INDUSTRIAL TRAINING REPORT

ON
Crimp Assembly Line, Core brazing, Manufacturing and process
Submitted in partial fulfillment of the requirements
For the award of
Degree of Bachelor of technology In
Mechanical Engineering

SUBMITTED BY:

Anshul Saxena
2022749

SUBMITTED TO:

Department of Mechanical Engineering

I.K GUJRAL PUNJAB TECHNICALUNIVERSITY,

MAIN CAMPUS, KAPURTHALA, PUNJAB
 DECLARATION
I hereby declare that the Industrial Training Report entitled ("Crimp Assembly Line , Core
brazing , Manufacturing and Process") is an authentic record of my own work as
requirements of Industrial Training during the period from 06-02-2024 to 06-04-2024 for the
award of degree of B.Tech. (Mechanical Engineering), Main Campus, I.K. Gujral Punjab
Technical University, Kapurthala, Punjab, under the guidance of Manoj Kumar Sir.

Date: 06-04-2024 Signature

ANSHUL SAXENA
2022749
CERTIFICATION
 ACKNOWLEDGEMENT
It is always a pleasure to remind the fine people in the Engineering Program for their sincere
guidance I received to uphold my practical as well theoretical skills in engineering. With a
sense of great pleasure and satisfaction I present this Industrial training report for the partial
fulfillment of training, the training program at “Crimp Assembly Line, Core Brazing,
Manufacturing and Process”. This report is no doubt a product of invaluable support and
contribution of a number of people.

Out of deep sense of gratitude I express my sincere thanks to Sanjeev Yadav (HR) for timely
helping me in throughout the training.
I would like to express my heartfelt gratitude to my mentor Mr.
Manoj Kumar (Production Manage) for being a constant guide, inspiration and a source of
illumination throughout this entire period.
This Training would not have been a success without my friends and family who have been my
constant support. I am grateful to each and every one of them and acknowledge them for their
love and affection.

ANSHUL SAXENA
 TABLE OF CONTENTS
SR. NO PARTICULARS PAGE NO
1. Declaration 2
2. Certification 3
3. Acknowledgement 4
4. Contents 5
5. Introduction 6
a Organization Profile 7
b Organization chart and Clients 7
c 3’C’ And 5’S’ 8

6. Manufacturing products
a Condenser
9
• Gauging & Inspection
10
• ALT & ILT
• Dessecant Bag & Cap Assy 10
• Tig Welding Assy 11
• Helium Leak Testing 12
12
• Final Inspection

Radiator
B
• Inlet & Outlet Crimping 13
• Skewness Station 14
14
• Dry Leak and Dunk Tank Testing
• Motor Shroud Assy 15
• Fan Balancing 16
• FSA Testing 16

7. Core Brazing

8. Conclusion 17
9. Reference 18
 INTRODUCTION
Organization Profile
Hanon Systems is an automotive parts manufacturing company headquartered in Daejeon,
South Korea. Hanon Systems is one of the world's largest suppliers of auto thermal
management systems.
It was Found in 1986 as a joint venture with Ford Motor Co.
In 1989 R&D was established in Korea and Ontario Canada.
Awarded “SUPPLIER OF THE YEAR” in 1998.
In April 2000 the company was certified to ISO/TS 16949 compliance and was selected as a
“Best under a Billion” company by forbes magazine in 2004.
In 2007 received 5-star certification from the Hyundai/Kia Group.
Organization Chart

Clients
3’ C’ And 5’ S’
 MANUFACTURING PRODUCTS
Condenser
It is a device to condense a substance from its gaseous state to its liquid state by cooling it
In doing so latent heat is given up by the substance and transferred to the surrounding
environment.

• Gauging & Inspection of Condenser-

In this Process the size and dimension of the condenser and their brackets are checked to
make it precise without any defects. And inspection is done for pass it to next Assembly.
 • ALT-
Air Leak Testing is an effective method of determining if a product has been manufactured to
meet leak tight specification.
Microscopic holes, failed seals, and countless other defects can cause air leaks that can lead to
significant problems.

• Dessecant Bag & Cap Assy-

Dessecant Bags are the part of the sub cooling section of the condenser and are used in
condenser to absorb water and moisture from the air to sustain dryness.
• Tig Welding Assy-
In this Assembly we do tungsten inert gas welding on the cap of cylinder of the
condenser.
It’s known for its precision and versality, often used for welding stainless steel,
aluminium and other metals.
It’s commonly used in industries where high quality welds are necessary such as
automotive and manufacturing.
• Helium Leak Testing-
In this testing helium gas is used to find minute leaks in the condenser. Because of its
small molecule size, helium can penetrate through leaks easily.

Only 5 ppm of helium gas exists in the atmosphere. It is less affected by the background
of test environment.

Helium is safe inert gas without toxicity and explosiveness.

• Final Inspection-
All the seals are checked in final inspection.
After that all the created parts goes for packaging and then send the packed parts to the
godown.
Radiator
• Inlet & Outlet Crimping-
In inlet and outlet crimping a gasket is used on two side of the radiator and it is applied
with the help of hammer which presses the gasket to the radiator and also for other parts
to get best fit.

Gasket
• Skewness station-
In this station we measure the symmetry, or more precisely, and lack of symmetry of the
part.

A "skewness station" could potentially refer to a station or point in data analysis where
skewness is being assessed or addressed.

• Dry Leak Testing-

It is the most accurate, efficient, and repeatable of the leak test methods to
Meet the low leaks rates of condenser.

• Dunk Tank and Bubble Leak Testing-

Dunk and bubble leak testing is a method of testing a part vessel or cavity for leaks by
submerging it in a water tank. The part is filled with gas typically compressed air and
leaks are identified by an operator monitoring whether a stream of air bubbles escapes
from the part.
 • Motor Shroud Assembly-

In this assembly motor and shroud are fitted on the Radiator.

The Radiator shroud is a piece of metal or plastic that is designed to fit snugly around your
radiator.

The shroud keeps radiator working more efficiently by channelling the air through the whole
radiator and not just through the spot where the fan sits.
 • Fan Balancing-
In fan balancing we check the speed of the fan in RPM of the Radiator
With today's radiators, the ideal fan speed for an adequately sized set of rads is 1200 rpm.
A radiator fan balancing machine with dynamic reference design. The dynamic reference design
enables balancing of radiator fans without the need for any reflective sticker. The dynamic
reference design also provides an electronic protractor remote angle system enables easy
identification of the unbalance at the closest proximity to a correction blade. The placeweights
program also enables the operator to determine without manual computation, the correction
weights required on each blade.

• Final Inspection-

All the seals are checked in final inspection.

After that all the created parts goes for packaging and then send the packed parts to the
godown.
 CORE BRAZING

The invention discloses a condenser core brazing method and relates to the technical field of
welding. The method comprises steps of placing a plurality of layers of condenser cores to be
brazed on a conveyor belt of a channel type brazing furnace; arranging carbon bars among
layers of condenser cores; spraying the condenser cores on the conveyor belt on spraying
stations by using spraying liquid; feeding condenser cores which are sprayed to a drying
furnace; drying the condenser cores at the drying temperature of 240 DEG C; feeding condenser
cores which are dried into a first brazing station, a second brazing station, a third brazing
station, a fourth brazing station and a fifth brazing station of the channel type brazing furnace
sequentially; conducting five brazing for condenser cores on the brazing stations; feeding
condenser cores which are brazed to a cooling pool for cooling; and outputting condenser cores
which are cooled out of the cooling pool. Compared with the prior art, the method has the
advantages that the brazing effect is good and the efficiency is improved by one time.
 METHODS OF CORE BRAZING

• Torch Brazing-

It is the most common method used for brazing AC condensers. It involves using
a hand-held torch to heat the joint area and melt the filler metal, which is then
drawn into the joint by capillary action.

• Induction Brazing-

Induction brazing is the process of joining two or more metals using induction heating.
Induction heating utilizes the electromagnetic field to provide heat without contact or flame.
Induction brazing is more localized, repeatable, and easier to automate compared to
traditional torch brazing.
 • Resistance Brazing-

Resistance brazing is the process of joining two metals using a low-temperature interface metal
called the “brazing alloy.” The goal is to join the two metals by melting the alloy without
simultaneously melting the metals.
 CONCLUSION

This internship report presents my experiences and learning as a trainee during my internship at
Hanon Climate System India Pvt. Ltd. which manufactures Climate control Products of cars
and Light Commercial Vehicles (LCV).
This internship provided me with the opportunity to gain practical experience and improve my
skills.

• Learning Outcomes-
1. Manufacturing and Processes of Condenser and Radiator.
2. Testing of the Product
3. Production Planning
4. Quality Control

• Skills Developed-
1. Technical skills- Proficiency in using diagnostic and technical equipment.
2. Communication Skill- Ability to write clear and concise technical reports.

• Responsibilities-
1. Reports- Prepare detailed reports on manufactured parts and the leaked parts.
2. Inspection of the leaked parts.
 REFERENCE

• https://www.hanonsystems.com/En
• https://www.slideshare.net/slideshow/manufacturing-of-radiator-229523410/229523410
• https://www.synergeticautomation.com/helium-leak-testing-machine.html
• https://chatgpt.com
• https://www.google.com/search