LUCAS TVS LIMITED, PADI

INTERNSHIP REPORT ON

PRODUCTION
Submitted by

BHUVANESH KUMAR . V (19MER006)

In the partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

VELALAR COLLEGE OF ENGINEERING AND

TECHNOLOGY, ERODE, THINDAL
AUTONOMOUS INSTITUTION
AFFILIATED TO ANNA UNIVERSITY, CHENNAI

FEBRUARY 2023
ACKNOWLEDGEMENT

I Would like to thank Mr.Velu,Manager,Training Centre,Lucas TVS

Limited,Padi for providing me the better opportunity to do internship
within the organization.

I express my deepest thanks to Mr.Arun Kumar,Mr.Sathish

Kannan,Mr.Sathish,Training Officers,Training Centre,Lucas TVS
Limited,Padi for their careful and precious guidance.

It is indeed with a great sense of pleasure and immense sense of

gratitude that I acknowledge the help of the individuals for their greater
guidance on the particular sectors: Mr.Kishore
Kumar, Mr.Suresh, Mr.Sunil, Mr.Ramesh, Ms.Vinitha,
Mr.Venkatesh, Mr.Selavaraj and Mr.Noel Braide.

BHUVANESH KUMAR. V(B.E )

VELALAR COLLEGE OF ENGINEERING AND TECHNOLOGY (ERODE)
INDUSTRY
PROFILE
 INTRODUCTION
ABOUT LUCAS TVS:
Lucas TVS, established in 1962, is a leading provider of mechatronic
solutions for automotive, consumer and industrial goods companies, with
over 50 years experience in design, manufacturing and supply of products
to OEMs in India and abroad. With a work force of over 6,000 people and
state of the art engineering and manufacturing facilities integrating TQM,
TPM, 6 sigma and lean manufacturing principles. Lucas TVS has end to
end product development capabilities. We have 7 plants in India and a
global network with sales and sourcing offices in USA, China, South
Korea, Japan and Germany.

LUCAS TVS LIMITED: Established in 1962 as a Joint venture between

Lucas UK and TVS, Lucas TVS is a leader in Automotive electrical in
India, supplying a wide range of electrical components for two wheelers,
3 wheelers, cars, commercial vehicles, tractors and the industrial sector.
Lucas-TVS is a Deming Grand Prize certified for TQM Practices Group
Turnover / group employee count.
HISTORY:

Lucas - TVS was set up in 1961 as a joint venture of Lucas

Industries plc., UK and T V Sundaram Iyengar & Sons (TVS),
India, to manufacture Automotive Electrical Systems. One of the
top ten automotive component suppliers in the world, Lucas Varity
was formed by the merger of the Lucas Industries of the UK and the
Varity Corporation of the US in September 1996.

The company designs, manufactures and supplies advanced

technology systems, products and services to the world's
automotive, after market, diesel engine and aerospace industries.

The combination of these two well-known groups has resulted in

the establishment of a vibrant company, which has had a successful
track record of sustained growth over the last three decades.TVS is
one of India's twenty large industrial houses with twenty-five
manufacturing companies and a turnover in excess of US$ 1.3
billion.

The turnover of Lucas-TVS and its divisions is US$ 233 million

during 2003-2004.Incorporating the strengths of Lucas UK and the
TVS Group, Lucas TVS has emerged as one of the foremost leaders
in the automotive industry today.

Lucas TVS reaches out to all segments of the automotive industry

such as passenger cars, commercial vehicles, tractors, jeeps, two-
wheelers and off-highway vehicles as well as for stationary and
marine applications. With the automobile industry in India currently
undergoing phenomenal changes, Lucas-TVS, with its excellent
facilities, is fully equipped to meet the challenges of tomorrow.
TVS GROUP COMPANIES:
The TVS Group is India’s leading supplier of automotive
components and one of the country’s most respected
business groups.
With a combined turnover of more than over $ 6.5 Billion ,
the TVS Group employs a total workforce of close to over
39,000 employees . Charting a steady growth path of
expansion and diversification, it currently comprises
around over 50 companies. These operate in diverse fields
that range from two-wheeler and automotive component
manufacturing to automotive dealerships, finance and
electronics. Uniting these multiple businesses is a common
ethos of quality, customer service and social responsibility.
4 LUCAS TVS GROUP COMPANIES:

 Delphi TVS : Delphi TVS was established in 1989, combining the

vast expertise of 2 large automotive systems suppliers - TVS and
Delphi. Delphi TVS manufactures Diesel Fuel Injection Equipment
for cars, commercial Vehicles, tractors and single & 2 cylinder
engines. Delphi TVS is ISO certified and has been honored with
ACMA Gold Award for Manufacturing Excellence.
 Lucas Indian Service Limited:
Lucas Indian Services is a leader in aftermarket service for auto-
electrical with over 85 years of experience and more than 550
Service dealerships and a network of over 2,000 dealers, 15,000
retailers and 30,000 registered auto electricians / mechanics.
 India Nippon Electricals Limited:
India Nippon Electricals Ltd was established in 1986 as a joint
venture between Lucas Indian Services and MAHLE Electric
Drives, Japan and manufactures Electronic Ignition Systems, and
other auto electrical for two wheelers, three wheelers and General
Purpose Engines. INEL has 3 manufacturing plants – Hosur,
Rewari and Pondicherry.

 INDIA JAPAN LIGHTING: India Japan Lighting Pvt. Ltd. was

incorporated in December 1996. It is a 50:50 joint venture between
Lucas-TVS Limited, Chennai, and Koito Manufacturing Company
Limited, Japan. Lucas-TVS Limited is an acknowledged leader in
Auto Electricals in India, while Koito Manufacturing Company
Limited is the leader in automotive lighting in Japan. Koito have
been in the lighting business for 90 years.
 CUSTOMERS

MARUTI SUZUKI TATA KENT MINERAL

RO

FORD PACCAR HYUNDAI

FIAT TAFE MAHINDRA

TVS SWARAJ VOLVO

HERO KIRLOSKAR FIAT

BAJAJ DENSO HONDA

RENAULT NISSAN WABCO ARCTIC CAT

JOHN DEERE GODREJ KOMATSU

LIVPURE YAMAHA POLARIS

CATERPILLAR IVECO KOHLER

ENGINES
 LUCAS TVS -SOLUTIONS
EV Power Train Solutions:
All-electric vehicles produce zero direct emissions, which specifically
helps to improve air quality in urban & rural areas. Lucas TVS is at fore
front in developing of new technology for EV segment. Lucas TVS works
with new vision to make cleaner and safer environment.

Electric Bicycle
Lucas TVS BLDC Hub Motor is a new generation drive system for e-
bikes. Extremely compact design in wheel hub motor, Lucas TVS offers
ideal user-oriented performance. This makes the system not only more
streamlined but also significantly lighter. The Lucas TVS e-bike solution
is therefore perfectly suited to sports and leisure applications as well as
everyday mobility.
Hub Motor & Controller :
Hub Motor are in-wheel drive motors which does not have interaction
with the primary bicycle chain, no additional transmission required,
Inexpensive easy to mount the most mechanically simple concept.

Features :

 Light powerful and extremely durable

 High torque generation using Epicyclic gear train mechanism
 High efficiency during climbing, and better acceleration
 Low noise, high torque
 Excellent performance characteristics
 Maximum efficiency over the entire speed range
 High power and torque density due to optimal heat dissipation
 Multiple spokes size options
 High-precision sensor technology for control and regulation
 Aluminum motor housing powder-coated with great care and
finished with meticulous attention to detail
 Powerful response; smooth performance
 Energy recovery when riding downhill reduces wear and tear on
the brakes and recharges the battery
 Excellent water and dust resistance
2 Wheeler:

The Traction motor & Hub Motors were exclusively developed

for Indian driving conditions considering the overloading factor and road
conditions. Detailed validation tests were performed not only to validate
the performance of the motor but also its durability and sealing capability.
They are perfectly compatible and optimized with regard to high power
density. The compact design of the electrical system is one of its strengths.
The system yields a high performance in all driving conditions. we
combine the requirements of each consumer to shape the future of EV
with a advanced High technology BLDC / PMSM Motor & Controller for
two wheeler.
Mid Drive Motor & Controller:
Traction Motors Allows for a great deals of customization in design,
Silent operation and free from Un-sprung weight or mass and does not
adds weight to the wheel.

Features:
 Light weight and small dimension compare to hub motor
 High performance benefit from flux weakening
 High efficiency during climbing, and better acceleration
 High combined efficiency in operating zone >90%
 Long working life (>20,000 hours)
 Low noise, high torque
 Excellent performance characteristics
 Regenerative braking
 Work with multiple voltages: 36V min and 56V max with the same
controller
 CAN Communication
 Report failures by CAN message
 Motor phase self detection and calibration
 Support Forward and Reverse Control
 Over Current Protection
 Over Voltage Protection
 Under voltage protection.
Electric Three Wheeler:
E-Rickshaw & E-Loader are low speed vehicle below 25kmph which
support Last mile commercial transportation in India. These low speed
3W uses a LI-battery for energy, Lucas TVS has developed a highly
efficient Motors and Controllers keeping an eye on Indian monsoon
condition and commercial affordability of E-rickshaw owners.

BLDC Motor & Controller – E-Rick Shaw /

E-Cart (L3):
Lucas TVS BLDC Motors & controllers are designed exclusively for
Indian consumers which are highly efficient and supports for smoother
operation.
PMSM Motor & Controller – E- Auto / E-
Loader (L5):
Lucas TVS PMSM Motor & FOC controller forms a combination which
produces constant torque and power while cruising, which are highly
efficient and yields a high range.

Features:
 High performance benefit from flux weakening
 High efficiency during climbing, and better acceleration
 High combined efficiency in operating zone >90%
 Long working life (>20,000 hours)
 Low noise, high torque
 Excellent performance characteristics
 Regenerative braking
 Work with multiple voltages: 36V min and 56V max with the same
controller
 CAN Communication
 Report failures by CAN message
 Motor phase self detection and calibration
 Support Forward and Reverse Control
 Over Current Protection
 Over Voltage Protection
 Under voltage protection
AUTOMOTIVE SOLUTIONS
APPLICATIONS:
Lucas TVS is a one-stop provider of comprehensive solutions in the auto
electrical field, especially emission reduction and fuel economy increases.
Lucas TVS has been in the auto electrical business since 1961.We earned
a reputation for innovation, high quality, modular design, competitive
pricing, excellent reliability, and meeting needs of the global auto industry
through our rich experience in auto electrical. The motto of our company
is to provide a wide range of innovative products and satisfactory
customer service to the worldwide market.

2 Wheeler:
Lucas TVS designs , develops and manufactures a wide range of
Automotive Electrical Parts for Two Wheelers. Lucas TVS products are
best known for Product reliability and dependability. Lucas TVS Compact
Size Starter Motors with advanced start/stop features are preferred choices
of today’s new generation vehicles. Products are designed and validated
to withstand the tough road conditions.

Applications
PRODUCT: STARTER MOTOR

3 Wheelers
For the current demand of three-wheelers, Lucas TVS has introduced gear
reduction starter motor, which directly supports the improvement of
engine performance with a compact design and reduced noise. We provide
wiper motors for 3 wheelers with and without parking functions in the
wiper system. We validate our products in different modes and different
environmental conditions to meet global requirement.

APPLICATIONS:
PRODUCTS:
WIPER MOTOR:

STARTER MOTOR:
POWER GENERATION:

Passenger Vehicle:
We offer a wide range of Lucas TVS products for passenger vehicles
like starter motors, alternators, wiper systems and ignition coils. These
products assure the highest level of reliability on your journey regardless
of environmental conditions. Our products are designed and validated
with real world specifications. We have advanced start/stop starter
motors, high efficiency alternators, compact size wiper motors, and
ignition coils for fuel saving and carbon emissions reduction. Excellent
performance of our power steering motor and ABS motor makes
pleasant and comfort journey.

APPLICATION:
PRODUCT

WIPER MOTOR

REAR WIPER MOTOR SMART &COMPACT

WIPER SYSTEM
FRONT WIPER SYSTEM WIPER SYSTEM

Commercial Vehicle:
For the weight optimization in CVs, Lucas TVS has introduced gear
reduction starter motor, high efficiency internal fan alternators which
directly supports the improvement of engine performance with a compact
design, improvement in battery life and reduced noise. Electronically
interface wiper motor are developed to cater the different operating modes
and been validated at the vehicle level under critical conditions.
Main products that are manufactured in
Lucas TVS:
1. Alternator

2.Starter motor

3.Wiper motor

4.Compressor motor

5.Distributor

ALTERNATOR:

High Efficient and Co2 Emission Friendly

Alternator
Features:
 Higher VDA Efficiency : 70%
 Compact in size
  Higher Power density
 Multi-Function Regulator
 High load dump capable Zener diode
 Solderless electrical joints – Resistance
 LIN regulator/ clutch pulley (Optional)

Customer Benefits:
 Improved Fuel Efficiency
 Lighter in weight
 Improved Power to Weight Ratio
 Better Ergonomics
 Welding for more reliability

Product Specification:
 Frame size : Ø 130mm
 Voltage : 12V
 Output : 140A
 Mass : 5.1kg (w/o Pulley)
 Range : 110A ~ 140A
 Dual Asymmetric Internal Fan Type
 Operating Temp : -30°C to +120°C
PERFORMANCE CURVE

CUSTOMERS OF ALTERNATORS:
 ASHOK LEYLAND
 TATA MOTORS
 TAFE
 MARUTI SUZUKI
 MAHINDRA
ALTERNATOR ASSEMBLY LINES:
 ROTOR ASSEMBLY

 STATOR ASSEMBLY

 RECTIFIER ASSEMBLY

 VACCUM PUMP ASSEMBLY

 SRE AND DE BRACKET ASSEMBLY

 MAIN ASSEMBLY
PRODUCT FUNCTION
Alternator convert chemical energy to
electrical energy so that you
can charge and replenish the
battery in your engine and
other electrical components in
a car

Rotor Rotors are the moving part in

an Alternator that have
permanent magnets that move
around the Stator's iron plates
to generate an Alternating
Current (AC).

Stator the stator converts the rotating

magnetic field to electric
current

Rectifier The rectifier is used

to convert current from
alternating current (AC) to
direct current (DC) during the
charging process.

Regulator The alternator regulator

must monitor and control the
process to charge the battery.
 ALTERNATOR PROCESS FLOW
SUB ASSSEMBLY-ROTOR ASSEMBLY
Shaft:

KNURLING GROOVING HARDENING

GRINDING STRAIGHTENI
NG
ROTOR COIL WINDING:

COIL FORMER AND

CORE INSERTION

COIL WINDING

WINDING OUTER TAPPING

HOT FORMING AND

STABILIZING

FLUXING THINNING INSUL

TUBE INSPECTION

STAMPING AND FINAL

INSPECTION
ROTOR ASSEMBLY

Claw driving
rotor od
and ring bearing press
turning
punching

protective
Straightening varnishing
disc assembl y

Slip ring dynamic

fan pressing
pressing balancing

claw and drill

Twisting and electrical hole pre dispatch
soldering testing inspection
deburri ng

slip ring sre fan electrical lacquering

welding welding testing apply
STATOR ASSEMBLY

insul forming
extra pitch cutter soldering sre load welding
and insertion

pin insertion tig welding final inspection rectifier testing

conductor push bush press (sre

through cropping electrical testing bracket)

insul strip
twisting gauge testing sleeve insertion
insertion
 CORE FORMATION

STEEL BLANKING
RIVETING
COIL PRESS

PAINTIN
COINING MILLING
G

VACCUM PUMP PROCESS:

 HOUSING ASSEMBLY WITH CHECK VALVE AND
CONNECTOR
 CENTRE PLATE O RING ROTOR AND VANES ASESEMBLY
WITH HOUSING ASSEMBLY
 ALL LEAK TEST.
ALTERNATOR MAIN ASSEMBLY

SRE+SLIDING
BUSH ASSEMBLY

SRE+LOCK
DISC+OIL SEAL
ASSEMBLY

CHECK THREAD
AND FAN GAP
AND SPAN AND
POSITIVE TERM
NUT TIGHTNESS

SRE
BRACKET+RECTIF
IER ASSEMBLY

LOCKING PIN
ASSEMBLY
 STARTER MOTOR

A starter (also self-starter, cranking motor, or starter motor) is

a device used to rotate (crank) an internal-combustion engine so as to
initiate the engine's operation under its own power. Starters can
be electric, pneumatic, or hydraulic. The starter can also be another
internal-combustion engine in the case, for instance, of very large
engines, or diesel engines in agricultural or excavation applications.
The starter motor is responsible for turning the engine over during
ignition and allowing everything else to happen. When you turn the
ignition on, the starter motor engages and turns the engine over allowing
it to suck in air.
The starter motor has only one function which is the first and second
rotations the engine need. Apart from that the device is just an extra load
for the vehicles.

Starter motor that are manufactured in Lucas TVS,

 Commercial starter motor – used in heavy vehicles
 Gear reduction starter motor(GRS,used in light vehicles)

CHILD PARTS OF STARTER MOTOR:

 Armature
 Commutator
 Brushes
 Solenoid
 Plunger
 Field coil
 PRODUCTS FUNCTIONS
Yoke pole and field coil To create magnetic flux
assembly
Armature assembly The armature's role is twofold.
The first is to carry current
across the field, thus creating
shaft torque in a rotating
machine or force in a linear
machine. The second role is to
generate an electromotive force
(EMF).

Drive assembly It is used to connect and

disconnect rotating starter
motor shaft to the engine for
cranking.
Brush gear assembly(BG) conduct electricity at the back
of the starter motor housing
for the electromagnet
Fixing bracket assembly
It acts as a housing for drive and
armature to fix the starter in
engine
CE bracket To cover the commutator end
and hold the bg assembly
Solenoid switch assembly A solenoid switch is an
electrical switch that is often
used where a high current
circuit, such as a starter motor
circuit, is brought into
operation by a low current
switch. When the key switch is
turned to Start and the gearshift
is in neutral, the circuit between
 the battery and the solenoid
switch is complete.

Engaging lever assembly The lever moves the pinion

drive to engage the flywheel,
and back once the engine can
run on its own. The solenoid is
responsible for moving the fork
back and forth during the engine
starting session.
TYPES OF STARTER MOTOR

COMMERCIAL STARTER GEAR REDUCTION

STARTER
Large ,low speed motor Small, fast motor
Rotates a pinion in a 1:1 ratio Rotates a pinion ina4:1 ratio
Typically cheaper Typically more expensive

COMMERCIAL STARTER MOTOR

Features
 Compact in size and light weight
 Snouted D.E bracket design
 Wide operating Temperature range
 Better cold start ability
 High power to weight ratio
 Sintered Annulus with cushion pad
 Low Noise
 Shroud provided in solenoid assembly
 Higher durability -400 K Cycles (Optional)
 TCO and Fuse (Optional)
Applications
 PV/ LCV/ SUV/ 3W

Product Specification
 Frame size : Ø 70mm
 Voltage : 12V
 Output : 1.7KW @ 12D
  Mass : 3.0 kg
 Range : 1.2 ~ 1.7 KW

Customers Benefits

 Improved power weight ratio

 Longer life
 Less weight to improve fuel savings. 








ASSSEMBLY LINES
CORE ASSEMBLY

LAMINATIONS PRESSING
FRO ALUMINIUM SHEETS CORE PACK STACKING

SHAFT DIAMETER
DIAL GAUGE RUNOUT
SOFTENING AND
CHECK
STRAIGHTENING

B-INSUL SETING
 ARMATURE ASSEMBLY PROCESS FLOW

PIN
COMMUTATOR
FIXING(SLEEV BRAZING EDC TESTING
ASSEMBLY
E)

PUSH HIGH HIGH

THROUGH
SHEARING FREQUENCY FREQUENCY
BENDING THE
TEST TEST
WIRE)

DIAMOND
CONNING TWISTING BANDING TURNING

SECOND CORRUGATIO UNDER

CNC TURNING
FORMING N ASSEMBLY CUTTING
YOKE POLE AND FIELD COIL ASSEMBLY

JUMP RING PROOF LOAD

ASSEMBLY CHECK

FIXING
ENGAGING
BRACKET AND
LEVER
THRU STUD
ASSEMBLY
ASSEMBLY

FIELD COIL
PIVOT PIN AND
MANUAL
NUT ASSEMBLY
FORMING

FIELD COIL
POLE SCREW
PNEUMATIC
PRE ASSEMBLY
FORMING

FLASH TESTING
POLE SCREW
AND ID
TIGHTENING
CHECKING
COMMERCIAL STARTER MOTOR MAIN ASSEMBLY
THRUST AND HYLEM WASHER

BG ASSEMBLY ,FIELD COIL,BRUSH INSERTION

EARTH STUD ASSEMBLY

NAME PLATE RIVETING

CE COVER PRESSING

BG,THRU BOLT TIGHTENING

DUST CAP ASSEMBLY

SOLENOID SWITCH ASSEMBLY

LEAD ASSEMBLY

RELAY AND TCO ASSEMBLY

LIGHT RUN TESTING

PERFORMANCE TESTING

10 TIMES CRANKING TESTING

SEALANT STICKER,PROTECTIVE CAP ASSEMBLY

GEAR REDUCTION STARTER MOTOR

Gear reduction starters feature a reduction in gear ratio between the

armature and the pinion gear of anywhere between 2.5 and 4.5:1,
and the armature is designed to rotate at a higher speed when energized
by the solenoid.

Features
 Snout/ Snout less DE bracket designs
 Internal fuse link to protect starter from extended locking
conditions
 TCP protection is optional
 Long life Overrunning clutch
 6 Pole permanent magnet type
 Planetary gear reduction
 External through bolt arrangement
Applications
 LCV and Tractor OEMS
Product Specification
 Frame size : Ø 78mm
 Voltage : 12V
 Mass : 4.4 kg
 Range : 1.9 ~ 2.5 KW @ 6.9 mΩ
Customers Benefits
 Sealed Gear reduction starter motor
 Compact in size
 Less weight than direct drive starters
EXPLODED VIEW OF GEAR REDUCTION STARTER
 SUB ASSEMBLY- PROCESS FLOW
YOKE,POLE AND FIELD COIL ASSEMBLY

SHEET METAL SHEET ROLLING YOKE WELDING

YOKE SOAPING GROOVING TURNING

SLOT
POLE WELDING ACID PAINTING
CUTTING(GIMPING)

YOKE AND
PROOF LOAD HOLDER CLIP
MAGNET
CHECKING EXPANSION
ASSEMBLY

YOKE PRE DISPATCH

MAGNETISING INSPECTION
 DRIVE ASSEMBLY

SLEEVE SPACE
HOT TURNING COLLAR AND
OF PINION SNAPRING
ASSEMBLY

ASSEMBLY OF
SLEEVE ROLLER AND
GREASING SPRING IN
SLEEVE

ROLLER AND
PINION WITH
SPRING
SLEEVE
PRESENCE
ASSEMBLY
CHECKING

DRAG TORQUE
COVER SIZING
CHECKING

LASER PRE DISPATCH

MARKING INSPECTION
BRUSH GEAR ASSEMBLY

INSUL PLATE AND INSUL PLATE AND BG

BRUSH BOX 1 2 ROLL RING ROLL OVER
OVER ASSEMBLY ASSEMBLY

BRUSH GEAR RING

AND BRUSH BOX 3 4 CARBON BRUSH AND
ROLL OVER BG RING WELDING
ASSEMBLY

CONNECTOR AND
BRUSH AND
CARBON BRUSH
SLIPHOUSE WELDING
WELDING

LEAD ASSEMBLY AND

CONNECTOR SPRING ASSEMBLY
WELDING
 ARMATURE ASSEMBLY-WHITE STAGE
(BEFORE VARNISHING)

5 INSUL
INSUL
CORE DRIVING FORMING AND
EXPANSION
INSERTION

MANUAL PIN CONDUCTOR

PIN FORMING
INSERTION PUSH THROUGH

COIL TWISTING COMMUTATOR RADIAL

AND EXPANSION FIXING INSERTION

EXCESS
RESIGLASS
CONDUCTOR HOT STACKING
BANDING
MACHINING

STEEL RING
INSERTION
ARMATURE ASSEMBLY-BROWN STAGE
(AFTER VARNISHING)

BEARING DIA CORE OD

POLISHING TURNING UNDER CUTTING

COMMUTATOR
COMMUTATOR COMMUTATOR
RUNOUT
BRUSHING FINISH TURNING
CHECKING

ARMATURE TRACEABILITY(
DYNAMIC ELECTRICAL LASER
BALANCING
TESTING MARKING)
GEAR REDUCTION STARTER MOTOR
MAIN ASSEMBLY
DRIVE SHAFT AND ANNULUS ASSEMBLY

THRUST COLLAR AND JUMPRING ASSEMBLY

FIXING BRACKET AND ENGAGING LEVER ASSEMBLY

ANNULUS AND SHAFT GREASING

PLANETARY GEAR ASSEMBLY

YOKE AND ARMATURE ASSEMBLY

BRUSH GEAR ASSEMBLY

CE BRACKET ASSEMBLY

BG SCREW AND THRU BOLT TIGHTENING

SOLENOID ASSEMBLY TIGHTENING

STA NUT TIGHTENING

LIGHT RUN TESTING

PERFORMANCE TESTING

PRE DISPATCH INSPECTION

PACKING AND LABELLING

 WIPER MOTOR
Windshield wipers are powered by a small electric motor, usually
mounted on the firewall or under the cowl (the area under the
windshield’s base). The motor activates linkage that moves the wiper
arms back and forth. On vehicles with a rear window wiper, a separate
motor powers the one in the rear. Signs that a wiper motor is about to
fail include slow or intermittent operation, wipers that will operate at
only one speed, or arms that stop in the middle of the windshield when
turned off. If your wipers don’t work, the fault could also lie with other
parts of the wiper system.
Smart and Compact Wiper Motor

Product Specification
 Rated Voltage : 12V
 Technology : 4 Pole
 Frame size : Ø52 mm
 Torque range : 19 – 34 Nm
 Ingress Protection : IP66
 Rated Speed : 45 rpm Low speed, 65 rpm High speed
 RFI suppression : LC Filters ( 2 inductors and 2 capacitors)
 Motor Noise : 45 dBA in Low speed 55 dBA in High speed

Applications
 Cars and Utility Vehicle

Features
 Over load protection
 EMI / EMC as per CISPR 25 class3
 Built in Mechanical Snow clutch (Optional)
 Life – 1.5 Million cycles as per SAE J 903 C
 Weight – 880gms
Customer Benefits
 Light weight
 Compact
 Low operating current
 WIPER MOTOR-CHILD PARTS

Produce the required

WIPER MOTOR torque for wiping action to
take place

Convert rotary to
LINKAGE oscillating motion and also
to transfer the motion to
wiper arms and blades

Used to remove
WIPER ARMS AND dust,rain,snow,ice and
BLADES debris from windscreen or
windshield
WIPER MOTOR-ASSEMBLY LINES
REAR WIPER MOTOR ASSEMBLY

FITMENT
CHECKING

GROMMET AND
CAPTIVE SCREW
ASSEMBLY

NOISE TESTING

LIGHT RUN
TESTING
FRONT WIPER MOTOR ASSEMBLY
GEAR BOX AND BRUSH
PLATE ASSEMBLY

ARMATURE PRESSING
AND SPACER FIRING

VISUAL INSPCTION AND

JUMPRING ASSEMBLY

GEAR BOX AND YOKE

ASSEMBLY

COVER PLATE AND

SCREW TIGHTENING

MAGNETISING

LIGHT RUN TESTING

ROTARY LINE
ASSEMBLY AND TESTING

PERFORMANCE TESTING

NOISE TESTING(MANUAL
AND AUTO)

PRE DISPATCH
INSPECTION
WIPER MOTOR ASSEMBLY
(HYUNDAI AND KIA)
MOUNTING TUBES PIVOT
HOUSING CRIMPING

AFTER CRIMPING GAUGE

CHECKING

SPINDLE LINK
ASSEMBLY

MOTOR PACKING

MOUNTING BRACKET
ASSEMBLY

TANDEM LINK PRESSING

PRIMARY LINK PRESSING

ANGLE OF WIPE TESTING

AUTO NOISE TEST

FINAL FITMENT GAUGE

CHECKING

SLEEVE HEATING

PRE DISPATCH
INSPECTION
 COMPRESSOR MOTOR

Air compressors are machines that provide power to machinery. These

are used in many places, from the refueling stations to water purification
units and everything in between you will come across a lot of these
devices being used. The basic purpose of these devices is to provide
power and hence its output is measured at the crankshaft, just like with
automobile engines.
Compressor Motor for Air Suspension

Product Specification

 Frame Size : 76.5 mm

 System Voltage : 12.0 Volts
 Power : 384 Watts
 Mass : 2.2Kgs
 2 Pole permanent magnet type Motor. Motor drives the reciprocating
air pump with twin piston technology

Customer Benefits
 Lighter in weight
 Low cost
 Customized design to customer specification
Features
 720 hours of Salt Spray Life
 EMC: Class 5 of CISPR 25
 Operating Life – 1000 Hours. Duty Cycle – 20%
 Motor Service life -15 years
 It is a eco-friendly product with no heavy metals
 Protection class IP69

Applications
 Luxury Cars like Audi, Tesla, Porsche
EXPLODED VIEW OF COMPRESSOR MOTOR

CHILD PARTS OF COMPRESSOR MOTOR

Compressor Pump: The pump compresses the air and discharges it Into
the receiver. Two-stage air compressors have a minimum of two pump
cylinders. By compressing the air twice, first in a larger, low pressure
cylinder, then in a smaller, high pressure cylinder, two-stage compressors
can produce pressures.
 Actuators: The actuator creates rotary or linear movement and is
what outputs the compressed air to the tools or processes that use
pressurized air for power. Any leaks or other deficiencies in the
air movement coming into the actuator will result in a
decrease in the air force coming out. Small particles that have
found their way into the air will cause blockages in the actuator,
as well as many other parts of your air compressor.
 Bearings: Industrial-class bearings ensure a long operating life for
the most demanding of operations. Quality bearings will give
you peace of mind as your air compressor operates at high
revolutions with high pressure. Bearings are highly dependent on
the proper lubrication at the right viscosity.
 Belts: Belt tension should be checked every 40 hours for wear and
operation. The belts need to be of the highest quality and fit
properly, as they work to drive the operation of your compressor.
 Bumpers: Valve bumpers surround the valves for added protection
from accidental contact. Replace this small shielding part when
needed to prevent the more expensive replacement of valves.
 Bushings: Bushings create some space between moving parts and
are used in the internal components of the air compressor.
Your bushings offer protection from serious breakdowns,
minimizing side-to-side play.
 Couplings: These parts are used on internal components to prevent
leaking from the high-pressure system.
 Gaskets and seals: For reliable airflow and to maintain intended
pressure, your air compressor should be air-tight with quality
seals and gaskets. There are various sections of your air
compressor that have gaskets and seals: valve plate to head
gasket, crankcase gasket, intercooler gasket, oil seal and the shaft
seal, to name a few. These small parts keep contaminants out and
the pressurized air inside.

PROCESS FLOW OF COMPRESSOR MOTOR

SUB ASSEMBLY-ARMATURE ASSEMBLY
 SHAFT

KNURLING OF
SHAFT

BURNISHING OF
SHAFT

LAMINATION OF
CORE

INSERTING THE
SHAFT

APPLYING THE
LOAD

CLEANING IN
SOLVENT TANK
TO REMOVE THE
GREASE OIL
HEATING AND
DIPPING IN
EPOXY POWDER

END INSUL FIXING

COMMUTATOR FIXING

ARMATURE WINDING

HOT STACKING

ARMATURE TEST RIG

VARNISHING
 GEL
COATING(ANABOND)

ARMATURE GEL CURING

DYNAMIC BALANCING

DIAMOND TURNING

COMMUTATOR BRUSHING

POLISHING THE
COMMUTATOR

ELECTRICAL TESTING

BEARING PRESS

PRE DISPATCH
INSPECTION
YOKE ASSEMBLY

ACTIVATOR
APPLICATION

GLUEING

POLE
ASSEMBLY

CURING OVEN

UNLOADING

PROOF
LOADING

PRE DISPATCH
INSPECTION

CRANK SHAFT:

 Normal Crankshaft(BMW)

 Twin Crank shaft(Audi)

PROCESS FLOW:

INCOMING MATERIAL

First operation – inspection using air gauge output

Second operation-inspection

 FACING * CHAMFERING

 DRILLING * GROOVING

 TAPPING * TURNING

FLANGE AND CRANKCASE PROCESS FLOW

1. INCOMING MATERIAL CRANKCASE

2. INSERTION OF BALL BEARING AND RETAINER

3. CRANKSHAFT ASSEMBLY IN CRANKCASE

4. GAUGING

5. PROTECTIVE CAP
 BRUSH BOX FLOW LINE ASSEMBLY

CONTACT PLATES BASE MOULD BOTTOM

BRUSH ASSEMBLY
ASSEMBLY ASSEMBLY ASSEMBLY

BRUSH BRAIDE INDUCTOR AND

CARBON BRUSH AND INDUCTOR CONTACT PLATES WELDING TEST
WELDING JOINING

BRUSH BRAIDE
O RING ASSEMBLY
AND INDUCTOR CABLE SLEEVE LEAK TESTING
AND LOCK MOULD
RESISTANCE COMPACTING
INSERTION
TESTING

BRUSH BOX AND CAPACITOR

EARTH SCREW CABLE SLEEVE CROPPING AND
CE BRACKET
TIGHTENING COMPACTING FORMING
ASSEMBLY

CAPACITOR CAPACITOR BRUSH PIN BRUSH BOX

BENDING WELDING ASSEMBLY INSPECTION
COMPRESSOR MOTOR MAIN ASSEMBLY

FLANGE LOCATION IN PALLET

ARMATURE PRESSING AND HIGH VOLTAGE TESTING

YOKE GREASING AND LOCLITE APPLICATION

YOKE ASSEMBLY

CABLE LENGTH CHECKING

O RING ASSEMBLY AND DISPENSE GREASE ON CE BRACKET

LEAK TEST

MAGNETIZING

HIGH VOLTAGE END OF LINE TESTING

LIGHT RUN TEST

PERFORMANCE TEST

NOISE AND VIBRATION TEST

PRE DISPATCH INSPECTION

RUST OIL APPLICATION

Lucas undergoes various methods of testing to
examinealternator,starter motor and compressor motor in proving and
reliability test lab

ALTERNATOR TESTING:

1. HIGH SPEED HIGH AMBIENT TESTING

2. ACELERATION AND DECCELERATION TESTING

3. OPERATIONAL HIGH TEMPERATURE TEST

4. NORMAL ENDURANCE TESTING

5. LOAD DUMP TEST

WIPER MOTOR TESTING:

WIPER MOTOR ENDURANCE TESTING

STARTER MOTOR TESTING

 BURST TESTER

 ARMATURE FILING TEST

 CLIMATIC CHAMBER

 SOLENOID SWITCH
COMPRESSOR MOTOR:

COMPRESSOR MOTPOR ENDURANCE TESTING

SOME OF THE IMPORTANT TESTINGS ARE

COLD ROOM TESTING:

PURPOSE: To test products at sub-zero temperature. The

product can be tested in the engine/vehicle mounted condition.

MAX SUB ZERO TEMPERATURE: 40C

TIME TO REACH: - 25C -12 hrs

PROCEDURE FOR COLD ROOM TESTING:

PETROL ENGINE:

The recommended engine oil,anti freeze coolant to be changed

and a new spark plug to be fitted before placing the
engine/vehicle inside the cold room.

DIESEL ENGINE:

The recommended engine oil, antifreeze coolant cold application

diesel to be changed, ignitor to be cleaned and glow plug to be
checked for proper functioning.
CONCLUSION:
The components and the products manufactured are high in quality,
good in life at the best of customers satisfaction, lead the company to
te greater vantage point makes the profit and its lifetime to the next
level. The way of manufacture and the culture ensures thegreater
good and indestructible company that been made those years, its
been a proud to spend few days in the company learning something
academic and ethical in the way that LUCAS-TVS been all these
years and sure paves way to the best.