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SUMMER TRAINING PRESENTATION

PREFACE

THE BASIC idea of the training was to understand the different child components used in the steering mechanism of passenger cars of various makes. My total focus was on the different parts which are later on assembled together to make the end product ready for installation into the vehicle. Basically my focus was on Plant I. which manufactures Rack and Pinion steering assembly. However my report will also be consisting some extra relevant information as these information are the part of the whole procedure. I hope you will like the Report and will appreciate its content and layout and will also find it useful for further study of the Steering as a component. However I have tried my best to avoid any sort of errors but as I also belong to the Homo sapiens species so one can accept some errors or faults.

COMPANY HISTORYEstablished in 1985, Sona Koyo Steering Systems Ltd. is the group's flagship company, and the largest manufacturer of steering systems in India, catering to passenger cars, utility vehicles and light commercial vehicles. Sona Koyo has technical and financial collaboration with JTEKT Corporation, Japan (formally known as Koyo Seiko Co. Ltd.), the largest producer of passenger vehicles' steering systems in the world. Sona Koyo's customers include major vehicle manufactures in India such as Maruti Suzuki, Toyota, Hyundai, Tata Motors, Mahindra & Mahindra, General Motors and Mahindra-Renault. Independently, as well as through its network of overseas joint-venture partners, it exports high quality precision products to USA, Europe and Japan.

INTRODUCTION

Sona Koyo Steering Systems Limited (SKSSL)the flagship company of The Sona Group, is currently the largest manufacturer of steering systems for the passenger car and utility vehicle market in India. Its collaborator and partner, JTEKT Corporation, is the market leader in Japan and in the recent past announced a merger with Toyota Machine Works. Post this merger, JTEKT will become the world's largest steering systems manufacturer. The company also has a technical collaboration with Mando Corporation, Korea.As part of Sona Koyo Steering Systems Ltd's (SKSSL) globalization strategy, the company has acquired a position in Fuji Autotech. France, SAS, the 4th largest steering system supplier in Europe. Via Fuji Autotech, The Sona Group footprint extends to Eastern Europe and South America.

Sona Koyo Steering Systems Limited (SKSSL) is a technical and financial joint venture company of Koyo Seiko Company, Japan. With a Market share of 50%, the company is the largest manufacturer of steering gears in India and is the leading supplier of: Hydraulic Power Steering Systems Manual Rack & Pinion Steering Systems Collapsible, Tilt and Rigid Steering Columns for Passenger Vans and MUVs

PLANT LOCATION

38/6, Delhi-Jaipur Road, NEAR HERO HONDA CHOWK, Gurgaon (Haryana), India38 Km from New Delhi,22 Km from Delhi Airport,10 Km from Maruti Udyog Ltd.Total Site Area 56,970 square metersTotal floor Area 14,125 square meters

Brief view to SONA KOYO

PLANT -1

PLANT -2

PLANT - 3

PLANT - 4

CUSTOMERS TO SONA KOYO STEERING SYSTEMS LTD.

PRODUCTSPower Rack and Pinion Steering SystemClutch Driven PlatesPower Re-circulating Ball Screw Steering SystemBall JointsElectrical Power Steering SystemTie Rod EndsManual Rack and Pinion Steering SystemSuspension ComponentsWarm forged Synchronizer Rings

Tilting and Collapsible Column AssemblyUniversal JointsCold Forged Steering StudsPropeller ShaftsCold Forged Ball StudsRear Axle AssembliesCold Forged Case/SocketSub-differential AssembliesCold Forged Spiders and YokesRigid Type Collapsible Column Assembly

Carrier differential assembly

WORKING OF Case differential

During Turning

TYPES OF MANUAL STEERINGS

Rack and Pinion STEERING (RPS)

Recirculating Ball Type steering (RBS)

Rack and Pinion STEERING (RPS)

In the rack and pinion type steering, the steering main shaft has a steering pinion at the lower end. This steering pinion meshes with the steering rack. As the steering wheel is turned, the steering pinion rotates to move the steering rack to the right or left. The movement of the steering tack is transmitted to the knuckle arms via the steering rack ends and the tie rod ends.

The rack-and-pinion gear set does two things: It converts the rotational motion of the steering wheel into the linear motion needed to turn the wheels. It provides a gear reduction, making it easier to turn the wheels.

Steering columnsThe automotivesteering columnis a device intended primarily for connecting thesteering wheelto thesteeringmechanism by transferring the driver's input torque from the steering wheel.

A steering column may also perform the following secondary functions:

Energy dissipation management in the event of a frontal collision; Provide mounting for: the multi-function switch, column lock, column wiring, column shroud(s), transmission gear selector, gauges or other instruments as well as the electro motor and gear units . Offer (height and/or length) adjustment to suit driver preference.

Steering columns

Electrical Power steering column

Intermediate column shafts

Spider universal joints

The cross-shaped inner member of a universal joint is sometimes called a spider. Universal joints allow for a small variable angle between the axis of the transmissions output shaft and theaxis of the propeller shaft, and between the axis of the propeller shaft and the axis of the input shaft of the rear axle

(1)The spider (6) ends (3) are called gudgeon. Around the gudgeons there are rollers (4) kept in place by a cap (5), that allows them to roll freely. The Circlip (7) fits into the (2) hole in the yoke and lock the cap.Steering yoke, clamps & pipes

Steering front and rear axle

An axle is a central shaft for a rotating wheel or gear. In some cases the axle may be fixed in position with a bearing or bushing sitting inside the hole in the wheeler gear to allow the wheel or gear to rotate around the axle. In other cases the wheel or gear may be fixed to the axle, with bearings or bushings provided at the mounting points where the axle is supported.

A straight axle or the front axle is a single rigid shaft connecting a wheel on the left side of the vehicle to a wheel on the right side. The axis of rotation fixed by the axle is common to both wheels. Such a design can keep the wheel positions steady under heavy stress, and can therefore support heavy loads. Straight axles are used on trains, for the rear axles of commercial trucks, and on heavy duty off-road vehicles. The axle can be protected and further reinforced by enclosing the length of the axle in a housing.

Front axle

In split-axle designs, the wheel on each side is attached to a separate shaft. Modern passenger cars have split drive axles. In some designs, this allows independent suspension of the left and right wheels, and therefore a smoother ride. Even when the suspension is not independent, split axles permit the use of a differential, allowing the left and right drive wheels to be driven at different speeds as the automobile turns, improving traction and extending tire life

Propeller shaftAdrive shaft,driveshaft,driving shaft,propeller shaft, orshaftis a mechanical component for transmittingtorqueand rotation, usually used to connect other components of adrive trainthat cannot be connected directly because of distance or the need to allow for relative movement between them. Drive shafts frequently incorporate one or moreuniversal jointsorjaw couplings, to allow for variations in the alignment and distance between the driving and driven components.

POWER STEERINGHydraulic power steering: There are a couple of key components inpower steeringin addition to the rack-and-pinion or recirculating-ball mechanism.There are a couple of key components inpower steeringin addition to the rack-and-pinion or recirculating-ball mechanism.There are a couple of key components inpower steeringin addition to the rack-and-pinion or recirculating-ball mechanism.There are a couple of key components inpower steeringin addition to the rack-and-pinion or recirculating-ball mechanism. There are a couple of key components inpower steeringin addition to the rack-and-pinion or recirculating-ball mechanism.

PUMPThe hydraulic power for the steering is provided by arotary-vane pump(see diagram below). This pump is driven by the car's engine via a belt and pulley. It contains a set of retractable vanes that spin inside an oval chamber.As the vanes spin, they pull hydraulic fluid from the return line at low pressure and force it into the outlet at high pressure. The amount of flow provided by the pump depends on the car's engine speed. The pump must be designed to provide adequate flow when the engine is idling. As a result, the pump moves much more fluid than necessary when the engine is running at faster speeds

ROTARY VALVEA power-steering system should assist the driver only when he is exerting force on the steering wheel (such as when starting a turn). When the driver is not exerting force (such as when driving in a straight line), the system shouldn't provide any assist. The device that senses the force on the steering wheel is called the rotary valve.

The key to the rotary valve is a torsion bar. The torsion bar is a thin rod of metal that twists whentorqueis applied to it. The top of the bar is connected to the steering wheel, and the bottom of the bar is connected to the pinion or worm gear (which turns the wheels), so the amount of torque in the torsion bar is equal to the amount of torque the driver is using to turn the wheels. The more torque the driver uses to turn the wheels, the more the bar twists.

The input from the steering shaft forms the inner part of aspool-valve assembly. It also connects to the top end of thetorsion bar. The bottom of the torsion bar connects to the outer part of the spool valve. The torsion bar also turns the output of the steering gear, connecting to either the pinion gear or the worm gear depending on which type of steering the car has.

As the bar twists, it rotates the inside of the spool valve relative to the outside. Since the inner part of the spool valve is also connected to the steering shaft (and therefore to the steering wheel), the amount of rotation between the inner and outer parts of the spool valve depends on how much torque the driver applies to the steering wheel.

When the steering wheel is not being turned, both hydraulic lines provide the same amount of pressure to the steering gear. But if the spool valve is turned one way or the other, ports open up to provide high-pressure fluid to the appropriate line.

It turns out that this type of power-steering system is pretty inefficient. Let's take a look at some advances we'll see in coming years that will help improve efficiency

ELECTRICAL power steering: EPS in modern cars can significantly reduce fuel consumption when compared to cars using hydraulic solutions. Industry studies have shown that EPS can save up to 85 percent of the energy normally needed to steer a vehicle with conventional hydraulic systems. The result is fuel consumption reductions of up to 0.3 liters per 100 kilometers driven. EPS is so efficient because the system is only activated when steering support is really needed. As a result, a permanent engine load is not required. EPS systems also can help ensure safer driving. The steering torque is adapted to the vehicles speed and optimized for different driving situations. For example, during low-speed driving maneuvers, such as parking, EPS provides a higher level of assistance than it does at higher speeds, when electronic power assist is gradually reduced to enable more direct steering and better feedback from the road.

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