135, EAST COAST ROAD, KANATHUR, CHENNAI – 603112

TAMIL NADU, INDIA

“TRAINEE IN KSRTC DEPOT”

A Report on Internship

in the

Department of Mechanical Engineering

Submitted by

“VARSHANTH PRINCE”

“BME18079”

APRIL 2022
 BONAFIDE CERTIFICATE
Certified that this is a Bonafide of the Internship done by Mr Varshanth Prince with Register
No BME18079 studying in VIII Semester during the year 2021-2022 for the degree of B.E.
Mechanical Engineering at Academy of Maritime Education and Training (AMET) Deemed
to be University has done his Internship at KSRTC Depot (CHRY) for a period of 15 days
from 30/03/2022 to 15/04/2022.

SIGNATURE SIGNATURE

Dr. R. KARTHIKEYAN Mr. P. RAMANATHAN

HEAD OF THE DEPARTMENT, FACULTY INCHARGE,
DEPARTMENT OF MECHANICAL DEPARTMENT OF MECHANICAL
ENGINEERING ENGINEERING
AMET UNIVERSITY AMET UNIVERSITY
135, EAST COAST ROAD, 135, EAST COAST ROAD
KANATHUR, CHENNAI 603112 KANATHUR, CHENNAI 603112
 ACKNOWLEDGEMENT

It is indeed a great pleasure and privilege to present this report on Internship at KSRTC
Depot located at Changanaserry.

I am extremely grateful to Dr. R. KARTHIKEYAN, Head of the Department,

Department of Mechanical Engineering, AMET Deemed to be University, for his
constant encouragement and valuable support throughout the course.

I thank the Mr. JOJU GEORGE, Assistant Depot Engineer of KSRTC Depot for
considering my potential in doing this training and providing this wonderful opportunity.
It was a great learning working at the company.

I would like to express my gratitude to Mr. P. RAMANATHAN, faculty coordinator

and
Mr. M. BALAKUMARAN, my class advisor for their invaluable suggestion,
motivation, guidance and support throughout the training. His methodology to start from
simple and then deepen through made me to bring out this Internship report without
anxiety.

Thanks to all the KSRTC Depot officials, operators and all other member of the
organization, yet uncounted for their help in completing the Internship and see the light of
success.

I extend my sincere thanks to all the faculty members, technical staff of the department
for providing their guidance, inspiration and support throughout my course.

I am very thankful to friends, colleague and all other persons who rendered their
assistance directly or indirectly to complete this internship successfully.
INTERNSHIP CERTIFICATE
 PREFACE

Every student of Bachelor of Engineering in Mechanical Engineering studying at Academy of

Maritime Education and Training (AMET) Deemed to be University has an essential requirement

to do minimum 15 days of internship in a well reputed company / Organization. The purpose of

such internship is to acquire sufficient practical application of the theoretical concepts taught to

the students during the course of study.

It was a wonderful opportunity to have a close comparison of theoretical concepts in practical

field through this Internship. I have understood the roles and responsibilities of each employee in

the organization, ethics in the organization and the work culture followed the industry. This

report aims to summarize the learning through the Internship gained from KSRTC Depot which I

have undergone during 30/03/2022 and 15/04/2022.

 Learning Objectives/Internship Objectives

 Internships are generally thought of to be reserved for college students looking to gain
experience in a particular field. However, a wide array of people can benefit from Training
Internships in order to receive real world experience and develop their skills.

 An objective for this position should emphasize the skills you already possess in the area and
your interest in learning more

 Internships are utilized in a number of different career fields, including architecture,

engineering, healthcare, economics, advertising and many more.

 Some internship is used to allow individuals to perform scientific research while others are
specifically designed to allow people to gain first-hand experience working.

 Utilizing internships is a great way to build your resume and develop skills that can be
emphasized in your resume for future jobs. When you are applying for a Training Internship,
make sure to highlight any special skills or talents that can make you stand apart from the rest
of the applicants so that you have an improved chance of landing the position.
WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES

1st Week

DATE DAY WORK DONE AS DIRECTED BY SUPERVISIOR

30/03/2 Wednesday Introduction to Basic Parts
2
31/03/2 Thursday KL 15 A 345 (Gear Box)
2
01/04/22 Friday KL 15 A 2217(Back Door Jamming)
02/04/22 Saturday KL 15 A 1935(Radiator Coolant Leak)

2nd Week
DATE DAY WORK DONE AS DIRECTED BY SUPERVISIOR
04/04/22 Monday KL 15 A 1377(Brake Down)
05/04/22 Tuesday KL 15 A 1935 (Leaf Spring Broke)
06/04/22 Wednesday KL 15 A 1269 (Clutch Plate)
07/04/22 Thursday KL 15 A 1935 (Air Bella Changed)
08/04/22 Friday KL 15 A 128 (Front Joint Change)
09/04/22 Saturday KL 15 A 345 (Gear Box)

3rd Week
DATE DAY WORK DONE AS DIRECTED BY SUPERVISIOR
11/04/22 Monday KL 15 A 1508 (Air leak in Air Valve)
12/04/22 Tuesday KL 15 A 1269 (4XW Ball Bearing)
13/04/22 Wednesday KL 15 A 1935 (4XW Ball Bearing)

14/04/22 Thursday KL 15 A 2218 (Brake Pad)

15/04/22 Friday KL 15 A 1935 (Front Bumper)

 CHAPTER 1
INTRODUCTION

The main objective of an engineering course is to implement the knowledge in to practical

application and analysing the skill in technical subjects. As far as mechanical engineering is
considered it is very important to have practical knowledge along with theoretical knowledge. It is
hard to achieve such practical experience, only availing the resources and practical classes of our
college. Also, it is impossible to provide such a platform in college. So, we decided to undergo an
in-plant training at KSRTC Regional Workshop, where most of the repairing and maintenance
works of KSRTC buses are done. KSRTC has been one of the most successful establishments of
Kerala government undertaking. Begun in the late 1960’s it has been providing excellent service
to the people both within the state and the neighbouring states. The KSRTC has buses like
ordinary, limited stop, fast and superfast buses, super deluxe, which caters to the different sections
of the society.

The KSRTC has five regional workshops. They are at Pappanamcode, Mavelikkara, Aluva, Edapal
and Kozhikode, other than the local garages available at all important bus stands. These Regional
workshops do the yearly overhauling of the buses and the buses which are heavily damaged due to
accidents.

This is the report of in-plant training done at KSRTC Workshop, Changanaserry, Kerala, dated
from 30th March 2022 to 15th April 2022.
 CHAPTER 2
MAINTENANCE SECTIONS

The regional workshop consists of different sections for the smooth and easy maintenance of the
buses. The different sections and their activities are explained below.

2.1 ENGINE ASSEMBLY SECTION

The internal combustion engine is an integral part of a vehicle in which combustion of fuel
{generally, fossil fuel} occurs with an oxidizer (usually air) in a combustion chamber. In an
internal combustion engine, the expansion of the high-pressure gases which are produced during
the combustion process occurs. During this process force is applied to components of the engine
such as the pistons or turbine blades or nozzle, and by moving it over a distance result in
generation of useful mechanical energy.

In KSRTC buses we generally use 4- and 6-cylinder engines of TATA and LEYLAND. Here, we
were able to observe much about the engine parts, its working and functions and also the repairing
methods adopted. Cylinder block from the dismantled engine is cleaned and then boring and
honing is done to remove wear. The valve is grinded to proper finish and valve seat is lapped. The
damaged piston is replaced by a new one. The weared crankshaft is ground so that ovality and
taper are within permissible limits. Crank shaft is coated with recommended lubricant . Figure 2.1
shows an engine and its crankshaft with connecting rods.

Fig. 2.1 Engine and engine components of a KSRTC bus.

2.2 GEAR BOX SECTION

A machine consists of a power source and a transmission system, which provides controlled
application of power. Merriam-Webster defines transmission as an assembly of parts including the
speed-changing gears and the propeller shaft by which the power is transmitted from an engine to
a live axle. The most common use is in motor vehicles, where the transmission adapts the output at
the internal combustion engine to drive wheels. Such engines need to operate at a relatively high
rotational speed, which is inappropriate for starting, stopping and slower travel. The transmission
reduces the high engine speed to the slower wheel speed, increasing torque in process.

Fig. 2.2 Synchromesh gear box.

Most modern manual-transmission vehicles are fitted with a synchromesh gearbox, as shown in
the Figure 2.2. Transmission gears are always in mesh and rotating, but gears on one shaft can
freely rotate or be locked to the shaft. The locking mechanism for gear consists of a collar (or dog
collar) on the shaft which is able to slide sideways so that teeth on its inner surface bridge two
circular rings with teeth on their outer circumference: one attached to the gear, one to the shaft.
When the rings are bridged by the collar, the particular gear rotationally locked to the shaft
determines the output speed of the transmission.

The gearshift lever manipulates the collar using a set of linkages, arranged such that one collar
may be permitted to lock only one gear at any one time; and while shifting gear, the locking collar
from one gear is disengaged before another one is engaged. One collar often serves for two gears:
sliding in one direction selects one transmission sped, in the other direction selects another. In the
overhauling of gear box, the teeth of all gears and the needle bearing are checked. The dog clutch
and the sleeve are checked for pitted teeth and the splines are checked for wear. If the wear is
more, they are replaced with new ones and assembled back.
2.3 PROPELLER SHAFT SECTION

A drive shaft or propeller shaft (prop shaft) or Cardan shaft is a mechanical component for
transmitting torque and rotation, usually used to connect other components of a drive train that
cannot be connected directly because of distance or the need to allow for relative movement
between them.

Fig. 2.3 Propeller Shaft.

Drive shafts are carriers of torque: they are subjected to torsion and shear stress, equivalent to the
difference between the input torque and the load. They must therefore be strong enough to
withstand or bear the stress, while avoiding too much additional weight as that would turn increase
their inertia. Figure 2.3 shows in detail the parts of a propeller shaft.

All the buses of KSRTC have a clutch and a gearbox mounted directly on engine with a drive shaft
leading to a final drive in the rear axle. Universal joint couplings are used to connect the two
shafts. Overhauling of propeller shaft consists of checking the propeller shaft for bends and it is
straightened out using hydraulic press.
2.4 SMALL UNIT SECTION

Small unit section consists of reassembling of clutch, air brake compressor, DD unit, air drier.

2.4.1 Air Brake Unit

Compressed air brake system is typically used in KSRTC buses. The system consists of service
brakes, parking brakes, a control pedal on engine driven air compressor and a compressed air
storage tank. For the parking brake there is a disk or drum brake arrangement which is designed to
keep in the applied position by spring pressure.

Fig. 2.4 Air Brake System.

Air pressure must be produced to release these spring pressure parking brakes. For the service
brakes (the ones used while driving to slow or stop) to be applied, the brake pedal is pushed,
routing the air under pressure (approximately 100-125 Pa) to the brake chamber, causing the brake
to reduce wheel speed. Most types of truck air brakes are drum units, though there is an increasing
trend towards the use of disc brakes in this application. The air compressor draws filtered air from
the atmosphere and forces into high-pressure reservoirs at around 120 psi. Most heavy vehicles
have a gauge within the driver's view, indicating the availability of air pressure for safe vehicle
operation, often including warning tones or lights. Setting of the parking/emergency brake releases
the pressurized air pressure in the lines between the compressed air storage tank and the brakes.
Thus, actuating the (spring brake) parking brake hardware. An air pressure failure at any point
would apply full spring brake pressure immediately.
2.4.2 Clutch Unit

A clutch is a mechanism which enables the rotary motion of one shaft to be transmitted, when
desired, to a second shaft, the axis of which is coincident with that of the first.

Fig. 2.5 Clutch.

Clutches are used whenever the transmission of power or motion needs to be controlled either in
amount or over time (e.g., electric screwdrivers limit how much torque is transmitted through use
of a clutch, clutches control whether automobiles transmit engine power to the wheels).

In the simplest application, clutches are employed in devices which have two rotating shafts (drive
shaft or line shaft). In these devices, one shaft is typically attached to a motor or other power unit
(the driving member) while the other shaft (the driven member) provides output power for work to
be done. Overhauling of clutch assembly includes checking for wear of the clutch lining wear,
length of the springs, and cracks in the clutch plate steel disc. Pressure plate is checked for heat
damages, cracks and flatness. The replacement of the springs, disc and clutch lining are done if
necessary and assembled.

2.4.3 Front Axle Unit

This is the assembly that support the vehicle on the front side. There is no power transmitted to the
front axle. The main parts of the front axle are s cam, roller, hub, carrier plate, bearings, air
chamber, stack adjuster, lay lender, brake drum, break shoes etc. The steering action comes to one
tire and as the tires are interconnected, both works simultaneously.
The braking action occurs with help of air pressure since it is air brakes. As the brake pedal is
pressed on the valve, s cam rotates, the brake shoes expand and touches the brake drum, thus the
braking action works. Figure 2.6 shows the inspection of a front axle for damages.

Fig. 2.6 Front Axle System.

2.5 DIFFERENTIAL SECTION

A differential is a device, employing gears, through which it transmits torque and rotation. Except
in some special purpose differentials, there are no other limitations on the rotational speeds of the
shafts.

In automobiles and other wheeled vehicles, a differential allows the driven road wheels to rotate at
different speeds. This is necessary when the vehicle turns, making the wheel that is travelling
around the outside of the turning curve roll faster than the other.

If the engine is running of a constant speed, the rotational speed of each driving wheel can vary,
but the sum (or average) of the two wheels speeds cannot change. An increase in the speed of one
wheel must be balanced by an equal decrease in the speed of the other.

In the overhauling of differential each tooth is inspected minutely for any pitting or broken teeth
on crown wheel pinion, sun and star pinion. Then they are checked for the back lash of the sun
pinion with star pinion.
 Fig. 2.7 Differential gear.

2.6 FUEL INJECTION SECTION

Fuel injection system consists of fuel tank, fuel feed pump, fuel injection pump, fuel filter, fuel
injection nozzle and a governor. Pump is the device that pumps fuel into the cylinders of a diesel
engine. Traditionally, the pump is driven indirectly from crankshaft by gears, chains or a toothed
belt (often the timing belt) that also drives the camshaft. It rotates at half crankshaft speed in a
conventional four-stroke engine.

Its timing is such that the fuel is injected only very slightly before top dead centre of that cylinder's
Compression stroke. In some systems injection pressures can be as high as 200 MPa. Earlier diesel
pumps used an in-line layout with a series of cam operated injection cylinders in a line, rather like
a miniature inline engine.

The pistons have a constant stroke volume, and injection volume (i.e., throttling) is controlled by
rotating the cylinders against a cut-off port that aligns with a helical slot in the cylinder. When all
the cylinders are rotated at once, they simultaneously vary their injection volume to produce more
or less power from the engine. Figure 2.8 shows a diesel fuel pump.

The injection pump must give equal quantity of fuel to all cylinders and the supply should
commence and stop at fixed degree of crank angle both of which are checked and adjusted on the
injection pump test bench.
 Fig. 2.8 Diesel Fuel Pump

Fuel filter is necessary to supply clean fuel which needs to be replaced at regular intervals.
Facilities have been provided for suitable testing of the injectors which includes; Leak off test:
The injector tester is worked up to build a pressure of 150 atm, which is kept for 10 seconds
(without spraying). In case there is a drop in pressure, the body seat and the needle are lapped.

Spray test: The injector is fixed up as done earlier and pressure gauge is disconnected by closing
the valve. The tester is worked up four times and a second and the spray pattern is noted. If the
spray pattern is in the form of a stream or jet, the needle and the nozzle body seat require grinding.

2.7 ELECTRICAL SECTION

Electrical section includes the engine starter. As the key is inserted, the circuit activates, that is the
solenoid coil magnetize, pinion comes in contact with fly wheel. As the starting motor rotates, the
fly wheel and the pistons reciprocate, thus the engine starts working. After the engine starts, the
motor stops working.

Another machinery in the electrical section is the alternator, which is used for charging the
batteries. The alternator has two parts, they are stator and rotor. The parts of starter are stator and
armature.

2.8 STEERING SECTION

The main parts of steering section are sector arm, bearing, oil and roller shaft. In Tata vehicles, 74
rollers are used whereas in Leyland only 42 rollers are used. They won't have play on the shaft.
There exist two types of steering wheels. They are power and ordinary steering wheels.
 Fig. 2.9 Steering System.

2.9 SUSPENSION SECTION

The suspension system mainly used in the KSRTC buses are leaf spring suspension system. The
semi-elliptic leaf springs are the almost universally used for the suspension in heavy commercial
vehicles. The spring consists of number of leaves called blades. The blades vary in length. The
lengthiest blade with eyes on its end is called the master leaf. All the blades are bound together by
means of steel straps. Figure 2.10 shows a leaf spring suspension system.

Fig. 2.10 Suspension system.

After prolonged use or over loading, spring assembly gets flattened or one or two of its leaves gets
broken. The centre bolt is then removed and the broken leaf is dismantled and replaced with the
new one. The rubber bushes, which are used to hinge the suspension systems to the chassis, are
greased and are replaced if these are worn out.
2.10 BODY BUILDING SECTION

At Pala KSRTC regional workshop, there are two building sections;

1. New body building section

2. Old body building section

Automobile body building is an important activity. The chassis is supplied by automobile

manufacturers, and body is built by automobile body builders. Bus bodywork is usually geared to
short trips, with many transit features. Coach bodywork is for longer distance trips, with luggage
racks and under-floor lockers. Other facilities may include toilets and televisions.

Here it mainly deals with accident cases, i.e., buses which are damaged due to accidents. In
extreme accidents, body building of damaged bus is similar to new body building. The patch
works of the buses are being done here. New buses are also built here.
Welding, riveting, sheet metal works, painting works etc. are done.

Fig. 2.11 New chassis for body work. Fig. 2.12 After body work completion.
 CHAPTER 3
CONCLUSION

By this industrial training program, we were able to know the functions and operations of different
parts of an automobile and we were familiarized with the tools used for different operations.

We saw all the inner parts and repair works of KSRTC buses and the making of a bus from chassis
to its completed form. Also, this training helped us to practice the theories we studied in our
syllabus. This was the best chance we ever had, to do some practical with experienced workers in
a live workshop and to see the internal parts of engines, gearbox and other parts. So, this training
program was very helpful for us in studying about the public transportation buses of Kerala and to
experience the processes involved in repair and manufacture of those buses. By this we gained a
lot of practical knowledge which we hope will help in our studies and our future jobs.
 DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP EVAULATION REPORT 2021-2022

Name of the Student

Register No. and Roll No.
Programme of Study
Year, Batch and Group
Semester
Title of the Internship
Duration of the Internship
Period of internship
Company Name
Supervisor at the Company

ASSESSMENT SCORE

S.No. Criterion Max. marks Marks Secured

1 Adequacy and quality of information recorded 20

2 Organization of the information, format, drawing, sketches, 20

language used in the Internship report
3 Details of study during the Internship and relating the 20
theoretical concept
4 Originality of the content 10

5 Regularity in maintenance of work schedule. 10

6 Presentation skills 20

Total 100

Internal Co-Ordinator HoD

Guide/Mentor

KSRTC DEPOT CHANGANSERRY

(BUSES ARE STANDING IN WORKSTATION)