Sahil

DEENBANDHU CHHOTU RAM UNIVERSITY OF SCIENCE AND
TECHNOLOGY , MURTHAL -131039
PROFESSIONAL TRAINING LEVEL-2
SUBMITTED IN THE PARTIAL FULFILLMENT FOR THE AWARD OF DEGREE OF BECHELORS IN

TECHNOLOGY IN ELECTRICAL ENGINEERING
BY
SAHIL VERMA
(22001002044)
TO
Dr. DK JAIN
Dr. RAVI LATHWAL
(EED)
ABOUT THE ORGANISATIONS
• Maruti Suzuki India Limited (MSIL), founded in 1981, is India’s largest automobile manufacturer and a joint venture between the
Government of India and Suzuki Motor Corporation, Japan. It revolutionized the Indian market with the launch of the Maruti 800
in 1983 and currently holds the highest market share in the passenger vehicle segment.
• Key Highlights
• Manufacturing Units: State-of-the-art plants in Gurugram and Manesar, Haryana, with a production capacity exceeding 1.5
million units annually.
• Popular Models: Alto, Swift, Baleno, Vitara Brezza, and Ertiga.
• Technological Focus: Incorporates advanced systems like PID controllers in engine management, ABS, and climate control for
enhanced performance and safety.
• Vision & Sustainability
• Maruti Suzuki’s mission is to provide affordable, high-quality vehicles while focusing on innovation and sustainability through
electric and hybrid solutions. It remains committed to shaping the future of mobility in India with customer-centric products and
services.
CONTENTS
• Transmission production flow chart
• Continuous carburizing furnace overview
• Role of gas mixing and temperature in furnace
• How temperature and gas controller work
• PID controller and ON-OFF controller working
• Components of controller
• Coordination
• Features of controller
• Conclusion
Transmission production flow chart
Car Manufacturing Process Overview
Creating a car in a factory is a multi-stage, coordinated process that begins with raw material
procurement. In the forging shop, raw metals are shaped into essential components through
forging. These parts then undergo soft machining to achieve precise dimensions.
Role of the Transmission

Production and Maintenance
Department
At Maruti Suzuki, the Transmission
Department plays a key role in producing
the vehicle’s transmission system. It
handles forging, soft machining, and heat
treatment processes to ensure the
transmission efficiently transfers power
from the engine to the wheels.
CONTINUOUS CARBURIZING FURNACE OVERVIEW
Carburizing Furnace and Temperature Control in Heat Treatment
In car manufacturing, carburizing is a heat treatment process used to enhance the hardness
and wear resistance of steel parts by introducing carbon into their surface layer. The process is
conducted in a furnace operating between 850°C to 950°C, where maintaining precise
temperature control is crucial for optimal results.
Role of Gas Mixture and Temperature in the

Furnace
Gas mixtures, such as endothermic gas, play a critical role in
carburizing by increasing the carbon content of steel surfaces. In this
process, gases like methane or propane decompose into atomic
carbon and hydrogen, allowing carbon to diffuse into the steel.
The furnace atmosphere, primarily consisting of CO, H₂, and N₂, is

regulated to prevent decarburization (loss of carbon). Techniques like
carbon pulsing and gas jet mixing are employed to maintain an
optimal carbon concentration. Precise control of the gas mixture and
furnace temperature ensures that the treated steel achieves the
required material properties for enhanced performance.
PID Controller
A PID controller continuously adjusts the control variable (e.g.
heater power or gas flow) to minimize the error between the
setpoint and the measured variable (e.g., temperature).
Key Characteristics:
Continuous Control: Fine-tunes output to maintain the

setpoint.
Precision: Minimizes overshoot and steady-state error.
Complexity: Requires tuning of P, I, and D parameters.
Stability: Smooth and stable control for high-precision
processes.
Applications:
Used in complex systems like industrial

furnaces or advanced machinery.
On-Off Controller
An on-off (bang-bang) controller switches the control variable fully on or off based on
the process variable’s relationship to the setpoint.
Key Characteristics:
Binary Control: Operates only in two states—on or off.

Simplicity: Easy to design and maintain.
Inaccuracy: Can cause oscillations around the setpoint.
Instability: Without hysteresis, it may result in rapid switching (chattering).
Applications:
Suitable for simple systems like household appliances

or basic industrial equipment.
COMPONENTS OF CONTROLLER
• Proportional Control (P):
Adjusts the control output based on the current error
(difference between the setpoint and the measured value).
• Integral Control (I):

Corrects for accumulated past errors, ensuring the
system reaches the setpoint accurately over time.
• Derivative Control (D):

Responds to the rate of change of the error, minimizing
overshoot and preventing oscillations.
Applications in Car Manufacturing

PID controllers are essential in processes like temperature
control in carburizing furnaces and engine management
systems, where precise control is critical for performance and
safety.
Coordination
Thermocouple sensor
Thermocouple sensor is a type of temperature sensor that
measures temperature based on the thermoelectric effect—
the generation of a voltage when two different metals are
joined and exposed to temperature changes.
Key Characteristics
• Wide Temperature Range: Suitable for both high and
low-temperature environments.
• Durability: Withstands harsh conditions, making it ideal
for industrial use.
• Cost-Effective: Offers reliable performance at a relatively
low cost.
Coordination
O2 sensor
An oxygen sensor (O2 sensor) is a vital component in
modern automotive engines, designed to measure the
oxygen levels in exhaust gases. This data is essential for
the engine control unit (ECU) to optimize the air-fuel
mixture, ensuring efficient combustion.
Key Functions
• Fuel Efficiency: By adjusting the air-fuel ratio, the O2
sensor helps improve fuel economy.
• Emission Reduction: Accurate readings allow for lower
emissions, contributing to environmental protection and
compliance with regulations.
• Engine Performance: Ensures smooth operation by
maintaining the correct mixture for combustion,
enhancing overall engine responsiveness and
performance.
Coordination
Heater SCR controller

Silicon Controlled Rectifier (SCR) controller is an electronic
device used to regulate the voltage supplied to electrical loads,
such as furnaces, by adjusting the power delivered to heating
elements.
Key Features
Voltage Control: Modulates the voltage to maintain desired
temperature levels in industrial applications.
Precision: Provides accurate temperature control, essential for
processes requiring strict thermal management.
Coordination
Gas Flow controller

In industrial furnaces, including those used in car
manufacturing, a gas flow controller is a critical component that
regulates the flow rate of gas into the combustion chamber.
Key Functions
• Efficient Combustion: Maintains optimal gas flow, ensuring
complete combustion and minimizing waste.
• Temperature Control: Adjusts gas flow to help achieve and
maintain desired temperature levels within the furnace.
• Safety Assurance: Prevents dangerous conditions by
ensuring proper gas flow and combustion ratios, enhancing
overall safety in the operation of industrial processes.
Coordination
PLC
In Maruti Suzuki, Programmable Logic Controllers (PLCs) are integral to automating and
controlling various aspects of the carburizing process in furnaces.
Key Utilizations
• Temperature Control:
PLCs regulate the internal temperature by managing heating elements for optimal heat
treatment.
• Process Sequencing and Timing:

They oversee the sequence of operations, including heating, soaking, and cooling stages,
ensuring precise control throughout the process.
• Gas Control:
PLCs manage the flow of gas into the furnace chamber, maintaining the required atmosphere
for carburizing by controlling gas valves and flow meters.
• Safety Monitoring and Alarming:

Continuous monitoring of safety parameters—such as temperature, pressure, and gas levels—
ensures safe operation, with alarms for any anomalies.
• Data Logging and Reporting:

PLCs log crucial data from sensors, tracking temperature profiles, cycle times, and alarm
events for operational insights.
• Remote Monitoring and Control:

Equipped with communication modules, PLCs allow for remote monitoring and control of
furnace operations, enhancing efficiency and response times.
FEATURES OF PID CONTROLLER
1. High Accuracy with Multi-Range Input
The system offers multi-range input capabilities, supporting thermocouple, resistance temperature detector
(RTD), DC voltage, and DC current inputs. With an accuracy of ±0.1% FS ± 1 digit and a sampling cycle of
0.1 seconds, it ensures consistently high-precision control for various applications.
2. Wide Range of Control Output Types

Multiple models support various control output types, including relay time proportional output, position-
proportional output, current output, voltage time-proportional output, and heat/cool output. Additionally,
models (excluding heat-cool control) feature neural net-based auto-tuning and smart-tuning to minimize
overshoot, alongside a 2 degrees of freedom PID control.
3. Enhanced Compatibility with PLCs

With 12 external switch inputs (eight optional), three event outputs, and five-time event outputs (optional),
the system ensures seamless integration with auto-mating systems based on PLC architecture.
4. Easy Operation
Users can register up to eight frequently changed parameter setups to the PARA key for easy recall. When
paired with the Smart Loader Package (sold separately), programs and parameters can be conveniently set
up via a personal computer.
The PID (Proportional-Integral-Derivative) controller
is a vital component in industrial control systems,
including those used in carburizing furnaces. By
effectively minimizing the error between a desired
setpoint and the actual process variable, PID
controllers ensure precise control of critical
parameters such as temperature and pressure.

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DEENBANDHU CHHOTU RAM UNIVERSITY OF SCIENCE AND

TECHNOLOGY , MURTHAL -131039

PROFESSIONAL TRAINING LEVEL-2

SUBMITTED IN THE PARTIAL FULFILLMENT FOR THE AWARD OF DEGREE OF BECHELORS IN

Role of the Transmission

Role of Gas Mixture and Temperature in the

The furnace atmosphere, primarily consisting of CO, H₂, and N₂, is

Continuous Control: Fine-tunes output to maintain the

Used in complex systems like industrial

Binary Control: Operates only in two states—on or off.

Suitable for simple systems like household appliances

• Integral Control (I):

• Derivative Control (D):

Applications in Car Manufacturing

Heater SCR controller

Gas Flow controller

• Process Sequencing and Timing:

• Safety Monitoring and Alarming:

• Data Logging and Reporting:

• Remote Monitoring and Control:

2. Wide Range of Control Output Types

3. Enhanced Compatibility with PLCs

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