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ABSTRACT

The main objective of vocational training program is to provide practical

knowledge of the product being manufactured and working process in the

factory, besides the theoretical and practical knowledge from their institution.

Bajaj auto ltd. in India and all over the world has grown exponentially its over the

past few years. Growing at the pace that it is, to understand functionally was my

basic objective.

To be a part of Bajaj auto ltd. was very exciting and knowledgeable. On site work

gave me a better understanding of mechanical systems. Classroom knowledge

was insufficient and was given more meaning. Thus suddenly all theories and

derivations seemed logical.

More over this training gave me a chance to interact with working techniques,

and to get familiar with facilities and formalities that one should follow in a

factory.

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OBJECTIVE

1. To facilitates realization of team and effective organization.2. Create business and strategic thinking.3. Build management and technical competences.4. Promote a culture of achievement and excellence.5. Improve quality of work life in organization.6. Optimize resource utilization.7. Atmosphere of east consciousness.8. Encourage improvements of team and individuals

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INTRODUCTION

The Bajaj Group was founded in 1926 by Jamnalal Bajaj and now consists of 27companies. In 1945, Jamnalal Bajaj had formed M/s Bachraj Trading Corporation

Private Limited, the flagship company, to sell imported two-wheelers and three-

wheelers. The company acquired a license from the government in 1959 to

manufacture these vehicles and went public the next year. By 1977, the company

saw its plant rolling out 100,000 vehicles in a single year. In another nine years,

Bajaj Auto could produce 500,000 vehicles in a year. The present Chairman of the

Bajaj group, Rahul Bajaj, took charge of the business in 1965. He was the first

licensee of the Indian make of the Italian Vespa scooter. Japanese and Italian

scooter companies began entering the Indian market in the early 1980s.

Although some boasted superior technology and flashier brands, Bajaj Auto had

built up several advantages in the previous decades. Its customers liked the

durability of the product and the ready availability of maintenance; the company's

distributors permeated the country. By 1994-95, Bajaj was racing to beat Honda,

Suzuki and Kawasaki in the two-wheeler segment internationally. By 1997, Bajaj

faced tough competition in the domestic market and its market share stood at

40.5%. Under the leadership of Rahul Bajaj, the turnover of Bajaj Auto has gone

up from Rs.72 million to Rs.46.16 billion (USD 936 million), its product portfolio

has expanded from one to many and the brand has found a global market. Bajaj

as a brand is well-known across several countries in Latin America, Africa, Middle

East, South and South East Asia.

The company has a network of 498 dealers and over 1,500 authorised service

centers and 162 exclusive three-wheeler dealers spread across the country.

Around 1,400 rural outlets have been created in towns with populations of 25,000

and below.

The current dealer network of Baja is servicing all these outlets. Bajaj is

convinced that the real impetus of future two-wheeler growth will come from

upcountry rural India. Bajaj Auto has defined specialist dealerships for rural

markets, called 'Rural Dealerships'. During the year 2008-09, twenty new rural

dealers became operational. Bajaj has identified a segment of customers called

'Probikers', who are knowledgeable about motorbikes and appreciative of

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contemporary technology. They are trendsetters and very choosy about what

they ride. Hence, Probikers need to be addressed in a meaningful way that goes

beyond the product.

Bajaj Autos vehicle manufacturing capacity currently stands at 3.96 million unitscomprising 3.6 million two-wheelers and 360,000 three-wheelers. The plant at

Pantnagar (Uttarakhand) has a capacity to produce 900,000 two-wheelers.

It is the most advanced plant of bajaj auto .It has Capacity of 0.9 million vehicles

per year .product manufactured here are platina and XCD.

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RECIPIENTS OF AWARDS

1. Pulsar- AME 2010Most Efficient Use of Branded Content

2. Kawasaki Ninja 250RCNBC Overdrive 2010 Bike of the Year

3. Discover DTS-iCNBC Overdrive 2010

Storyboard Auto Commercial of the Year (Bike)

4. Kawasaki Ninja 250RET NOW Zigwheels

Award 2009 250cc Bike of the Year

5. Kawasaki Ninga 250RBusiness Standard

Motoring 2010

Motoring Bike Of The Year

6. Kawasaki Ninga 250rImoty 2010

Indian Motorcycle Of The Year

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7.Pulsar Mania

Effie Awards 2010

Category: Consumer Durable

8.Kawasaki Ninga 250R

NDTV Profit Car And Bike Awards 2010

Two Wheeler Of The Year

9. Bajaj AutoNDTV Profit Car And Bike

Awards 2010

Best Integrated Campaign 2 Wheeler

10. Kawasaki Ninja 250RNDTV Profit Car & BikeAwards 2010

Motorcycle of the Year up to 250cc

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BAJAJ AUTO PRODUCTS

Bajaj has made motorcycles, scooters, auto-rickshaws and most recently, cars.

Bajaj Auto has the capacity to manufacture 400,000 three-wheelers per yearand

it exports a major part of it.Motorcycles in production are

theXCD,Platina,Discover,Pulsar andAvenger.Bajaj also distributes motorcycles

in India for other manufacturers, such as theKawasaki Ninja 250R,theNinja

650R and new for 2012, the KTM Duke 200.Cars include theBajaj ULC ultra-low-

cost car.

SCOOTER:

1. Bajaj Kristal DTSi

CARS:

1. Bajaj Lite concept2. Bajaj RE60 - theTata Nano competitor

MOTORCYCLE:

Bajaj Platina 100cc

Bajaj Platina 125 DTS-Si

Bajaj Discover 135 DTS-i

Bajaj XCD 125 DTS-Si

Bajaj XCD 135 DTS-Si

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Bajaj Pulsar 135 DTSi

Bajaj Pulsar 150 DTSi

Bajaj Pulsar 180 DTSi Bajaj Pulsar 200 DTSi

Bajaj Pulsar 220 DTS-Fi

Bajaj Pulsar 220 DTSi

Bajaj Avenger 220 DTS-i

Bajaj Pulsar 200 NS

Upcoming models

Bajaj XCD 125 sprint

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DIGITAL TWIN SPARK IGNITION

Digital - Since the spark generation will be initiated by a microchip. Twin - Since two spark plugs will be used. Spark ignition - Since the ignition will be done via a spark.

Bajaj developed a few years ago and has incorporated in many of its current

engines, takes care of the slow rate of combustion in a simple but novel way. The

cylinder head is equipped with two spark plugs, instead of the usual one. By

generating two sparks at either ends of the combustion chamber, (approximately

90 to the valve axis) the air-fuel mixture gets ignited in a way that creates two

flame fronts and, therefore, a reduction in flame travel of the order of 40 per cent

is achieved. A fast rate of combustion is achieved leading to faster rise in

pressure. The obvious outcome of this is more torque, better fuel efficiency and

lower emissions.

A conventional 4 Stroke engine has a Single Spark Plug located at one end of the

combustion chamber and hence the combustion is inefficient leading to sub

optimal mileage and sub optimal performance & can even have problems with oil

flow. Hence forth there was a requirement to change engines' design, fuelling,

ignition, production and quality to achieve the following objectives. Uniform

power delivery in all operating conditions:-

1. A high degree of drivability2. First rate standards of reliability3. Long service life.

With a view to overcome the above limitations a new patent wasintroduced that

is known as DTS-I technology & its use is increasing day by days.

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DIGITAL TWIN SPARK ignition engine has two Spark plugs located at opposite

ends of the combustion chamber and hence fast and efficient combustion is

obtained. The benefits of this efficient combustion process can be felt in terms of

better fuel efficiency and lower emissions. The ignition system on the Twin sparkis a digital system with static spark advance and no moving parts subject to wear.

It is mapped by the integrated 4 digital electronic control box which also handles

fuel injection and valve timing. It features two plugs per cylinder. This innovative

solution, also entailing a special configuration of the hemispherical combustion

chambers and piston heads, ensures a fast, wide flame front when the air-fuel

mixture is ignited, and therefore less ignition advance, enabling, moreover,

relatively lean mixtures to be used. This technology provides a combination of the

light weight and twice the power offered by two-stroke engines with a significant

power boost, i.e. a considerable "power-to-weight ratio" compared to quite a

few four-stroke engines. The actual picture of Bajaj Pulsar Bike is

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Moreover, such a system can adjust idling speed & even cuts off fuel feed when

the accelerator pedal is released, and meters the enrichment of the air-fuel

mixture for cold starting and accelerating purposes; if necessary, it also prevents

the upper rev limit from being exceeded. At low revs, the over boost is mostly

used when overtaking, and this is why it cuts out automatically. At higher speeds

the over boost will enhance full power delivery and will stay on as long as the

driver exercises maximum pressure on the accelerator.

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MAIN CHARACTERISTICS OF DIGITAL TWIN

SPARK IGNITION ENGINE

Digital electronic ignition with two plugs per cylinder and two ignitiondistributors;

Twin overhead cams with camshaft timing variation; Injection fuel feed with integrated electronic twin spark ignition; A high specific power; Compact design and Superior balance;

This power unit, equipping the naturally aspirated 2-litre used on the Alfa 164, is a

direct dilative of the engine fitted on the 2.0 Twin Spark version of the Alfa 75, a

recent addition to the Alfa car range. It includes a number of exclusiveengineering solutions resulting in superior power output and exceptional peak

torque for this cylinder capacity. Its main characteristics are:

Digital electronic ignition with two plugs per cylinder and two ignitiondistributors

Twin overhead cams with camshaft timing variation Injection fuel feed with integrated electronic twin spark ignition

Cylinder capacity amounts to 1,962 cc thanks to an 84 mm bore and 88.5 mm

stroke with the Compression ratio 10: 1.Maximum power output at 5,800 rpm is a remarkable 148 BHP DIN, while

maximum torque, of 19 MKG DIN, is reached at 4,000 rpm. The shape of the

torque curve has been perfected to make available fully 16 MKG when revving

speed reaches 2,000 rpm and 18 MKG as early as 3,000 rpm, thus making the

engine's performance much more responsive.

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CONSTRUCTION OF DTS-I ENGINE

The engine used on the Alfa 164 T. Spark is a four-in-line cylinder unit whose

weight has been considerably reduced with all aluminium-alloy engine block,cylinder head, oil sump and tappet covers.

Eight counterweights ensure optimal balancing of the high strength nitride steel

crankshaft.

The pressed-in cast iron cylinder liners feature wet mounting for more effective

heat dissipation.

CONSTRUCTIONAL DETAIL

The construction of DTS-i engine is same as that of the conventional 4-Stroke

engine. It consists of following parts:

Piston

Cylinder

Crankshaft

Connecting rod

Fly wheel

Carburetor

2-sparkplug

2-ports

2-valves

Here the only change made is that the 2 sparkplug placed at the two opposite end

of the combustion chamber At 90 degree to each other.

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Detonation in DTS-i engine....

In petrol engine major problem is DETONATION. Detonation occurs when the

flame travel time from center to the side walls increases the self ignition temp.time.It happens often in the engines having single spark plug.

This is overcome by the DTSi by having 2 spark sources on the opposite sides

which reduces the flame travel as stated above. Hence no detonation..

VALVE DRIVE

The twin overhead cams, driven by a double chain, act directly on the valves set in

a tight Vee configuration (46o).

The timing of the valve train is not fixed as in most present day engines, but canbe adjusted by a patented device conceived and produced by Alfa Romeo, the

timing variation.

This is an electro-hydraulic actuator keyed onto the gear that drives the camshaftacting on the intake valves. This actuator enables the camshaft to be shifted into

two different angular positions and to modify the intake valve opening durations.

Its operation is controlled by the electronic control box of the integrated ignition

and fuel injection system.

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Valve timing actuator logic is predetermined so that overlap - i.e. that fraction ofthe engines operating cycle when both the exhaust and the intake valves are

open simultaneouslyis shorter at low revs and with lighter loads, and longer at

higher engine speeds when extra power is required.

At high and medium-high engine speeds or whenever additional power hasto be provided (normal timing) cylinder filling is optimal, maximizing power

output and torque

At low and medium-low revs and lighter loads (delayed timing), fluctuation-free operation is ensured combined with a reduction in specific

consumption.

At all engine speeds, noxious emissions are minimized.FUEL FEED

The Alfa 164 T. Spark power plant is equipped with the ML 4.1 Bosch Motronic

multi-point injection system, controlled by the same microprocessor which

governs the twin spark ignition and variable valve timing Systems.

The excellent volumetric efficiency of the Twin Spark engine is also enhanced by

the special straight section individual intake man folding that cuts down losses

and fully exploits intake resonance for better mid-range torque.

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Having all thermodynamic cycle components under the wings of a single

electronic control unit means that the power plant used on the Alfa 1 64 T. Spark

can guarantee-in addition to outstanding torque and power figures-regular,

smooth running at all speeds regardless of

load. Moreover, this engine features particularly attractive specific fuel economycompared with rival naturally aspirated units in the same displacement class (with

savings of up to 20- 25%).

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WORKING OF DIGITAL TWIN SPARK IGNITION

ENGINE

The working of DTS-i engine is very similar to 4-stroke engine but here the onlymodification done is we are using two spark plug at two ends of the combustion

chamber. Which require less time to reach the farthest position of the

combustion chamber and optimize the combustion chamber characteristics.

There are some advance technology used in DTS-i engine which makes it more

powerful than the conventional single sparkplug 4-stroke engine like

1. Tricks III technology

2. CDI technology

TRICS III.Throttle Responsive Ignition Control System 3rd generation. It is a means of

controlling the Ignition by operating the Throttle. Depending on the needs of the

Rider whether it be cruising, acceleration or max speed, the ignition requirements

constantly change. Based on a particular amount of Throttle opening, the

Magnetic field generated by the Magnet opens or closes the Reed switch. The

Reed switch is connected to the Digital CDI, which signals the CDI to

change/switch, the desired Ignition Advance Timing Maps. This helps in achievinga good balance between driveability and Optimum

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Ignition Spark advance, resulting in an almost perfect Ignition Spark advance for

every Throttle opening and Engine rpm.

IGNITION WITH A DIGITAL C.D.I.

A Digital CDI with an 8 bit microprocessor chip handles the spark delivery. The

programmed chips memory contains an optimum Ignition timing for any given

engine rpm, thereby obtaining the best performance characteristics from the

combustion chamber. Working together with the TRICSIII system, it delivers

Optimum Ignition Timing for varying load conditions.

IGNITION

The ignition system on the Twin spark is a digital system with static spark advance

and no moving parts subject to wear. It is mapped by the integrated digital

electronic control box which also handles fuel injection and valve timing. It

features two plugs per cylinder.

This innovative solution, also entailing a special configuration of the

hemispherical combustion chambers and piston heads, ensures a fast, wide flame

front when the air-fuel mixture is ignited, and therefore less ignition advance,

enabling, moreover, relatively lean mixtures to be used. As a result, the adoption

of twin spark ignition yields:

A remarkable improvement in thermodynamic efficiency and hence aconsiderable increase in the amount of power available; more effective

combustion at low load and at idling speed;

A sizeable reduction in specific fuel consumption; A reduced exhaust emission; Less chance of ignition system failure... (Failure of either circuit will not stop

the engine, which can still work with single spark ignition).

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SALIENT FEATURES OF PULSAR DTS-I BIKE

Pulsar dts-I bike is the first bike in the world (in small cc engine) to have twin

spark ignition system

1. In pulsar DTS-I there are 2 spark plugs of same heat range (championrg4hc) and have similar electrode gaps. They also spark

simaltaneously. This has been done to improve the combustion

process by redusing the time of combustion. The end results and low

emissions,good fuel economy and good drivebility.

2. The pulsar DTS-I engine is capable of revving very high, quite easily.To keep them mechanically safe, a engine rpm limiter has beenincorporated in the digital C.D.I. This curtails the sparks to the spark

plugs there by limiting the engine rpm and thus keeps the engine

mechanically safe.

3. The engine has been turned for more power and torque.4. The dts-I technology has enable pulsar to meet 2005 norms without

any secondary air injection devices, hot tubes or catalytic converters.

PERFORMANCE:

Pulsar DTS-I dilivers out class performance in its class of vehicle. The performance

characteristics are:

High power: 180 cc=16.01 ps(11.77 kw) at 8000 rpm

150 cc=13.02 ps(9.57 kw) at 8500 rpm

Greater torque: 180 cc= 14.72 N-m at 6500 rpm150 cc =11.68N-m at 6500 rpm

Max. speed: 180cc= 127 kmph

150 =120 kmph

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STARTING OF PULSAR DTS-I BIKE

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MANUFACTURING PROCESS OF PULSAR DTS-I BIKE

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ADVANTAGES OF USING TWIN SPARK

Less vibrations and noise

Long life of the engine parts such as piston rings and valve stem.

Decrease in the specific fuel consumption

No over heating

Increase the Thermal Efficiency of the Engine & even bear high loads on it.

Better starting of engine even in winter season & cold climatic conditions orat very low temperatures because of increased Compression ratio.

Because of twin Sparks the diameter of the flame increases rapidly thatwould result in instantaneous burning of fuels. Thus force exerted on the

piston would increase leading to better work output.

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DISADVANTAGES OF USING TWIN SPARK

There is high NOx emission.

If one spark plug get damaged then we have to replace both.

The cost is relatively more.

You spend double the amount on spark plugs when it is time to replacethem.

The engine tends to overheat and loose power at higher speeds ascompared to a single plug engine.

In case the Engine is kept unused for a long time soiling of spark plugsoccur. Twin Spark system helps to reduce this problem.

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CONCLUSION

Hence it can be concluded that the application of these technologies in the

present day automobiles will give the present generation what they want i.e.power bikes with fuel efficiency. Since these technologies also minimize the fuel

consumption and harmful emission levels, they can also be considered as one of

the solutions for increasing fuel costs and increasing effect of global warming.

From this report I have concluded that perfect Combustion in Internal

Combustion engine is not possible. So for the instantaneous burning of fuels in

I.C. engine twin spark system can be used which producing twin sparks at regular

interval can help to complete the combustion.

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REFERENCE

www.bajajauto.com http://bajajauto.com/services_gparts.asp. Wikipedia.org WWW.google.com www.thehindubusinessline.com www.nseindia.com