INDUSTRIAL TRAINING REPORT AT

ROKI MINDA CO. PVT. LTD.

SURAJ COLLEGE OF ENGNEERING & TECHNOLOGY BUCHOLI ROAD (M/GARH)

SUMMER TRAINING REPORT

Submitted to: H.R. Deptt. ROKI MINDA CO. PVT. LTD , BAWAL Submitted by:
SUNIL KUMAR

B.TECH. (8h Sem.) MECHNICAL

INDUSTRIAL TRAINING REPORT

In partial fulfillment of requirements of prescribed course Of The Award Of Bachelor Of Technology In MECHNICAL ENGINEERING Of Suraj College of Engneering & Technology Bucholi road (M/Garh) At ROKI MINDA CO. PVT. LTD. Period of Training: 15 JAN. To 15 MAY

Submitted to:
Mr. Pankaj Yadav (H.O.D) Mechanical Department

Submitted by:
Sunil Kumar
B.TECH. (8th Sem.) MECHANICAL

ACKNOWLEDGEMENT I am very grateful to my supervisor KAPIL DEV who has given me the chance to participate in several interesting industrial projects. He has supported me with his encouragement and many fruitful discussions. I would also like to express my sincere thanks to Mr. ANKUR JAISWAL for his invaluable experience and advice. The close cooperation with Mr. PAWAN TYAGI as well as many other industrial members was a great experience, which lead to many joint activities. The internship at learning centre was a unique experience and I would like to thank Mechanical Department, head of the training conductance, for this great opportunity.

Starter Batteries Product Portfolio

Product Range Segments

CAR

ORIGINAL EQUIPMENT

TRUCK

Cars, trucks, motorcycle manufacturers and other OEMs (boats, tractors, etc.)

MOTO

AFTERMARKET

MARINE

Wholesalers, accessory shops, garages, franchised dealers, fast-fit, auto-centres, etc.

ROKI MINDA Device Technological Leadership

Disc Horns The largest Disc Horn range with the flexibility offered by the range of voltages, connectors & brackets. Electro-magnetic Horn Horn Sound Only Available in High SPL and electronic versions Multi-Sound Device The MSD is capable of complex sounds such as alarm, voice and chirps, in addition to horn sound

Multi-Sound Horn Horn sound plus the flexibility offered by variable frequency driver to produce limited range of sounds.

Our Exports Customers: 4W

GM-USA
CATERPILLAR TORICA JAPAN YANMAR KOBELCO

Volkswagen
FORD MEXCO

GM
KOREA

FORD CHINA GM Mexico

FORD VIETNAM

Mazda
FORD ARGENTINA

Horn Range (After Market)

AC/DC Horn
K-82 Twin

Air Horn-2 Pipe

K-82

SD-7

K-90 Twin

EC-120

MINDA Product Range

K-95 Twin Jericho-Air

TR99 V3 Grave K-95 Twin with Grill

PNEUMATIC MOUNTINGS

ADVANTAGE OF USING PNEUMATICS

Weight Compare the weight of several valves and cylinders to that of the motors, gears, belts, and chains used on some lift mechanisms and you will find the weight comparable, if not much lighter. Adjustable Force To adjust the force of the cylinder, all you have to do is adjust the regulator in front of it. The force is equal to the area of the cylinder piston times the pressure. Remember that the valves need at a minimum of 15-30psi to work properly. Durable All of us have problems burning up motors from time to time. We can stall an air cylinder against a load indefinitely and turn off the compressor. These are industrial grade products. Last Minute Additions At the last minute, you can add a cylinder and valve very quickly.

COMPRESSOR
we have the same compressor provided by Thomas Industries that weve had for the last few years. The compressor will put out approximately 120psi before the Norgren relief valve opens (that would give you 376 pounds of output force on a 2.00 bore cylinder). Because the compressor can produce a significant amount of vibration, we have included vibration isolation mounts donated by the Lord Corporation. They can be screwed directly into the feet of the compressor as shown on the following picture. In order for these to isolate the vibration, they need to be mounted to a stiff piece of metal such as a 1/4 aluminum plate. The distance between the front feet is 3.5. The distance from the centerline of these feet to the rear foot is 5.19. A spike relay must be used to control the power to the compressor using a 20amp breaker, not a fuse. Ensure that the relay is programmed to provide forward power only to the compressor. Do not reverse the compressor! Norgren has supplied the pressure relief valve. It is shown installed on the compressor.

PRESSURE SWITCH
We have included a pressure switch manufactured by The Nason Company. These switches are normally closed. The switches will open at approximately 115psi and will not close again until the pressure drops to approximately 95psi. This will allow you to turn off the compressor once you are up to 115psi, saving power in the battery. It should be wired directly to the robot controller digital input bank with PWM type cable. No specific Digital Input Port is designated for the pressure switch. The Robot Controller must be programmed to react to the Input Port that is connected to the pressure switch The Robot Controller will activate the designated Spike Relay to turn the Compressor on and off.

REGULATOR
Norgren has donated the primary pressure regulator. These are relieving regulators. Assume that you extend the cylinder or the apparatus the cylinder is attached to against a wall. Then push against the wall with your robot. That would increase the pressure in the cylinder. The increased pressure will relieve out of the regulator and the cylinder will slowly retract. Please note: the specification states that the nominal output pressure range is 0-50psi. It also has an arrow on it to denote the outlet of the regulator. The opposite port is the inlet. A pressure gauge may be placed in either of the other ports.

ELECTRIC VALVES
SMC has provided two double solenoid valves and one single solenoid valve. For the double solenoid, if you energize one of the solenoids to make the cylinder extend, you must then energize the opposite solenoid to make it retract. Either solenoid may be left in the energized state or you may leave it un-energized and the valve will hold its position. This is a great valve to use to maintain position when the power is turned off at the end of the match. A double solenoid valve will maintain its position until you turn on the opposite solenoid. The orange buttons on the top of the valves are manual overrides. With a double solenoid valve you can depress the override and the valve will shift and stay in that position. The valve is pilot operated and requires a minimum pressure of 20 psi to work.

PNEUMATIC SYSTEM
Pneumatic systems use pressurised air to make things move (for example, pistons), to hold things up (for example, car tyres), or to move things (for example, air lines inside hopper feeder tubes). Dealing with pneumatic systems poses some dangers: if you puncture the balloon tyres on an earth mover they may rip open and injure you. If you puncture a high pressure air line, small particles of flying dust or metal may damage your eyes. Pneumatic systems are used mainly in the Mechanical systems in industry,

PNEUMATIC CYLINDER
One of the main uses for compressed air in industry is to make things move - from printing machines to advanced robotic assembly systems. The main component in these systems is the pneumatic cylinder. Cylinders work 'in reverse' to an average bike pump. Air is inject at one end or the other. This moves the piston inside the cylinder, and the rod connected to it. The power with which this takes place is proportional to the diameter of the piston - the greater the more power. Unlike hydraulic systems, where fluid is conserved, in pneumatic systems the compress air is always released. Whereas a hydraulic ram needs to be pushed in both directions.

PNEUMATIC VALVE
Pneumatics valve are used mainly inthe following situations: Mechanical systems in industry, mainly using piston/cylinders to move rods or levers, where heavy pressure is used. On automotive equipment air brakes are widely used where large amounts of energy need to be used quickly (e.g. braking systems for lorries and trains) Many hoppes and material storage systems use streams of air to move dust or small particles.

5/2 Solenoid valve

Connectors type QS, QST

FLOW CONTROL VALVE

Maintain constant flow with inlet pressure changes from 15 to 120 PSI (1 bar to 8 bar). Standard flow ranges from 1/4 GPM (see note) to 120 GPM (1.0 l/m - 454.2 l/m). Automatic in operation - no adjustments. These flow controls are designed for liquids similar in viscosity to water. All applications should be tested for flow characteristics and chemical compatability to insure desired results. The standard Series "FC" flow controls are constructed of TYPE 1, GRADE 1 PVC (Polyvinyl Chloride) with diaphragms controls are used to maintain a constant pre-determined flow in a system. They must be installed in the correct flow direction (indicated by label) to work properly.

INDUCTIVE PROXIMITY SENSOR

INDUCTIVE PROXIMITY SENSOR

A proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact. A proximity sensor often emits an electromagnetic or electrostatic field, or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal.Different proximity sensor targets demand different sensors. For example, a capacitive or photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor requires a metal target. The maximum distance that this sensor can detect is defined "nominal range". Some sensors have adjustments of the nominal range or means to report a graduated detection distance. Proximity sensors can have a high reliability and long functional life because of the absence of mechanical parts and lack of physical contact between sensor and the sensed object.

BASIC DESIGN OF PHOTOELECTRIC SENSOR

PHOTO ELECTRIC SENSORS

A PHOTOELECTRIC SENSOR, OR PHOTOEYE, IS A DEVICE USED TO DETECT THE DISTANCE, ABSENCE, OR PRESENCE OF AN OBJECT BY USING A LIGHT TRANSMITTER, OFTEN INFRARED, AND A PHOTOELECTRIC RECEIVER. THEY ARE USED EXTENSIVELY IN INDUSTRIAL MANUFACTURING. THERE ARE THREE DIFFERENT FUNCTIONAL TYPES: OPPOSED (A.K.A. THROUGH BEAM), RETROREFLECTIVE, AND PROXIMITY-SENSING (A.K.A. DIFFUSED). SOME PHOTOEYES HAVE TWO DIFFERENT OPERATIONAL TYPES, LIGHT OPERATE AND DARK OPERATE. LIGHT OPERATE PHOTOEYES BECOME OPERATIONAL WHEN THE RECEIVER "RECEIVES" THE TRANSMITTER SIGNAL. DARK OPERATE PHOTOEYES BECOME OPERATIONAL WHEN THE RECEIVER "DOES NOT RECEIVE" THE TRANSMITTER SIGNAL.

REED SWITCH
The basic reed switch consists of two identical flattened ferromagnetic reeds, sealed in a dry inert-gas atmosphere within a glass capsule, thereby protecting the contact from contamination. The reeds are sealed in the capsule in cantilever form so that their free ends overlap and are separated by a small air gap.

How does a reed switch work ? When a magnetic force is generated parallel to the reed switch, the reeds become flux carriers in the magnetic circuit. The overlapping ends of the reeds become opposite magnetic poles, which attract each other. If the magnetic force between the poles is strong enough to overcome the restoring force of the reeds, the reeds will be drawn together. What magnetic force is required to close a reed switch ? Minimum force - expressed in ampere-turns, will cause the reeds to close, and is called the just-operate force. Since the force between the poles increases as the gap decreases, a force of approximately half the justoperate force will maintain the operated state. Speed of operation of the reed switch is determined by the excess of operating force over the justoperate force. What are the advantages in using reed switches ? They are hermetically sealed in glass environment, free from contamination, and are safe to use in harsh industrial and explosive environments. Reed switches are immune to electrostatic discharge (ESD) and do not require any external ESD protection circuits. The isolation resistance between the contacts is as high as 1015 ohms, and contact resistance is as low as 50 milli-ohms. Reed switches can directly switch loads as low as a few microwatts without needing external amplification circuits, to as high as 120W. When used in combination with magnets and coils.

PUSH BUTTON
Resistant to dust and frost . The IA seraies actuator consists of a polyurethane membrane which depresses when the switch is actuated. The sealed push button switch features include an IP67 front panel seal, a low profile soft feel actuator, a 16mm dia bushing and wire leads. IA Specification . 10 mm threaded bushing Single and double pole momentary configurations with solder lug terminals. Gold plated silver or coin silver contacts are available plus optional color caps. CECC approved.

EMERGENCY SWITCH
For Protection Against Accidental Actution Emergency switch guards are designed to work with APEMs IP and IS series sealed pushbutton switches. The switch guard mounts flush into the panel providing a distinct target for the pushbutton switch and protection against accidental actuation. The guards fit into a 22 mm round panel cut-out. Available in black and clear anodized finish.

THANKU