Basic understanding of bearings & component of tractor and

Research on solution for improvement of radiator and hydraulic System.

A PROJECT REPORT
Submitted in partial fulfilment of the
requirement for the award of the
degree of
BACHELOR OF TECHNOLOGY (B. Tech)
in
Mechanical Engineering
by

(ANIRUDH CHANDRA)
(189402140)

Department of Mechanical Engineering

MANIPAL UNIVERSITY
JAIPUR, JAIPUR-303007
RAJASTHAN, INDIA
JUNE/22
 DEPARTMENT OF (NAME OF THE DEPARTMENT)
MANIPAL UNIVERSITY JAIPUR, JAIPUR – 303 007 (RAJASTHAN), INDIA

Date

CERTIFICATE

This is to certify that the project titled BASIC UNDERSTANDING OF BEARINGS &
COMPONENTS OF TRACTOR AND RESEARCH ON SOLUTIONS FOR
IMPROVEMENT OF RADIATOR AND HYDRAULIC SYSTEM is a record of the
bonafide work done by ANIRUDH CHANDRA (189402140.) submitted in partial fulfilment
of the requirements for the award of the Degree of Bachelor of Technology (B. Tech) in
(Discipline) of Manipal University Jaipur, during the academic year 2019-20.

Dr. Ashish Goyal

Department of Mechanical Engineering
Manipal University Jaipur

Dr. Rahul Goyal

HoD, Department of Mechanical Engineering
Manipal University Jaipur
Date

CERTIFICATE

This is to certify that the project entitled BASIC UNDERSTANDING OF BEARINGS &

COMPONENTS OF TRACTOR AND RESEARCH ON SOLUTIONS FOR IMPROVEMENT

OF RADIATOR AND HYDRAULIC SYSTEM was carried out by ANIRUDH

CHANDRA(189402140) at ESCORTS KUBOTA PVT LTD, FARIDABAD under my guidance

during JANUARY 24TH 2022 to MAY 24TH 2022.

Amit Kumar Singh

Senior manager
Escorts Kubota pvt Ltd, Faridabad
 ACKNOWLEDGMENTS

The achievement that is associated with the successful completion of any task would be
incomplete without mentioning the names of those people whose endless cooperation made
it possible. Their constant guidance and encouragement made all my efforts successful.

I take this opportunity to express my deep gratitude towards my project mentor Dr. Ashish
Goyal and organization mentor , Mr. Amit Kumar Singh , for giving such valuable
suggestions, guidance, and encouragement during the development of this project work. I
would also like to thank my Department of Mechanical for always supporting me helping
me when I needed it the most. I would like to thank my H.O.D. Dr. Rahul Goyal

Last but not the least I am grateful to all the employee’s at Escorts Kubota Pvt Ltd
Faridabad, Haryana .
 ABSTRACT

The agriculture machinery are the most important part in India as we are second largest producer of
wheat and rice ,India ranked under world’s five largest producer of over 80% of agriculture items. So
working under this sector is important from a point of view of mechanical engineer as it teaches you
how this machinery are able to perform well in field as well as on roads for transportation and are able
to contribute in infrastructure sector , so learning of tractors and its component will help me in being
better engineer to work in this particular sector .

My objective in the organization was to do analysis of basic designing concept that is GD&T
(geometrical dimension and tolerance ) to correct the drawing with reference to GD&T parameter that
is form, position ,orientation ,location, and profile of the component after that I have to report to my
external mentor regarding the correction which I have done, in LD ( learning and development part
my role was to do analysis of different types of bearing which are feasible for new transmission and
in power train to check their testing parameter like dynamic load ,dimensional limits ,rotational speed
,misalignment all the reading of testing I have to give a report to my external supervisor and In R&D
department I have learned basic understanding and working of component & done research on
solution for improvement of radiator and hydraulic system and conceptual design of radiator. My aim
is to learn as much as I can about the workings and functioning’s of the tractor, so as to use and manipulate
this information to my profit in the future aspect. The intention of this report is to provide decision makers
and authorities with an overview of the working of tractor and innovative design for future aspect in
agriculture machinery .

While I was learning new things in the industry I also learned about the practical implementation and
measuring of hardness in components like gear , spline gear and shafts in heat treatment how to measure
effective case depth of any component what are the scale of ECD it should be between 0.6 to 0.9 mm at
513 HV vicker’s hardness and four parameter in measuring hardness are surface hardness , core hardness
ECD and microstructure .

I gained sound knowledge of software like Creo parametric and Nx modelling and also learned how to do
surfacing FRP parts like fender bonnet , metal casing in front , learned about shape testing machine cv
3200 h4 how to operate it , gear profile machine TTI 300 R used to measure gear profile .
 LIST OF FIGURES
Fig.1 Kubota tractor Page 10
Fig.2 Starter motor & connection Page 11
Fig.3 Alternator Page 13
Fig.4 PTO housing Page 14
Fig.5 Example of design release Page 17
Fig.6 Cad design and chassis Page 19
Fig.7 Tapered bearing Page 19

Fig.8 Needle bearing Page 19

Fig.9 Ball bearing Page 19
Fig.10 Ball bearing Page 19
Fig.11 Cellular radiator Page 21
Fig.12 Tubular radiator Page 21
Fig.13 Radiator cap Page 22
Fig.14 Hydraulic system and ADDC Page 24
Fig.15 Pressure release valve Page 26
Fig.16 Variable displacement pump Page 27
Fig.17 Shape testing machine Page 30
Fig.18 Heat treatment process chart Page 31
Fig.19 PTO circuit Page 33
 INDEX page No
1. Introduction ……………………………………………………………………………… 8

2. Motivation………………………………………………………………………………. 16

3. Objective of work ………………………………………………………………………… 17

4. Conceptual theory...……………………………………….……………………………… 18

5. Methodology………………………………………………………………………….…… 28

6. Conclusion ………………………………………………………………………………… 34

7. Reference………………………………………………………………………………… 35

______________________________________
 INTRODUCTION

Kubota Corporation ( Kabushiki-Kaisha Kubota) is a Japanese multinational corporation based in Osaka. It

was established in 1890. The corporation produces many products like tractors and including other agricultural
machinery, construction equipment, engines, vending machines, pipe, valves, cast metal, pumps, and
equipment for water purification, sewage treatment and air conditioning.
Kubota engines are in both diesel and gasoline or spark ignition forms, ranging from the tiny 0.276 Litre
engine to 6.1 Litre engine, in air-cooled and liquid cooled designs, naturally-aspirated and forced induction.
There are a variety of cylinder configurations, ranging from single to six cylinders, with single to four cylinders
being the most common. Above mentioned engines are widely used in agricultural equipment, construction
equipment, tractors, and marine propulsion.

In 2019 global organization named Kubota which is also leading organization in production of agriculture
machinery and equipment’s in Japan decided to have a joint venture with Escorts India Pvt Ltd in 2019 they
form Escort Kubota pvt ltd from that time the production and manufacturing of Kubota tractors and escorts
are done in Faridabad.

The Research and development department of Kubota are in Japan the designs of new tractors and new proto
are built in Japan only but the correction of the design of parts that are required for development of product
are done here as we are localizing the child parts of tractor so we have to do the changes and testing according
to Indian parameters and for escorts Research and development are done here so also validation testing and
reliability factors new proto all are done in Faridabad manufacturing plant.

ABOUT THE PRODUCTS

MU4501 2WD
A Kubota MU4501 2WD tractor is considered to be one of the brand's most stylish and efficient models. The
brand is known for its products developed using Japanese technology. The 45 hp tractor model was designed
with highly advanced Japanese technologies and is full of innovative features. Kubota MU4501 2WD tractor
with 2434 CC engine capacity and 4 cylinders that generate 2500 engine rpm. This tractor also features a 45-
horsepower engine, a 38.3-horsepower PTO, and advanced liquid-cooling technology with a dry-type air filter,
making it a powerful one. Kubota's 4501 tractor is equipped with a Kubota Quad 4 Piston (KQ4P) engine
which is said to be extremely powerful and fuel-efficient. It is believed this tractor’s engine is enough to handle
all kinds of farming errands. All the functions of a tractor's engine increase a tractor working life. Both the
facilities mentioned enhance the working capability and ability of the model. All these additional features
make it more efficient and trustworthy for agriculture and allied sectors. It has two balancer shafts that rotate
the engine speed twice to minimize the noise and overall vibration of the engine. The Kubota tractor MU4501
model is fully loaded with a synchromesh main gearbox which has a synchronizer unit that provides shifting

8
instead of a collar, therefore resulting in less noise produced while shifting the gear in tractor. In addition, the
smooth gear’s transmission decreases wear and tear. Kubota MU4501 has a single-piece bonnet that is simple
to open and use with higher accessibility. This tractor is equipped with dual PTO, that includes standard and
economy PTO. The standard PTO is specifically used for heavy load application, whereas economy PTO is
for light load application. The best thing about this tractor is that it calls for much less maintenance, simply
normal check-ups keep it in good condition for a long time.

MU5501 4WD
Kubota tractors are a wide range of tractors having great efficiency and outstanding efficiency in performance.
Kubota MU5501 2WD tractor engine efficiency of this tractor is 55 HP and PTO HP is NA. The tractor has 8
Forward and 4 Reverse gears with oil-immersed brakes. The fuel tank capacity of the tractor is 65 litres which
makes it durable and long-lasting and in performance. There are 4 cylinders attached with the tractor with
outstanding ability and maximum efficiency. The company always provides the tractor according to the
customer’s choice, features, quality, and the best price of it making it suitable and affordable as per
everybody’s budget. This Kubota tractor in India is powered by a fuel-efficient engine that is compatible and
robust in use and applications. Kubota MU5501 2WD tractor has a 4-wheel drive that helps you in completing
all the tasks at ease. Moreover, these tractors are kept for all kinds of cropping like cotton, sugarcane,
vineyards, and orchards. The highly efficient transmission of the tractor ensures more PTO power delivering
superior performance in rotary implements. Kubota MU5501 2WD tractor in India in 2022 will hopefully
maintain its great functionalities too

LEARNING AND ANALYSIS IF DIFFERENT TRACTOR COMPONENT IN

DIFFERENT DEPARTMENT
The area comes under research and development EKI where research about all the basics of tractors and its
component like how radiators work and what type of air filter tractors use in normal cars we use a dry filter
but in tractors both dry and wet air filters are used as tractor works in a rural area and in the field so air filter
doesn’t work much better as wet air filter works as dust particle settle down in wet air filter which gives better
performance in the field. Most dry, or non-oiled, filter elements are made of several layers of paper, although
some people in the market do use a cotton gauze fabric. These filters generally are capable to trap dirt particles
down to less than ten microns in size. wet, or oiled, the air filter is made up of a few layers of cotton gauze
coated with a slight amount of oil because the oil acts as a sticky dirt-trap. The openings in the filter material
can be slightly larger than those in a paper filter which makes this type of filter slightly less restrictive.

HARNESS AND ELECTRICAL COMPONENT

Then harness and electrical wiring from front to end of the tractor main wiring housing the wire should be
covered with plastic pipe to avoid water from entering basically it is done after the tractor comes back to the
line from paint shop the all necessary masking should be done before doing paint as big issue comes in
grounding as paint strip of from place where screw or bolt is going to be fitted which result in the bad circuit.
9
Connections of the electric component should be checked twice before rollout as nowadays all the troubleshoot
are checked and eliminated by plugging the OBD reader in ECU so if electrical connections are not proper the
engine malfunction light will blink from beginning only.

Fig.1
Kubota tractor

10
ELECTRICAL COMPONENT AND THEIR MECHANISM
Starter motor:-Gained knowledge of starter motor and its sub-component-Armature coil, commutator,
bushes, solenoids, plunger, lever fork, pinion, and field coil working of this component is a simple and very
important role in the automotive sector as it helps in starting up the engine as we turn the key the engine turns
on and crank the starter motor engages and turn the engine allowing it to create a suction and to suck in air.
On the engine a flywheel with a ring gear is attached around the edge is fitted to the end of the crankshaft. on
the starter the pinion is designed to fit into the groover of the ring gear. when you turn the ignition switch the
electromagnet inside the body engages which pushes out a rod lever fork basically which the pinion is attached
the pinion meets the flywheel and the starter motor turn on.

Fig.2 Starter motor

Types of starter motor: -

Direct Drive starter motor and gear reduction type starter motor
1. Planetary gear reduction - it is a permanent magnet that transmits power between the pinion shaft and the
armature. The armature spins faster and with more torque.
2. Permanent magnet gear reduction - The permanent magnet gear reduction is designed to offer less weight,
easy construction, and less heat generation it features four or six magnet field assemblies rather than a field
coil starter.
3. permanent magnet direct drive – same as direct drive type only field coil is replaced with a permanent
magnet in the permanent magnet type.

11
4. Offset gear reduction- high speed low current lighter more compact easy to assemble, as it increases
cranking torque more automotive sector prefers offset gear reduction
5. Inertial starters – They are among the best starter motors, as they work perfectly during the cranking process
and even ensure that the motor part remains safe while it is cranking the engine.

Alternator
Main work of alternator is to power your car electronic like, headlight and other electronic components it
keeps electrical component running it supplies these component (headlight, electric steering taillight) with
direct current DC power and also responsible for charging battery while driving.
Location of alternator: - toward the front of your engine and are powered by engine rubber belt. power used
from crankshaft and rubber belt to move a magnet over a special surface of wire cable called conductor
working of alternator
Working of alternator
Alternator basically works on the principle of changing energy from one form to another form that is from
mechanical energy to electrical energy our engine powers a drive belt that rest on a pulley attached to the
alternator. the pulley turns the alternator rotor shaft which spins a set of magnets around the coil these spinning
magnets create alternating AC around the coil which is then sent to the alternator rectifier the rectifier converts
AC to DC.
Child parts of the alternator
1. Voltage regulator
2. The stator- the copper nest
3. The rotor- group of magnets
4. alternator rectifier – convert AC to DC
5. material used- aluminum.

___________________________________

12
 Fig.3 alternator

DRIVETRAIN
After this about the drive train how adaptor cylinder works in front axle use of knuckle arm clamps that are
attached in front axle how front axle is mounted on the front axle with the help of cross member and long
members steering mechanism, delivery of steering system as in tractor steering mechanisms in old days were
tough nowadays they use hydraulics for steering also in which delivery hose for LHS and RHS are present on
the opposite side as for left turn the delivery is in the right side and vice versa for 2WD but for 4WD for left
turn the delivery of hydraulics to adaptor cylinder for left turn present on left side only.

ADDC
ADDC section on automatic depth and draft control. The automatic depth and draft control system consists of
a depth control lever, a draft control lever, a housing, a pressure reducing valve (PRV), and a pair of lift arms.
The depth control lever is actuated for facilitating raising, lowering, and maintaining the implement at the
desired position with respect to the ground for defining the initial depth setting of the implement.

13
PTO OPERATIONS
PTO power takeoff unit It is a device that transfers power from a tractor’s engine to an implement or machine
that doesn’t have its own engine. Regardless of whether a tractor is moving or at rest, PTO transfers the power
directly from the engine to the implement. At the upper rear of a tractor, there's a hitch that has a fixed pivot
connection.

Working of PTO
PTO Shaft. The power take-off is accessed most often via an air valve or through a mechanical, electrical, or
hydraulic pump to transfer mechanical energy through a fluid system on the vehicle. A hydraulic motor
converts the fluid force back into the rotary or mechanical force.

PTO and their types: -

1. Transmission PTO: - it works only when the gear is engaged as the PTO clutch and transmission are
synchronized together to do work so their fore gear should be engaged to drive power in PTO.
2. Live PTO: - it works when the tractor is moving, or it is stationary position doesn’t matter as its uses a
two-stage clutch which means it has a separate clutch for engaging and disengaging the PTO so you can
use PTO while driving also.

Fig.4 PTO housing

14
MINOR PROJECT TOPICS
minor project of new development, research and development area where they are now building new
transmission and powertrain in which my work was to do an analysis of the different type of bearing they were
using in old transmission and what is suitable for new transmission where I did testing of transmission with
different types of bearing studied their dynamic load, rigidity where I learned the criteria of selecting new
bearing cost-effectiveness as cost matters a lot what arrangement is necessary for which bearing from the
supplier brochure testing of transmission in reliability lab with rigs, how dyno plays an important role in these
types of testing how the result is calculated by dyno runs reading mapping, etc.
the second part of the minor project contains Research on improving the functioning of the radiator as well as
the hydraulic system which includes learning the whole mechanism of radiator and hydraulics system
identifying general troubleshoot in radiators providing a solution to improve cooling mechanism in extreme
conditions proper analysis of valve used in the hydraulic system giving ideas of radiator design so that we can
make it compact and efficient.

QUALITY AND INSPECTION

Quality and inspection department where different parts and components are checked from the designing
aspect whether the part is ok or ng, different types of vernier caliper are used to measure different criteria GD
and T is the main parameter they use to measure runout, form, orientation, location and profile also different
types of machines are used for a different parameter like roughness, sharpness, contact of gear hardness of any
component, etc.

HEAT TREATMENT
Heat treatment is an important process in the automotive field as it is done for providing carbon hardness to a
particular component which can experience various wear and tear while running tractors like a shaft, gear,
spline gear, etc.

__________________________________________

15
 MOTIVATION
The main motivation behind working in this sector as previously worked in Volvo Eicher commercial vehicle
on EV skateboard chassis from working and learning from there about these sectors understanding that this
sector and agriculture sector are the main economic sector as commercial vehicles are used in transporting and
tractors are used in agriculture field of India which will lead to experience and learning.
Which will eventually help me in building my knowledge in these particular automotive in the future aspect
which is beneficial for an individual working in this sector one can contribute to our country's economy and
personal growth .

The work done presently in R&D is very much important right now as well as in future aspect because as we
know that nowadays industries always try to introduce new things in every sector whether it is automotive or
IT sector the industries are fascinated toward new development and new research as well new technologies
people who work in R&D will help me in building my ability to work with different parameters like testing
reliability and designing, this field helps you to build your vision for the upcoming time it helps you to think
in a different way to counter future problems in present time so if I am gaining knowledge from this for future
problems which will eventually enhance my learning in the automotive sector, as I am interested in design so
it will be very helpful for me to learn all things including different software and there interface.

The uniqueness of methodology is that in this organization are multiple minor projects are going on like change
of relay switches and multiple electrical as well as mechanical components with which I am able to learn all
the parameters which are used in development like as I am doing a minor project on the selection of bearing
for powertrain like in other organization the method of bearing selection is done manually by calculating the
dynamic load and static load and referring to the different brochure of bearing supplier but in this, we use dyno
reading by rolling transmission and vehicle on dyno roller which gives us reading of pressure, torque, load,
the rotational speed of bearing which is much easy for us to choose to bear which suitable for transmission
and powertrain its gives reading of each and particular area like in-vehicle not only one bearing is used but
there are different bearing in differential different in transmission so we get reading of each bearing differently
on a single dyno run.

____________________________________

16
 OBJECTIVE OF THE WORK

1. The main objective of the work is that by working on new development of product it is helpful for me
to learn about the bearing as bearing plays an important role in any mechanical machinery whether it
is an automotive vehicle or another machine, working in research and development it gives me a great
understanding of how new development of the product is done what is the process of new development.
2. It gives me a good knowledge of vision gate, concept gate, freeze gate, , pre-production gate and release
gate as my interest is in designing so it is helpful for me from future aspects working under the project
also gives me understanding regarding how testing and reliability part work in the organization for any
new development of product.
3. Learning and training in the quality and inspection department will eventually help to enter the
designing sector of commercial vehicles as GD&T (geometrical dimension and tolerance) plays an
important role in sub-component design and their validation and doing research on the improvement
of the radiator and hydraulic system are key to gain a basic understanding of the mechanism of radiator
about their coolant and hydraulic oil their behavior in different temperature and working.

Fig.5 development process

17
 CONCEPTUAL THEORY

Recent work which is going on in research and development department is the building of new transmission
dual 45 C in which working on the bearing section where we deal with different types of bearing and we are
also working on the small tractor for which capable of doing small work in the field as well as very good in
the transportation of goods in a rural area which is very cost-effective for those who only have less use of
tractor on the field it is very economical for people as well as efficient. The main work which is going on is of
surfacing and styling of that tractor.

As the main project is of transmission the theory and parameter used to shortlist bearing are as follows:-
Dimensional limits there is a wide range of standardized bearing types dimensions for bearings it is necessary
to select the optimal bearing types and dimension that fits the space allowed in the transmission.

The second parameter which we take as the most important parameter for the selection of bearing is bearing
load there can be various directional loads of different magnitude, for the selection of bearing it is also
necessary whether the acting load is a radial load or a combined load of radial and axial whether the angle of
contact of the bearing will be less than 45 degrees or more than 45 with help of load it is much easy to shortlist
the bearing type and size in our case when we have done testing the dynamic load and static load was 75400
and 69200 respectively.

The third parameter is the rotational speed of bearing which will differ depending upon bearing type, size,
tolerance cage type load lubricating conditions, and cooling condition as we know that bearing runs at high
speed and their running time is much greater which also generates heats so that’s why the cage of the bearing
is made of carbon steel which has a high melting point which also plays a key role in the life of the bearing.

The fourth parameter is rigidity as elastics deformation occurs along the contact surface of a bearing rolling
elements and raceway surface under loading with certain types of equipment it is necessary to reduce the
deformation as much as possible. Roller bearings exhibit less elastic deformation than ball bearings. In some
cases, bearings are loaded in advance to increase their rigidity, such as deep groove ball bearings angular
contact ball bearings, and tapered roller bearings.

The fifth parameter is a misalignment of inner and outer rings as shaft flexure, variation in shaft housing
accuracy, and fitting errors result in a certain degree of misalignment between the bearing's inner and outer
rings in situations where the degree of misalignment is liable to be relatively large self-aligning bearing
spherical roller bearing are used.

18
 Fig.6 cad design of chassis

Tapered bearing fig.7 needle bearing fig. 8 ball bearing fig.9

Ball bearing fig. 10

19
After going through all the theories and parameters of selection of bearing we shortlist some of the bearings
that are suitable for power train after that we do the final run and testing with a vehicle on dyno run where
after getting the different readings we come to the P release that is the release of the final prototype as A B
and C release are the proto build, testing phase and tooling development after that the design comes to P release
That is the final product after that the production of new transmission starts.

The basic A release is the concept design where we decide and do concept research as we did in bearing
selection working under parameters and theory after that the proto build is the B release where we build a
mock-up of the original part we run that mock through some tests after that the tool building is there where
the design passes now its tooling part will be in making we give designs to suppliers after that p release comes
where production of new development starts this whole process is known as NPI new product integration
process.

Research on solutions for improvement of the radiator and hydraulic system

The main use of a radiator is to prevent the breakdown of the engine from overheating, radiator plays important
role in engine functioning without any problem in any weather conditions you can identify and categorize a
radiator with the radiator core
1. radiator core (child part): -
The core is a major part of the radiator that performs its main purpose of cooling it is a metal block with small
aluminum fins
Types of cores: - one core, two core, three core radiator
1. Tubular core type: - the upper and lower tank are connected by a series of tube. that passes the water within
the radiator. due to coolant passing through all the tubes in the radiator as tubes are connected in series any
defect in the single tube will affect the whole cooling process (a drawback of tubular core)
2. Cellular core type: - In the cellular core type of radiator, the coolant flows through the spaces between tubes.
the core is made of many individual air cells surrounded by the coolant. air passes through the tubes while
coolant flows in space between them also known as honeycomb radiator because of its appearance so this core
is advantageous as clogging in one tube doesn’t affect the whole cooling but an only small part of the core.
Radiator hose (child part): -
A radiator hose that transfers coolant from an engine water pump to its radiator is a connected nipple on the
radiator or engine water pump by a clamp.
Types of hoses: -
Accordion hoses, molded hoses, and common hoses mostly molded hoses are used for application

20
Fig.11

Fig.12

21
Clamp type (spring steel clamp)
Also used inside of the hose to prevent it from being sucked by the force of water pump return radiator hose
(lower house on the radiator) coolant sucked from the radiator by the water pump and it enters the engine
block
Hose size criteria: -
The coolant needs to have time in the engine to absorb heat as well as time in the radiator to expel it. the size
of the hose can help to achieve this time which is known as saturation time therefore bottom hose are greater
in size as compared to the upper hose.
Radiator cap (child part):-
A small device that helps to control the pressure of the hot coolant in the radiator as the temp of the coolant
increases it will begin to turn into vapor it helps in increasing the boiling point by 45 Fahrenheit as the
boiling point of the coolant is 212 Fahrenheit.
Multipurpose functioning of radiator caps.
• Radiator pressure caps keep the system pressure at 16 PSI( avoiding coolant from boiling off even when it
gets hotter
• It helps coolant to go out in reservoir tank to keep the proper amount of coolant in the radiator when
expanding
• Prevent trapping of air in the cooling system the air in the system will cause poor cooling and cause
corrosion to the cooling system

Types of radiator coolant: -

1. Inorganic additive technology: -this type of coolant is generally good for old engines they better work
with steel and iron and need to be changed after every 2 years (generally recommended) in this the mixture
of water is to additive like ethylene glycol are generally 60-40.
2. Organic acid technology: -this type of coolant is generally good for new engines they better work with
aluminum need to be changed after 5 years, in this mixture of water to additive like ethylene glycol is 50-50.

Automotive industry switched from IAT to OAT due to new engines

Fig.13 radiator cap

22
Working of radiator
Atmospheric air hit a radiator and cools down cooling water (LCC/coolant, the liquid for cooling an engine)
and then its liquid runs around the engine. With this system, the engine can keep the temperature at a certain
level. The circulation path from the tank that stores the cooling water is called a radiator hose and plays an
important role in engine cooling. Other parts also have necessary roles, for example, the radiator core prevents
dust and dirt from getting inside. A radiator cap works that apply pressure to the inside of the tank to high the
boiling point of the cooling water. The cooling fan operates to cool the cooling water. By these parts’ roles,
the engine cooling system can work normally. Hot cooling water that has been heated around the engine and
returned to the radiator top tank is cooled by the wind that enters through the cooling fan and repeats flow
around the engine through the hose again.

SOLUTION AND IDEAS FOR IMPROVING RADIATOR COOLING EFFECT

The general issue with radiators: -
Issue No.1
White spots were noticed in radiator hoses reasons behind this are as follows: -
• Flow of coolant is not proper in hoses due to which coolant settle down in some part of hose which
creates this spot, spots were also noticed in the reserve tank
• Coolant type can be an issue like we use IAT inorganic additive changing and mixing of coolant old
and new due to which coolant becomes thick like a slime can be an issue for arising of white spots

Ideas for these issues: -

• introduced a type of fin inserted into them called a turbulator, which increases the turbulence of the
fluid flowing through the tubes.
• We shifted from IAT to OAT in which the water percentage and ethylene glycol percentage are 50-50
which prevents corrosion as water is hungry for ions and is considered to be an aggressive solvent
• And for the issue of mixing coolant we can add more di ionized water to it to prevent scaling in hoses
as mixing increased the content of antifreeze which resulted in scaling in hoses and reserve tank

Issue No.2
• The core of the Radiator is the major part that serves its main purpose it is a metal block with small
metal fins. Radiators are classified with the help of core one core, two core, and three core Radiators
• So as core increases Radiator thickness also increases which also affects the rate of heat exchange.
• Tubular core by which upper tank and lower tank are connected by a series of the tube so if one tube
gets defected which eventually affect the cooling rate

23
 Ideas for these Issues: -
• Replace an older water pump with a more powerful pump as the rate of the heat transfer from the
engine to the cooling system is directly proportional to the mass flow rate of coolant.
• We changed the core of the radiator from three cores to 2 cores and replaced the tubular core
with honeycomb meshing in which defects in one part will not affect the whole cooling.
• We can replace the aluminum fins with carbon foam sheets whose pore size is bigger compared
to aluminum fins and carbon foam porosity is 70% higher than aluminum fins.

Hydraulic system and its child parts

The main function of the hydraulic system is to provide ease in implementing equipment working in fieldwork
as well as to provide multidirectional power for the lift arms to work smoothly.
• Hydraulic cylinder (child part): It is a bigger cylinder fitted with a piston and a connecting rod, also
called a ram cylinder. The piston moves in the hydraulic cylinder, causing it to reciprocate and the
connecting rod within cylinder that transmits power from the piston to the lifting arms. Despite being
raised by hydraulic pressure, the lifting arm is lowered by its own weight.
• Hydraulic tank (child part): It is used for storing hydraulic oil. In some tractors, the transmission
chamber functions as a hydraulic tank, and the same oil is used for both the transmission and hydraulic
systems.
• Control valve (child part): It controls the movement of hydraulic oil to have desired direction,
magnitude, and speed for lifting.
• Oil filter (child part): It is a small filter located at a convenient position in the passage of the oil.

Types of oil used in the hydraulic system: generally, for the hydraulic system there is a separate tank of oil
we call as sump but in Kubota, we use transmission oil as a common reservoir for functioning for transmission
as well as a hydraulic system.

Fig.14 hydraulic system and addc

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Mechanism of hydraulic system
The hydraulic pump draws oil from the reservoir and sends it under high pressure to the control valve. Next,
the oil is sent to the hydraulic cylinder to operate the piston, which raises the lifting arms. The hydraulic
pump is driven by gears that are connected to the engine.

Hydraulic pumps: There are several types, including gear pumps, plunger pumps, vane pumps, and screw
pumps. The gear pump is widely used in tractors since it can flow a large amount of oil when compared to a
plunger pump. The oil pressure in the pump varies between 150 and 200 kg/cm2

IDEAS AND SOLUTIONS FOR IMPROVEMENT OF HYDRAULIC SYSTEM AND

LIFT ARM
• Replacing the old (DCV) with a new spool valve which spool valve consists of a cylindrical spool that can
block and open channels in the hydraulic system.
• A spool valve can change the direction of the flow of fluid from a hydraulic pump to an actuator by blocking
off the route.
• Three-way spool valve can be used in the hydraulic systems as its routing and flow are less complicated
and have quick response for changing the direction of the lifting arm.

WORKING OF 3 WAY SPOOL VALVE (DCV)

The 3-way valve is connected to the cylinder actuator from there fluid is applied to port P of the valve and c
of the cylinder (ram cylinder) where the T port of the valve is connected to drain or return of the tanks and
port A of the valve connected to B of cylinder
(Spool moves right side) The high-pressure flow from port A to B the moves to the right due to pressure fluid
and displacing the fluid c to P
(Spool move left side) High-pressure fluid comes into the cylinder through C the piston moves to the left
causing the fluid into the tank via ports B and A and T.

CHANGE OF HYDRAULIC PUMP

Changing the old pump with a variable displacement pump. Hydraulic pump with bigger displacement that
can freely alter the quantity of discharge and a load sensing hydraulic system that can control the pump
discharge and fluid pressure distribution valve instantly response to change implement load.

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UPGRADING PCV VALVES
• A hydraulic system needs resistance in the flow of fluid to produce pressure, if the amount of resistance
could not be controlled, the weakest component might burst.
• Types of PCV: - conventional spring-loaded, pilot operated
• We changed PCV pilot operated to conventional spring-loaded, when the circuit pressure (back pressure)
at valve inlet is less than spring pressure than the ball is seated as pressure increase ball moves flow opened
valve opened.
• Conventional spring valve is simple and less costly and works on a simple mechanism of ball and spring.

Fig.15 PRV

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 Fig.16 variable displacement pump

._______________________________________________

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 METHODOLOGY

The methodology that is adopted: -

1. Pre-Study: -
Define the scope of the project by establishing project conditions, goals, directives, target description, and pre-
requisites for hard and soft product development requirement and alternative solution concept

2. Concept study: -
Analyses of alternative concepts and selection for development, freeze project pre-requisites and sign the
project description

3. Detailed development: -
Define and approve the solution to be implemented and the project delivery from all areas freeze and sign the
project description

4. Final development: -
Build, verify, validate, and refine the product, solution, refine market and aftermarket, manufacturing, and
assembly solutions

5. Industrialization and commercialization: -

Install prepare and verify the industrialization system launch the product and the aftermarket product sign the
product release approval

6. Follow up: -
Hand over the project to the line organization follow up on project target fulfillment summarize the experience
and close the project

Component and equipment used in the working following project were dynamometers on which we do the test
runs of proto from where we get the following reading of different parameters like torque rotational speed
dynamic load static load on the shaft and other components and equipment, we used to be different types of
rigs that are specially made for different particular test for durability reliability of different components like
engine, transmission, body, chassis, and cabin. Extra tooling required was some software like Kess v2 master
for dynamometer and NX modeling for surfacing and AVL Puma 2 for testbed reliability.

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For reliability and testing, there is a separate team that does the analysis by taking the prototype to the testbed
where they attach the different motors to the part which they are testing for example for transmission they
attach the transmission shaft to a motor which behaves like an engine drive from where they attain a particular
power that is same as engine.

After they attach the clutch housing as we are using an independent clutch for transmission and PTO shaft
after which the PTO shaft is attached to the main housing so the whole drive train now acts like one power
train now, they do the dynamometer test on dyno run where we get all reading for transmission as well as PTO
shaft.

From there we also get the synchronizer ring timing to a different gear at different speeds and rpm as our PTO
works on two different rpm 540 rpm and 710 rpm so we also check whether the drivetrain and PTO are working
together or not and whether the PTO clutch bearing are responding while the tractor is moving or not.

After the testing and reliability, the c release proto is signed and get frozen and now the tooling of that
component is validated now after that the mass production will be going to start for commercial purposes.

QUALITY AND INSPECTION

In quality and in inspection the methodology that we follow we take one part from the supplier end that batch
which is going to be manufacture for our tractor then by the drawing generated by design department that
provide special parameter like GD&T orientation, form, profile, location, and runout.
Types of GD&T
Form and their types: -
1.Straightness: - In this you check this parameter with the help of stylus gauge or with the help of plunger dial
or liver dial, no datum is required in these criteria.
2.Flatness: - in this you check this parameter with the help of stylus gauge or tip or can be measured with liver
dial, no datum is required in this criterion.
3.Circularity: - same equipment’s are used in these criteria also no datum is required in this also.
4.Cylindricity: - same equipment’s are used in these criteria also no datum is required in this also.
Orientation and their types: -
Parallelism: - this is the parameter in which we check particular part is parallel to reference part or not that’s
why it requires a datum to check parallelism.

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Perpendicularity: - perpendicularity is also measured by using a datum or reference part this can be measured
with plunger dial or stylus tip in this modifier are also used like MMC and LMC.
Angularity: - this can be check by measuring it with the help of datum or we can measure it on shape testing
machine also known as contour cv3200 H4.

Fig.17 shape testing machine

Profile and their types: -

Profile of line: -this parameter is little complex parameter so therefore they are measured in CMM machine
only.
Profile of a surface: -this parameter can be measured at CMM machine as well as with plunger dial but to
measure with plunger dial, we will be requiring gauge block.

The parameter can be measured without help of datum.

Runout and their types: -

Circular runout:- this parameter requires RFS always (regardless of feature size ) in this a datum is also require
which we always fix that datum to surface and then measure the runout by revolving stylus tip circularly at a
point.

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Total runout: - this parameter also requires RFS and a datum also the difference in measuring circular and total
runout is that in circular runout we run stylus tip at a point but in total runout we run the stylus tip circularly
as well as in path direction.

Location and their types: -

Position: -in this parameter modifier are also used it also requires datum but to check position in a particular
part is little difficult, so it is done on CMM machine.
Concentricity: -in this parameter no modifier is required only datum needed to measure concentricity with
refence plane and can be measured with help of stylus tip or plunger dial.
Symmetry: - in this parameter we generally measure it with datum modifier like RFS is there and can be
measured on CMM or with the help of plunger dial.

HEAT TREATMENT AND ITS PROCESS

Fig.18 heat treatment process.

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The heat treatment process starts with charge preparation where a charge is prepared after the pre-wash of
different components like shaft gears and spline gear in the different boilers. After that, only some components
like spline gear are particularly pre-heated and after that carburizing is done for around 8 hours to achieve an
effective case depth of 0.6 to 0.9 mm and this effective case depth will be achieved around 513HV Vickers
hardness after that quenching is done (basically water or oil bath) after that post-wash of components.
Tempering is done after post wash and the hardness before tempering should be 58 to 62 HRC and after
tempering it should be 63 to 64 HRC the main parameter that we are concerned about after heat treatment is
surface hardness, core hardness, ECD (effective case depth) and microstructure.
After tempering shot, blasting is done to super clean the gears and shafts and after this gear and component
that have teeth undergoes a process known as deburring. after this sometimes going through this process the
part or component shrink a little bit so straightening is done at the end of the process.

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 .

Fig .19 PTO circuit

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 CONCLUSION

Working in this organization under this department gives me an understanding that the agriculture field is a
big sector that plays a key role in India’s economy and people who are in the agriculture field always think
about less cost and more efficiency so by working in this sector I learned the different process of development
and research to increase the efficiency of tractor and decrease cost.
basic understanding of tractors and its component how they work how to do analyses of a selection of
bearing what parameters should be taken into consideration or not, I learned what is the process of starting
any new development of the product, what are different gates are followed in the global development of the
new product, how testbed rigs work with which software like testbed works with AVL puma v2, surface
modeling on NX, what are the different key role of which bearing and their types.
working on the radiator and hydraulic provided a deep knowledge of their mechanism and doing research
on improvement of the radiator and hydraulic I understood that designing and making changes in an existing
component requires a GD and T knowledge and as well as design should be appropriate according to the
sector, learning about radiator and hydraulic are an important part because cooling and performance both are
important aspects for tractor while working in the field so it will be beneficial for me to work in this sector,
at last, I would like to conclude that learning in the different department I gained a good knowledge of
mechanical component, the requirement for design, drawing analysis, GD and T, metallurgy parameter, heat
treatment process and about effective case depth, I am sure that this information will prove to be very
significant in the future and I am very grateful for this opportunity.

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 REFERENCES

• CAD photos from R and D department

• The parameter of selection of bearing from NTN supplier side
• Diagrams and process from manual of escorts Kubota and from Wikipedia
• Reliability and testing parameter and process from testing team
• Heat treatment process chart from department.
• GD and T from quality department

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