Documente Academic
Documente Profesional
Documente Cultură
ON
ESCORTS AGRI MACHINERY (FARMTRAC)
Submitted by:
SHUBHAM MANN
1/16/FET/BME/1/019
Manav Rachna International Institute of Research and Studies
AN
INDUSTRIAL TRAINING REPORT
Submitted to
Manav Rachna International Institute of Research and
Studies
FACULTY OF ENGINEERING
Submitted By
SHUBHAM MANN
B-TECH(MECHANICAL)
VII SEMESTER
ROLL NO. 1/16/FET/BME/1/019
Acknowledgement
I would like to thank to all those with whom I worked and whose
thoughts and insights helped me in increasing my knowledge and understanding of
working in the organization. I would like to pay my sincere gratitude to MR. Sunil
Dahiya & all employees, who helped me during the course of my training by
providing his valuable suggestion, ideas and guidance which proved beneficial for
completion of my training.
Besides I would also thank to all the supervisors, Foreman and workers who
helped me to understand the depth of my training, what they want out of the
project. These people made me comfortable to understand the functioning of each
machine & about the operation occurring on the machines.
They tried their best to make me understand about the fixtures, tools and gauges
used on the machine. These peoples never made me feel as a trainee in the
department rather provide an atmosphere like a family and feel proud being the
part of their through for short while. Without their help this training would never
have taken its present form. Lastly, but not least I thank one and all who have
helped me directly or indirectly in completion of the report.
I have been really opportunistic to be a part of the Escort Group during my summer
training, which is one of the leading tractor company in today’s scenario.
It is proven fact that bookish knowledge is not sufficient because things are not as
ideal in practical field as they should be.
Escorts Ltd. is one of the best examples to understand the production process and
productivity in particular of Tractor and its parts.
This report is an attempt made to study the overall processes KMC, Assembly
plant and Cylinder block machining. This report presents the Escorts Ltd’s
introduction, technical collaboration, Products. This report also reflects the brief
Introduction Of Engine And Tractor Testing And Metrology Lab. This is also
includes Assembly Line of Farmtrac Tractor.
Machine shop is the focused part as it was the department allotted to me in Escorts
Farmtrac group. The machining processes of cylinder block is carried out at line
E4.286 like facing, drilling, boring, gallarying, turning, finishing etc. The process
in layout of line E4.286 is studied by me during 8 weeks summer internship are
mostly emphasized within this report.
IV
Content
Certificate
Acknowledgement
Abstract
List of Figures
List of Tables
List of Abbreviation
1. Introduction 1
1.1 About escorts Ltd
1.2 Mission
1.3 Quality policy
1.4 Hystory
1.5 Logo
1.6 Key persons
2. Agri machinery Group 6
2.1 Features of AMG
2.2 Turn over
2.3 Product
2.4 Awards
3. KMC 9
3.1 Design
3.2 Metrology
4. Assembly Plant 12
4.1 Assembly Layout
4.2 Rear axle assembly
4.3 Transmission Assembly
4.4 Assembly of Engine and Clutch Mechanism
4.5 Front axle and accessories and paint
4.6 Rear and Front wheel fitting
4.7 Final Testing
V
List of figures
List of abbreviations
Chapter-1
Introduction
In today’s competitive world with fast depleting material resource, and with all its
limitations, it has become imperative to develop human resources and its
effectiveness. The continued effectiveness and efficiency of an organization to
some extent depend on the ability of its employees to produce at high levels of
efficiency, and to keep abreast with role, which the job demands. Training should
be a long terms investment in human resources.
In order to meet the challenges in the future and to leave an indelible mark on the
industrial scenario, Escorts has restructured the group along six business lines,
each headed by an independent CEO. The business groups are as follows:-
1.2 Mission
“Escorts Endeavour’s to transform lives in rural and urban India by leading the
revolution in agricultural mechanization, modernization of automotive and railway
technology, as well as transformation of Indian construction industry”
1969 - Escorts Tractors Limited was born a technical and financial joint venture
with the global giant Ford Motor Company, USA, to manufacture Ford tractors in
India. The years ahead saw Escorts grow as the largest tractor manufacturer in
India.
Escorts Institute of Farm Mechanization (EIFM) established at Bangalore.
Escorts Employees Ancillaries Ltd. (EEAL), a unique venture in industrial
democracy comes into being.
1971- 1st February, the first tractor FORD 3000 rolled out of the factory. Escorts
diversifies and starts manufacturing construction equipment.
1974 - Crossing national boundaries, Escorts exports for the first time. After
winning a global tender, 400 tractors were exported to Afghanistan, which was
perhaps the world's largest ever airlift of tractors.
1977 - Escorts enters the world of self-developed technology by setting up its first
independent R&D Center. Escorts Scientific Research Centre marked its beginning
at Faridabad by developing its own Engines for E-27 and E-37. Due to constant
technology absorption, indigenization level touched 72% for FORD tractors. 2nd
plant at Bangalore for manufacturing piston assemblies was set up.
1979 - Collaboration with JCB Excavators Ltd., UK for manufacture of excavators.
1980 - Foray into healthcare, Escorts Hospital and Research Center set up in
Faridabad.
1983 - Escorts Tractors Limited (ETL) established a state-of-the-art research and
development centre to spearhead newer breakthroughs in Farm Mechanisation and
to maintain industry leadership. Line concept introduced for engine block
machining. 11,000 ton floating dry-dock Escorts I launched.
1984 - JV Escorts - Yamaha to manufacture motorcycles.
4
1984 - Signing of agreement with the Japanese bike giant Yamaha to manufacture
motorcycles with Yamaha technology. Collaboration with Jeumont Schneider of
France to manufacture EPABX systems Collaboration with Dynapac of Sweden to
manufacture vibratory road compactors.
1988 - Escorts Heart Institute and Research Centre (EHIRC), a world class cardiac
care facility launched in New Delhi.
1989 - Joint Venture with Claas of Germany to manufacture harvester combines.
1990-91 - First Public Issue in February 1991, over-subscribed four times. Shares
listed on Delhi and Bombay Stock Exchanges.
1993 - FORD 3620 tractor launched.
1996 - Disengagement of joint venture collaboration with New Holland and launch
of FARMTRAC Tractor.
1997 - Joint Venture with Carraro of Italy for manufacturing and marketing of
transmission and axles. Joint Venture with First Pacific Company of Hong Kong -
Escotel Mobile Communications.
1998 - POWERTRAC series of tractors launched. MoU was signed with Long
Manufacturing Company, USA for setting up a Joint Venture in USA.
1999 - MoU for Joint Venture with a Polish Company POL-MOT was signed for
assembly, manufacturing and marketing of Farm Machinery.
2004 - Divested Escotel Mobile Telecommunications to Idea Cellular
TS16949 certification for Agri Machinery Group.
2005 – Divested Escorts Heart Institute and Research Centre (EHIRC) to Fortis
Healthcare.
2006 - Divested in Carraro India Ltd.
2008 - ECEL launches Fully Hydraulic Crawler Cranes
2009 - ECEL has recently commissioned its state-of-art manufacturing plantrolling
out pick-n-carry cranes and vibratory compactors.
5
A hexagonal nut (in red) representing a geometric perfection. The nut has been a
functional device that has stayed at the core of mankind’s engineering adventures.
In spite of modern technologies coming in, it still remains unarguably a symbol of
technology and all that holds it together. Locked into the nut is a spanner (in
white), the turning force for the symbol of technology. The two pictorial elements
are configured together to form an 'E', a pneumonic for Escorts.
Chapter -2
KMC
Component Plant
Tractor Assembly Plant
Crankshaft & Hydraulic Plant
Component Plant consists of Machine shops in which all major castings such as
Engine blocks, Gear Box housings, Differential housings are being machined along
with Gears & Shafts. Machine shop consists of State of the Art machines such as
CNC Horizontal Machining Centers, CNC Turning Centers and variety of other
precision machines, including Gear Hobbing and Shaving machines, etc. It is
important to note that all critical components are machined in house.
Tractor Assembly Plant is divided into two lines as Farmtrac Line and the
Powertrac Line. Farmtrac Line is a composite line that has machining as well as
assembly activities of Engine, Transmission & Tractor whereas on Powertrac line
1111
only Assembly activities of Engine, Transmission & Tractor are being carried out.
Tractor Assembly Plant has State of the Art Paint Shop that has CED paint shop
facilities. Engine Shop has State of the Art testing facilities that includes AVL
make Eddy Current Dynamometers in Engine Test House.
Crankshaft & Hydraulic Plant is divided into two parts as Crankshaft Line and
Hydraulics Line. Crankshaft line consists of machine shop where crankshafts of all
Tractor models are being machined. It has State of the Art machines such as Rotary
Miller, Pin Grinder, Journal Grinder, etc. Hydraulic line consists of Machining as
well as Assembly activities where critical parts of tractor hydraulics such as
Distributor, Hydraulic Cylinder, etc. are being machined and assembled. It has
State of the Art Honing and other precision machines.
1.3 Product
Product Brand
Hero, Champion, FT-
Farmtrac 6040, FT-6045, FT-6050,
Tractors FT-6055, FT- 6090
Powertrac PT 425, PT434, PT-439,
PT- 445, PT-4455
Engines Escorts 2-cylinder, 3-cylinder, 4-
cy;inder , Genset, EPI and
normal
Lubricants Farmtrac Gear oil, FT15W40
Transmission Oil,
Engine
Oil
1111
1.4 Awards
a). Greentech Environment Excellence Award-2011-Knowledge
Management Centre (KMC) has bagged the Gold Category award in Engineering
Sector instituted by Greentech Foundation, Delhi for outstanding performance in
“Environment Management”
b). Escorts Agri Machinery (EAM) wins accolades at INSSAN-Employees
of EAM participated in various competitions organized by the Indian National
Suggestion Scheme Association New Delhi (INSSAN) at ESSEX farms,
Convention Centre, New Delhi on 3rd and 4th June 2011. INSSAN is a platform to
recognize the value of employees for their intelligence, experience, attitude and
feelings.
c). Escorts won Flower Festival Awards 2011 -organized by Haryana
Urban Development Authority.
d). Recognition of Escorts R&D Centre renewed for next five years i.e. up to 31st
March 2016 based on R&D Projects under taken during last three years.
e). Company was the First Winner in Solid Model Contest 2011- this award is
about the focus on 3D imaging and predictive analysis to reduce the number of
physical prototype to save time, cost and energy consumption.
1111
Chapter-3
KMC
Introduction
Escorts Knowledge Management Center unites professional
expertise with long practical experience in Product Design, Computer Aided
Engineering (Simulation & Virtual Testing), Product Evaluation & Testing. It is in
about 10000 s.m area. Escorts expertise in this area has been developed from
nearly six decades of knowledge & experience in designing and innovating
products and machines for escorts group's own manufacturing companies.
Knowledge management centre have many depart as Design, testing, metrology
etc.
3.1 Design
In this section there are design of engine, transmission, vehicle
are being done. For this purpose they use
10
Figure 3.2
Engine
1111
3.2 Metrology
Figure 3.3
Chapter-4
Assembly Plant
Introduction
The final processed parts from the various parts of production
shop and Heat Treatment reach the assembly Shop. Escorts have two assembly
shop different for each powertrac and farmtrac. In farmtrac assembly line
assembled 124 tractor per day and powertrac capacity is 80 tractor per day. For
lifting the component there are hydraulic lift are used and for small part the used
roller. Conveyor is used for moving in forward direction. The various parts reaches
the assembly shop only after being washed, cleansed and dried, which takes place
when the different parts are on their way to assembly shop. The above washing
process takes place automatically i.e. the machinist has to drop the final Part on the
roller conveyor, and the parts reach the assembly shop after being automatically
washed and dried.
We were advised to walk within the yellow line boundary because of the safety
measures.
The assembly shop can be divided into various subparts being assembled. These
groups are:
Rear Line
Transmission Assembly
Engine Assembly Line
Front Line
Paint Shop
Wheel Assembly
13
Engine
sub
assembly
Gear
box sub Paint
ft
Accessorie Hydraulic
s lift test
14
Figure 4.1
Assembly layout
The various bolts required making the assembly of about parts and integral one are
bolted using a pneumatic bolter gun. After this, the differential cage is collected
from the conveyor firstly fitted with the necessary bearing races. Then the
differential Cage unit and the pto shaft are assembled, making up a complete one
unit.
The Axles are assembled in a different sub assembly shop. First rear axle wash and
dry and then fixed wheel side bearing and there on the whole unit along with the
bull gears is assembled to the differential Cage. Differential cover assemble after
these assemblies.
First gear on main shaft with 38 teeth and reverse gear with 38 teeth, second gear
with 35 and third with 28 teeth. This is the constant mesh type transmission.
After assembly of the transmission there is leakage testing is perform. In this test
first gear box is full of oil and then sealed. After that the pressure is increase up to
10 bar. Then the by the motor power the clutch shaft is revolve at 2700 rpm. This
test check meshing of gears. After that whole unit is assembled to the main line
and make a complete one unit.
Engine from sub assembly are assembled to the main line. A four stoke 3 cylinder
diesel engine first assembled at the engine sub assembly.
The various links and mechanism between the engine and the gear box is fastened
together and the whole integral unit is checked for its complete accessories etc. In
all the above stages of assembly, the skilled workers are used to accomplish all the
stages of assembly. But they are also held by the pneumatic bolt guns and the over
head automatic conveyors and the alarm conveyor etc to make their job easy.
16
Figure 4.4
Paint shop is completely automatic. In the paint shop first there is dressing , water
rinsing and demineralized water rinsing. After that air blowing is done. Paint
Baking Oven removes the moisture from water-based coatings and adhesives.
After that unmasking and touch up and painted the body.
18
Figure 4.5
Figure 4.6
Rear hood
Steering wheel
Mirror
Air filter
Front light
20
Seat
Silensor
Figure 4.7
Fitment of radiator
21
4.7 TESTING
There are different testing at each departments
Rear axle testing is done at the last station of the rear axle assembly line.
Transmission and hydraulic tests are also done at the last station of their assembly
line.
ENGINE TESTING
There are 12 Beds for engine testing and the parameters that are checked are smoke,
torque, power, inlet and outlet valve timing and rocker are set.
At every bed same parameters are checked and each engine is run for 30-40 minutes at
full RPM.
TRACTOR TESTING
After the main tractor assembly the tractors tested in the industry at particular testing
road. These tractors are tested at full power and full throttle.
The import tractors are tested for 25-30 minutes and export tractors are tested for 4
hours.
Then PTO and hydraulics are checked by applying different load.
If there is any issue found in the tractor they are sent to MAJOR REWORK, where the
issues are checked and repaired.
Chapter-5
Introduction
Bolts are defined as headed fasteners having external threads
that meet an exacting. Bolt are manufactured in a wide range of materials from
common steel to titanium, plastic and other exotic materials. Many materials are
further separated into different grades to describe specific alloy mixtures,
hardening processes, etc. In addition, some materials are available with a variety of
coatings or plating to enhance the corrosion resistance, or appearance of the
fastener.
5.1Bolt Grading
There are three grades of bolt in common used. Most bolts which
you will come across will only deviate slightly from these three grades. The lowest
grade is 4.6, commonly known as commercial grade. Next comes grade 8.8, known
as structural grade, and finally, the highest grade is 12.9, known as high tensile
bolts. In between these there are many grades are used such as 4.8, 5.6, 9.8 and
10.9 etc.
24
4.6
i.e. 0.6*4*100=240MPa
Size Range
Class Head Marking Material
(mm)
Low or medium
4.6 M5 - M36
carbon steel
25
34
Size Range
Class Head Marking Material
(mm)
Low or medium
5.8 M5 - M24
carbon steel
When applied torque and the resulting tension (preload) in the bolt are measured
during tightening and plotted on a graph, there is a linear relationship between the
torque and the tension. The bolt tension is directly dependent, and proportional to,
the applied torque. This is illustrated by the graph, which is based upon
experimental results, that is shown in the diagram above. From such test results it
is possible to establish the appropriate torque for a required bolt preload that may
be preload.
Figure 5.1
M12×1.75×80-8.8
Figure – 5.2
Bolt View
TYPES OF FAILURES
Figure5.3
Figure6.5
FIGURE 5.6
34
Chapter-6
Conclusion
Summer training in Escorts Ltd. really helped me to familiarize myself to the practical
knowledge of industrial production and processes. The whole training period was very
interesting, instructive and challenging. Through this training I was able to gain new
insights and more comprehensive understanding about the real industry working
condition and practice.
I got the idea of working of automatic CNC machines, Testing techniques of Diesel
engine, tractors and different processes used in machining of cylinder block and
Assembly plant. All of this valuable experience and knowledge that I have gained were
not only acquired through the direct involvement in task given but also through other
aspect of the training such as work observation, interaction with operators, supervisor
and other peoples involved in the process.
In assembly plant i saw how tractor are assembled. I get knowledge about different-
different sub assemblies of tractor assembly plant. Differential sub assembly,
transmission sub assembly, transmission testing, paint of body and different sub
stations.
It was a good idea and good chance to expose to the work environment that we will
have to face and practice after we graduate. As a result of the training now I am more
confident to enter the employment world and build my future career.
35
References
1. http://euler9.tripod.com/bolt-database/22.html
2. http://www.escortsagri.com/
3. http://www.standardsbis.in/Gemini/search/BasicSearch.action?sear
chValue=hexagonhead bolts#
4. http://www.boltscience.com/pages/quality.htm
5. http://www.boltscience.com/pages/nutorbolttightening.htm
6. Introduction to Design Behavior of Bolted Joint by John H.
Bickford.
7. http://www.scribd.com/doc/51438283/1364-1
8. Material given to me by the company