Plant & Machineries

Maurya Motors private limited manufacturing unit is

located at bihta in patna, where producing many types of
hydraulic tippers, municipal applications, police applications
and many more type of bodies as per requirements of
customers.

For manufacturing of above inventions bodies are listed as below:-

 Electricity / Transformer/ Generator

 Shearing Machine
 CNC Bending Machine
 Plasma Cutting Machine
 Shot Blasting Machine
 Lathe Machine
 Grinding Machine
 Welding Machine
 Pneumatic Air Compressor
 Paint Booth
Electricity / Transformer/
Generator
Electric transformers are an integral part of our day-to-day life.
Transformer applications can be either domestic or industrial.
Different types are used to step-up or step-down the voltage for
various devices.

The principle how transformers and generators work is based on

electromagnetic induction. Generators generate current
and transformers convert between current and voltage.
A generator is a machine which, with the help of magnetic induction,
converts mechanical energy into electrical energy.

Transformers are widely used in the electric power industry to

increase voltages—called step-up transformers—before long-
distance transmission via high-voltage wires. They are also used to
decrease voltages—called step-down transformers—to deliver power
to homes and businesses.

Applications:-
Electric vehicles are the up and coming automobiles to create buzz in
the market. Their batteries are charged by a power source. However,
needed to moniter and control the voltage or electricity that is being
used for charging the batteries. Advanced technology and
innovations have led to development of “Smart transformers” that
can be used for charging multiple electric vehicles at a time.
Plasma cutting
Plasma cutting is a process that cuts through electrically conductive materials by
means of an accelerated jet of hot plasma. Typical materials cut with a plasma
torch include steel, Stainless steel, aluminium, brass and copper, although other
conductive metals may be cut as well. Plasma cutting is often used
in fabrication shops, automotive repair and restoration, industrial construction,
and salvage and scrapping operations. Due to the high speed and precision cuts
combined with low cost, plasma cutting sees widespread use from large-scale
industrial CNC applications down to small hobbyist shops.

Process:-
The basic plasma cutting process involves creating an electrical
channel of superheated, electrically ionized gas i.e. plasma from
the plasma cutter itself, through the work piece to be cut, thus
forming a completed electric circuit back to the plasma cutter via
a grounding clamp. This is accomplished by a compressed gas
(oxygen, air, inert and others depending on material being cut)
which is blown through a focused nozzle at high speed toward
the work piece. An electrical arc is then formed within the gas,
between an electrode near or integrated into the gas nozzle and
the work piece itself. The electrical arc ionizes some of the gas,
thereby creating an electrically conductive channel of plasma. As
electricity from the cutter torch travels down this plasma it
delivers sufficient heat to melt through the work piece. At the
same time, much of the high velocity plasma and c ompressed
gas blow the hot molten metal away, thereby separating i.e.
cutting through the work piece.

Plasma cutting is an effective way of cutting thin and thick

materials alike. Hand-held torches can usually cut up to 38 mm
(1.5 in) thick steel plate, and stronger computer-controlled
torches can cut steel up to 150 mm (6 in) thick. Since plasma
cutters produce a very hot and very localized "cone" to cut with,
they are extremely useful for cutting sheet metal in curved or
angled shapes .
CNC Plasma Cutting Configuration
There are 3 main configurations of CNC Plasma Cutting, and
they are largely differentiated by the forms of materials before
processing, and the flexibility of the cutting head.

 2 Dimensional / 2-Axis Plasma Cutting

This is the most common and conventional form of CNC
Plasma Cutting. Producing flat profiles, where the cut edges
are at 90 Degrees to the material surface. High powered CNC
plasma cutting beds are configured in this way, able to cut
profiles from metal plate up to 150mm thick. up to thickness
30mm
 3 Dimensional / 3+ Axis Plasma Cutting
Once again, a process for producing flat profiles from sheet or
plate metal, however with the introduction of an additional axis
of rotation, the cutting head of a CNC Plasma Cutting machine
can tilt whilst being taken through a conventional 2 dimensional
cutting path. The result of this is cut edges at an angle other
than 90 Degrees to the material surface, for example 30-45
Degree angles. This angle is continuous throughout the
thickness of the material.. The angular cutting capability of 3
Dimensional plasma cutting can also be used to create
countersunk holes and chamfer edges of profiled holes.
 Tube & Section Plasma Cutting
Used in the processing of tube, pipe or any form of long
section. The plasma cutting head usually remains stationary
whilst the workpiece is fed through, and rotated around its
longitudinal axis There are some configurations where, as with
3 Dimensional Plasma Cutting, the cutting head can tilt and
rotate. This allows angled cuts to be made through the
thickness of the tube or section, commonly taken advantage of
in the fabrication of process pipework where cut pipe can be
provided with a weld preparation in place of a straight edge.
CNC Bending Machine
A bending machine is a forming machine tool). Its purpose is to
assemble a bend on a workpiece. A bends is manufactured by using a
bending tool during a linear or rotating move. The detailed
classification can be done with the help of the kinematics.

Computer numerically controlled (CNC) bending is a manufacturing

process that is carried out by CNC press brakes (also known as CNC
brake presses). These machines can bend sheet metal work from
just a few mm across to sections many metres long on the largest
industrial machines. CNC press brakes either have a fixed bottom
bed with the V block tooling clamped in place and a top beam which
travels under force with the V blade tools this is known as down
forming. The opposite is an up forming machine with the bottom
bend moving and the top beam fixed. Both process methods will
produce the same sheet metal components and there are no
restrictions to the design of your component to suit either machine.

The maximum length of the sheet metal component that can be bent
up is obviously defined by the length of the CNC press brake bed but
the thickness of material is a function of the material tensile strength
and the amount of tonnage available from the machine to form the
sheet metal. The larger the bottom V block opening the greater the
sheet metal gauge can that can be bent for the same tonnage. But,
as the V block opening is increased so does the internal radius of the
bend on the sheet metal work.
Lathe Machine
A lathe is a tool that rotates the workpiece about an axis of
rotation to perform various operations such
as cutting, sanding, knurling, drilling, deformation, facing,
and turning, with tools that are applied to the workpiece to create an
object with symmetry about that axis.
Lathes are used in woodturning, metalworking, metal
spinning, thermal spraying, parts reclamation, and glass-working.
Lathes can be used to shape pottery, the best-known design being
the potter's wheel. Most suitably equipped metalworking lathes can
also be used to produce most solids of revolution, plane surfaces and
screw threads or helices. Ornamental lathes can produce three-
dimensional solids of incredible complexity. The workpiece is usually
held in place by either one or two centers, at least one of which can
typically be moved horizontally to accommodate varying workpiece
lengths. Other work-holding methods include clamping the work
about the axis of rotation using a chuck or collate, or to a faceplate,
using clamps or dogs.
Examples of objects that can be produced on a lathe
include screws, candlestick holders, gun barrels, cue
sticks, table legs, bowls, baseball bats, musical instruments
(especially woodwind instruments), crankshafts, and camshafts.
Shearing machines
Shearing machines are multipurpose devices used in the cutting of
alloys and other sheet metal. Some shearing machines use a scissor-
like, angular shear action to cut metal into sheets or strips. Other,
larger machines use a straight shear action with the blade fixed at an
angle as opposed to the angular movement. Shearing operations are
performed by the action of two blades, one fixed in the shear bed
and the other moving vertically with little or no clearance. Shear
action moves progressively from one side of the material to the
other. The angular configuration of the blades is called the rake. Both
rake and clearance are a function of the type and thickness of the
material to be cut. In press type shears, the upper blade is inclined in
relation to the lower blade, about 0.5 to 2.5 degrees. The typical
shear consists of a fixed bed to which one blade is mounted, a
vertically advancing crosshead and a series of hold-down pins or feet
that hold the material in place while the cutting occurs. A gauging
system with stops is used to produce specific workpiece finish sizes.
Grinding Machine
A grinding machine, often shortened to grinder, is any of
various power tools or machine tools used for grinding, which is a
type of machining using an abrasive wheel as the cutting tool. Each
grain of abrasive on the wheel's surface cuts a small chip from the
workpiece via shear deformation.
Grinding is used to finish workpieces that must show high surface
quality (e.g., low surface roughness) and high accuracy of shape and
dimension. As the accuracy in dimensions in grinding is of the order
of 0.000025 mm, in most applications it tends to be a finishing
operation and removes comparatively little metal, about 0.25 to
0.50 mm depth. However, there are some roughing applications in
which grinding removes high volumes of metal quite rapidly.
Grinding machines remove material from the work piece by abrasion,
which can generate substantial amounts of heat. In high-precision
grinding machines (most cylindrical and surface grinders), the final
grinding stages are usually set up so that they remove about 200 nm
(less than 1/10000 in) per pass - this generates so little heat that
even with no coolant, the temperature rise is negligible.

Types of grinding machines are:-

 Belt grinder
 Bench grinder
 Cylindrical grinder
 Surface grinder
 Tool & cutter grinder
 Jig grinder
 Gear grinder
 Die grinder
 Angle grinder
 Shot Blasting
Shot blasting is a method used to clean, strengthen (peen) or polish
metal. Shot blasting is used in almost every industry that uses metal,
including aerospace, automotive, construction, foundry, shipbuilding,
rail, and many others.

Shot blasting machine Design

The main design idea:

 Based on experience, we use roller shot blasting machine. The

models are available from the truck or driving feed rollers directly,
can work, high efficiency, operational safety of workers. But also
take into account the surface cleaning and steel profiles and
structural parts.
 For customers work information, we designed an opening device
width, height 1700mm. 1520mm diameter steel pipe feeding a
time. Projectile body to ensure overall coverage.
 In the sealing chamber at both ends of the installation of
equipment wear-resistant steel sheet clip to prevent projectiles
spill. To ensure that the work site without projectile.
 roller spacing device designed to 1000mm, to ensure the carrying
capacity of 1T / m. And the installation of the spacer rollers to
prevent rolling steel pipe rollers to ensure security.
 6 sets with 11kw motor direct-attached blasting device, the device
is turned on, placed in a steel rollers to 1.2-1.6m /min speed
through the blasting zone. When steel hanging out roller can be
tilted through pipe, steel pipe dumping projectile to collect balls
spiral, which will help the projectile recovered.
Overhead Bridge Crane
An overhead crane, commonly called a bridge crane, is a type
of crane found in industrial environments. An overhead crane
consists of parallel runways with a traveling bridge spanning the gap.
A hoist, the lifting component of a crane, travels along the bridge. If
the bridge is rigidly supported on two or more legs running on a fixed
rail at ground level, the crane is called a gantry crane or a goliath
crane.
Unlike mobile or construction cranes, overhead cranes are typically
used for either manufacturing or maintenance applications, where
efficiency or downtimes are critical factors.
Overhead cranes are commonly used in the refinement of steel and
other metals such as copper and aluminium. At every step of the
manufacturing process, until it leaves a factory as a finished product,
metal is handled by an overhead crane. Raw materials are poured
into a furnace by crane, hot metal is then rolled to specific thickness
and tempered or annealed, and then stored by an overhead crane
for cooling, the finished coils are lifted and loaded onto trucks and
trains by overhead crane, and the fabricator or stamper uses an
overhead crane to handle the steel in his factory.
The automobile industry uses overhead cranes to handle raw
materials. Smaller workstation cranes, such as jib cranes or gantry
cranes, handle lighter loads in a work area, such as CNC mill or saw.
Paint Booth
A few of the most common items painted in a spray booth are cars,
trucks, boats, planes, parts and furniture, and the basic structural
design of a paint booth is essentially the same no matter the size,
industry or application. Paint booths are either fully enclosed (with
walls or doors on all sides) or feature an open front (without walls or
doors in the front of the booth). Paint booths can be standalone
pieces or included as part of a conveyorized finishing system.
Using a spray booth ensures that paint jobs are done faster, safer
and cleaner. The most important function of a paint booth is to
contain paint overspray, keeping your employees and the
environment safe. By confining the application of a hazardous
material to a controlled environment, paint booths prevent
hazardous overspray from causing fire or explosion, control air
fuel/mixture so that a combustible combination cannot occur and
ultimately, provide a clean environment in which to paint.
In addition to safety, quality can be significantly improved with a
paint booth. Enclosed paint booths offer a contaminant-free
environment for better quality paint jobs. Before air enters the paint
booth, it is filtered through high-efficiency filters that prevent small
dirt and dust particles from coming into the booth and landing in
your paint job. Cleaner paint jobs also mean less rework, saving
businesses valuable time.
Often used to pressurize paint booths, air make-up units (AMUs) are
responsible for moving air continuously throughout the booth and
help the booth maintain an optimal spraying temperature. In
addition to a paint spraying mode, most paint booths also have a
cure mode, which helps the paint adhere and dry faster.
Pneumatic Air Compressor
An air compressor is a device that converts power (using an electric
motor, diesel or gasoline engine, etc.) into potential energy stored in
pressurized air. By one of several methods, an air compressor forces
more and more air into a storage tank, increasing the pressure.
When tank pressure reaches its engineered upper limit the air
compressor shuts off. The compressed air, then, is held in the tank
until called into use. The energy contained in the compressed air can
be used for a variety of applications, utilizing the kinetic energy of
the air as it is released and the tank depressurizes. When tank
pressure reaches its lower limit, the air compressor turns on again
and re-pressurizes the tank. Pneumatic systems are similar to
hydraulic systems but in these systems compressed air is used in
place of hydraulic fluid.

A pneumatic system is a system that uses compressed air to transmit

and control energy. Pneumatic systems are used extensively in
various industries. Most pneumatic systems rely on a constant
supply of compressed air to make them work. This is provided by an
air compressor. The compressor sucks in air from the atmosphere
and stores it in a high pressure tank called a receiver. This
compressed air is then supplied to the system through a series of
pipes and valves.
Chassis
A chassis is the internal framework of an artificial object, which
supports the object in its construction and use. An example of a
chassis is a vehicle frame, the underpart of a motor vehicle, on which
the body is mounted; if the running gear such as wheels and
transmission, and sometimes even the driver's seat, are included,
then the assembly is described as a rolling chassis.
In the case of vehicles, the term rolling chassis means the frame plus
the "running gear" like engine, transmission, drive shaft, differential,
and suspension.
An under body (sometimes referred to as "coachwork"), which is
usually not necessary for integrity of the structure, is built on the
chassis to complete the vehicle.
For commercial vehicles, a rolling chassis consists of an assembly of
all the essential parts of a truck (without the body) to be ready for
operation on the road The design of a pleasure car chassis will be
different than one for commercial vehicles because of the heavier
loads and constant work use. Commercial vehicle manufacturers sell
"chassis only", "cowl and chassis", as well as "chassis cab" versions
that can be outfitted with specialized bodies. These include motor
homes, fire engines, ambulances, box trucks, etc.
An armoured fighting vehicle's hull serves as the chassis and
comprises the bottom part of the AFV that includes the tracks,
engine, driver's seat, and crew compartment. This describes the
lower hull, although common usage might include the upper hull to
mean the AFV without the turret. The hull serves as a basis for
platforms on tanks, armoured personnel carriers, combat
engineering vehicles, etc.
Hydraulics
Hydraulics is a technology and applied science using engineering,
chemistry, and other sciences involving the mechanical properties
and use of liquids. At a very basic level, hydraulics is the liquid
counterpart of pneumatics, which concerns gases. Fluid
mechanics provides the theoretical foundation for hydraulics, which
focuses on the applied engineering using the properties of fluids. In
its fluid power applications, hydraulics is used for the generation,
control, and transmission of power by the use of pressurized liquids.
Hydraulic topics range through some parts of science and most of
engineering modules, and cover concepts such as
pipe flow, dam design, fluidics and fluid control circuitry, pumps. The
principles of hydraulics are in use naturally in the human body within
the heart and the penile erection. Free surface hydraulics is the
branch of hydraulics dealing with free surface flow, such as occurring
in rivers, canals, lakes, estuaries and seas. Its sub-field open-channel
flow studies the flow in open channels.
Tippers as a product
A dump truck (known in the UK as a dumper/tipper truck) is
a truck used for transporting loose material (such as sand, gravel, or
demolition waste) for construction. A typical dump truck is equipped
with an open-box bed, which is hinged at the rear and equipped
with hydraulic rams to lift the front, allowing the material in the bed
to be deposited ("dumped") on the ground behind the truck at the
site of delivery. In the UK, Australia and India the term applies to off-
road construction plant only, and the road vehicle is known as
a tipper lorry(UK, India), tip-truck, tip-trailer or tipper (AUS).
A standard dump truck is a truck chassis with a dump body mounted
to the frame. The bed is raised by a vertical hydraulic ram mounted
under the front of the body, or a horizontal hydraulic ram and lever
arrangement between the frame rails, and the back of the bed is
hinged at the back of the truck. The tailgate can be configured to
swing up on top hinges (and sometimes also to fold down on lower
hinges) or it can be configured in the "High Lift Tailgate" format
wherein pneumatic rams lift the gate open and up above the dump
body.
Dump trucks are normally built for some amount of off-road or
construction site driving; as the driver is protected by the chassis and
height of the driver's seat, bumpers are either placed high or omitted
for added ground clearance. The disadvantage is that in a collision
with a standard car, the entire motor section or luggage
compartment goes under the truck. Thus, the passengers in the car
could be more severely injured than would be common in a collision
with another car. Several countries have made rules that new trucks
should have bumpers approximately 40 cm (16 in) above ground in
order to protect other drivers. There are also rules about how long
the load or construction of the truck can go beyond the rear bumper
to prevent cars that rear-end the truck from going under it.
Welding Machine
Welding is a fabrication or sculptural process that joins materials,
usually metals or thermoplastics, by causing fusion, which is distinct from lower
temperature metal-joining techniques such as brazing and soldering, which do
not melt the base metal. In addition to melting the base metal, a filler material
is typically added to the joint to form a pool of molten material (the weld pool)
that cools to form a joint that, based on weld configuration (butt, full
penetration, fillet, etc.), can be stronger than the base material (parent
metal). Pressure may also be used in conjunction with heat, or by itself, to
produce a weld. Welding also requires a form of shield to protect the filler
metals or melted metals from being contaminated or oxidized.

Welding machines are usually classified as constant current (CC) or

constant voltage (CV); a constant current machine varies its output
voltage to maintain a steady current while a constant voltage
machine will fluctuate its output current to maintain a set
voltage. Shielded metal arc welding and gas tungsten arc welding will
use a constant current source and gas metal arc welding and flux-
cored arc welding typically use constant voltage sources but constant
current is also possible with a voltage sensing wire feeder.
The nature of the CV machine is required by gas metal arc welding
and flux-cored arc welding because the welder is not able to control
the arc length manually. If a welder attempted to use a CV machine
to weld with shielded metal arc welding the small fluctuations in the
arc distance would cause wide fluctuations in the machine's output.
With a CC machine the welder can count on a fixed number of amps
reaching the material to be welded regardless of the arc distance but
too much distance will cause poor welding.
Hypratek Cylinder Specifications
Hypratek FMET 130-3630/3/N FMET 150-3830/3/N
Cylinder Type
B1 201 201
(mm)
C 152 172
(mm)
J 82 86
(mm)
K* 1529 1609
(mm)
H 1582 1662
(mm)
P&T 1” BSP 1” BSP
(mm)
U 60 60
(mm)
Y-FMET 50 50
W-FMCT
(mm)
Z-FMET 42 42
A1-FMCT
(mm)
Stroke Length 3630 3870
(mm)
Wt. Of Cylinder 141 171
Only (KG)
Total Vol. 40 57
(L)

Hypratek Cylinder Selection

Cylinder Model FMET 130-3630/3/N
Chassis Model 6X2, 6X4
Eicher Terra
Chassis GVW/ 25 to 28
GCW TON
Body CAP. 12 to 16
(Cu. M.)
Tipping 33-59
Weight (Ton)
Max Thrust 25
1st Stage(Tons)
Volume Calculator
The volume calculator will calculate the volume of some of the most
common three-dimensional solids. Before you go in to how to
calculate volume, you must know the definition of volume. It is the
measure of amount of space taken up inside a solid figure. Volume
differs from the area, which is the amount of space taken up in a two-
dimensional figure. Therefore you might be confused as to how to
find the volume of a rectangle versus how to find the volume of a
box. The calculator will assist in calculating volume of a sphere,
cylinder, cube, cone and rectangular solid.

How to calculate volume

It depends on the type of geometric solid. Here are the formulas for
some of the most common figures:

1. Cube = s³, where s is the length of the side.

2. Sphere = (4/3)πr³, where r is the radius.
3. Cylinder = πr²h, where r is the radius and h is the height.
4. Cone = (1/3)πr²h, where r is the radius and h is the height.
5. Rectangular solid (volume of a box) = lwh, where l is the
length, w is the width and h is the height.
6. Input the values needed into the volume calculator to find the
volume of the solid.
7. Note the volume is always in cubic units, as opposed to area
which is in square units.
 Weight calculator for sheet metal
Steel, aluminium and stainless steel are the most used construction
materials. A precise weight calculation is extremely important for big
metal constructions, in the the transport sector and for lifting
facilities. It is also important to know the weight for machining metal
sheets no matter the material.

Above all there is a economic advantage to reduce the weight of a

metal construction. The less metal you need to construct a stable
construction, the more more money can be saved. Especially for
complex constructions weight calculations can be difficult. To
calculate the weight for a single sheet is rather simple and can be
done with this tool.

Formula : Weight = L/1000 * W/1000 * T * S

 L = Length in mm
 W = Width in mm
 T = Thickness in mm
 S = Specific material density (Steel = 7.85)

Material Specification:-
The materials used in automotive industry need to fulfil several
criteria before being approved. Some of the criteria are the results of
regulation and legislation with the environmental and safety concerns
and some are the requirements of the customers. In many occasions
different factors are conflicting and therefore a successful design
would only be possible through an optimised and balanced solution.
Requirements of the materials in automotive
1) Light Weight
2) Cost
3) Crashworthiness
i) Crashworthiness tests
(a) Frontal offset crash test details
(b) Side impact crash testing/ratings criteria
(c) Rollover evaluations
4) Recycling and life cycle considerations

Current materials in use

i) Metals
(a) Steel
a. New grades of sheet & alloys
b. Advances in manufacturing and joining
technique
i. Hydro forming
ii. tailored blanks
iii. laser welding
(b) Aluminium
a. Aluminium alloys for body-in-white
applications
b. Aluminium alloys for brazing sheet applications
(c) Magnesium
ii) Plastics & Composites
(i) Fabrication
(ii) Cost
(iii) Manufacturability
(iv) Design data/test methodologies
(v) Joining & Inspection
Contents
PLANT & MACHINERIES

ELECTRICITY / TRANSFORMER/ GENERATOR

SHEARING MACHINE

CNC BENDING MACHINE

PLASMA CUTTING MACHINE

SHOT BLASTING MACHINE

LATHE MACHINE

GRINDING MACHINE

WELDING MACHINE

PNEUMATIC AIR COMPRESSOR

PAINT BOOTH

OVERHEAD BRIDGE CRANE

CHASSIS

HYDRAULICS

TIPPERS AS A PRODUCT

HYPRATEK CYLINDER SPECIFICATIONS

VOLUME CALCULATOR

WEIGHT CALCULATOR FOR SHEET METAL

MATERIAL SPECIFICATION