MUFFLER BOX CELL

INTRODUCTION
Emission control equipments play a great role in the smooth functioning of a vehicle engine. It is an important part in vehicle which uses petroleum products as fuel. It controls the toxic gas emitted from the engine due to the internal fuel combustion. Mainly emission control involves two steps. First is the conversion of toxic gases like carbon monoxide into less toxic carbon dioxide. Next function is to reduce the noise coming from engine due to the expansion and compression in engine. The part which converts the emission gas is called catalytic converter and noise reduction is done by muffler box. These are connected to the engine through metal boxes of suitable material. All these parts together make the emission control system of a vehicle. The emission control system can be divided widely into two. Hot end and cold end parts. The Parts which carry gas just emitted from the engine is called hot end. Catalytic converter comes under this section. Parts which comes at the outlet end is called cold end. Muffler comes in this end. When the gas is emitted it is transferred to the catalytic converter. Then the converted gas is passed through perforated tubes inside the muffler box. After the conversion and noise suppression the smoke is emitted outside through the tail pipe.

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PROJECT BRIEF
Aim
To make Muffler Boxes for various vehicles as part of my Industrial Training.

Objective
To get the industrial experience by doing a real time project in an industry. To have basic idea about the production and functioning of vehicle exhaust system.. To get familiarized with different industrial management techniques like Kanban, kaizen etc. To have a basic idea about quality control and product development methods in an industry. To have a basic idea about loading, operation and unloading in different machines.

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PROJECT TARGET

Target
Muffler boxes are used to reduce the noise from vehicles by absorbing the noise coming from engine. Sound of engine may vary according to the fuel used and engine design and output.

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PROJECT DETAILS
Project Relevance
Today the motor vehicles population is increasing day by day. The environmental sound pollution created by vehicles will be the greatest pollution if it is having no mufflers. By the sudden expansion and compression strokes inside the engine, the air outside the piston rod also expands and converges suddenly. It creates a continuous sound of low and high frequencies. Low frequency high amplitude sound is created by cylinder strokes also have high frequency low amplitude noises also by the friction and small vibrations in the engine. By using a suitable muffler box both low and high frequency noises can be reduced to a considerable range. The designing of muffler is done according to the noise created by the engine.

Customers Requirements
Sound coming from the engine should be within the range given by the government of the country where the mufflers are using. Moreover it should be acceptable for the customer. The size and shape of the muffler should be designed in such a way that it should fit correctly inside the vehicle. The material used for muffler should be resistant to corrosion and should not get broken by impact.

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The Emission Control System

Before going to the detailed study about the production of emission control devices we should have some basic idea about the emission control system. Three main parts of an emission control system are; 1. Catalytic converter 2. Muffler box 3. Boxes

Catalytic Converter Pipe

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1. Catalytic Converter

A catalytic converter is a device used to reduce the toxicity of emissions from an internal combustion engine. A catalytic converter provides an environment for a chemical reaction wherein toxic combustion by-products are converted to less-toxic substances

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Construction
The catalytic converter consists of several components: 1. The core or substrate.

The core is often a ceramic honeycomb in modern catalytic converters. The honey-comb surface increases the amount of surface area available to support the catalyst. 2. The washcoat. A washcoat is used to make converters more efficient, often as a mixture of silica and alumina. The washcoat, when added to the core, forms a rough, irregular surface, which has a far greater surface area than the flat core surfaces do, which then gives the converter core a larger surface area 3. The catalyst

Platinum is the most active catalyst and is widely used. Palladium and rhodium are two other precious metals used. Platinum and rhodium are used as a reduction catalyst, while platinum and palladium are used as an oxidization catalyst.

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Muffler Box

CASE SKIN

OUTLET INLET

BAFFLE PLATES PERFORATED TUBE END PLATES Mufflers are used to reduce the noise coming from the engine. Sound of the vehicle is a pressure wave formed from pulses of alternating high and low air pressure. These pulses make their way through the air as sound. In an engine, pulses are created when an exhaust valve opens and a burst of high-pressure gas suddenly enters the exhaust system. The molecules in this gas collide with the lower-pressure molecules in the pipe, causing a sound wave to generate. Mufflers are a set of specially designed tubes and perforated plates which cancels the sound. The tubes and plates inside the mufflers are collectively called as gut. Parts of muffler are; 1. 2. 3. 4. Case skin Perforated tubes Baffle plate End plate
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1. Case skin It is the outer casing of muffler. Most of the vehicle uses stainless steel for case. Some company uses titanium or aluminum alloys of iron. Its function is to protect the gut from external environment and impacts which cause destruction of muffler. 2. Perforated tubes These are the steel tubes inside the muffler which absorbs the low frequency sound and functions as a passage for emission gases to move in and out of the muffler.

3. Baffle plates It is a perforated stainless steel plates in which tubes are welded to form the gut. Perforations are made in according to the rate of sound coming from engine. It also increases the strength of case skin. 4. End plates It is used to close the two ends of muffler case. It is provided with hole to connect the tubes inside muffler with outer boxes.

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How mufflers work

We know main part of a muffler is a simple set of tubes with some holes in them. These tubes and chambers are actually as finely tuned as a musical instrument. They are designed to reflect the sound waves produced by the engine in such a way that they partially cancel themselves out. The tubes enclosed by the case skin makes the resonating chamber. In this chamber the sound waves undergoes reflection. The chamber is tuned to cause destructive interference, where opposite sound waves cancel each other out.

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PRODUCT MATRICS
In muffler box cell we are making muffler boxes for 1. 2. 3. 4. Ford India Ltd. Toyota Kirloskar Motor Ltd. Land Rover Britain. International Tractors Ltd.

1. FORD VEHICLE MODELS Figo Fiesta Icon DESIGNATION Petrol 1.19 AE 1.4 BF C195 BA Diesel 1.19 DV4 BC 1.4 DV4 CE C195 AJ

2. TOYOTA VEHICLE MODELS Innova New Innova Corolla Corolla Altis Qualis DESIGNATION Petrol 10L02 10L03 188W 10C03 Diesel 942L 186W 10N02

3. LANDROVER Land rover Diesel 4. ITL ITL Diesel and Petrol

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CELL LAYOUT
GUT 1 TROLLEY 1

MULTI SPOT WELDING

GUT 1 INSERTER

BAFFLE CHUTE GUT 2 INSERTER

WIP STAND

GUT 1 TROLLEY 2

FLANGER SINGLE SPOT WELDER 2

WIP STAND

END PLATE CHUTE

SINGLE SPOT WELDER 1

END SPINNER CASE MAKER

LEAK TESTER CASE SKIN TROLLEY F.G. TROLLEY

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CELL ALLOCATION
MULTI SPOT WELDER CHUTE

GUT 1 INSERTER

4
CHUTE GUT 2 INSERTER

CHUTE

WIP FLANGER

3
SINGLE SPOT WELDER 2 W IP

SINGLE SPOT WELDER 1 W IP

2
CASE MAKER

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MUFFLER BOX CELL

LEAK TESTER F.G. TROLLEY

1
CASE SKIN TROLLEY

WALK WITH PART

WALK W/O PART

CELL LAY-OUT EXPLANATION CASE MAKER

Case maker is the first machine in box assembly line. It is used to make the metallic case for the muffler box. It folds and lock the two opposite ends of sheet metal to form the case. It is driven by a hydraulic motor and electro pneumatic cylinders for clamping. It is controlled by push buttons and sensors. It uses a set of rollers to lock the two edges of sheet metal.

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SINGLE SPOT WELDER

It is used to do spot welding on the lock seam of the muffler case. It uses a 10mm dia spot welding tip. It uses a foot lever operated pneumatic cylinder for pressing the welding head.

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PNEUMATIC CYLINDER

WELDING HEAD WELDING TIP WORK HOLDING RODE

FOOT PEDAL SWITCH

The welding head is actuated by the pneumatic double acting cylinder. It uses a foot pedal operated switch to activate the pneumatic valve. It is given with an air supply of 4 to 6 bar.

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A small fluctuation in the pneumatic air pressure from the allowable tolerance can change the welding strength. A low pressure creates a weak welding and a high pressure makes over penetration of welding tip on work which cause leak in spot weld. So a pressure switch is connected to the pneumatic supply. If there is a change in pressure from given range the pressure switch will open and stops the welding operation. It is a resistance spot welding machine. The welding process need not requires any filler materials flux or gas. In this two layer of similar material are joined by melting and pressing the melted point. The spot is melted by the temperature created by the resistance of sheet metal to pass electricity from one electrode to other. The electrodes are the welding tip and the work holding rode. To avoid welding of electrode with the sheet metal copper is selected as electrode; which is having less resistance. Heating of copper is prevented by circulating water through the electrode. A laser torch is fixed on the machine which is used as a pointer for spot welding.

FLANGER
It is used for make a particular profile on the case skin for joining thee end plate with the case skin. Flanger make a small folding on the edge of muffler box for spinning the muffler box edge with the end plate. End plate is a metal plate with a hole on it. It closes the two end of muffler box. The pipe is connected with the muffler through the hole in end plate.
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It is done by vertically pressing the case skin with a flanging tool driven by a hydraulic press. It uses a electrical push button controlled hydraulic cylinder with a pressure of 15 Bar. It uses a limit switch to sense the cylinder forward motion and to make the press to stop at exact position and to retract back after pressing.

FLANGER TOOL PANEL BOARD

PUSH BUTTON ACTUATORS

TOP TOOL

BOTTOM TOOL

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Flanger is a fully hydraulics operated press tool. It is given with an hydraulic supply from the hydraulic tank and pump kept near the machine. The flanger is operated by two serial pushbuttons. Two buttons are provided to ensure operator safety. As two buttons has to press, there is no chance of getting the hand inside the press while operating. The cylinders are operated by electro hydraulic valves. It is having manual and auto mode of operation. In auto mode, by pressing the pushbutton the cylinder will extends and it will press the work. After pressing, the cylinder will go back to the home position. In manual mode, there are separate switches for moving the cylinder to forward and backward. The top plate and bottom plate are stopped by mechanical stoppers to avoid the accident or damage to part if the limit switches or sensors are failed to operate.

FLANGER HYDRAULIC PUMP

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ELECTRIC MOTOR HYDRAULIC PUMP FLUID LEVEL INDICATOR TANK

PRESSURE GUAGE

THE HYDRAULIC PUMP Hydraulic cylinders are used to actuate the double acting hydraulic cylinders in the flanger. The hydraulic pump is mounted at the back side of the flanger. The hydraulic fluid is supplied from a centralized hydraulic fluid to the small hydraulic tank in the machine. It helps to keep the fluid level in the small tank in same level. A hydraulic pump is fitted on the tank. It pumps the hydraulic fluid to actuate the cylinder. It is rotated by a 230V induction motor. A pressure gauge is used to monitor the pressure level of hydraulic fluid. The oil level in the hydraulic tank is monitored by a fluid level indicator fitted on the hydraulic tank. The pressure range for flanger is from 80 to 110 kg/cm2. The motor used is a single phase induction motor having 2 HP power working by a 230V ac supply.

OPTICAL SAFETY GUARD

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TRANSMITTER MODULE

RECIEVER MODULE

The press is connected with an optical safety guard module. It is kept on both sides of the press. It consists of a transmitter and receiver module. It uses an IR transmitter array in the transmitter section. Parallel to the transmitter module the receiver is mounted on the opposite side. The receiver will always sense the signal if there is no barrier in between. When the press is coming down the safety guard is on. If anything came in between the field of safety guard, the cylinder will stop at that position. The cylinder will continue the operation, if the barrier is removed.

TRANSMITTERER MODULE

RECIEVER MODULE

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The fluid gets heated due to the continuous motion of cylinder and hydraulic pump. So the fluid is passed through a cooling tower before going back to hydraulic tank after operation. Inside the cooling tower water is circulated to cool the fluid. The hot water is collected in a cooling plant outside the cell.

Same specification hydraulic power supply is used for gut inserter pressing machines also.

GUT INSERTER
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It is a hydraulic press which is used to insert the gut inside the case skin. It uses two hydraulic cylinders actuated by push buttons. The cylinder expansion and retracted end is sensed by using limit switches. The gut is loaded on the top tool. The case skin is loaded on the bottom tool. It uses 15 Bar pressured hydraulic fluid power. For Ford and Land Rover models whole part of the gut is inserted at a time. So it uses only one gut inserter machine. For Toyota the gut is inserted by two stages so it uses both Gut 1 and Gut 2 Inserter machines.

Gut 1 Inserter

Gut 2 Inserter
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Gut inserter 2 is not used inserting in all models. In Toyota it is used for inserting a third baffle into the case skin, in which already the gut is inserted. But in land rover only gut 1inserter 2 only is used to insert ythe gut. It have no secondary gut insertion. The hydraulic pump and cylinder used in it is similar to that of gut inserter 1.

MULTI SPOT WELDER

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It consists of an array of eight pneumatic cylinder operated spot welding heads. By pressing one push button it make spot eight spot weld on case skin. One cycle consists of four steps in which each step consists of simultaneous actuation of two cylinders. The spot welding tip and work holding fixture is made of copper. It uses resistance welding. The diameter of spot weld is 4mm. The cylinder is actuated by a 5 bar pressure pneumatic DAC. The controller for multisport welder is a PLC which actuates the solenoid operated pneumatic valves. Retraction and expansion is sensed by optical proximity switches.

This machine is used only for Corolla and Innova models of Toyota Kirloskar Motor Limited.
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It is having two stations. Station 1 is for corolla and station 2 is for Innova.

CYLINDER

WORK HOLDING FIXTURE

WELDING TIP

OPTICAL PROXIMITY SWITCH

PLC PANEL BOARD

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PLC MODULE POWER SUPPLY

TIMER ARRAY

RELAY ARRAY

TRANSFORMER

CONNECTOR ARRAYS All operations in the multisport welder is controlled by a PLC based control system. It takes the inputs from various input devices in the machines. It includes input push buttons and different sensors for various purposes. In this some sensors are optical proximity switches which acknowledges the cylinder extracted and retracted end positions which is used to actuate the welding heads. Other sensor input devices are some limit switches which senses the position of work to check whether work is clamped at the correct position or not. The photo guard for operator safety is also connected to the PLC. Other devices connected to the PLC are the output of pneumatic pressure switch and external timers. The pressure switch produces a signal when the input air pressure is out of the given range. External timers are used for changing the time delay given for various processes to start or stop. Even PLC can provide timer operation, but external timer is used so that without going to plc programming any operator can change the time delay easily.

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Relay array are used to connected many devices with PLC input and output. It helps to provide electrical isolation between external devices and plc input/output modules. Connecter arrays are a set of parallel connectors. All wires to, and from the PLC panel board is connected to a connector. Each connecter is a given with a tag which shows which contact the wire is connected. So for changing a connection in PLC there is no need to disturb the panel board wiring and PLC module connections

CONTROL PANEL BOARD

The control panel board consists of switches and indicator lamps and an LCD display and a job counter. Switches includes machine ON / OFF switches Job counter ON / OFF switch and SET/RESET button. Welding ON/OFF switch. Welding parameters changing switches. Fault reset switch. Machine home position switch.

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SWITCHES AND INDICATORS ON MULTISPOT WELDER

1. Power Lamp It indicates whether the machine has switched on and ready for operation. If any interrupts are present then power lamp goes off. 2. Home position Lamp The home position lamp indicates whether the machine in home position and ready for operation. 3. Program Error Lamp The error lamp indicates whether any error occurs in PLC or any parameter. If the error lamp is glows then we have to wait until it goes off. Sometimes we have to manually correct the error or bring the machine to home position.

4. Cycle ON indicator Lamp It as a lamp which indicates whether the Welding cycle is ON or OFF. It will be ON when the machine starts the welding cycle is going on. 5. Power ON/OFF switch The power ON/OFF switch is used to switch on the power supply to the machine 6. Master start switch The master start switch is used to start and initialize PLC. After pressing the switch we have to wait until lamp glows. 7. PLC Program reset switch This switch is used to reset the PLC after some error occurs. If the program execution is stopped due to an interrupt from the safety guard, the cycle can be restarted by this switch, 8. Fault reset switch It is used to continue a stopped program from where it is stopped; when the program execution is interrupted by the error in loading or an interrupt signal from safety guard. 9. Job selector switch The job selector switch is used to select the type of operation. The multi spot welder is having two type operations. One for petrol and other for diesel boxes
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10. Manual / Auto selector switch The manual/auto selector switch is used to select manual mode or automatic mode of operation. In auto mode, by pressing one push button all spot welding in that raw is done and the part is ejected. In manual mode only one operation is done and it will not continue to next operation. For checking machine and for doing a partial cycle, manual mode is used. 11.Emergency stop switch This button is used to stop the machine in its last position if any problem occurs for operator or part. 12.Welding parameter controller module. It is a microprocessor based controller which is used to control the different parameters for multisport welding like welding temperature, weld head on time, etc. It is having a 16x2 alphanumeric LCD matrix keypad which displays the parameters. 13.Weld ON/OFF switch The weld on off button is used to on and off the welding. It is kept in off position when testing is going on.

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END SPINNER
It is a machine used to join the two end slate with the case skin. The end plate is joined with the case skin should be a leak proof permanent joint It has a pair of two different type rollers. One roller for spinning the edges of case and end plate, and the other is for flattening the spanned joint. Spinning roller makes the two sheets of metal o get joined tightly by interlocking of the sheets. Flattening roller increase the strength of joint by pressing the spanned joint. It helps to make the joint fully leak proof, so that the high pressure emission gases will not get leaked through the jointed end. Both top tool and bottom tool is doing the end spinning operation. It is having one flattening roller and one spinning roller on both top and bottom tool. In this machine the box is loaded vertically. A hydraulic motor rotates the box slowly. At the same time the spinning rollers is pressed against the edges of case and end plate .The rollers are mounted on a shaft with a bearing so that it can rotate over the box end freely. The box shape will be different for different model. The top tool can be moved up and down so that the tool can be adjusted for different height by a lock nut. The rollers should move according to the cross sectional shape of box. It is done by specially designed cam on each vehicle models spinning tool. After each operation the top tool will go up so that loading and unloading of part can be done. When next part is loaded the top tool will come down and clamp the box and spinning is done. The up and down motion of top tool is done by a hydraulic cylinder.

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END SPINNER

TOP TOOL

ROLLER

BOTTOM TOOL

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END SPINNER BOTTOM TOOL

FLATTENING ROLLER

SPINNING ROLLER The rollers are made of carbide. The rollers are rotating over case skin continuously, and this will cause the roller to get worn out. The wear and tear to roller cause a considerable change in the desired profile to be achieved by spinning. The spinning tool for different models changes according to the cross sectional shape and size of each muffler models.

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LEAK TESTER
It is a machine which is used for the final checking of muffler. In this the leak value for each box is measured. It passes air of a given pressure into the muffler box through its inlet pipe by closing the outlet opening. Then the pressure inside the box is measured. For each box a particular leak value range is given by the customer. If the leak value is matching to this range a green indicator will glow. Then the leak value is written on the box and the box is sent for further assembly. If the actual leak value is more than the given range , a siren is blown and the box should be checked for any crack or damage. If it cannot be corrected, the box will be rejected. Some boxes can be corrected by closing the leaked area without affecting its quality requirements. While testing the leak value the box is immersed in water so that the leaking place can be seen visually by the inspecting person.

AIR SUPPLYING BUNK AND CYLINDER MUFFLER HOLDING FIXTURE

WATER TANK
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Material Rack

The material rack is used to place the row materials for production. The raw materials which are kept in small bin are kept on this stand for loading into the machine. In box cell, baffle plates end plates etc. are keeping on this stand. It is having three platforms. Two platforms on the topside are used to keep the filled bin. The lower platform is used to keep the empty bins.

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WIP stand
The WIP (work in process) tables are used to keep the parts undergoing process before loading to the machine. In our cell we are using around 3 WIP stands. The number of WIP stands will be changed according to the parts which is manufactured. The WIP stand is a small table in which the part can be keep safely while it awaits machining. `

In box cell, first WIP stand is used to keep the flanged case skin which has to be loaded to the gut inserter 1. Second WIP stand is used to keep the box after finishing the multisport welding. From this WIP stand the next person will load it to he gut inserter two. Third WIP stand is used to keep the boxes which are waiting for end spinning operation; after unloading from the gut inserter two.

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GUT TROLLEY
It is used to carry the gut from the gut assembly cell to the box cell. The gut for all models will be made and kept in the finished goods area of gut assembly cell is kept inside this trolley. The trolley containing the required gut will be brought near the gut inserter in this trolley. It is having a kanban slot to put the kanban card for the corresponding model. The number of gut inside trolley will be different according to the size of gut.

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FINISHED GOODS AREA

It is the place to keep the finished boxes coming from the box cell. The boxes are collected in the box cell FG trolley and it is moved to this area. Each model will be having specific columns to keep the boxes, which is marked by lines. In this further assembly of ford model is done in the same company. For Toyota it is done at Bangalore plant. Land Rover is done at UK. The boxes which are going out for further assembly is checked thoroughly at here to avoid the quality problems.

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PROCEDURE OF WORKING
From starting of the shift to the end there is a prior planning and procedure for every activity happening in the cell in a shift. Before starting the work in a shift the operator has to verify that all machines and safety devices are functioning properly. For ensuring that all the procedure are done correctly, there are certain check list for all activities. It includes the work standards, OPM sheets etc. For ensuring proper daily preventive maintenance we are following a method which is called as OPM. OPM means Operator Preventive Maintenance. In each and every machine there will be a check sheet which is mentioning the check points of that particular machine. This sheet is called as OPM sheet. It is compulsory that before starting the work the operator should have to fill the OPM sheet. One of the important things is that, the operator should wear the goggles, safety shoes, ear plug, cotton gloves and over coat to work safely in every cell. Before starting the work the team should plan that which all the products are today going to make. The supervisor will be giving the sheet which contains the customer requirements for the particular shift of 8 hours. So, as per the plan the operator have to place the KANBAN cards in the TAKT time shelf. TAKT time is the time given for the operator to manufacture one trolley of finished goods. Each and every model will be having its own cycle time. As per the cycle time operator has to produce the boxes. Each and every model there is a separate trolley, and the number of boxes can placed over it can be varies. The standard trolley size varies and also number of boxes per trolley varies according to the size of model. Each products FG trolley has its own standard capacity that how much it can carry. As per this we have to place the KANBAN card. One KANBAN card is only for one FG trolley. We must not put more than the number of part specified in the KANBAN card for every model. A KANBAN can be put if the trolley contains the correct amount of part as per the KANBAN. After completing one trolley the operator has to put accepted tag as well as KANBAN card for the FG trolley and move the trolley into FG storage area. If some boxes are need any rework means, that boxes we can keep in a
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separate trolley and we have to keep aside. In that trolley we have put the hold tag which is mentioning what rework has to do for that boxes.

KANBAN card This is a KANBAN card of the pipe bending cell. By looking the card we can be able to know all details about the material in that trolley. The background color given in the PART NAME is the color code for that model vehicle. Each card has its own serial number. It is given on the card above as CARD # 2

Accepted card

It is kept with the finished parts coming from each cell if the part is checked OK

Hold card
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It is kept in the trolley where parts to be reworked are kept.

Rejected Card

It is kept in the trolley where rejected part are kept.

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CONCLUSION
By this industrial training I got a direct exposure to an industry and the different methods and techniques adopted in production and management of an industry. I also got familiarized with the production steps of the exhaust system of a vehicle; especially the production of different muffler boxes in the muffler box assembly cell.

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