DIFFERENTIAL (Project under Scooters India Ltd. (Govt. of India Enterprise) A differential is a particular type of simple planetary gear train that has the property that the angular velocity of its carrier is the average of the angular velocities of its sun and annular gears. Submitted By: ALTAF NAZEER B.Tech 2nd yr. (Manufacturing Engineering) CIPET Lucknow . Submitted To: H.R. Manager Scooters India Ltd. Lucknow
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
DIFFERENTIAL (Project under Scooters India Ltd.
(Govt. of India Enterprise)
A differential is a particular type of simple planetary gear train that has the property that the angular velocity of its carrier is the average of the angular velocities of its sun and annular gears.
Submitted By:
ALTAF NAZEER B.Tech 2nd yr.
(Manufacturing Engineering) CIPET Lucknow
. Submitted To: H.R. Manager
Scooters India Ltd. Lucknow
Acknowledgement
I wish to express my sincere gratitude to Mr Anand Kumar (H.R.
Manager) for providing me an opportunity to do my project work on
“DIFFERENTIAL” in Scooters India Ltd. This project bears on imprint of
many peoples. I sincerely thank to Mr Raghavendra Satyarthi (Deputy
Manager Vehicle Assembly) for guidance and encouragement in
carrying out this project. I also wish to express my gratitude to official
and other staff members of Scooters India Ltd. who rendered their help
during period of my project. My special thanks Scooters India Ltd. to
give as opportunity for their kind co-operation to the completion of my
project work. Last but not least I wish to avail myself of this
opportunity, express a sense of gratitude and my friends and my
beloved parents for their manual support.
Place: Scooters India Ltd. Lucknow
Date: 19 Feb 2015
Certificate
This is to certify that Mr Altaf Nazeer student of Manufacturing
Engineering from Central Institute of Plastic Engineering & Technology,
Lucknow has done this project at Scooters India Ltd. Lucknow from 21
January 2015 to 19 February 2015. This project entitled DIFFERENTIAL
embodies the original work done by Mr Raghavendra Satyarthi during
his above full project training period.
PROJECT GUIDE
Mr Raghavendra Satyarthi
HEAD OF TRAINING DIVISION
Mr Anand Kumar
Contents
About Scooters India Ltd.
Products from Scooters India Ltd.
Introduction to Differential
Future Planning of Scooters India Ltd.
Vision & Mission of Scooters India Ltd.
Conclusion
About Scooters India Ltd.
Incorporated in 1972, Scooters India Limited is an ISO 9001:2000 and ISO 14001 Company, situated at 16 Km mile stone, South-west of Lucknow, the capital of Uttar Pradesh on NH No 25 and is well connected by road, rail and air.
It is a totally integrated automobile plant, engaged in designing, developing, manufacturing and marketing a broad spectrum of conventional and non-conventional fuel driven 3-wheelers.
Company’s plant owes its origin to M/s. Innocenti of Italy from which it bought over the plant and machinery, design, documentation, copyright etc. The company also possesses the world right of the trade name LAMBRETTA / LAMBRO.
In 1975, company started its commercial production of Scooters under the brand name of Vijai Super for domestic market and Lambretta for overseas market. It added one more wheel to its product range and introduced three wheelers under the brand name of VIKRAM/LAMBRO. However, in 1997, strategically, the company discontinued its two-wheeler production and concentrated only on manufacturing and marketing of 3 wheelers. These three wheelers have become more relevant in the present socio-economic environment as it transports goods and passengers at least cost.
The company has its own marketing network of Regional Sales Offices all over India, catering to customer’s requirements in the areas of sales and services.
Products of Scooters India Ltd.
Scooters India Limited makes various & versatile types of three
When used in this way, a differential couples the input shaft (or prop shaft) to the pinion,
which in turn runs on the crown wheel of the differential. This also works as reduction
gearing to give the ratio. On rear wheel drive vehicles the differential may connect to half-
shafts inside an axle casing or drive shafts that connect to the rear driving wheels. Front
wheel drive vehicles tend to have the pinion on the end of the main-shaft of the gearbox and
the differential is enclosed in the same casing as the gearbox. They have individual drive-
shafts to each wheel. Older 4x4 vehicles and tractors usually have a solid front axle, the
modern way can be a separate differential and drive shaft arrangement for the front.
A differential consists of one input, the drive shaft, and two outputs which are the two drive
wheels, however the rotation of the drive wheels are coupled by their connection to the
roadway. Under normal conditions, with small tyre slip, the ratio of the speeds of the two
driving wheels is defined by the ratio of the radii of the paths around which the two wheels
are rolling, which in turn is determined by the track-width of the vehicle (the distance
between the driving wheels) and the radius of the turn.
Non-automotive uses of differentials include performing analog arithmetic. Two of the
differential's three shafts are made to rotate through angles that represent (are proportional to)
two numbers, and the angle of the third shaft's rotation represents the sum or difference of the
two input numbers. The earliest known use of a differential gear is in the Antikythera
mechanism, circa 80 BCE, which used a differential gear to control a small sphere
representing the moon from the difference between the sun and moon position pointers. The
ball was painted black and white in hemispheres, and graphically showed the phase of the
moon at a particular point in time.[1] See also the Chinese South-pointing chariot. An equation
clock that used a differential for addition was made in 1720. In the 20th Century, large
assemblies of many differentials were used as analog computers, calculating, for example, the
direction in which a gun should be aimed. However, the development of electronic digital
computers has made these uses of differentials obsolete. Military uses may still exist. See
Electromagnetic pulse. Practically all the differentials that are now made are used in
automobiles and similar vehicles.
History
There are many claims to the invention of the differential gear, but it is possible that it was
known, at least in some places, in ancient times. Some historical milestones of the differential
include:
100 BC–70 BC: The Antikythera mechanism has been dated to this period. It was discovered in 1902 on a shipwreck by sponge divers, and modern research suggests that it used a differential gear to determine the angle between the ecliptic positions of the Sun and Moon, and thus the phase of the Moon.[1][2]
30 BC–20 BC: Differential gear systems possibly used in China
227–239 AD: Ma Jun from the Kingdom of Wei in China invents the first historically verifiable
south-pointing chariot, which provided cardinal direction as a non-magnetic, mechanized
compass. Some such chariots may have used differential gears.
658, 666 AD: two Chinese Buddhist monks and engineers create south-pointing chariots for Emperor Tenji of Japan.
1027, 1107 AD: Documented Chinese reproductions of the south-pointing chariot by Yan Su and then Wu Deren, which described in detail the mechanical functions and gear ratios of the device much more so than earlier Chinese records.
1720: Joseph Williamson uses a differential gear in a clock. 1810: Rudolph Ackermann of Germany invents a four-wheel steering system for carriages,
which some later writers mistakenly report as a differential. 1827: modern automotive differential patented by watchmaker Onésiphore Pecqueur
(1792–1852) of the Conservatoire National des Arts et Métiers in France for use on a steam wagon.[3][4]
1832: Richard Roberts of England patents "gear of compensation", a differential for road locomotives.
1874: Aveling and Porter of Rochester, Kent list a crane locomotive in their catalogue fitted with their patent differential gear on the rear axle.[5]
1876: James Starley of Coventry invents chain-drive differential for use on bicycles; invention later used on automobiles by Karl Benz.
1897: first use of differential on an Australian steam car by David Shearer. 1958: Vernon Gleasman patents the Torsen dual-drive differential, a type of limited-slip
differential that relies solely on the action of gearing, instead of a combination of clutches and gears.
Epicyclic differential
Epicyclic gearing is used here to apportion torque asymmetrically. The input shaft is the green
hollow one, the yellow is the low torque output, and the pink is the high torque output. The force
A relatively new technology is the electronically controlled 'active differential'. An electronic
control unit (ECU) uses inputs from multiple sensors, including yaw rate, steering input
angle, and lateral acceleration—and adjusts the distribution of torque to compensate for
undesirable handling behaviours like understeer. Active differentials used to play a large role
in the World Rally Championship, but in the 2006 season the FIA has limited the use of
active differentials only to those drivers who have not competed in the World Rally
Championship in the last five years.
Fully integrated active differentials are used on the Ferrari F430, Mitsubishi Lancer
Evolution, and on the rear wheels in the Acura RL. A version manufactured by ZF is also
being offered on the B8 chassis Audi S4 and Audi A4.[11] The Volkswagen Golf GTI Mk7 in
Performance trim also has an electronically controlled front-axle transverse differential lock,
also known as VAQ.[12]
The second constraint of the differential is passive—it is actuated by the friction kinematics
chain through the ground. The difference in torque on the roadwheels and tires (caused by
turns or bumpy ground) drives the second degree of freedom, (overcoming the torque of inner
friction) to equalise the driving torque on the tires. The sensitivity of the differential depends
on the inner friction through the second degree of freedom. All of the differentials (so called
"active" and "passive") use clutches and brakes for restricting the second degree of freedom,
so all suffer from the same disadvantage—decreased sensitivity to a dynamically changing
environment. The sensitivity of the ECU controlled differential is also limited by the time
delay caused by sensors and the response time of the actuators.
Rotation rate governing differentials
A rotation rate-governing differential eliminates the aforementioned time delay issue by
mechanically coupling the two wheels together through a set of planetary gears and then
strictly governing the allowable difference in their relative rotation rates at all times. This
forces power to be applied fully and instantly to both wheels (similar to a locking
differential), while also preserving the vehicle's cornering agility. Unlike traditional active-
differentials, these systems do not use brakes, clutch packs, or any other friction parts to
respond to wheel slip. Instead, they use a small, low-speed stepper motor to keep the
differential rotation rates of the wheels within a plausible bound for the given steering
angle.[13]
Automobiles without differentials
Although most automobiles in the developed world use differentials there are a few that do
not. Several different types exist:
Race cars and trucks in certain classes. Drag racing is done in a straight line (and often on a prepared surface), which obviates the need for a differential. A spool is used to make a solid connection between both drive wheels, which is simpler and less likely to break under very heavy acceleration. Racing on dirt or mud tracks also allows the use of spools, because the loose surface gives way while cornering. NASCAR mandates the use of spools in their cars, which does cause axle wind-up, and degrades handling in turns. Other forms of racing
without differentials includes tractor pulling, mud bogging and other 4x4 motorsports where differential action is not needed.
Vehicles with a single driving wheel. Besides motorcycles, which are generally not classified as automobiles, this group includes most three-wheeled cars. These were quite common in Europe in the mid-20th Century, but have now become rare there. They are still common in some areas of the developing world, such as India. Some early four-wheeled cars also had only one driving wheel to avoid the need for a differential. However, this arrangement led to many problems. The system was unbalanced, the driving wheel would easily spin, etc.. Because of these problems, few such vehicles were made.
Vehicles using two freewheels. A freewheel, as used on a pedal bicycle for example, allows a road wheel to rotate faster than the mechanism that drives it, allowing a cyclist to stop pedalling while going downhill. Some early automobiles had the engine driving two freewheels, one for each driving road wheel. When the vehicle turned, the engine would continue to drive the wheel on the inside of the curve, but the wheel on the outside was permitted to rotate faster by its freewheel. Thus, while turning, the vehicle had only one driving wheel. Driving in reverse is also impossible as is engine braking due to the freewheels.
Vehicles with continuously variable transmissions, such as the DAF Daffodil. The Daffodil, and other similar vehicles which were made until the 1970s by the Dutch company DAF, had a type of transmission that used an arrangement of belts and pulleys to provide an infinite number of gear ratios. The engine drove two separate transmissions which ran the two driving wheels. When the vehicle turned, the two wheels could rotate at different speeds, making the two transmissions shift to different gear ratios, thus functionally substituting for a differential. The slower moving wheel received more driving torque than the faster one, so the system had limited-slip characteristics. The duplication also provided redundancy. If one belt broke, the vehicle could still be driven.
Light vehicles with closely spaced rear wheels, such as the Isetta and Opperman Unicar, or very low mass vehicles.
Vehicles with separate motors for the driving wheels. Electric cars can have a separate motor for each driving wheel, eliminating the need for a differential, but usually with some form of gearing at each motor to get the large wheel torques necessary. A multi-motor electric vehicle such as the Dual Motor Tesla Model S can electronically control the power distribution between the motors on a millisecond scale, in this case acting as a centre differential where open differentials are still employed left-to-right.[14]
Furnace, one sand muller machine, two shot blasting machine, two set jolting machines for
green sand moulding, fettling and shot blasting equipments, its normal range of production
weighs upto 8 Kgs. on a pattern plate of 450x600 mm. However, foundrymen are trained to
make casting even of 1 ton weight if emergent requirement arises.
The foundry is not fully loaded with its captive requirement. Spare capacity is utilised for
producing sophisticated castings of prestigious customers like BHEL, Indian Railways,
Aerospace, Brakes India Limited, Crompton Greaves limited.The induction furnace has a
capacity of 1.3 tons. The two types of moulding is been done here. 1. Shell moulding 2.
Green sand moulding. The foundry can manufacture a wide range of products namely
Differential housing, Differential cages, Power transimission wheel, Crankcase flange,
Magneto motor, Engine output flange, Adapter plate for electric vehicle, Cylinder for both
Vikram 410 petrol version and Vikram 750 diesel version
Foundry Shop
Die Casting
Shop
Machine Shop
Paint Shop
Vehical Assembly
Die Casting Shop
The biggest die casting shop in this part of the country handles both Aluminum and Zinc
alloys. Equipped with pressure die casting machines of 160, 250, 400 and 1,000 tons locking
pressure, the metal is fed to machines from individual holding furnaces of 75/150 kg., which
in turn are fed by mother melting furnace of 500 kg. aluminum capacity.
The shop based on projected area, is capable of producing aluminum die casting upto 5 kg. in
weight. The shop is backed by chemical and metallurgical labs as also with a die maintenance
section. The well-equipped machineries are used in this department in single shift, except two
machines that are used in two shifts; that produce all the accessories required by this
organization. The die casting of various type of components like Gear box housing,
Crantcase, Front wheel drum, Rear wheel drum, Bell housing, Magneto flange, Cylinder
head, lower and upper Handle bar, Levers, Differential housing cover, Brake shoe etc are
undertaken.
Die casting some components for fulfilling customers' requirement are also taken up. Some
of our customers are BHEL, Bhopal; Greaves India Limited, Aurangabad to whom supplying
the Gear boxes and 422 cc aluminium Engine are supplied.
Machine Shop
Machine shop has a wide variety of machines like General purpose machine, Special purpose
machine, Multispindle automatic machine, Single spindle automatic machine etc; which are
mainly working on single shift through eight different lines. Line no 2 is basically machining
the aluminium components. crank shaft and cylinder machining is usually done on line no 3.
Line no. 4 is the Grinding line where the grinding process is done. Heat treatment is
performed in line no 5, while different turning of shafts and gear shaping and shaving are
carried on line no 6.Line no. 7 includes the functioning of gear manufacture process mainly
broaching, hobbing, finish turning, gear shaving etc.Machining of different levers, centreless
grinding of tubes and shafts, serration / thread rolling operations is achieved in line no. 8 &
lastly different components are fed in two other lines by line no. 9. Blank turing of gear and
machining of parts is done on multi spindle and single spindle automatic machine. Engine
components and some vehicle component are the prime production
Paint Shop
Processes and coatings
Preparation
High pressure water spray jets are directed to the body. Without proper pretreatment,
premature failure of the finish system can almost be guaranteed.
A phosphate coat is necessary to protect the body against corrosion effects and prepares the
surface for the E-Coat.
The body is dipped into the Electro Coat Paint Operation (ELPO/E-Coat), then a high voltage
is applied. The body works as a cathode and the paint as an anode sticking on the body
surface. It is an eco-friendly painting process. In E-Coat, also called CED paint, utilization is
approximately 99.9% and has great SST life compared to other painting processes.
Primer
The primer is the first coat to be applied. The main functions of the primer are to act as a
leveler and protector, and to make the base coat easier to apply to the component to which it
is applied. The primer serves several purposes. It serves as a leveler, which is important since
the cab often has marks and other forms of surface defect after being manufactured in the
body shop. A smoother surface is created by leveling out these defects and therefore a better
final product. It serves as a protector, the primer will protect from corrosion, heat differences,
bumps, stone-chips, UV-light, etc. It also servers improve ease of application by making it
easier for paints to stick to the surface, a more varied range of paints can be used.
Basecoat
The base coat is applied after the primer coat. This coat contains the visual properties of color
and effects, and is usually the one referred to as the paint. Base coat used in automotive
applications is commonly divided into three categories: solid, metallic, and pearlescent
pigments.
Solid paints have no sparkle effects except the color. This is the easiest type of paint to apply, and the most common type of paint for heavy transportation vehicles, construction equipment and aircraft. It is also widely used on cars, trucks, and motorcycles.
Metallic paints contain aluminium flakes to create a sparkling and grainy effect, generally referred to as a metallic look. This paint is harder to manage than solid paints because of the extra dimensions to consider. Metallic and pearlescent paints must be applied evenly to ensure a consistent looking finish without light and dark spots which are often called "mottling".
Pearlescent Paints contain special iridescent pigments commonly referred to as "pearls". Pearl pigments impart a colored sparkle to the finish which works to create depth of color. Pearlescent paints can be two stage in nature (pearl base color + clear) or 3 stage in nature (basecoat + pearl midcoat + clearcoat).
Clearcoat
Usually sprayed on top of a colored basecoat, clearcoat is a glossy and transparent coating
that forms the final interface with the environment. For this reason, clearcoat must be durable
enough to resist abrasion and chemically stable enough to withstand UV light. Clearcoat can
be either solvent or water-borne. One part and two part formulations are often referred to as
1k and 2k respectively.
Assembly
The components manufactured in plant as well as those bought have to be finally assembled to
make the product three wheelers. In the process many sub assemblies, too, are involved. However,
two main assemblies worth mentioning are engine assembly and vehicle assembly. Both are
conveyorised. Every 5 minutes a three wheeler rolls down the conveyor. The vehicle conveyor has 23
stations. Speed can be adjusted to meet increasing demand.