TATA MOTORS LTD.

SUMMER TRAINING PROJECT REPORT ON

Installation of ABS (Anti-Lock Braking system) in two Vehicles (Bus)

24th May 2016 – 5th July 2016

Department: PLANNING

Under The Guidance of: Mr. Ritesh Srivastava(Asst. General Manager)Mr. Vipin C Jaiswal(Manager)Mr. Vishal Ranjan

(Asst. Manager)

Submitted by: ABHAY KUMAR VERMA

MOTILAL NEHRU NATIONAL INSTITUTE OF TECHNOLOGY, ALLAHABAD

ACKNOWLEDGEMENTWords fail to express my sincerest gratitude to this esteemed organization, which has conferred on us the privilege to pragmatically convert our theoretical knowledge into practical viable experience. During the course of my training at TATA MOTORS, LUCKNOW, many people have guided me and I will remain indebted to them throughout my life for making my training here a wonderful learning experience.

I wish to express my indebted gratitude and special thanks to my project guide, Mr. Ritesh Srivastava, Tata Motors Limited, Lucknow’ who inspite of being extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct path and allowing me to carry out my industrial project work in his department of PLANNING.

I express my deepest thanks to project mentor, Mr. Vipin C Jaiswal, and Mr. Vishal Ranjan, Tata motors Limited, Lucknow for taking part in useful decision & giving necessary advices and guidance and took keen interest in my project work. All that, I have acquired would not have been possible without the kind guidance of him.

I would also like to thank all my colleagues and the employees for supporting to complete my work and also help me to get a better knowledge.

The exposure to the working of the industry that I have got here would not have been possible without their support. My mentors took keen interest in my project and ensured that my tenure at TATA MOTORS is a fruitful experience for me. Without their help, it would have been an uphill task for me to complete the project successfully.

I perceive this opportunity as a big milestone in my career. I will strive to use gained skills and knowledge in the best possible way, and I will continue to work on their improvement, in order to attain desired career object.

Dated: 5th July, 2016 ABHAY KUMAR VERMA MNNIT, ALLAHABAD

Contents

INTRODUCTION...................................................................................................................................................4

TATA GROUP OF COMPANIES......................................................................................................................4TATA MOTORS.................................................................................................................................................5LUCKNOW PLANT...........................................................................................................................................6

PROJECT 1..............................................................................................................................................................8

NEW PRODUCT INTRODUCTION.................................................................................................................9NEED FOR NPI IN TATA MOTORS..............................................................................................................10ABS IMPLEMENTATION DATE...................................................................................................................10ANTILOCK BRAKE SYSTEM (ABS)............................................................................................................11GLOSSARY......................................................................................................................................................13

BOM..............................................................................................................................................................13ERC...............................................................................................................................................................14PLM..............................................................................................................................................................14PPAP.............................................................................................................................................................14SAP...............................................................................................................................................................15UPL...............................................................................................................................................................16

VLO................................................................................................................................................................16 IFD................................................................................................................................................................17 ICA.................................................................................................................................................................17 PCA...............................................................................................................................................................18 RISK MITIGATION SHEET...............................................................................................................................18 FLOW DIAGRAM............................................................................................................................................19

INTRODUCTION ABOUT PROJECT.........................................................................................................................20

PARTS OF ABS ................................................................................................................................................21PULSE WHEEL....................................................................................................................................................22WHEEL SENSOR..................................................................................................................................................24

FITMENT OF PULSE WHEEL AND SENSOR.........................................................................................................26 ECU....................................................................................................................................................................27

ABS INDICATOR LAMP.......................................................................................................................................30 TRACTION CONTROL SYSTEM.............................................................................................................................31

PROCEDURE FOLLOWED DURING PROJECT......................................................................................................33CONCLUSION.....................................................................................................................................................34

SUMMARY.........................................................................................................................................................35

INTRODUCTION

“A promise is promise and I kept my promise”- this is the historical statement which Mr. RATAN TATA said when he launched his ambitious TATA NANO; the people’s car in India on 13th March

Fig.1 Mr Ratan Tata 2009. Tata has always given value products in theIndian Car Market whether it is path breaking recently launched TATA NANO or TATA INDICA (which created great brand into the car industry in the diesel segment

TATA GROUP OF COMPANIES The Tata group’s core purpose is to improve the quality of life of the communities it serves globally, through long-term stakeholder value creation based on leadership with trust.

Founded by Jamsetji Tata in 1868, the Tata group is a global enterprise headquartered in India, and comprises over 100 operating companies, with operations in more than 100 countries across six continents, exporting products and services to over 150 countries. The revenue of Tata companies, taken together, was $103.27 billion around Rs624,757 crore) in 2013-14, with 67.2 percent of this coming from businesses outside India. Tata company’s employee over 581,000 people worldwide.

Fig.2 Mr Jamsetji Tata

Good corporate citizenship is part of the Tata group’s. Sixty-six percent of the equity of Tata Sons, the promoter holding company, is held by philanthropic trusts, thereby returning wealth to society. As a result of this unique ownership structure and ethos of serving the community, the Tata name has been respected for more than 140 years and is trusted for its adherence to strong values and business ethics. Tata Industries has initiated and promoted Tata ventures in several sectors, including control systems, information technology, financial services, auto components, advanced materials, telecom hardware, airlines and telecommunication services. In more recent times, its pioneering spirit has been showcased by companies such as TCS, India’s first software company, and Tata Motors, which made India’s first indigenously developed car, the Indica, in 1998 and recently unveiled the world’s lowest-cost car, the Tata Nano.

Areas of business:

Tata Industries has two operating divisions which function as independent profit centres: Tata Strategic Management Group: An independent management consulting division that assists Tata as well as non-Tata companies in enhancing their competitive edge.

Tata Interactive Systems: Among the world's leading e-learning organizations, it offers services such as project management, instructional design and graphics, and technical know-how.

Tata Motors makes passenger cars, multi-utility vehicles and light, medium and heavy commercial vehicles.

Passenger cars: compact Tata Indica in 1998, the sedan Indigo in 2002 and the station wagon Indigo Marina in 2004. Tata Motors also distributes Fiat’s cars in India.Utility vehicles: The Tata Sumo was launched in 1994 and the Tata Safari in 1998Commercial vehicles: The commercial vehicle range extends from the light two-tonne truck to heavy dumpers and multi-axle vehicles in the above 40-tonne segment. Passenger buses: The Company also manufactures and sells passenger buses, 12seaters to 60-seaters, in the light, medium and heavy segment.

TATA MOTORS Tata Motors Limited (formerly TELCO, short form for Tata Engineering and Locomotive Company) is an Indian multinational automotive manufacturing company headquartered in Mumbai, Maharashtra, India and a subsidiary of the Tata Group. Its products include passenger cars, trucks, vans, coaches, buses, construction equipment and military vehicles. It is the world's seventeenth-largest motor vehicle manufacturing company, fourth-

largest truck manufacturer and second- largest bus manufacturer by volume. Founded in 1945 as a manufacturer of locomotives, the company manufactured its first commercial vehicle in 1954 in collaboration with Daimler-Benz AG, which ended in 1969. Tata Motors entered the passenger vehicle market in 1991 with the launch of the Tata Sierra, becoming the first Indian manufacturer to achieve the capability of developing a competitive indigenous automobile.

In 1998, Tata launched the first fully indigenous car, the Indica, and in 2008 launched the Tata Nano, the world’s most affordable car. Tata Motors acquired the South Korean truck manufacture Daewoo Commercial Vehicles Company purchased Land Rover from Ford in 2008. Established in 1945, Tata Motors' presence indeed cuts across the length and breadth of India. Over 6.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company's manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat power trains. The company's dealership, sales, services and spare parts network comprises over 3,500 touch points. Tata Motors is also expanding its international footprint, established through exports since 1961. The company's commercial and passenger vehicles are already being marketed in several countries in Europe, Africa, the Middle East, South East Asia, South Asia, CIS, Russia and South America. It has franchisee/joint venture assembly operations in Bangladesh, Ukraine, and Senegal. The foundation of the company's growth over the last 66 years is a deep understanding of economic stimuli and customer needs, and the ability to translate them into customer-desired offerings through leading edge R&D. With over 4,500 engineers and scientists, the company's Engineering Research Centre, established in 1966, has enabled pioneering technologies and products. The company today has R&D centres in Pune, Jamshedpur, Lucknow, Dharwad in India, and in South Korea, Spain, and the UK.

Tata Motors is equally focused on environment-friendly technologies in emissions and alternative fuels. It has developed electric and hybrid vehicles both for personal and public transportation

LUCKNOW PLANTTata Motors, Lucknow is one of the youngest production

facilities among all the Tata Motors locations and was established in 1992 to meet the demand for Commercial Vehicles in the Indian market. The state of art plant is strongly backed by an Engineering Research Centre and Service set-up to support with latest technology and cater to the complexities of automobile manufacturing. Fully Built Vehicle business, which is one of the fast growing areas of our business, is also established in Lucknow.

The plant, rolls out commercial vehicles and is specialized in the designing and manufacturing of a range of modern buses which includes Low-floor, Ultra Low-floor, CNG & RE Buses. The Lucknow facility also specializes in manufacturing HCBS (High capacity Bus System) buses.

Fig.4 Tata Motors Ltd, main entry, Lucknow Plant

The HCV/MCV/LCV assembly line is semi-automated and is divided into 19 stations. Over these stations frame transforms to a full CV chassis.

The major facilities at the plant are:

Vehicle Factory - Assembly Plant for Trucks and Bus Chassis. There are total 3 assembly lines with two of them in Eastern Complex and one in Western Complex.

Integral Bus Factory - Assembly Plant for Module Buses catering to the needs of Tata Marcopolo Motors Limited and FBV operations.

Transmission Factory - Gear Parts, Crown wheel & Pinion and Heat Treatment facility.

Production Engineering Shop catering to the tool design and manufacturing needs.

A well established Training Centre through which around 500 apprentices are trained in various trades.

Engineering Research Centre with specific focus on buses, including a Digital prototyping lab, use of PLM software etc.

Service Training Centre providing training to drivers and technicians of the STU's

RECON Factory (for Reconditioning Business). The satellite plant of TMML which caters to the Hi-end

buses for the Northern Market.

State of the art facilities like the Paint Shop, BIW Shop and the TCF factory with automated lines have been benchmarked with the best in the world.

MODELS MANUFACTURED AT TATA MOTORS LUCKNOW: -

LCV (Light Commercial Vehicles) - GVW less than 10 tons.1. Truck Models- SFC 407 CNG, LPT 407, LPT 909 CNG.2. Bus Models- LP 407 CNG, LP 909 CNG, LP 709.

MCV (Medium Commercial Vehicles) - GVW 11 ton to 24 tons.

1. Truck Models- LPT 1613, LPT 1615 2.

2. Bus Models - LPO 1316 RHD, LPO 1316 LHD, LP 1512, LPO 1512, LPO 1612, LPO 1613, LPO 1613 CNG, LPK 1616, LPK 1618, LPO 1618 RHD,LPO 1618 LHD, LPO 1623 DTC CNG, LPO 1624, LPO 1628, LPO 1924.

HCV (Heavy Commercial Vehicles) - GVW 25 ton and above.

1. Truck Models- LPT 2518, LPK 2518, LPT 3118, LPS 3518, LPT 3723, LPS 4018

HR

Lucknow Works

Finance

Manufacturing Materials & Planning Central Plant Commercial NPI & TSSupply Chain Quality Services Services

Assy Assy Assy Weld Cab CowlLine 1 Line 2 Line 3 Shop Trim Trim

Assy Assy

Cowl IntegralTransmissi Paint AutoTrim Bus

MaintenancAssy EC Factory on Factory Shope

CX CXCX Heat CX

CV Module Module Treatment MachiningFabrication Assembly

Fig.5 Various departments at CVBU, Lucknow

Role of Planning Department

Planning, installation and commissioning of facility for improving line productivity, safety and quality.

Capital budgeting, facility, process planning and validation for NPI (New Product Introduction) in commercial vehicle segment.

PROJECT INSTALLATION OF ABS IN TWO VEHICLES

NEW PRODUCT INRODUCTION (NPI):

The new product introduction (NPI) is the process by which a new product idea is conceived, investigated, taken through the design process, manufactured, marketed and serviced. In the automotive industry, within the context of ISO/TS16949:2002 (the automotive quality management system international standard), these related to the product realization process (PRP) which consists of five phases: “Plan and Define Program”, “Product Design and Development”, “Process Design and Development”, “Product and Process Validation”, and “Production Launch, Feedback Assessment and Corrective Action”. These phases may be done concurrently and have correlated activities.

INTRODUCTION:

The product quality planning, which is sometimes used interchangeably with new product introduction (NPI), however, the second one seemed to represent the broader term, is the process by which a new product idea is conceived, investigated, taken through the design process, manufactured, marketed and serviced through obsolescence. The competitive advantage of a company can be linked to two key factors: (i) the ability to generate new intellectual property that offers superior value to customers and (ii) the ability to capitalize on it quickly. Superior quality and project management optimize the performance excellence of organizations, unfortunately, the combined leverage of quality and project management is often underutilized due to inadequate related knowledge and experience, time pressures or budgetary cutbacks. The quality planning road map is described as the activity determining customer needs and developing the products and

processes required meeting those needs. The Automotive Quality Management System (QMS) International Standard, ISOTS16949:2002, the particular requirements for the application of ISO 9001:2000 for automotive production and relevant service part organizations, defined “Product Realization Process (PRP)” as one of major parts of the standard, a useful framework for understanding the product quality planning in general. The methodology for managing new product introduction is defined as Advance Product Quality Planning (APQP), in the automotive supply chains. ISO/TS16949:2002 determines this as one of the means to achieve the PRP (NPI)’s objectives. Since it is published, the APQP play an important role in the automotive industry worldwide, especially in TATA Motors, as it appeared to be significantly practical to the NPI team. In other words, implementing the PRP without more specific methodology like APQP, especially for the local companies in India, result in less competitiveness to the market. The APQP embodies the concepts of error prevention and continual improvement in contrasted to error detection, and is based on a multidisciplinary approach. The APQP consists of five phases as follows:

Phase 1 - Plan & Define Program.

Phase 2 - Product Design and Development.

Phase 3 - Process Design and Development.

Phase 4 - Product and Process Validation.

Phase 5 - Production Launch, Feedback Assessment and Corrective Action.

In real practice, these phases may overlap and many tasks are done in parallel (concurrent engineering) to streamline and maximize resource utilization.

Fig.6 Advance Product Quality Planning (APQP)

Need for NPI in Tata Motors:

As per new CENTRAL MOTOTRS VEHICLE REGULATIONS (CMVR) Rule-96 ABS fitment has been made mandatory for all M3 (Buses) & N3 (Goods) category of vehicles manufactured on & after, as per final notification GSR 389(E) dated 9th June 2014.

M3 category: A vehicle used for the carriage of passengers, comprising nine or more seats in addition to the driver’s seat and having a GVW exceeding 5 ton

N3 category: A vehicle used for the carriage of goods and having a GVW exceeding 12 tons.

ABS Implementation date:

New models of M3 and N3 categories of vehicles manufactured on and after the :1st April 2015

Existing models of M3 and N3 categories of vehicles manufactured on and after the :1st Oct 2015

Due to new CMVR Rules, following is the distribution of the Vehicles affected produced in the Lucknow Plant.

10 | P a g e

ANTI-LOCK BRAKING SYSTEM (ABS):

The braking system of any vehicle must be capable of slowing and stopping the vehicle safely within reasonable limits. Our present Air brake system for heavy commercial vehicles fulfils this by generating adequate brake torque to arrest the wheel rotation while braking. Safe braking of heavy vehicles not only depends on brake system but also on control of acceleration, road condition and steering inputs given by driver. A good driver keeps a sharp eye on traffic and road conditions anticipating any changes well before they occur and tries to make appropriate control to avoid any unsafe condition while riding or braking. However, during a panic braking situation even an experienced driver can over-brake the vehicle causing wheel lock up especially on slippery roads. This causes skidding and even makes the vehicle to go out of driver's control often causing accidents. Many of us would have experienced this skidding in a two-wheeler or car while applying sudden brake. In order to stop the vehicle during hard-braking without losing stability, the brakes must apply quickly, at the same time they must release quickly so that a driver can quickly regain control in the event of a wheel getting locked and starts to skid.

Incorporation of Antilock brake system over the conventional brake system prevents this wheel locking thereby avoids skidding thus ensuring stability of vehicle. A brake is one of the most important parts of any type of vehicle. Brake is used to retard or stop a vehicle. Here Kinetic energy is transferred into Heat energy. The kinetic

energy increases with the square of the velocity. So, K.E.=1/2mv².An anti-lock braking system is a safety system that allows the wheels on a motor vehicle to continue interacting tractively with the road surface as directed by driver steering inputs while braking, preventing the wheels from locking up (that is, ceasing rotation) and therefore avoiding skidding.

Stopping a car in a hurry on a slippery road can be very challenging. Anti-lock braking systems (ABS) take a lot of the challenge out of this sometimes nerve-wrecking event. In fact, on slippery surfaces, even professional drivers can't stop as quickly without ABS as an average driver can with ABS.

An ABS generally offers improved vehicle control and decreases stopping distances on dry and slippery surfaces for many drivers; however, on loose surfaces like gravel or snow-covered pavement, an ABS can significantly increase braking distance, although still improving vehicle control. Since initial widespread use in production cars, anti-lock braking systems have evolved considerably. Recent versions not only prevent wheel lock under braking, but also electronically control the front-to-rear brake bias.

ABS Operation:ABS operation can be broken down into three stages or functions.

Data Inputs Data Processing Output or Control Actions

Inputs Processing OutputFig.7 Stages for ABS operation

Fig.8 ABS implementation flow chart

Data inputs are the wheel speed signals generated by sensors fitted in each wheel, switches and diagnostic equipment’s. The data inputs are sent to the Electronic Control Unit (ECU) where the signals are interpreted and operating strategy is determined. The final output commands are sent from ECU to the system components such as valves, lamps etc.

ABS takes over control of the air pressure whenever a wheel starts to lock up. Sensors continuously monitor wheel speed and send this information to an Electronic Control Unit (ECU). When a wheel starts to lock, the ECU, using the wheel-speed information and programmed data, sends output signals to control the operation of the ABS valves. The ECU causes the ABS valves to adjust air pressure supplied to the brake chambers to control braking and prevent wheel lockup.

A typical ABS includes a central electronic control unit (ECU), four-wheel speed sensors, and at least two hydraulic valves within the brake hydraulics. The ECU constantly monitors the rotational speed of each wheel; if it detects a wheel rotating significantly slower than the others, a condition indicative of impending wheel lock, it actuates

the valves to reduce hydraulic pressure to the brake at the affected wheel, thus reducing the braking force on that wheel.

The wheel then turns faster. Conversely, if the ECU detects a wheel turning significantly faster than the others, brake hydraulic pressure to the wheel is increased so the braking force is reapplied, slowing down the wheel. This process is repeated continuously and can be detected by the driver via brake pedal pulsation. Some antilock system can apply or release braking pressure 16 times per second.

The ECU is programmed to disregard differences in wheel rotation speed below a critical threshold, because when the car is turning, the two wheels towards the center of the curve turn Slower than the outer two. For this same reason a differential is used in virtually all raod going vehicles. If a fault develops in any part of the ABS, a warning light will usually be illuminated on the vehicle instrument panel, and the ABS will be disabled until the fault is rectified.

The modern ABS applies individual brake pressure to all four wheels through a control system of hub-mounted sensors and a dedicated micro-controller. ABS is offered or comes standard on most road vehicles produced today and is the foundation for ESC systems, which are rapidly increasing in popularity due to the vast reduction in price of vehicle electronics over the years. Modern electronic stability control (ESC or ESP) systems are an evolution of the ABS concept. Here, a minimum of two additional sensors are added to help the system work: these are a steering wheel angle sensor, and a gyroscopic sensor. The theory of operation is simple: when the gyroscopic sensor detects that the direction taken by the car does not coincide with what the steering wheel sensor reports, the ESC software will brake the necessary individual wheel(s) (up to three with the most sophisticated systems), so that the vehicle goes the way the driver intends. The steering wheel sensor also helps in the operation of Cornering Brake Control (CBC), since this will tell the ABS that wheels on the inside of the curve should brake more than wheels on the outside, and by how much.

The ABS equipment may also be used to implement a traction control system (TCS) on acceleration of the vehicle. If, when accelerating, the tire loses traction, the ABS controller can detect the situation and take suitable action so that traction is regained. More sophisticated versions of this can also control throttle levels and brakes simultaneously.

GLOSSARY

BOM: BOM or bill of material is a list of raw materials , sub assembe mblies

Intermediate assemblies , sub component parts and quantttities of eachNeeded to manufacturing partners, or confined to a single manufacturing plant. It can define products as they are designed, as they are ordered, as they are built, or as they are maintained (service bill of materials or pseudo bill of material). The different types of BOMs depend on the business need and use for which they are intended.

ERC: The Engineering Research Centre (ERC) is the R&D Department of Tata Motors and is behaviour of activity where engineers and designers work on 20 different engine platforms with 250 variants of vehicles. It is one of the most modern in the Indian automobile industry, featuring state-of the-art equipment and facilities such as a noise, vibration and harshness (NVH) lab and a crash test lab. The ERC has come a long way from the time it was set up in 1966, just three years before the collaboration between Telco (as Tata Motors was known then) and Daimler-Benz AG was to end. It is responsible for the Design and Development of new parts and products and carrying out Research on existing facilities and models for further improvement. They are also required to release detailed technical drawings of their projects and models for better understanding of the technical staff.

PLM: Product lifecycle management (PLM) is an information

management system that can integrate data, processes, business systems and, ultimately, people in an extended enterprise. PLM software allows you to manage this information throughout the entire lifecycle of a product efficiently and cost effectively, from ideation, design and manufacture, through service and disposal. Diverse functions and technologies converge through PLM, including:

Product data management (PDM) Computer-aided design (CAD) Computer-aided manufacturing (CAM) 3D computer-aided engineering (CAE) and simulation Finite element analysis (FEA) Modal testing and analysis Digital manufacturing Manufacturing operations management (MOM)

Fig.10 PLM ScreenShot

PPAP: Production Part Approval Process (PPAP) is used in the automotive supply chain for establishing confidence in component suppliers and their production processes, by means of demonstrating that “all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.”

The PPAP process is designed to demonstrate that the component supplier has developed their design and production process to meet the client's requirements, minimizing the risk of failure by effective use of APQP. Requests for part approval must therefore be supported in official PPAP format and with documented results when needed. The result of this process is a series of documents gathered in one specific location (a binder or electronically) called the "PPAP Package". The PPAP package is a series of documents which need a formal approval by the supplier and customer. The form that summarizes this package is called PSW (part submission warrant). The approval of the PSW indicates that the supplier responsible person (usually the Quality Engineer) has reviewed this package and that the customer has not identified any issues that would prevent its a SAP.

SAP: SAP stands for Systems Applications and Products and is a

German multinational software company known for making enterprise resource planning (ERP) software. ERP software allows organizations to manage business operations, and usually refers to suite of modular applications that collect and integrate data from different aspects of the business.

SAP is an ERP system provided by the SAP Company that handles almost all departments of organizations. SAP handles an organization's Finance, Controlling Human Resource, Sales, Distribution, Material management, Warehouse, Production, Security, Research and many other departments.

Fig.11 Systems Applications and Products

UPL: Unique Parts List (or UPL) is a subset of BOM. It is the list of

the raw materials, sub-assemblies, intermediate assemblies, sub- components and parts which are unique with respect to a vehicle model. These parts are either a part of any other model or may be a new fresh part that needs to be ordered from a new supplier or an existing one. UPL is created to classify the parts for if their Development is required (i.e. when they are new to the vehicle and not been manufactured in the plant earlier or procured from a supplier which means their Purchase Order was not available) and if their Purchase order is available, then to distribute its Share of Business (SOB among the different suppliers.

e

Fig.12 UPL Screenshot

INFO FITMENT DRAWING (IFD):

These drawings are released by the ERC (Engineering research centre) and can be download by PLM software. IFD’s are used for knowing the parts fitment position and how that part will be fitted on vehicle. What is the routing of wire harness? And how many clamps should be used for holding that component? these all information is taken by the IFD’s.

Fig. 13 screenshot of info fitment drawing (tail wiring and abs connection)

VLO: VLO stands for vehicle lay out. After roll out the vehicle Quality Engineering Department conform the vehicle with the drawings and make a report of defects in that vehicle according to the drawing like – some parts are missing which is in drawing but not fitted in vehicle, some parts are not fitted as per the drawing. This report is called VLO report. Quality engineering department gives some pointers to every defect according to their critical parameters. Pointers ranges between 10 to 100. Every 40 and 100 pointer defects are said to be very critical issues. All 40 and 100 pointer issues should be closed before VLO closure.

Fig. screenshot of VLO report

TMPS: TMPS means TATA Motors Production System. According to this there may many critical issues beyond the drawings i.e. pipe fouling, AC pipe and fuel pipe is tied together. These are many critical issues which are not shown in drawings. So these issues are listed under the TMPS. These also should be closed before VLO closure.

ICA: ICA stands for Immediate Corrective Action. After getting the VLO report from the CQ department, Planning department has to work on that issues which are described in report.Vehicle goes in R1 area and rework has been performed there under the guidance of planning staff. All the issues are corrected there and again CQ conform this vehicle and gave the pointers. This process will not be completed until the total score of TMPS and VLO does not become under 400 and all the 40 and 100 pointer issues must be closed.

PCA: Permanent Corrective Action that means which issues had corrected from the VLO and TMPS report, now are going to be as PCA. All the issues are informed to the respective departments that these issues should not be repeated in the future vehicle of same model, and get the signature of respective officers.

RISK MITIGATION SHEET: This sheet is prepared by Launch Quality Department, because there are many technical risk after the rework.That may be Wheel Base or Locking angle, Max. torque. This department conform the data provided by ERC in the form of VPN (Vehicle Pass of Norms) to the roll out vehicle and prepared a risk mitigation sheet. After that planning department again make correction in that vehicle and send the report to all the department. After taking the signature from all the departments and being confirmed that vehicle can be dispatched with theses left little risk, vehicle is dispatched.

Fig. screenshot of risk mitigation sheet

FLOW DIAG. OF ALL THE WORKS DURING NEW PRODUCT INTRODUCTION

fig. 13 flow diagram

INTRODUCTION ABOUT PROJECT:

To Study about the ABS and work with the team in installation of ABS in vehicle: LP 1512/42 WB MSRTC LPO 1512/53 WB SBSTC

Parts of ABS:

PULSE WHEEL: Each speed sensor usually has a pulse wheel (toothed wheel), like a gear, that rotates at the same speed as the vehicle wheel or axle.

fig.14 pulse wheel or toothed wheel

Wheel Speed Sensor: A wheel speed sensor or vehicle speed sensor (VSS) is a type of tachometer. It is a sender device used for reading the speed of a vehicle's wheel rotation. It usually consists of a toothed ring and pickup. Wheel speed sensors are installed directly above the pulse wheel, which is connected to the wheel hub or the drive shaft. The pole pin inside a coil is connected to a permanent magnet and the magnetic field extends to the pulse wheel. The rotational movement of the pulse wheel and the associated alternation of teeth and gaps effects a change in the magnetic flux through the pulse wheel and the coil. The changing magnetic field induces an alternating voltage in the coil that can be measured. The frequencies and amplitudes of the alternating voltage are related to the wheel speed. Passive inductive sensors do not need a separate power supply from the control unit.

fig. 15-wheel speed sensor

fig. 16 setup of sensor with pulse wheel

ELECTRONIC CONTROL UNIT (ECU):

The ECU connects to the following ABS components: wheel speed sensors, ABS modulator valves, power source, ground, warning lamps, blink code switch, diagnostic connector, and retarder control device. During braking, the ECU uses voltage pulses from each wheel speed sensor to determine wheel speed changes. If the ECU determines that the pulse rate of the sensed wheels indicates imminent lock-up, it cycles the ABS modulator valves to modify brake air pressure as needed to provide the best braking possible. The ECU sends signals to the ABS malfunction indicator lamp or blink code lamp to communicate ABS faults. It also sends signals to the retarder control to disengage the retarder when the ABS is working. When the ABS stops modulating the brake pressure, the ECU permits retarder use once again.

fig. 17 flow dig. ECU

MODULATOR VALVE:

ABS modulator valves regulate the air pressure to the brakes during ABS action. When not receiving commands from the ECU, the modulator valve allows air to flow freely and has no effect on the brake pressure. The ECU commands the modulator valve to either:

Change the air pressure to the brake chamber, or Hold the existing pressure.

However, it cannot automatically apply the brakes, or increase the brake application pressure above the level applied by the driver. The modulator valve typically contains two solenoids. The modulator valve and relay valve may be incorporated into a single unit. The modulator valve may also be separate, inserted into the service line to the brake chamber(s) after any relay valve, located as close as practicable to the chamber(s) itself. When the modulator valve is separate, it has to control more air flow and, therefore, includes two larger diaphragm valves which are controlled by the solenoids. It usually has three ports: the supply port, the delivery port and the exhaust port

The supply port receives air from a quick release or relay valve.

The delivery port sends air to the brake chambers. The exhaust port vents air from the brake chamber(s).

Typically, when an ECU controlling a separate modulator valve detects impending wheel lockup, it activates the solenoids to close the supply port and open the exhaust port. When enough air is vented to prevent wheel lockup, the exhaust valve will close and the ECU will - depending on the situation - either:

Keep the supply port closed to maintain existing pressure, Open the supply port to allow brake application pressure to

increase and repeat the cycle.

fig.18 modulator valve fitted at the cross member

ABS Malfunction Indicator Lamp: Indicator lamp are required to light up for short periods of time for a bulb check whenever the ABS starts to receive electrical power. In-cab ABS indicator lamps are typically located on the instrument panel.

fig.19 ABS indicator lamp on

TRACTION CONTROL SYSTEM:

Traction control systems are designed to prevent wheel spin in the power mode. Traction control attempts to regain traction by braking the spinning wheels, and sometimes throttling back engine power. Unlike an ABS, traction control can automatically apply the brakes. The driver

does not need to depress the brake pedal for traction control to engage. Traction control electronics are integrated into the ABS ECU. The system applies the brakes on the spinning wheel’s when the wheel speed sensors tell the ECU that a wheel is accelerating at a much faster speed than the wheel on the other end of the axle. It does this by energizing a solenoid valve, which directs reservoir pressure to the relay valve and simultaneously activates the modulator valves to keep air pressure from the brake chambers. The ECU then directs the modulator valve to open, and pulse air into the brake chamber on the spinning wheel until wheel speed balance is regained. On some systems, the ECU will throttle back engine power if both wheels are spinning too fast. If all the drive wheels on a tractor are spinning too fast, the tractor can become unstable, spin or jack knife. Traction control is especially valuable when a light drive wheel load might allow the wheels to spin under power, or when a tractor is pulling multiple trailers.

Traction control systems are designed to prevent wheel spin in the power mode.

Unlike an ABS, traction control can apply the brakes automatically. The driver does not need to depress the brake pedal for traction control to engage.

Traction control is not required by law, but it is a common ABS option.

PROCEDURE FOLLOWED DURING PROJECT:

study and analyze the working of ABS. understand the process of new product introduction. Work in the team for installation of ABS in two vehicles

LP 1512/42 WB MSRTC, LPO 1512/53 WB SBSTC We have to close all the all the severe point from the VLO

report which was provided by the CQ department. After the closure of VLO we have to work on risk

mitigation list. Finally, the closure of VLO report and risk mitigation report

has been done, and now the vehicle is ready to dispatch.

CONCLUSION: Concluding the project, I had worked on

understanding the challenges faced by staffs in installation of ABS and came up with suggestions which I hope would be helpful improving the further operations.

SUMMARY

The entire training period at TATA Motors, Lucknow was a memorable experience for me. This experience gave me a deeper insight into the work culture of the company. I greatly value the project undertaken by me during this period since this proved to be extremely enlightening. The project gave me an opportunity to work in the industrial environment. My project head was extremely helpful and guided me throughout the period. I cherish the experience gained by me during this endeavour and hope this would be of great help in future. I also owe a lot to our fellow trainees and other employees in this facility that were extremely supportive and made my training experience here very enlightening as well as enjoyable.

Finally, I would like to thank Mr. Prashant Pandey for having given us this wonderful opportunity.