed 3mm.

Clinching – At this place, brackets insert in Reinforcement

Upper and Lower Bracket at 0.5 bar

Hydraulic Pressure -- 60 to 70 kg/cm2