Industrial Training Report

Industrial Training Report

Jasdev Singh Sandhu Institute of Engineering & Technology Kauli (Patiala)

Training At

MALHOTRA MOTORS Sirhind (Fathegarh Sahib)

Submitted To :- Submitted By:-

Mechanical Engg. Deptt. Surinder Singh

Roll No. 90431175333 Branch Mechanical

PREFACE

This vocational training report on “Malhotra Motors” Sirhind has been carried out to undertaken the various machines and knowledge of automobile parts. In the report on approach has been mode to understand the basic information to service of car. I will be thankful to him. At the end I would like to say that it was an excellent experience for me.

INDEX

Tools Used Machines Used Engine

Internal Combustion Engine External Combustion Engine

Four Stroke I. C. Engine Turbocharging CRDI System in Cars

How does CRDI works

ABS System Working of ABS Services of a Car Tyre Rotation

Wheel Balancing Wheel Alignment

TOOLS USED

1. Screw Driver2. L – key3. T – rod4. Hammers5. Pliers6. Nose Pliers7. Bench Vice8. Chisels9. Spanners10. Ring Spanners11. Tappet Gauge12. Torque Wrench13. Ring Compressor14. Hacksaws15. Oil Filter Clamps16. Files

17. L Key Set 18. Pipe Wrenches

MACHINES USED

1. Wheel Balancing Machine

2. Hydraulic Crane

3. Car Lift

4. Air Compressor

5. Air Gun

6. Grinder

7. Car Washer

8. Wheel Alignment Machine

ENGINE

An engine is a machine designed to convert energy into useful mechanical motion. It may also serve as a "prime mover", a component that transforms the flow or changes in pressure of a fluid into mechanical energy. An automobile powered by an internal combustion engine may make use of various motors and pumps, but ultimately all such devices derive their power from the engine. The term "motor" was originally used to distinguish the new internal combustion engine-powered vehicles from earlier vehicles powered by steam engines, such as the steam roller and motor roller, but may be used to refer to any engine.

Internal combustion engine

The internal combustion engine is an engine in which the combustion of a fuel (generally, fossil fuel) occurs with an oxidizer (usually air) in a combustion chamber. In an internal combustion engine the expansion of the high temperature and pressure gases, which are produced by the combustion, directly applies force to component of the engine, such as the pistons or turbine blades or a nozzle, and by moving it over a distance, generates useful mechanical energy.

External combustion engine

An external combustion engine is a heat engine where working fluid is heated by combustion of an external source, through the engine wall or a heat exchanger. The fluid then, by expanding and acting on the mechanism of the engine produces motion and usable work. The fluid is then cooled, compressed and reused, or dumped, and cool fluid pulled in (open cycle air engine).

Four Stroke I. C. Engine

The internal combustion engines in cars, trucks, motorcycles, aircraft, construction machinery and many others, most commonly use a four-stroke cycle. The four strokes refer to intake, compression, combustion (power), and exhaust strokes that occur during two crankshaft rotations per working cycle of the gasoline engine and diesel engine.

The cycle begins at top dead centre (TDC), when the piston is farthest away from the axis of the crankshaft. A stroke refers to the full travel of the piston from Top Dead Center (TDC) to Bottom Dead Center (BDC).

1. INTAKE Stroke: On the intake or induction stroke of the piston, the piston descends from the top of the cylinder to the bottom of the cylinder, reducing the pressure inside the cylinder. A mixture of fuel and air is forced by atmospheric (or greater) pressure into the cylinder through the intake port. The intake valve(s) then close.

2. COMPRESSION Stroke: With both intake and exhaust valves closed, the piston returns to the top of the cylinder compressing the fuel-air mixture. This is known as the compression stroke.

3. POWER Stroke.: While the piston is close to Top Dead Center, the compressed air–fuel mixture is ignited, usually by a spark plug (for a gasoline or Otto cycle engine) or by the heat and pressure of compression (for a diesel cycle or compression ignition engine). The resulting massive pressure from the combustion of the compressed fuel-air mixture drives the piston back down toward bottom dead center with tremendous force. This is known as the power stroke, which is the main source of the engine's torque and power.

4. EXHAUST Stroke.: During the exhaust stroke, the piston once again returns to top dead center while the exhaust valve is open. This action evacuates the

products of combustion from the cylinder by pushing the spent fuel-air mixture through the exhaust valve.

Turbocharging

The turbocharger was designed as a part-time method of compressing more air into the cylinder head. It consists of a two piece, high-speed turbine assembly with one side that compresses the intake air, and the other side that is powered by the exhaust gas outflow.

When idling, and at low-to-moderate speeds, the turbocharger is not engaged and the engine operates in a naturally-aspirated manner. When much more power output is required, the engine speed is increased until the exhaust gases are sufficient to 'spin up' the turbocharger's turbine to start

compressing much more air than normal into the intake manifold.

Turbocharging allows for more efficient engine operation at low-to-moderate speeds, but there is a design limitation known as turbo lag. The increased engine power is not immediately available, due to the need to sharply increase engine RPM to spin up the turbo, before the turbo starts to do any useful air compression.

CRDI System In Cars

CRDI is an intelligent way of controlling a diesel engine with use of modern computer systems. CRDI helps to improve the power, performance and reduce harmful emissions from a diesel engine. Conventional Diesel Engines (non-CRDI engines) are sluggish, noisy and  poor in performance compared to a CRDI engine.

CRDI or common rail direct injection system is also sometimes referred to by many similar or different names. Some brands use name CRDe / DICOR / Turbojet / DDIS / TDI etc. All these systems work on same principles with slight variations and enhancements here and there.

How does CRDI works :-

CRDI system uses common rail which is like one single rail or fuel channel which contains diesel compresses at high pressure. This is a called a common rail because there is one single pump which compresses the diesel and one single rail which

contains that compressed fuel. In conventional diesel engines, there will be as many pumps and fuel rails as there are cylinders.

As an example, for a conventional 4 cylinder diesel engine there will be 4 fuel-pumps, 4 fuel rails each feeding to one cylinder. In CRDI, there will be one fuel rail for all 4 cylinders so that the fuel for all the cylinders is pressurized at same pressure.

The fuel is injected into each engine cylinder at a particular time interval based on the position of moving piston inside the cylinder. In a conventional non-CRDI system, this interval and the fuel quantity  was determined by mechanical components, but in a CRDI system this time interval and timing etc are all controlled by a central computer or microprocessor based control system.

To run a CRDI system, the microprocessor works with input from multiple sensors. The input sensors include throttle position sensor, crank position sensor, pressure sensor, lambda sensor etc. The use of sensors and microprocessor to control the engine makes most efficient use of the fuel and also improved the power, fuel-economy and performance of the engine by managing it in a much better way.

ABS System

An anti-lock braking system, or ABS is a safety system which prevents the wheels on a motor vehicle from locking up (or ceasing to rotate) while braking.

A rotating road wheel allows the driver to maintain steering control under heavy braking by preventing a skid and allowing the wheel to continue interacting tractively with the road surface as directed by driver steering inputs. ABS offers improved vehicle control and decreases stopping distances on dry and

especially slippery surfaces. However, on loose surfaces like gravel and snow-on-pavement, it can slightly increase braking distance while still improving vehicle control. On others, it may not improve control at all.

Since initial widespread use in production cars, anti-lock braking systems have evolved considerably. Recent versions not only prevent wheel lock under braking, but also electronically control the front-to-rear brake bias. This function, depending on its specific capabilities and implementation, is known as electronic brakeforce distribution (EBD), traction control system, emergency brake assist, or electronic stability control.

Working of ABS

The anti-lock brake controller is also known as the CAB (Controller Anti-lock Brake)

A typical ABS is composed of a central electronic control unit (ECU), four wheel speed sensors, one for each wheel and two or more hydraulic valves within the brake hydraulics. The ECU constantly monitors the rotational speed of each wheel, and when it detects a wheel rotating significantly slower than the others, a condition indicative of impending wheel lock — it actuates the valves to reduce hydraulic pressure to the brake at the affected wheel, thus reducing the braking force on that wheel. The wheel then turns faster.

when the ECU detects it is turning significantly faster than the others, brake hydraulic pressure to the wheel is increased so the braking force is reapplied and the wheel slows. This process is repeated continuously, and can be detected by the driver via brake pedal pulsation. A typical anti-lock system can apply and release braking pressure up to 20 times a second.

The ECU is programmed to disregard differences in wheel rotative speed below a critical threshold, because when the car is turning, the two wheels towards the center of the curve turn slower than the outer two. For this same reason, a differential is used in virtually all roadgoing vehicles.

If a fault develops in any part of the ABS, a warning light will usually be illuminated on the vehicle instrument panel, and the ABS will be disabled until the fault is rectified.

Services of a Car

First service---------------------1000 km ( Oil change, general checking )

Second services------------------5000 km ( Oil change, air filter and nut bolt checking and cleaning )

Third service----------------------10,000 km ( Oil change, Plug & oil filter change, air filter check and tyre rotation )

Fourth service----------------------15,000 km ( Oil change, Plug & oil filter change, air filter checking and cleaning )

Fifth service-------------------------20,000 km ( Brake oil change, Oil change, Plug & oil filter change, air filter check and tyre rotation )

Tyre Rotation

Wheel Balancing

Out-of-balance tires will cause a car to vibrate at certain speeds, usually between 50 and 70 mph. A tire is out of balance when one section of the tire is heavier than the others. One ounce of imbalance on a front tire is enough to cause a noticeable vibration in the steering wheel at about 60 mph.

To balance a wheel, the technician will mount it on a balancing machine which spins the wheel to locate the heavier part. He will then compensate for the heavy part by attaching a lead weight on the opposite side. Many people are pleasantly surprised at how smooth their car drives after balancing all four wheels.

Most high quality tires will hold their balance fairly well and go out of balance very gradually. If you notice a vibration that wasn't there the day before, it is possible that one of the lead balancing weights fell off. If you feel the vibration mostly in the steering wheel, the problem is most likely in a front wheel. If the vibration is mostly in the seat, the problem is probably in the rear.

For those of you who are very sensitive about vibrations and your shop can't seem to get that last bit of vibration out, check to see if you have locking wheel lugs. Some locking lugs are as much as 1.5 ounces heavier than the other lug nuts which translates to about 1/2 ounce at the wheel rim. Try putting a 1/2 ounce weight opposite the locking lug and see if it helps.

Wheel Alignment

Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tire life and a vehicle that tracks straight and true when driving along a straight and level road. 

To find out if you need an alignment, first check each tire and look for uneven wear patterns.

At each tire, take a coin and insert it in the tread at the inside, center and outside.

If the tread is deeper on the edges than in the center, the tire is over inflated.

If the tread is deeper in the center than the edges, the tire is under inflated.

If the tread is deeper on one side than the other, have your wheel alignment checked soon.

Run your hand back and forth across the tread, being careful not to cut yourself on any debris or exposed steel belt wire. If the tread is smooth in one direction, but jagged in the other you have what is called a "saw-tooth" wear pattern which is caused by a toe-in problem. Have the alignment checked as soon as possible as this condition causes rapid tire wear.The best type of wheel alignment is a four wheel alignment. Many cars today have adjustable rear alignment settings, but even for cars without adjustments in the rear, a four wheel alignment will allow the technician to identify any rear tracking problems and compensate for them with adjustments to the front.After the wheel alignment is finished, you should drive the car on a straight and level road and check

that the car goes straight and that the steering wheel is in the proper position with the spokes level.