Report of Major Project

In

Automation of Eyelet Assembly of

Monoshock Damper.

By

Aditya V Mishra (TYA-06)

Kapil K Bhusare (TYA-32)
Sheeban Akhtar (TYB-00)

Submitted in partial fulfillment of the requirement for

Degree of Bachelor of Technology

(Mechanical Engineering)

Of

Dr. Babasaheb Ambedkar Marathwada University,

Aurangabad.

Department of Mechanical Engineering,

Maharashtra Institute of technology,

Aurangabad.
2018-2019

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 CERTIFICATE

This is to certify that the Minor Project Report

Submitted by

Aditya V Mishra (TYA-06)

Kapil K Bhusare (TYA-32)
Sheeban Akhtar (TYB-00)

Is completed as per the requirement of Dr. Babasaheb Ambedkar

Marathwada University, Aurangabad in partial fulfillment of

Degree of Bachelor of Technology (Mechanical Engineering)

For the academic Year 2018-2019

Prof. B. D. Gurav Dr. A. J. Keche Dr. S. P. Bhosle

Guide Head of Department Principal
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 ACKNOWLEDGMENT

The satisfaction that accompanies the successful completion of this project work would
be incomplete without the mention of the people who made it possible, without whose constant
guidance and encouragement would have made of efforts go in vain. We consider our self-
privileged to express gratitude and respect towards all those who guided us through the
completion of this Project work.

Our guide Prof. B.D. Gurav provided we lot of knowledge of this Major Project also
gives the meaning of Industrial Project and said the increase world’s technology towards do
something. It is chiefly to their untiring efforts and an analytical guidance which encourages us
at every step during Project work.

We are grateful to Dr. A. J. Keche, Head of the Mechanical Engineering Department for
giving us support and encouragement that was necessary for the completion of this Project work.

We express our deepest regards towards our Principal Dr. S.P.Bhosle and library for
providing required books time to time.

We are also grateful to Mr. R. K. Mishra, C.E.O of ACCRETE Group of Companies

For giving us the permission for doing the project in the company.

We are thankful to Mr. G. Hatekar the plant head of ACCRETE ELECTROMECH

PVT.LTD. for giving us an opportunity to work in the plant.

We again thank the company for giving us an opportunity to fulfill the demands of world
class quality to achieve organization’s goal, thus promising to serve you better, today and
tomorrow.

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INDEX

1. Introduction …………………………………………………1

2. Literature Review…………………………………..….4

3. Objectives of Present work……………………………….2

4. Problem Statement………………………………………………3

5. Methodology of work…………………………………..….4

6. Proposed Result…………………………………..5

7. Time line of work completion Schedule……11

8. Conclusion ………………………20

9. References ………………………………………………21

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 List Of Figures

Figure 5.1

Figure 5.3(a) Pneumatic stirrer

Figure 5.3(b) Magnetic Stirrer

Figure 5.3(c) Electric Stirrer

Figure 6.2(a) Input Output of electric motor

Figure 6.2(b) DC motor

Figure 6.3(a) Johnson Geared Motor

Figure 6.3(b) Wireframe diagram of motor

Figure 6.4 Location of Stirrer

Figure 6.5(a) Tangential flow pattern

Figure 6.5(b) Radial flow pattern

Figure 6.5(c) Axial flow pattern

Figure 6.6 Electrical Component Circuit

Figure 6.7 Actual Stirrer

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 INTRODUCTION

1.1 Brief History of Accrete Group of Industries

Accrete Group of companies have more than two decades of experience in
ERW/CDW tubular products, sheet metal parts and machined components.
State-of-the-art manufacturing facilities at 4 locations in Aurangabad,
Maharashtra and 1 location in Ahmednagar, Maharashtra located 90 km from Pune,
Maharashtra.
Currently provides solutions for automobile components for 2-Wheelers and 4-
Wheelers, shock absorbers, boilers, suspension assembly, refrigerators etc.
“Customer First” philosophy, Ability to anticipate and Agility to adopt as per
changing market needs and most importantly Attitude of continuous learning have been
our growth drivers.
The major customers of the Company include Well known Automotive
Industries such as Gabriel Anand , Varroc , Endurance , Bagla Solutions , Magna and
Application and Communication Industries such as Electrolux , Videocon and
Alandick.
The products of the company include Flywheel Cup, Spring Seat, Machined
Outertube, Tubular Components, Sleeve, eyelet Assembly, Shocker Sub Assembly ,
Front and Rear Shocker Sub Assembly Etc.
The Project is being carried out in Plant 1 of Auranagabad Division situated at
H-16, MIDC, Waluj, Aurangabad , Maharashtra.
Accrete Electromech Pvt Ltd group of companies is promoted by first
generation entrepreneurs with more than 2 decades of rich experience in metal
conversion business. The group companies are led by professionally qualified team of
Engineers from Premiere institutes like VJTI, JNEC, BITS Pilani etc., MBA’s from
NMIMS, XLRI Jamshedpur and Cost Accountants. The team members have gained

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sound technical expertise and commercial acumen from their past experience working
with large organizations like BAJAJ Auto, NRB bearing, Glaxosmithkline CH,
Magneti Marelli, Endurance Technologies, Bundy India etc.

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 1.2 Accrete Group Plants & Offices

1. Accrete Electromech Pvt Ltd

Precision tubular component manufacturer for Shocker assemblies.

Fig:1.2.1

2. Mahesh Industries

Precision tubular component manufacturing for Shocker assemblies.

W-91,MIDC,Waluj, Aurangabad

Fig:1.2.2
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 3. Shree Pressings
Sheet metal component manufacturing.

M-180,MIDC,WALUJ, Aurangabad

Fig: 1.2.3

4. Yogananad Autocomp Pvt Ltd

Sub assemblies for 4 Wheeler & commercial vehicle shockers & wire condensers for
refrigeration industry.

D-86/1,MIDC,Supa Parner,Ahmednagar

Fig:1.2.4

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 1.3 Plants Establishments

1990 - Started Injection moulding plant in Aurangabad. Became C & F agent for Steel Tubes of
India (STI) for precision tubes for Aurangabad region

1996 - Expanding footprint in metal conversion business, the promoters ventured into
stamping space by setting up State of the art Press Shop in the name of Shree Pressings.

2001 - Forward integrating in precision tubes, Machine Shop was set up in name of Mahesh
Industries for providing components for 2 &3 Wheelers shock absorber assemblies.

2010 - Further expanding into auto component industry, the group started manufacturing
facility for welded sub-assemblies for 4 wheeler and commercial vehicles in the name of
Yoganand Autocomp Pvt Ltd in MIDC, Supa Ahmednagar.In the same year, wire condenser
for refrigerators manufacturing was started at Yoganand Autocomp Pvt Ltd.

2013 - With growing business in tubular components, Accrete Electromech Pvt Ltd was set up
in Aurangabad with state of art machining and fabrication facility.

2015 - Latest addition to group is Shree Pressings Plant-2 in Waluj, MIDC with press machines
ranging up to 250 tons.

2019- One Plant in Dewas, near Indore and One Plant in Sopa Ahmednagar is Under
construction

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1.4 Customers of Accrete Electromech Pvt.Ltd
1.Gabriel Anand
2.Varroc Engineering Pvt.Ltd
3.Endurance Technologies
4.Bagla Solutions
5.Magna International
6.Electrolux
7.Videocon Industries
8.Alandick
9.Bajaj
10.Honda, etc

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 1.5 Introduction to Mono Shock Damper
A Shock Absorber is a mechanical device designed to smooth out or damp
shock impulse, and dissipate Kinetic energy.

Fig: 1.5.1

The shock absorbers duty is to absorb or dissipate energy . Shock Absorbers are an important
part of Automobile and motorcycle suspensions , Aircraft landing gear and the supports for
many industrial machines.

Fig: 1.5.2

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 Fig: 1.5.2

Mono Tube Suspension is a type of Shock Absorbers used in Automobiles vehicles. In

a Mono tube shock absorber, the shock components are contained within a tube. It contains a
shell case which works as a cylinder. It has zero restrictions on Installation angles. It has 100%
efficiency through all temperature.

Fig: 1.5.2

Rod Extension is an integral part of a Mono Tube shock absorber .It contains the upper
and lower mount of the Shock absorber used to mount the shock absorber on the Automobile
Chassis .

The Upper Mount of the shock absorber connects to the vehicle frame. The Upper
mount is further attached to the Piston Rod of the Shock.

The Lower mount of the Shock absorber extends from the Base valve .
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2. Literature Review

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3. Objective of Present work

The objective of this work is to Automate the Eyelet assembly process carried out in the
Company . The Scope of this work includes:

 Study of various types of Automation Process.

 Study of various components used in Automation .
 Designing and Development of the Automation process for the Assembly .
 Design and Development of various components in Automation process by studying
the existing techniques and their specifications .
 Applying the known knowledge and the outcome of the education for solving the
Industrial problems .
 Development of Automation process to reduce Human Efforts and Fatigue .
 Study of the New Automated Process which reduces the Cycle time of the Assembly
thereby increasing the Productivity of the Company.
 Study of various parameters which affect the efficient working of the process.

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5. Problem Statement

The Eyelet Assembly process followed in the Company includes follownig steps
followed :

Fig:

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6. Methodology of work
Automation is done by using Various Components such as:
1. Torque Sensor

Fig

2. Indexing Device

Fig

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 3. DC Motor

Fig

4. Proximity Sensor

Fig

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5. Pneumatic Cylinders

Fig

6. Solenoid Valves

Fig

7. Gauges
8. Customised Splindle
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 With the help of Torque Sensor the torque is defined, which is input to DC motor.

With the help of standard gauges of company the eyelet assembly of Monoshock
Damper is operated using DC Motor and Torque Sensor.

The Automation consist of 3 steps:

1. Apply “GO Gauge” , and it should fit in the threads of eyelet assembly.
2. Apply “NO-GO Gauge” , and it should not fit in the threads of eyelet assembly.
3. Inspection of Eyelet Assembly.

All these three steps will be carried out by an indexing device programmed
Sucessfully in system.
Pneumatic Cylinders will be use to make movements of the sensors and DC motors.

6. Proposed Result

The Automation process of the Eyelet Assembly mechanism of the Company will help the
company to achieve following results :

 Reduce the Cycle Time of the process.

 Reduce the Human Efforts and Fatigue caused to the Labour.
 Increase the Productivity of the product per day to increase the Overall Productivity
and Profit to the company .
 Increase the Process Capability.

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  Decrease the Labor Cost.
 Decrease the Time required for the Assembly mechanism.

7. Timeline of work Completition Schedule

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8. Conclusion

Thus the system is prepared by designing and manufacturing the components, and
assembled these components with standard available parts. The machine setup is then tested to
ensure its satisfactory performance. During the testing it is found that, the machine is able to
work with specified rpm and sufficient movement is created with the help of indexing device.
The vibrations created during running condition are much less. The problem is that the machine

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is able to work in particular range and for particular product and it is able to handle the limited
capacity for which it is previously designed. For given conditions the performance of machine
is found to be satisfactory. In future for large capacity concept of increasing no. of, sensors and
devices are suggested.

9. References

[1]. Bhandari V B.Design of machine elements. New York: Tata McGraw-Hill; 1994.

2]. Carlson H. Spring designer’s handbook. New York: Marcel Dekker Inc.; 1978.

[3]. Shigley J. Mechanical engineering design. New York: McGraw-Hill; 1981.

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[4]. John C. Dixon, The Shock Absorber Handbook. John Wiley & Sons, Ltd; 2007.

[5] IFR Statistical department press release 23.05.2012, Available

http://www.worldrobotics.org/index.php?id=home&news_id =261, 25. August 2013

[6] ATI Industrial Automation, “Network Force/Torque Sensor System – Installation and
Operation Manual”, USA, 2010.

[7] KUKA GmbH, “KUKA.ForceTorqueControl 2.3.”, Augsburg, 2012.

[8] B. Siciliano, “Springer handbook of robotics”, Springer, Berlin, 2008.

[9] J. Loske, R. Biesenbach, ”Analysis of Options on the Integration of a Force-Torque Sensor

in the Control of KUKA KRC 2 edition05 of an Industrial Robot”, International Conference on
Engineering Science and Innovative Technology, ESIT 2014, Thailand, April 2014

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