Kk Project

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PROJECT REPORT

Development of Automatic ON-OFFSystem for various Electrical Equipmentsof Paint Touchup Zone

at

TATA MOTORS LIMITED, LUCKNOW

Submitted by

K AANCHAN K RISHNAB.Tech. 3 rd Year Electrical & Electronics Engineering

Northern India Engineering College, LucknowSummer Trainee

Cowl-Cx Assy

Under the Guidance of

Mr. Ritesh SrivastavaDiv. Manager [Cowl-Cx Assy]

Project Duration

13 th June 2012 11 th July 2012

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TABLE OF CONTENTS

S.No.

Content PageNo.

1 Declaration 32 Certificate 43 Acknowledgement 54 TATA MOTORS- An Introduction 65 TATA Journey-Year by year 76 TATA MOTORS (Lucknow Plant) 107 Organization Structure of Lucknow Plant 118

Organization Structure Of Trim cx12

9Divisions of Tata Motors Lucknow

13

10 My department Cowl Shop 1711 Process Flow for Manufacturing of Cowls 1812 Project: Development of Automatic ON-OFF System for

various Electrical Equipments of Paint Touchup Zone

21

13 Summary 35

DECLARATION

I KAANCHAN KRISHNA hereby declare that the project work

entitled Development of Automatic ON-OFF System for

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various Electrical Equipments of Paint Touchup Zone is an

authentic record of my own work carried out at TATA MOTORS,

LUCKNOW as requirements of 4 weeks project during trainingunder the guidance of MR. RITESH SRIVASTAVA DIV. MANAGER

(COWL-CX-TRIM ASSY ).

KAANCHAN KRISHNA

(SUMMER TRAINEE)

COWL-CX ASSY.

Date: 11 TH -JULY-2012

I certify that the above statement made by the student iscorrect to the best of our knowledge and belief.I wish him every success in life.

Mr. Ritesh Srivastava

(DIV.

Manager, COWL-CX ASSY) Tata Motor Ltd., Lucknow

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CERTIFICATE

I, RITESH SRIVASTAVA (Div. MANAGER TRIMLINE), HEREBY DECLARE THAT KAANCHAN

KRISHNA of B.Tech. 3 rd Year Electrical &

Electronics Engineering HAS COMPLETED HIS

PROJECT ON Development of Automatic ON-

OFF System for various Electrical Equipments

of Paint Touchup Zone DURING THE ACADEMIC YEAR 2012-13.THE INFORMATION SUBMITTED IS

TRUE AND ORIGINAL TO THE BEST OF MY

KNOWLEDGE.

Mr. RITESH SRIVASTAVA(Div. Manager,

COWL-CX ASSY.)

Ms. JASNEET RAKHRA(Manager, HR)

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ACKNOWLEDGEMENT

Industrial training is a crucial period in

engineering curriculum since it exposes a student to

the real world which he or she is going to enter afterthe completion of the Diploma. This is the period during

which an engineer actually becomes an engineer by

gaining the Industrial experience. I am extremely

happy that I was given the opportunity to get training

in TATA MOTORS, LUCKNOW one of the most

renowned organization of India.

I would like to take the opportunity to thank my

Project Head MR. RITESH SRIVASTAVA (Sr.

Manager, CX TRIM ASSY) for having provided me

with the wonderful & conductive environment to work

in. He has been ever helpful and supportive.

I would like to thank Ms. JASNEET RAKHRA

(Manager HR) for providing me the opportunity to adda new dimension to my personality. I will remain

indebted to her for her generous way of dealing with

industrial trainees.

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Kaanchan Krishna

(Summer Trainee)

Cowl-Cx Assy

AN INTRODUCTION

Type : Public (BSE: 500570 )

(NYSE: TTM)

Industry: Automotive

Founded: 1945

Founder(s): JRD Tata

Headquarters: Mumbai , Maharashtra ,

India

Key people: Ratan Tata , Chairman

Ravi Kant , Vice

Chairman

Carl Peter Forster , CEO

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http://en.wikipedia.org/wiki/Types_of_business_entityhttp://en.wikipedia.org/wiki/Public_companyhttp://en.wikipedia.org/wiki/Bombay_Stock_Exchangehttp://www.bseindia.com/bseplus/StockReach/AdvanceStockReach.aspx?scripcode=500570http://en.wikipedia.org/wiki/New_York_Stock_Exchangehttp://www.nyse.com/about/listed/quickquote.html?ticker=ttmhttp://en.wikipedia.org/wiki/Automotive_industryhttp://en.wikipedia.org/wiki/JRD_Tatahttp://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Maharashtrahttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Ratan_Tatahttp://en.wikipedia.org/wiki/Ravi_Kanthttp://en.wikipedia.org/wiki/Carl_Peter_Forsterhttp://en.wikipedia.org/wiki/Types_of_business_entityhttp://en.wikipedia.org/wiki/Public_companyhttp://en.wikipedia.org/wiki/Bombay_Stock_Exchangehttp://www.bseindia.com/bseplus/StockReach/AdvanceStockReach.aspx?scripcode=500570http://en.wikipedia.org/wiki/New_York_Stock_Exchangehttp://www.nyse.com/about/listed/quickquote.html?ticker=ttmhttp://en.wikipedia.org/wiki/Automotive_industryhttp://en.wikipedia.org/wiki/JRD_Tatahttp://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Maharashtrahttp://en.wikipedia.org/wiki/Indiahttp://en.wikipedia.org/wiki/Ratan_Tatahttp://en.wikipedia.org/wiki/Ravi_Kanthttp://en.wikipedia.org/wiki/Carl_Peter_Forster


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Prakash Telang, MD

(India Operations)

Ravi Pisharody,President (CVBU)

Products: * Automobiles

* Engines

Services: Outsourced

Engineering and Design

Revenue: $20.572 billion (2010)

Net income : $844 million (2010)

Total assets : $20.192 billion (2010)

Total equity : $2.224 billion (2010)

Employees: 50,000 (2010)

Parent : Tata Group

TATA JOURNEY YEAR BY YEAR:

1868: Jamsetji Nusserwanji Tata starts a privatetrading firm, laying the foundation

Of the TATA group.

1874: The Central India Spinning, Weaving andManufacturing Company are set up,marking the Group's entry into textiles.

1902: The Indian Hotels Company is incorporated toset up the Taj Mahal Palace and Tower, India's firstluxury hotel, which opened in 1903.

1907: The Tata Iron and Steel Company (now TataSteel) is established to set up India's first iron and steel

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http://en.wikipedia.org/wiki/Automobileshttp://en.wikipedia.org/wiki/Engineshttp://en.wikipedia.org/wiki/Outsourcinghttp://en.wikipedia.org/wiki/Engineeringhttp://en.wikipedia.org/wiki/Designhttp://en.wikipedia.org/wiki/Net_incomehttp://en.wikipedia.org/wiki/Assethttp://en.wikipedia.org/wiki/Equity_(finance)http://en.wikipedia.org/wiki/Holding_companyhttp://en.wikipedia.org/wiki/Tata_Grouphttp://en.wikipedia.org/wiki/Automobileshttp://en.wikipedia.org/wiki/Engineshttp://en.wikipedia.org/wiki/Outsourcinghttp://en.wikipedia.org/wiki/Engineeringhttp://en.wikipedia.org/wiki/Designhttp://en.wikipedia.org/wiki/Net_incomehttp://en.wikipedia.org/wiki/Assethttp://en.wikipedia.org/wiki/Equity_(finance)http://en.wikipedia.org/wiki/Holding_companyhttp://en.wikipedia.org/wiki/Tata_Group


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plant in Jamshedpur. The plant started production in1912.

1910: The first of the three Tata Electric Companies, The Tata Hydro-Electric Power Supply Company, and(now Tata Power) is set up.

1911: The Indian Institute of Science is established inBangalore to serve as a centre for advanced learning.

1912: Tata Steel introduces eight-hour working days,well before such a system was implemented by law inmuch of the West.

1917: The Tatas enter the consumer goods industry,with the Tata Oil Mills Company being established tomake soaps, detergents and cooking oils.

1932: Tata Airlines, a division of Tata Sons, isestablished, opening up the aviation sector in India.

1939: Tata Chemicals, now the largest producer of soda ash in the country, is established.

1945: Tata Engineering and Locomotive Company(renamed Tata Motors in 2003) is established tomanufacture locomotive and engineering products.

Tata Industries is created for the promotion anddevelopment of hi-tech industries.

1952: Jawaharlal Nehru, India's first Prime Minister,requests the Group to manufacture cosmetics in India,leading to the setting up of Lakme.

1954: India's major marketing, engineering andmanufacturing organization, Voltas, is established.

1962: Tata Finlay (now Tata Tea), one of the largesttea producers, is established. Tata Exports isestablished. Today the company, renamed TataInternational, is one of the leading export houses inIndia.

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1968: Tata Consultancy Services (TCS), India's firstsoftware services company, is established as a divisionof Tata Sons.

1970: Tata McGraw-Hill Publishing Company is createdto publish educational and technical books. TataEconomic Consultancy Services is set up to provideservices in the field of industrial, marketing, statisticaland techno-economic research and consultancy.

1984: Titan Industries - a joint venture between the Tata Group and the Tamil Nadu Industrial DevelopmentCorporation (TIDCO) - is set up to manufacture

watches.

1991: Tata Motors rolls out its millionth vehicle. (Thetwo-million mark was reached in 1998 and the thirdmillion in 2003.)

1995: Tata Quality Management Services institutes the JRD QV Award, modelled on the Malcolm BaldrigeNational Quality Value Award of the United States,laying the foundation of the Tata Business ExcellenceModel.

1996: Tata Tele services (TTSL) is established tospearhead the Group's foray into the telecom sector.

1998: Tata Indica - India's first indigenously designedand manufactured car is launched by Tata Motors,spearheading the Group's entry into the passenger carsegment.

1999: The new Tata Group corporate mark and logoare launched.

2000: Tata Tea acquires the Tetley Group, UK. This isthe first major acquisition of an international brand byan Indian business group.

2001: Tata-AIG - a joint venture between the TataGroup and American International Group Inc (AIG) -marks the Tata re-entry into insurance. (The Group's

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insurance company, New India Assurance, wasnationalized in 1956). The Tata Group ExecutiveOffice (GEO) is set up to design and implement change

in the Tata Group and to provide long-term direction.2002: The Tata Group acquires a controlling stake inVSNL; India's leading international telecommunicationsservice provider Tata Consultancy Services (TCS)becomes the first Indian software company to crossone billion dollars in revenues. Titan launches Edge, theslimmest watch in the world. Idea Cellular, the cellularservice born of a tie-up involving the Tata Group, theBirla Group and AT&T, is

Launched. Tata Indicom, the umbrella brand fortelecom services from the Tata Tele services stable,starts operations.

2003: Tata Motors launches City Rover Indicasfashioned for the European market. The first batch of City Rovers rolled out from the Tata Motors stable inPune on September 16, 2003.

2004: Tata Motors acquires the heavy vehicles unit of Daewoo Motors, South Korea. TCS goes public in July2004 in the largest private sector initial public offering(IPO) in the Indian market, raising nearly $1.2 billion.

2005: Tata Steel acquires Singapore-based steelcompany NatSteel by subscribing to 100 per centequity of its subsidiary, NatSteel Asia.

2009: Tata Motors launched Tata Nano, worldscheapest family car.

2010: Tata Ace becomes India's first 1-lakh brand in

goods commercial vehicles. Appointment of Mr. Carl-Peter Forster as

Managing Director of Tata Motors. Jaguar Land Rover announces opening of its

Dealership in New Delhi. Tata Motors to construct heavy truck plant in

Myanmar under Government of India's Line of Credit.

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Tata Motors declared as the Commercial VehicleMaker of the Year.

Chief Minister of Punjab inaugurates

Tata Motors supported State Instituteof Automotive and Driving Skills. Jaguar Land Rover announces

Dr. Ralf Speth as Chief Executive Officer. Tata Motors appoints Mr. Carl-Peter Forster as

GroupCEO. Tata Motors Group displays the widestrange of products and environment-friendlytechnologies at Auto Expo 2010.

Tata Motors launches Magic Iris. On 26th April

2010, Tata Motors soldits 4 millionth Commercial Vehicle. Tata Motors Passenger Car Division launches

Tata Motors Service Edge' for leading edgecustomer service.

Tata Motors displays Tata Nano EV atthe 80th Geneva Motor Show.

TATA MOTORS LTD. (LUCKNOW PLANT)

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Year of commencement: 1991

Plant Area: 600 acresNumber of employees 835

DivisionsBIW, Paint,

Assembly Training

TATA MOTORS Lucknow Works is a

third manufacturing unit of Tata Engineering and

Locomotive Company. This unit covers an area of 600 acres.In this unit the assembly of chassis and spare parts takes

place. On 14th January 1992 the recruitment of operators

started in Lucknow plant. On 25th June induction of

Engineers (first phase) started which also included ITI's and

Occupancy of administration office of assembly shop in

September 1992. First vehicle rolled out from Lucknow plant

on 20th October 1992 which was LP 1210 52. Constructionof MRS finished on 6th January 1993. It took approximately

9 years since the conception of the plan and to rollout the

first vehicle from this latest manufacturing facility of Tata

Motors.

ORGANIZATION STRUCTURE (Lucknow Plant)

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Organization Structure Of Trim cx

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Alok SaxenaPLANT HEAD

Umair TauheedA.G.M Trim

Assy/Weld Shop

S.N.VermaA.G.MManufacturing

Ritesh SrivastavaProcess Owner TrimCX-1

Mandar Puranik Process Owner CV-CX

Sunil KumarProcess Owner FramCX

Alok SaxenaPlant Head

Umair TauheedA.G.M Trim

Assy./Weld Shop

Ritesh SrivastavaProcess Owner

SHANTI SHAW/ N.L.Mishra

UMESH SHUKLAMANAGER

NARENDRAKUMAR/D.Chaudhary

NALIN KUMARASST..MANAGER

Navyug Navodaya Navshakti Navjeevan

1. Vijay Kumar2. Abraham K.G.

3. A.K.Shukla4. Anand Singh

5. ChandenSingh

6. G.D.Bhatt7. Rajendra

Singh8 B.N.Godwami

9. U.P.Singh10.Bagisg Prasad

1. A.K.Sahi2. Man Singh3. A.K.Srivastava4. V.S.Nagi5. Jai Kishor6. D.Vishwakarma7. M.S. Rawat8. P.K.Singh9. A. N. Dubey10.P.C. Ram

1. Nand Kishor2. Gauri Dutt3. D.Mathpal4. Chhabi Nath5. Mahesh Dutt6. Krishna Kumar7. B.S.Sajwan8. Moti Lal9. Rakesh10.VikashChandra11. Ram Taj

1.RameshChandra2.Balendra Singh3.M.K.Mishra4.M.K.Sharma5.Mukesh Katyer6. Budh Singh7. A.K.Tripathi8. R.K.Chaudhary9. Rajesh Kumar10. SanjayKumar

11. ArvindKumar12.J.C.Gupta


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Divisions of TATA Motors Lucknow:

Training division

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The Training Center at the Lucknow plant aims atproviding high quality Apprenticeship Training. In addition,

the Centre provides both internal and external training,

support to operators, supervisors and managers in areas

like special skills and technology, safety, personnel

practices etc.

The Lucknow plant, after a major restructuring

exercise, executed a smooth transition from function-based

to process-based structure. By this structure, process

owners are required to meet stretched targets, and in orderto do so, are required to encourage individual learning and

development of employees. A structured process is being

followed to establish and reinforce an environment that

encourages innovation.

Assembly division

Lucknow Plant started with the assembly of

Medium Commercial Vehicles (MCVs) to meet the demand

in the Northern Indian market. However, in 1995, the unit

started manufacturing bus chassis of Light Commercial

Vehicles (LCVs) and SUMOs. The facilities for manufacturing

the spare parts were set up and started supply of Crown

wheel & pinion (CWP) in 1994. Subsequently, G-16 & G-18

Gear Parts started in 1998. With the availability of G-16

gear parts manufacturing facility, the Plant also started

assembly of G-16 Gear Box to meet in-house requirement

for SUMO vehicles in the year 2000.Now TATA Motors

Lucknow has started assembling of CNG MCV`s to meet the

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consumers demand. TATA Motors is also producing Rear

Engine CV`s.

Manufacturing Division

In TATA Motors Lucknow Crown Wheel and Pinion are

manufactured by various gear cutting process. Machining

(grinding and heat treatment) of Gear Box parts is Aalso

done here. These gears are used in gear boxes or as spares.

Now TATA Motors is assembling Gear Box of ACE (Newly

launched small CV) in Lucknow itself. The Manufacturing

unit of Tata Motors at Lucknow is the latest manufacturing

facility of Tata motors and is located towards East of Lucknow plant.

There are five factories in Tata Motors, Lucknow:

- CV-CX (Commercial Vehicle) Factory

- Transmission Factory

- TATA MARKOPOLO MOTORS Limited

- Integral Bus Factory (IBF)- RECON Factory

Departments in TATA Motors Lucknow are:

Planning

Technical services

Central tool room

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Central procurement

Dispatch

Central logistics

Factory logistics group-CV

Factory logistics gear-transmission

Factory logistics Gr-sumo

SQIG

Engineering services

Central maintenance

FPIG - CV factory

FPIG-transmission factory

Central quality (CQ)

Area office, Lucknow

Regional sales office (Lucknow)

Service deptt., Lucknow works

Plant head office

Manufacturing head office

Human resources

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Business excellence

Finance

Internal audit

ERC Lucknow

Administration

Construction

COMMERCIAL VEHCILES CENTER OF

EXCELLENCE

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Over the last fifty years, Tata Engineering has built up

an impressive line up of commercial vehicles that can

match international benchmarks. Today Telco is Indias

largest and among the worlds top ten commercial vehicles

manufactures. They have over 130 models and variants of

vehicles designed to transport almost anything. Their

commercial vehicles can haul loads ranging from 0.75 tones

to 49 tones. They have mini buses that can seat 12 people

and buses that can accommodate as many as 60.Tippers,

tractors trailers, and 4x4off road vehicles.

ABOUT VEHICLE CLASSIFICATION

In the Commercial Vehicle Business Unit, the models are

classified on the basis of GVW as under:

HCV: Heavy Commercial Vehicles

MCV: Medium Commercial Vehicles.

LCV: Light Commercial Vehicles.

The HCV segment can be further classified into three

segments based on gross vehicle weight as follows: ICV : Intermediate Commercial Vehicle with GVW

of 8 to 10 ton. MCV : Medium Commercial Vehicle with GVW of 10

to 15 ton. HCV : Heavy Commercial Vehicle with GVW of 16

ton and above.

MCV & HCVs can also be classified into two categories

depending on their usage as Trucks and Buses . Buses are

passenger carriers. Trucks include goods carriers along with

specialized vehicles like dumpers, tractor-trailers etc. the

ICVs fall in the load category of 8 to 10 ton GVW and are

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often substituted for medium or heavy commercial vehicles

in trunk routes or cities. EICHER Motors and SWARAJ

MAZDA are two manufacturers operating in this segment.

About Cowl CX

Cowl is the front portion of the Chassis, which has driving

seat, engine hood, lights, blinkers, dashboard, different

meters, indicators and other electrical connections toregulate the vehicle. Bare Cowls are being received from

Tata Motors, Jamshedpur as well as from Eastern Complex

and are assembled here.

Bare Cowls are put on the trolley with the help of 0.5 ton

(JIB) hoist and different fitments are made. Cowls trimmed

on the floor slat conveyor. Cowls of all the vehicles are

firstly assembled at Cowl CX and then it is finally bolted tothe Chassis at the Chassis assembly line (cowl dropping

station).

The Cowl CX is divided into two areas:

1. Bare Cowl Rectification Area

2. Trim CX Assembly Area

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Process Flow for Manufacturing of Cowls

Whole process of manufacturing cowls is divided into

19 stages as under after which the cowl is transferred

to main assembly line where it is assembled with the

Chassis:

Stage 0 (bare line): Unloading, tapping, washing, inspection and

welding (if required) Filling of sealant at open joint

Denting cowl where dents are observed

Grinding, emery paper sanding and application of

putty Centre panel alignment and knob fitting and

stopper fitting

Stage 1 : Dropping of the cowl

Model determination by facing mascot

Fitment of the L bracket/Maxi Fuse bracket

Stay rod and sleeve attachment

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Pasting of the inspection card

Stage 2 : DTV mounting and fitment

Fitment of the rubber bellow

Fitment of accelerator paddle

Acc pedal stopper bolt

Fitment of retaining plate

Stage 3 : Hand brake fitment

Connection of hand brake with W/H main cable

Placing clutch container with pipe above the

rubber grommet Fitment of the wiper motor

Fitment of the high temperature buzzerStage 4 :

Insulation and fitment of elbow in flange tube

Fitment of flange pipe and service indicator

Fitment of the footrest in LHD vehicles

Stage 5 : Assembly of jaali

Engine hood beading

Fitment of the stay rod

Pasting of BS2, BS3 and caution stickers

Stage 6 :

Fitment of the letter TATA

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Fitment of the T-emblem

Fitment of reflector triangle bracket

Fitment of Auxiliary water tankStage 7 :

Harness layout and routing, placing grommets

over the holes Horn fitment & connection

Stage 8 :

Routing of bottom harness Place speed cable inside clamps and holes

provided

Stage 9 : Placing of W/H cable wire inside hole of dome and

tighten screws of dome Fitment of the head lamp

Tighten blinker with screw

Stage 10 : Fitment of power steering tank

Fitment of combi switch

Stage 11 : Panel wiring

Instrument cluster connection

Stage 12 : Fitment of beeper

Driver seat stand fitment

Thrust rod fitment

Stage 13 :

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Mounting of air filter assembly on the bracket with

straps

Fitment of air filter bracket Mount and connect air intake pipe assembly to

flange pipe

Stage 14 : Mounting of driver seat

Tightening of wiper motor

Stage 15 : Instrument cluster fitment

Ammeter fitment

Stage 16 : Mounting of steering column assembly on the

bracket Steering wheel fitment

Hydraulic Jack fitment

Stage 17 : Electrical testing

Stick OK marked

Stage 18 : Inspection of the cowl and its parts

Remove the cowl from the conveyor with the help

of tackle Finished cowl palletizing on empty pallet

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PROJECTDevelopment of Automatic ON-

OFF System for various

Electrical Equipments of Paint

Touchup Zone

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Development of Automatic ON-OFF

System for various ElectricalEquipments of Paint Touchup Zone

OBJECTIVE : To reduce wastage of electricity in Paint Touchup Zone in Bare Line by designing automatic shut

down system for blowers and other electrical equipments.

APPROACH OF THE PROJECT: -

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PROBLEM IDENTIFICATION:

The Paint Touchup Zone in the Bare line section is used to

touch up the paint of cowls whenever necessary. The Paint

Touchup Zone has many electrical equipment necessary for

painting such as Blowers, Exhaust, Halogen Lamps and

Tube lights etc. These equipments are kept ON in the whole

shift of 8 Hrs. but it is used occasionally according to need.

So a large amount of energy is being wasted. This is not

suitable on financial ground as well as for company policy of

eco-friendliness. This is the problem.

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Problem Identification

Current State

Proposed Ideas

Selection of best alternative

Solution Development

Plan Implementation

Benefits


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CURRENT STATE:

The layout of Paint Touchup Zone and current energyconsumption study is as following:

The Paint Touchup Zone in Bare Line in Cowl Cx. Contains

following electrical equipments-

1. Blowers - 4

2. Halogen Lamps - 2

3. Industrial Tube Lights - 16

The arrangement of these equipments is shown in the

following plan layout of Paint Touchup Zone.

Layout of Paint Touchup Zone:

The following figure shows the top view of Paint Touchup

Zone

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Energy Consumption Study of Paint Touchup Zone:

The following table shows the energy consumption of the

Paint Zone-

S.

No.

Equipme

nt

Power

Rating

No. of

Units

Used

Working

Hours

Power

Consumed

1 Blower 7.5 hp =

5.6 KW

4 8 179.2 kWh

2 Halogen

Lamp

400 W 2 8 6.4 kWh

3 Industrial

Tube Light

40 W 16 8 5.12 kWh

Total 190.72 kWh

Proposed Ideas:

For the above said problem following solutions are

proposed-1. Off Delay Timer Circuit

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Limiting Switch Delay Timer Circuit

Relay

Contactor coilPower Equipments

2. Sensor Based System

3. Manual System

These solutions are explained in detail as following-

1. Off Delay Timer Circuit:

In this system an Off Delay Timer is made using IC-555 and

this is used to control a relay which in turn controls the

various electrical equipments.

The following Flow chart shows the plan.

Block Diagram :

Working:

According to this plan a limiting switch senses the entry of

cowl in the paint booth and sends a trigger signal to the off

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delay timer circuit. Limiting switch is of Pushbutton type so

after the entry of cowl the off delay timer starts its count

down. After a predetermined time the timer goes off which

is controlling a relay so relay turns off which turn off the

equipments connected to it through contactor coil. Thus the

equipments of Paint touchup Zone are turned off after a

predefined time after cowl entry. This circuit keeps off until

another cowl comes in the zone.

Merits: Simple and Cheap construction of system

Large saving of power

Fully automatic System

Demerits: Installation is Difficult

Timing not very accurate

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Entry Sensor Switching Circuit

Relay

Contactor coilPower Equipments

Exit Sensor

2. Sensor Based System:

In this system sensors are employed at entry and exit of the

paint zone which gives triggering signal to a switchingcircuit which turns on and off a relay on receiving trigger

signals from sensors which in turn controls the various

electrical equipments.

The following Flow chart shows the plan.

Block Diagram:

Working:

According to this plan input and output sensors are used.

When a cowl comes in the booth the input sensor sends

signal to switching circuit which turns on a relay and on exit

the exit sensor senses the cowl exit and sends trigger to

switch off relays. Thus power is on only for the period when

it is being used to paint.

Merits: Large saving of power

Fully automatic System

Demerits:

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Costly system

On busy days frequent ON-Off can cause

breakdown of equipments Interference due to workers passing through

booth

3. Manual Operation:

A very simple and basic solution of our problem is that the

worker manually switches off the equipments from electrical

panel but this is not very suitable because its notautomated and increases strain on workers.

Merits: Large saving of power

No additional cost

Demerits: Not automatic

Increased burden on workers

Safety Threat

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Selection of best alternative:

In above explained proposals the Selection of bestalternative is done on the basis of effectiveness of system

and applicability. The most suitable alternative is selectedto be the Delay Timer based system because- Its cheap and simple to construct Helps to save considerable amount of power

Solution Development:

According to our need an OFF Delay Timer Controlled Relaybased system is developed. The entry of cowl in booth issensed by an pushbutton limiting switch and the triggersignal is sent to an off delay timer circuit which starts itscountdown as soon as cowl enters the booth. After apredetermined time the timer goes off and turns off allequipments. The suitable delay time is selected to bearound 5 minutes by interaction with workers andtechnicians as well as considering fatigue to equipments.

Thus following circuit is developed .

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Circuit Diagram:

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The above circuit shows the developed system forAutomatic ON-OFF for various Electrical Equipments of Paint

Touchup Zone.

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The circuit uses an IC-555 with various other components to

make an off delay timer circuit. The circuit containsfollowing components-

S.

No.

Part Rating

1 IC- 5552 Resistor 100 Kohm, watt, 12 v3 Resistor 2 Mohm, watt, 12 v4 Capacitor 100 F, watt, 12 v

5 Diode- 1N1004 watt, 12 v6 Relay 12V DC, 230V AC,7 Battery 12V8 Push Button Switch 12V, watts

Working:

The circuit is triggered by a switch between pin 1 and pin 8.

In actual case we use an limiting switch. When this switch is

pressed and released the circuit turns ON which energizes arelay coil which inturn turns on all equipments. After a pre

calculated time delay of around 250-300 seconds the circuit

turns off automatically.

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Plan Implementation:

The above discussed plan is made and implemented. Thecircuit is made on a matrix PCB. The images of actual circuit

are following-

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Circuit Developed

Back View

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Closer View

Benefits Achieved:

The plan for automation of Equipments of Paint TouchupZone has the sole purpose of saving electricity being

wasted. The following study shows how much energy could

be saved by this project-

Average number of cowls in an fair day = 40

System on Time per cowl through our system = 5 mins.

Total ON time per shift = 200

mins. 3.5 hrs.Energy consumed per shift with our system = 3.5 x

190.72 = 667.52 kWh

Energy consumed per shift without our system = 0 8 x

190.72 = 1525.76 kWh

Total energy saving per shift = 1525.76

667.52 = 858.24 kWh

Thus our system offers a energy saving upto56% which is very good for company as well

as environment.

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SUMMARY

The sole motive of this four weeks projecttraining is to give an idea what a real industry is all

about and getting training in such an esteemed

organization is definitely a thing to be proud of. I got

the chance to learn much more than I expected before I

came here.

In my training I learnt how to plan the

activities regarding different work and develop the

techniques to solve the problem. I also learnt the power

of team work that how onerous tasks can be

accomplished easily with the help of team work.

By working in the Cowl shop, I learnt about the

different processes which are being carried out in the

Cowl line and more specifically about the Electrical and

Electronic Systems used in industry, sensors and

controllers, safety systems, automation etc.

During training I was given a project to

develop an Automatic ON-OFF System for various

electrical equipments of Paint Touchup Zone

which were kept ON continuously during whole shift

causing lots of wastage of energy. I have designed,

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developed and built an Auto On-OFF system for the

Paint Zone. The system designed by me saves upto

56% of energy .Apart from the allotted project, I also learnt

a lot about Organizational Culture. Working with people

from different areas taught me a lot of managerial as

well as personal skills that are definitely very helpful for

my future.

My experience in TATA motors has been really enriching

and has provided me a stepping stone for a prospective

bright future in the industrial Sector. I wish that every

engineer should get a chance to get associated with

such a giant and reputed group.

Documents

Kk Project