CHAPTER 1 INTRODUCTION 1.0 HISTORY OF ASHOK LEYLAND Ashok Leyland is an Indian automobile manufacturing company based in Chennai , India. Founded in 1948, the company is one of India's leading manufacturers of commercial vehicles, such as trucks and buses, as well as emergency and military vehicles. Operating six plants, Ashok Leyland also makes spare parts and engines for industrial and marine applications. It sells about 60,000 vehicles and about 7,000 engines annually. It is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle (M&HCV) segment with a market share of 28% (2007–08). With passenger transportation options ranging from 19 seaters to 80 seaters, Ashok Leyland is a market leader in the bus segment.The company claims to carry over 60 million passengers a day, more people than the entire Indian rail network. In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25 ton range of trucks. However Ashok Leyland has presence in 1
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CHAPTER 1
INTRODUCTION1.0 HISTORY OF ASHOK LEYLAND
Ashok Leyland is an Indian automobile manufacturing company based
in Chennai, India. Founded in 1948, the company is one of India's leading
manufacturers of commercial vehicles, such as trucks and buses, as well as
emergency and military vehicles. Operating six plants, Ashok Leyland also makes
spare parts and engines for industrial and marine applications. It sells about 60,000
vehicles and about 7,000 engines annually. It is the second largest commercial
vehicle company in India in the medium and heavy commercial vehicle (M&HCV)
segment with a market share of 28% (2007–08).
With passenger transportation options ranging from 19 seaters to 80 seaters,
Ashok Leyland is a market leader in the bus segment.The company claims to carry
over 60 million passengers a day, more people than the entire Indian rail network.
In the trucks segment Ashok Leyland primarily concentrates on the 16 ton to 25
ton range of trucks. However Ashok Leyland has presence in the entire truck range
starting from 7.5 tons to 49 tons. The joint venture announced with Nissan
Motors of Japan would improve its presence in the Light Commercial Vehicle
(LCV) segment (<7.5 tons).
Ashok Leyland's UK subsidiary Optare has shut down its bus factory in
Blackburn, Lancashire. This subsidiary's traditional home in Leeds has also been
vacated in favour of a purpose built plant at Sherburn in Elmet. Early products
included the Leyland Comet bus which was a passenger body built on a truck
chassis, sold in large numbers to many operators, including Hyderabad Road
Transport, Ahmedabad Municipality, Travancore State Transport, Maharashtra
State Transport and Delhi Road Transport Authority.
By 1963, the Comet was operated by every State Transport Undertaking in
India, and over 8,000 were in service. The Comet was soon joined in production by
a version of the Leyland Tiger.
In 1968, production of the Leyland Titan ceased in Britain, but was restarted
by Ashok Leyland in India. The Titan PD3 chassis was modified, and a five speed
heavy duty constant-mesh gearbox utilized, together with the Ashok Leyland
version of the O.680 engine. The Ashok Leyland Titan was very successful, and
continued in production for many years.
Over the years, Ashok Leyland vehicles have built a reputation for reliability
and ruggedness. This was mainly due to the product design legacy carried over
from British Leyland.
Ashok Leyland had a collaboration with the Japanese company Hino Motors
from whom the technology for the H-series engines was bought. Many indigenous
versions of H-series engine were developed with 4 and 6 cylinder and also
conforming to BS2 and BS3 emission norms in India. These engines proved to be
extremely popular with the customers primarily for their excellent fuel efficiency.
Most current models of Ashok Leyland come with H-series engines.
In the journey towards global standards of quality, Ashok Leyland reached a
major milestone in 1993 when it became the first in India's automobile history to
win the ISO 9002 certification. The more comprehensive ISO 9001 certification
came in 1994, QS 9000 in 1998 and ISO 14001 certification for all vehicle
manufacturing units in 2002. In 2006, Ashok Leyland became the first automobile
company in India to receive the TS16949 Corporate Certification. Editor’s note:
This is part of a series of articles peeking into clean car industries and car
manufacturers of China, India, South Korea and Germany.
Among many other goals, Ashok Leyland aims to expand its operations to
penetrate into overseas markets. Included in the company’s plans is to acquire 2
smaller car manufacturers in China and in other developing countries. In October
2006, Ashok Leyland bought a majority stake in the Czech based- Avia. Called
Avia Ashok Leyland Motors s.r.o., this will give Ashok Leyland a channel into the
competitive European market. According to the company, in 2008 the joint venture
sold 518 LCVs in Europe despite tough economic conditions. Furthermore, the
company will expand its product offers into construction equipment, following a
joint venture with John Deere. Newly formed in June 2009, the John Deere
partnership is a 50/50 split between the companies. The company says negotiation
is progressing on land acquisition, and the production plans are in place.
The venture is scheduled to start rolling out wheel loaders and backhoe
loaders in October 2010. Aside from the full expansion planned for the company,
Ashok Leyland is also paying close attention to the environment. In fact, they are
one of the companies showing the strongest commitment to environmental
protection, utilizing eco-friendly processes in their various plants. Even as they
thrust into different directions, Ashok Leyland maintains an R&D group that aims
to uncover ways to make their vehicles more fuel efficient and reduce emissions.
When it comes to the development of environmentally friendly technologies,
Ashok Leyland has developed Hythane engines. In association with the Australian
company Eden Energy, Ashok Leyland successfully developed a 6-cylinder, 6-liter
92 kW BS-4 engine which uses Hythane (H-CNG,) which is a blend of natural gas
and around 20% of hydrogen. Hydrogen helps improve the efficiency of the engine
but the CNG aspect makes sure that emissions are at a controlled level. A 4-
cylinder 4-litre 63 KW engine is also being developed for H-CNG blend in a joint
1.1.1 iBUS
Ashok Leyland announced iBUS in the beginning of 2008, as part of the
future for the country's increasingly traffic-clogged major cities. Its Rs 60-lakh, 3
iBus, a feature-filled, low-floor concept bus for the metros revealed during the
Auto Expo 2008 in India, a vehicle for a first production run of pilot models should
be ready by the end of this year. The start of full production is scheduled for 2009.
Developed by a team of young engineers, the low-floored iBus will have the first
of its kind features, including anti-lock braking system, electronic engine
management and passenger infotainment.
The executive class has an airline like ambience with wide LCD screens,
reading lights, audio speakers and, for the first time, Internet on the move. A GPS
system enables vehicle tracking and display of dynamic route information on LCD
screens, which can also support infotainment packages including live data and
news. The bus will probably be equipped with an engine from the new Neptune
family, which Ashok Leyland also introduced at this exhibition, which are ready
for the BS4/Euro 4 emission regulations and can be upgraded to Euro 5.
1.1.2 DOST
DOST is a 1.25 ton light commercial vehicle (LCV) that is the first product
to be launched by the Indian-Japanese commercial vehicle joint venture Ashok
Leyland Nissan Vehicles. Dost is powered by a 55 hp high-torque, 3-cylinder,
turbo-charged Common Rail Diesel engine and has a payload capacity of 1.25
Tonnes. It is available in both BS3 and BS4 versions. The LCV is being produced
in Ashok Leyland's plant in Tamil Nadu's Hosur.
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1.1.3 ASHOK LEYLAND DEFENCE SYSTEMS
Ashok Leyland Defence Systems (ALDS) is a newly floated company by the
Hinduja Group. Ashok Leyland, the flagship company of Hinduja group, holds 26
percent in the newly formed Ashok Leyland Defence Systems (ALDS). The newly
floated company has a mandate to design and develop defence logistics and tactical
vehicles, defence communication and other systems. Ashok Leyland is the largest
supplier of logistics vehicles to the Indian Army. It has supplied over 60,000 of its
Stallion vehicles which form the Army's logistics backbone.
1.1.4 SHOPS IN ASHOK LEYLAND
1.1.4.1 ENGINE ASSEMBLY
STAGE 1: CAM BEARING
Cam bearings are attached to the crankcase of the engine.
STAGE 2: CAM SHAFT
Cam shaft is attached in the crankcase.
STAGE 3: CRANK SHAFT
It is fixed at the base end of crankcase.
STAGE 4: STUDS
M14 studs are fixed to the holes of crankcase.
STAGE 5: TIMING BRAKE PLATE
It is fixed to the side of the engine.
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STAGE 6: CAM GEAR
It is placed on the crankcase to operate cam shafts and to operate valves.
STAGE 7: FLYWHEEL
The flywheel is placed on housing; it also consists of seal housing and flange.
STAGE 8: OIL PUMP
It is fixed at top of crankcase. It is used to circulate oil to various parts of engine.
STAGE 9: PISTON
The piston is attached inside the bore of crankcase & it is connected to crankshaft. The oil ring and compression rings are also attached on the piston.
STAGE 10: CONROD BOLT
It is used to connect piston with crankshaft.
STAGE 11: IDLING GEAR
It is used to control the rotations of cam gear, crank gear and compression gear.
STAGE 12: CYLINDER HEAD
It is attached at the top of crankcase.
STAGE 13: OIL SUMP
It is placed at the bottom of crankcase.
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STAGE 14: ROCKER
Rocker is fixed with cylinder head.
STAGE 15: AIR COMPRESSOR
It is fixed with crankcase.
STAGE 16: FUEL INJECTION PUMP
STAGE 17: VALVE COVER
STAGE 18: OIL COOLER
STAGE 19: INJECTOR PIPE
STAGE 20: INLET MANIFOLD
STAGE 20: SIDE COVER
STAGE 21: WATER PUMP
STAGE 22: STARTER MOTOR
STAGE 23: EXHAUST MANIFOLD
STAGE 24: TURBO CHARGER
STAGE 25: EII FITMENTS
STAGE 27: FULLY ASSSEMBLED
Finally, the assemble is taken to the testing section for checking the performance.
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1.1.4.2 SHOP III
FRAME ASSEMBLY
There are several steps involved in frame assembly. They are as follows:
The side members and engine mounting are lifted using conveyor.
Assemble all cross members, steering mounting bracket, air cooler mounting bracket and rear spring brackets.
On rear end of the frame, both sides are aligned with taper pin.
Cross members are tightened well. Fit and tight FS and BKTS on both sides with dummy bolts.
Reaming process is done in the next step and the dummy bolts are removed.
Torque tightening in the rear brackets using M14 bolts on both sides.
Front and rear ends are fixed with four cab mountings.
Tighten the CB cross members using brake elbow adaptors.
Tilt the frame by 180o using tilting CUM lifting equipment.
Punch frame Sl. No. and spec on rear end of RH FSM.
Air blow the reamed burrs in assembled frame.
Lift and unload the assembled frame from conveyor on to trolley using tilting CUM lifting equipment.
Finally, the whole frame is carried to chassis assembly centre.
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1.1.4.3 SHOP IV
The shop IV is classified into two departments. They are given below:
o Rear axle assembly.
o Front axle assembly.
REAR AXLE ASSEMBLY
The rear axle assembly consists of several stages. They are shown below:
Load rear axle casing on pedestals and remove wire strip, axle shafts.
Assemble dust covers on brake shoes and tighten with bolts and nuts.
Apply torque on mounting nuts.
Assemble inner ring for oil seal.
Distance piece is fixed to align the outer and inner wheel bearings in the same axis.
Fix the wheel drum.
Punch the Sl. No. on the rear axle.
Unload rear axle from conveyor and it is taken to the chassis assembly centre.
FRONT AXLE ASSEMBLY
The front axle assembly consists of several stages. They are discussed below:
First, the axle beam is loaded at conveyor belt.
The number is punched in the axle beam.
Next, the axle arm is fixed to beam of steering with pin fin and cotter pin using dummy bolts.
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The tracking rod is fixed for the alignment of wheel. This will helps the left side of the tyre to turn along with the right side wheel.
Fix the air chamber and brake shoe.
Fix the hub and lock set using axle arm.
Fix the wheel drum to the both ends of axle arm.
Unload front axle from the conveyor and it is taken to the chassis assembly.
1.1.4.4 CHASSIS ASSEMBLY
The chassis assembly consists of 14 stages. They are discussed below:
In stage- 1, the front and rear axle is fixed on the main frame which is already fabricated from shop 3.
In stage- 2, the fr4ame assembly is placed on the conveyor belt, and then brake chamber is fitted into it.
In stage- 3, the steering gear box is fitted to the main frame.
In stage- 4, the propeller shaft is connected into the gear box flange. This propeller shaft is also coupled with universal joint.
In stage-5, the Vehicle Identification Number (VIN) is punched into the frame.
In stage- 6, the silencer tank is fixed into the main frame.
In stage- 7, the air tank and fuel tank is fixed at the rear end.
In stage- 8, the engine is mounted on the frame.
In stage- 9, the radiator is fixed at the front end of engine.
In stage- 10, the lever, fuel filter and accelerator assembly is linked with the engine.
In stage- 11, the tyres for the wheels are fitted to the wheel drum.
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In stage- 12, the battery box and cross bumpers are fitted.
In stage-13, the diesel is filled into the fuel tank.
Finally, the vehicle is taken to another unit for checking its performance.
1.1.4.5 SHOP II
In this shop, the components used for engine assembly may be manufactured
from this department. The facing and centering of the valves are also done in this
shop. The parts that are manufactured from this shop are as follows:
Cylinder head
Camshaft
Connecting rod
Piston
Con rod bolt
Crankcase
Spiral gear
Compound gear
For the preparation of con rod bolt, the workpiece is fitted in the multi spindle
lathe and the following processes will be done.
Head forming
Step turning
Chamfering
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In the camshaft, the processes like taping, drilling, milling, grinding,
tempering, checking hardness are done in this shop II. The gear hobbing is also
done with the help of gear hobbing machine, after that the oil hole drilling may
proceeds. The journal bearing grindings and the cam grindings are done here. The
flywheel housing is tested and fitted at engine case. Finally, the parts are taken to
another department for assemble.
1.2 LIFTING TACKLE
Lifting Tackle is a lifting equipment driven by mechanical power or
electrical power. It is used to raise, lower, suspend or transport load of different
objects like Passenger cowl & hub of vehicles. In the lifting tackle, two motors are
used to raise and lower the tackle frame. Motor shafts- coupled with chain slings.
Each chain slings are connected with grab hook to carry the frame. The frame
consists of two horizontal cross bars arranged to fix the block of weight. There are
two sprockets linked together with roller chain. In order to balance equal weight
while carrying vehicle hub or heavy objects; a weight is kept horizontally with
cross bar. A pulley and rope arrangement is provided at one end of the cross bar.
The pulley line is coupled with sprocket for adjusting the weights, so the hub
weight may be balanced and the hub may be placed perfectly on the chassis.
An electro-mechanical appliance whose principal function is lifting or
lowering, or both, of loads with a calibrated short link or roller chain between the
sheave and the lifting block. After the trolley has been installed on the travel rail,
always install a stopper on the end of the travel rail to prevent the trolley from
dropping off. The stopper is made up of rubber to absorb the shock when the
trolley strikes the stopper. The maximum safe working load in Kgs/ tonnes that the
hoist is designed to carry in service. This shall be specified by the manufacturer of
the hoist and marked boldly and clearly on the hoist and hook block.
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fig.1.1 lifting tackle
ELECTRIC BRAKE ASSEMBLY
The correct air gap between armature and field, when brake is not energized,
is 0.025 inch (0.635 mm) and need not be adjusted until the gap reaches 0.045
inches (1.14 mm). When checking brake gap, always reset to 0.025 inch (.0635
mm). To adjust the brake, proceed as follows:
1. Disconnect hoist from power supply.
2. Remove back frame cover.
3. Before adjusting the gap:
4. Turn adjusting nuts clockwise gaging the air gap at both ends.
5. Replace cover, reconnect the power and check operation.
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1.2.1 CHAIN HOIST
A chain hoist is a mechanical device used for lifting heavy loads of objects
and equipment. It is made with a pulley, which is held together by a closed chain.
The closed chain in the chain hoist forms a loop, which makes it easy to be pulled
by hand.
There are several large and small pulleys located throughout a chain hoist.
One large and one small pulley are situated on the same axle of the chain hoist.
There is also a mobile pulley on the chain hoist that holds the load in place.
For the load to be raised with the chain hoist, the closed chain has to be pulled.
When it is pulled, the large pulley draws in more chain than what is released by the
smaller side. From here, the lifting process begins.
Although the history of pulleys is unclear, it is known that primitive
methods were employed to move heavy objects around. One of the early attempts
at a pulley system was the single fixed pulley, which failed because friction
prevented the wheel from being turned. Rope pulleys, which were commonly used
for pulling water out of wells and are still in use today, are thought to have been