SUMMER TRAINING PROJECT REPORT
ASHOK LEYLAND, PANTNAGAR (HINDUJA GROUP)
PRESS SHOP WORKING & LINE LAYOUT
TRAINING SUPERVISOR SUBMITTED BY
Mr. NITIN PANCHOLI SHIVAM AGRAWAL
BATCH NO. :-16
SESSION 2011-2015
UNIVERSITY OF PETROLEUM & ENERGY STUDIES
DEHRADUN
CONTENTS
1.Introduction
a.Overview of the industry as a whole
b.Press line
2.What is Destacker?
3.Components of Destacker
4.Function of Destacker
5.What is ROBOT?
6.Components of ROBOT
7.Function of ROBOT
8.What is PRESS?
a.Types of presses in working line
b.Working
9.Components of PRESS
10. Working
11. Function and specifications of PRESS
a.Observations
b.Operations performed on the panel
12. Defects and Remedies
13. Advancements
INTRODUCTION
1.a Overview of the company as a whole
Over a period of more than two decades the Indian Automobile
industry has been driving its own growth through phases. Ashok
Leyland is an Indian automobile manufacturing company based
in Chennai, India. Founded in 1948, the company is one of India's
leading manufacturers of commercial vehicles, such as trucks and
buses, as well as emergency and military vehicles. Operating six
plants, Ashok Leyland also makes spare parts and engines for
industrial and marine applications. It sells about 60,000 vehicles
and about 7,000 engines annually. It is the second largest
commercial vehicle company in India in the medium and heavy
commercial vehicle (M&HCV) segment with a market share of
28% (2007–08). With passenger transportation options ranging
from 19 seaters to 80 seaters, Ashok Leyland is a market leader in
the bus segment. The company claims to carry over 60 million
passengers a day, more people than the entire Indian rail
network. In the trucks segment Ashok Leyland primarily
concentrates on the 16 ton to 25 ton range of trucks. However
Ashok Leyland has presence in the entire truck range starting
from 7.5 tons to 49 tons. The joint venture announced with Nissan
Motors of Japan would improve its presence in the Light
Commercial Vehicle (LCV) segment (<7.5 tons).
1.b Press line
Press line is a working line in which different funtions are
performed on a sheet to form a desired product.
The different components of press line are:-
1. Destacker
2. Robots
3. Infeed conveyor
4. Blank Washing unit
5. Blank Oiling unit
6. Centering unit
7. Press section
8. Inspection conveyor
2. What is Destacker?
Destacker is a machine where the sheets of metal are
placed in a form of stack and are removed one by one by
the help of a robot and proper positioning and sensing of
the pile are also done by a destacker. Destacker is the first
unit of the press line from where the process of
manufacture starts.
3. Components of a Destacker
A destacker consists of following components:-
ROLLER:- It is used for easy movement of stack and
prevent the surface damage.
HOLDING PINS:- These are used for proper positioning of
the stack and to avoid the unnecessary movement.
STOPPER:- When our destacker is moved inside the main
working line after being loaded it prevents the forward
motion of the stack when our destacker is in motion.
HOLDING MAGNETS:- They provide magnetic field for
proper positioning of sheet and to prevent motion of the
sheets.
SENSORS:- These senses the contact of the sheet metal to
the holding magnets and tells the presence of the sheets
on the destacker.
OBSTRUCTION DETECTION SENSOR:- They sense the
presence of the obstruction on the inlet when the working
is going on and stops the process when obstruction is
detected.
AIR FLOW UNIT:- These units flow the compressed air into
the sheets to separate them and makes it easy for the
robot to lift a single sheet.
4.Function of Destacker
The main function of a destacker is to provide the raw
material(metal sheets) to the main press line. For the time
management there are two destackers provided in the line.
Destacker is a machine where the sheets of metal are placed
in a form of stack and are removed one by one by the help of
a robot and proper positioning and sensing of the pile are
also done by a destacker.
5. What is ROBOT?
A robot is a mechanical or virtual agent, usually an electro-
mechanical machine that is guided by a computer
program or electronic circuitry. Robots can be autonomous or
semi-autonomous and range from humanoids. Robotics is the
branch of technology that deals with the design, construction,
operation, and application of robots, as well as computer systems
for their control, sensory feedback, and information processing.
These technologies deal with automated machines that can take
the place of humans in dangerous environments or manufacturing
processes, or resemble humans in appearance, behavior, and/or
cognition. Many of today's robots are inspired by nature
contributing to the field of bio-inspired robotics.
The robot used in press shop is of company ABB. ABB is
a multinational corporation headquartered in Zurich, Switzerland,
operating in robotics and mainly in
the power and automation technology areas. It ranked 143rd in
the Forbes Ranking (2010). ABB is one of the largest engineering
companies as well as one of the largest conglomerates in the
world. ABB has operations in around 100 countries, with
approximately 145,000 employees in June 2012, and reported
global revenue of $40 billion for 2011.
6.Components of robot
A robot consists of the following components:-
MOTORS:- There are 6 motors in a robot which gives six axis of
rotation to the robot. These motors are servo type.
BALANCING CYLINDER:- It prevents the unnecessary movement
of the arms of robot and provides balance to the machine.
VACUUM GENERATOR:- It is a device which sucks in the air
from the vacuum cups and generates vacuum in the cups in
order to lift the metal sheet.
SOLENOID VALVES:- These are used for the controlling of the
vacuum cups. According to the need the solenoid valves cut off
the air supply in the vacuum cups which are not needed.
SENSORS:- There are two sensors which senses the thickness of
the metal sheet which the robot is lifting. When the thickness
exceeds the given limit, the sensor detects and operation stops.
Generally we give tolerance of 3mm.
VACUUM CUPS:- These are the cups which lifts the metal sheets
by the use of vacuum generated by the vacuum generator.
There are 24 cups which are used according to the need of the
sheet.
7.Function of ROBOT
On the whole there are seven robots in press line and their
work is to provide the metal sheet from one unit to other and
the drawn part from one press to the other which in turn helps
in faster and accurate functioning. They also helps in time
reduction of production and also protects the sheets from
unwanted stains and defects. The vacuum cups are adjustable
according to the shape and size of the formed product.
8.What is PRESS?
A forming press, commonly shortened to press, is a machine
tool that changes the shape of a workpiece by the application
of pressure. Presses can be classified according to
their mechanism: hydraulic, mechanical, pneumatic;
their function: forging presses, stamping presses, press
brakes, punch press, etc.
their structure, e.g. Knuckle-joint press, screw press
their controllability: conventional vs. servo-presses
8.a Types of presses in working line
There are 5 presses in the working line as follows:-
DL4P-2000(LINK DRIVE)
DE4P-1200(ECCENTRIC DRIVE)
DE4P-800(3 Presses)
8.b Operations performed by presses
Different operations can be performed by the presses
according to the suitable die used and final panel to be
produced. Following are the general operation which are
performed.
DRAWING
TRIMMING
PIERCING
BLANKING
RESTRIKING
9. COMPONENTS OF PRESS
There are following components of press:-
Generally we have four basic components of a press
Bed
Column
Ram
Head
BED:-It is the lower most part of the press and used to take the
pressure exerted by the press.
MOVING BOLSTER:- It is the part mounted on the bed and it is
movable so that different dies can be installed in the press.
ANCHOR PIN:-Once the die has been kept on the bolster it is
matched with the center line of the die and the bolster
respectively and once they are matched die is forced inside to
fix in anchor pin it holds the lower portion of the die
MECHANICAL CLAMP:-After anchor pin is fixed lower portion of
the die is fixed by fixing the nut bolts to prevent the unwanted
motion of the die
COLUMN:-It support whole of the assembly to take the load
from the above supported unit and transfer it to the bed or
ground.
RAM:-The part which moves up and down to produce the
desired panel by exerting pressure on the fixed part is called
ram.
SLIDE:-lower portion of the movable ram on which other half of
the die is mounted.
DIE PNUEMATIC CLAMP:- These are 6 in no and are spring
loaded positive clamp and has the capacity of 10 ton used to
hold the upper portion of the die .These are less prone to
failure as loaded spring is used here unlike hydraulic clamp
more prone to failure
DIE ID/DIE SENSOR:-For producing a particular panel fixed type
and no of die are used they are given fixed id called die id so
that particular programe can be used and after the stroke the
part get fixed in the lower die due to high pressure so to ensure
proper removal of the part by the robo air is supplied done by
the die sensor.
HEAD:-All the gearing mechanism whether it is eccentric drive
or link drive motors power transmission unit is installed in the
head.
DIE CUISION SYSTEM:-
This system is install only in the DL4P-2000, 2000 is tonnage
capacity of press .It is most advance system used to prevent the
part from the brakage or any kind of defect arises from the high
pressure as in first press maximum tonnage is required for
drawing so due to high pressure our part may get ruptuterd but
by using cuision system it can be prevented
10. WORKING
A pressure of 500T is maintained in the cuision system through
hydraulics and high pressure works against this pressure and it
is transmitted slowly and decipatevely hence it act as the
cuision and our part get saved. Hydraulic fluid which is used
here is AW68 and to cool this system and other part of the
press where there is flow of lubricating oil we use The FORCED
AIR COOLED SYSTEM
11. FUNCTION AND SPECIFICATION OF THE
PRESS
The main function of the press as we have already discussed is
to perform the particular operation on the metal sheet by the
application of high pressure. So to achieve the same we have 5
presses in the shop line with different specification.
Specification of the press includes (Taking example of 2000 ton
press)
MODEL - DL4P-2000
CAPACITY - 2000 TON
STROKE LENGTH - 1000mm
STROKE/MINUTE - 10-20
DIE HT - 1400mm
SLIDE ADJUST - 600mm
SLIDE AREA - 400*2600mm 2
BOLSTER AREA - 4000*2600mm 2
BOLSTER THICKNESS - 300mm
MAIN MOTOR(KW*P) - A.C 315*4
ADJUST MOTOR(KW*P) - A.C 15*6
VOLTAGE(V*HZ) - A.C 415*50
11.a OBSERVATION
BODY SIDE OUTER RH
11.b OPERATION PERFORMED ON THE PANNEL
BLANKING
DRAWING
TRIMMING/PIERCING
CUTTING
RE-STRIKING
12. DEFECTS OCCURS IN THE FINAL PANEL
SCORING
BURR
REMEDY:-
Cushion pressure is adjusted
Proper lubrication flow
13. ADVANCEMENT:-
When the press lifts after performing the operation high load is
encountered by our motors and power required is more so to
increase the life of press we use the compressed air system
tank for easy lifting of ram it increases the efficiency and life of
press. This system is called counter balance.
14. NO OF PANEL AND DIE IN THE PLANT
In Ashok Leyland Press Shop ,there are
UNITS Number of units
1. Die 144
2. Die set 37
3. Panels 57
4. Press Machine 5
DELP 2000 Ton press 1
DE4P 1200 Ton press 1
DE4P 800 Ton press 3
5. ABB Robo unit 7
