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Snmmer Internship II JCB
Snmmer Internship II JCB
A Report on
Summer Internship – II carried out at
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
By
Mohammed Muthasib Baji 4SO21ME040
Under the guidance of
Mr Prashanth Kumar
Assistant Professor
Department of Mechanical Engineering
CERTIFICATE
1.
2.
CERTIFICATE
ACKNOWLEDGEMENT
I express my thanks to Mrs. Madhu S for his valuable guidance & the entire team of Joseph
Cyril Bamford (Advaith) for their constant support and help in thesuccessful completion of
my internship.
I would also like to express my profound appreciation to our esteemed college principal,
Dr Rio D'Souza, for his visionary leadership and dedication to fostering an environment of
continuous learning and growth.
A special mention goes to Dr Shreeranga Bhat, the Head of the Department of Mechanical
Engineering at SJEC, Mangalore. His invaluable insights and mentorship have played a
crucial role in shaping our understanding of the subject.
4 Conclusion..................................................................................................18
5 Reference....................................................................................................19
ABSTRACT
Beyond technical proficiency, the internship underscores the practical significance of these
skills in heavy machinery and engineering. The lessons learned extend beyond academia,
with tangible real-world applications. This experience is a pivotal stepping stone, enriching
my knowledge and instilling a deep appreciation for the seamless integration of hydraulics
and control systems in engineering.
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1. Introduction
1.1 Brief Description of the Company
JCB is particularly recognized for its iconic backhoe loader, a versatile piece of equipment
that combines the functions of a loader and an excavator. This invention revolutionized the
construction sector, providing a single machine capable of performing multiple tasks
efficiently. Over the years, JCB has expanded its product line to include a wide range of
construction and agricultural machinery, such as excavators, skid steer loaders, telescopic
handlers, and tractors.
Innovation lies at the core of JCB's success. The company has consistently introduced
cutting-edge technologies to enhance the performance, efficiency, and safety of its
equipment. This commitment to innovation is exemplified by JCB's investment in research
and development, leading to the introduction of features like EcoMax engines, Load all
telescopic handlers, and the incorporation of telematics for fleet management.
JCB's global footprint spans across continents, with manufacturing facilities and
distribution networks strategically positioned to cater to a diverse range of markets. The
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company's dedication to quality control and customer satisfaction has solidified its
reputation for producing robust and reliable machinery.
In summary, JCB stands as a pioneering force in the world of construction and agriculture
machinery, driven by a rich history of innovation, a commitment to quality, and a global
presence that continues to shape the industries it serves.
JCB's operations are a testament to its global influence and commitment to providing
cutting-edge solutions in the construction and agricultural machinery sectors. With a
history spanning nearly eight decades, the company has continually refined its operations
to stay at the forefront of technological advancements, manufacturing excellence, and
customer satisfaction.
Manufacturing Excellence:
Central to JCB's operations is its unwavering focus on manufacturing excellence. The
company boasts state-of-the-art production facilities strategically located around the world.
These facilities are equipped with advanced technologies and adhere to stringent quality
control measures. JCB's commitment to precision engineering ensures that each piece of
equipment leaving its assembly lines meets the highest standards of durability.
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Product Portfolio:
JCB's diverse product portfolio is a reflection of its deep understanding of industry needs.
The company produces a wide range of construction and agricultural machinery, catering
to various applications and sectors. From the iconic backhoe loaders to innovative
excavators, telehandlers, and compact track loaders, JCB's product offerings are designed
to address the evolving demands of its global customer base.
Global Presence:
JCB's operations span the globe, with a strong presence in key markets. The company
strategically positions its manufacturing facilities and distribution networks to ensure
efficient logistics and timely delivery. This global footprint allows JCB to adapt its products
to meet regional requirements and regulations while maintaining a consistent standard of
quality and innovation.
Sustainability Initiatives:
JCB recognizes the importance of sustainability in today's business landscape. The
company actively pursues eco-friendly technologies and manufacturing practices. This
includes the development of electric-powered equipment, fuel-efficient engines, and a
comprehensive approach to reducing its environmental impact. JCB's commitment to
sustainability extends beyond compliance, reflecting a proactive stance toward building a
greener and more sustainable future.
Customer-Centric Approach:
At the core of JCB's operations is a customer-centric philosophy. The company places a
high premium on understanding and addressing the unique needs of its diverse clientele.
This involves not only delivering reliable machinery but also providing comprehensive
support services, including maintenance, training, and technological assistance.
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In conclusion, JCB's operations are a harmonious blend of manufacturing prowess,
innovation, global adaptability, and a strong commitment to sustainability and customer
satisfaction. As the company continues to navigate the dynamic landscape of construction
and agriculture machinery, its operations remain a beacon of excellence and a driving force
for positive change in the industries it serves.
Introduction:
- JCB, or Joseph Cyril Bamford, is a renowned British multinational corporation
specializing in the manufacturing of construction equipment. Founded in 1945, JCB has
played a pivotal role in the industry, recognized for its innovative and technologically
advanced machinery. The company's excavators, backhoe loaders, and telescopic handlers
are widely used globally, contributing significantly to the efficiency and productivity of
construction and agricultural operations. JCB's commitment to engineering excellence has
established it as a key player in the heavy equipment sector.
Purpose of the Internship at JCB:
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-Since my interest was in going into deep insights of hydraulics and fluid power
transmissions, I decided to occupy my place for summer internship at JCB.
-Learning Theoretically and practically experiencing the applications of Pascals law for
static fluid in hydraulic power transmission system.
-Learn in depth on variation of force output with different cross-sectional areas.
-Learn electronic logic gates to control the arms connected to the actuators, valves etc.
-Learn movement of actuators and links, balancing forces, maintain frequencies that does
not match with natural frequency of the system and apply in academic subjects like Theory
of Machines.
-Ease the workload on the people of the society by using hydraulic system and advancement
in the fluid power transmission technology.
-Learn incompressible fluids behaviour in vacuum with variation in temperature .
Initial Impressions:
- Mission
JCB's mission is to be a global leader in innovative construction and agricultural equipment,
providing solutions that enhance productivity, efficiency, and sustainability. The company
aims to deliver cutting-edge technology while prioritizing customer satisfaction and
environmental responsibility.
- Core Operations
JCB's core operations revolve around the design, manufacturing, and distribution of
construction and agricultural equipment. This includes a diverse range of machinery such
as excavators, loaders, telehandlers, and compactors. JCB is known for incorporating
advanced technologies into its products, contributing to increased performance and fuel
efficiency. Additionally, the company emphasizes a commitment to sustainability by
implementing eco-friendly practices in its operations and promoting the use of cleaner
technologies in its equipment.
Work Environment:
- Company consists of knowledgeable and experienced people who can train us very
effectively.
- Company consisted of all service equipment’s and others.
- Worked on servicing he machineries and also bleeding the whole hydraulic power
transmission fluid lines.
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Hydraulics in Focus:
- Hydraulics play a pivotal role at JCB, contributing significantly to the functionality and
efficiency of their machinery. JCB, a renowned construction equipment manufacturer,
employs hydraulic systems to power various components in their equipment, such as
excavators, loaders, and backhoes.
- The hydraulic technology enables precise control, lifting capabilities, and smooth
operation of heavy machinery, enhancing overall performance on construction sites. This
emphasis on hydraulics reflects JCB's commitment to innovation and delivering high-
quality, reliable equipment for the construction industry.
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2.2 Week 2: Minor Service and General Instructions
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Basic Hydraulic System consists of mainly 5 components.
-Hydraulic Tank with hydraulic fluid stored.
-Hydraulic Pumps to pressurise the fluid and flow smoothly.
-Relieve valves to eliminate the excessive fluid to tank and also excessive pressure of the
fluid.
-Control Valve to control the flow of fluid in the lining.
-Actuators to covert fluid energy to mechanical energy in the form of movement.
Hydraulic tank:
Hydraulic tanks are vital components in hydraulic systems, serving as reservoirs for
hydraulic fluid. Key functions include storing fluid, managing fluid levels with features
like sight glasses, and facilitating air and foam separation. Tanks also incorporate filtration
systems to remove contaminants, and they contribute to heat dissipation through natural
convection or additional cooling mechanisms. Pressure
maintenance is crucial to ensure a constant fluid supply to
components and prevent cavitation. Tanks are constructed
from materials like steel or aluminium, chosen based on
system requirements. Overall, hydraulic tanks play a
crucial role in maintaining system efficiency and reliability.
Hydraulic Pumps:
In JCB equipment, hydraulic pumps are pivotal for powering functions like lifting and
digging. These pumps, which can be gear, vane, or piston types, often feature variable
displacement and load-sensing technology. Designed for high-pressure operation, they
seamlessly integrate with control systems for precise
coordination. Regular maintenance, compatibility with
recommended fluids, and protective features ensure
longevity and reliability. Tailored to specific
applications, JCB hydraulic pumps contribute
significantly to the efficiency and durability of the
machinery's hydraulic system.
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Relieve Valves:
Relief valves in JCB equipment are crucial components designed to prevent hydraulic
system damage by regulating pressure. These valves ensure that pressure does not exceed
safe limits during operation. Typically set to a predetermined pressure threshold, relief
valves open to redirect excess fluid back to the reservoir, protecting hydraulic components
from potential damage. In JCB machinery, relief valves are strategically integrated into the
hydraulic system to maintain safe operating pressures and
safeguard against overloads, contributing to the overall
reliability and longevity of the equipment.
Control Valve:
Control valves in JCB equipment regulate hydraulic fluid flow, directing movements such
as lifting and digging. They include directional, proportional,
and pressure control valves, each serving specific functions.
Seamlessly integrated into the hydraulic system, these valves
enable precise control, with operators using levers or joysticks
to manipulate machine actions. Known for durability and
reliability, control valves play a crucial role in achieving
efficient and coordinated machine performance in challenging
environments.
Actuator:
Hydraulic actuators in JCB equipment convert hydraulic energy into mechanical motion.
They come in two main types: hydraulic cylinders for linear motion and hydraulic motors
for rotary motion. Hydraulic cylinders extend or retract a piston
rod, while hydraulic motors drive a rotating shaft. Controlled by
manipulating hydraulic fluid flow through valves, these actuators
provide high force, precise control, and versatility in applications
such as construction equipment. Regular maintenance is crucial
for ensuring their reliability and longevity in JCB machinery.
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Within the realm of hydraulic system maintenance, my internship involved a systematic
approach to ensure the optimal functioning of JCB machines. I actively engaged in routine
inspections, meticulously examining hydraulic components for wear, leaks, or other
potential issues. This process included disassembling hydraulic cylinders, pumps, and
valves, allowing me to gain an intricate understanding of the interplay between these
components.
Moreover, I was exposed to the world of fluid dynamics, learning how hydraulic fluids
transfer energy and how temperature fluctuations can impact performance. This hands-on
experience extended to fluid replacement and filtration, emphasizing the critical role of
clean and properly specified hydraulic fluids in maintaining the longevity of machinery.
Through this aspect of my internship, I not only developed technical skills but also learned
to appreciate the symbiotic relationship between precision and preventive maintenance in
hydraulic systems.
Engine Overhauls:
The engine overhauls during my internship were a highlight, providing me with a
comprehensive understanding of the internal combustion engines that power JCB
equipment. I actively participated in the disassembly and inspection of engines, gaining
insights into combustion chamber dynamics, piston functionality, and the intricacies of fuel
delivery systems. This hands-on exploration extended beyond theory, allowing me to
witness firsthand the wear patterns and stress points that
contribute to engine degradation.
Rebuilding engines became a nuanced process where I
honed my skills in selecting and fitting replacement parts.
This experience instilled in me an acute awareness of the
tolerances and clearances crucial for optimal engine
performance. The significance of precision in torque
application and alignment during the reassembly process
underscored the meticulous nature of engine overhauls,
shaping my approach to intricate tasks within the heavy
machinery service domain.
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control modules, actively troubleshooting and diagnosing issues. This hands-on experience
extended beyond the conventional classroom setting, allowing me to understand the
practical challenges associated with identifying and resolving electrical faults in real-world
scenarios.
The collaborative environment at JCB played a pivotal role in my overall growth. Working
alongside seasoned technicians, I not only absorbed technical knowledge but also imbibed
a sense of teamwork and shared responsibility. Engaging in collaborative problem-solving
sessions further enhanced my troubleshooting skills, as diverse perspectives contributed to
comprehensive and effective solutions.
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In conclusion, my hands-on experience at JCB went beyond the technical aspects of major
service operations. It was a transformative journey that cultivated a mindset of precision,
adaptability, and collaborative problem-solving—attributes that are indispensable in the
dynamic field of heavy equipment maintenance. The skills acquired during this internship
have undoubtedly laid a robust foundation for my future endeavours in the realm of heavy
machinery servicing and maintenance.
1. Basic Structure:
- The solenoid valve consists of a coil, a plunger (also known as a core), and a valve
body.
- The valve body contains ports and passages through which hydraulic fluid flows.
2. Electromagnetic Activation:
- When an electrical signal is sent to the solenoid coil, it generates a magnetic field around
the coil.
- This magnetic field attracts the plunger towards the center of the coil.
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3. Plunger Movement:
- The movement of the plunger is connected to the valve mechanism.
- As the plunger moves, it either opens or closes the valve, controlling the flow of
hydraulic fluid through the ports in the valve body.
For example, a solenoid valve might control the flow of hydraulic fluid to a cylinder
responsible for raising or lowering a loader arm on a JCB machine. The operator's input or
the equipment's control system sends electrical signals to the solenoid valve, dictating when
and how hydraulic power is applied to specific functions, ensuring efficient and controlled
operation of the construction equipment.
Starter Motor:
This component is responsible for initiating the engine's
operation by turning it over, providing the necessary
mechanical energy to kickstart the combustion process.
Alternator:
Playing a crucial role in the machine's electrical system, the
alternator converts mechanical energy from the engine into
electrical energy, ensuring a continuous charge to the
battery and powering various electrical components.
Sensors:
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1. Proximity Sensors: These sensors detect the presence or absence of objects in close
proximity to the JCB. They work by emitting electromagnetic fields or beams and sensing
changes in the field when an object is nearby, triggering a response in the machine's control
system.
2. Pressure Sensors: Found in hydraulic systems, pressure sensors monitor fluid pressure.
They work by converting the mechanical force exerted by the hydraulic fluid into an
electrical signal. This signal is then interpreted to gauge the pressure levels within the
system, allowing for precise control.
4. Position Sensors: Used to determine the position of movable parts, such as the bucket
or arm in an excavator. These sensors utilize various technologies like potentiometers or
encoders to provide accurate position feedback, aiding in precise control and maneuvering.
5. Speed Sensors: Monitoring the speed of rotating components, such as the engine or
hydraulic motors, speed sensors contribute to the control and efficiency of the JCB. They
often work by generating electrical signals proportional to the rotational speed of the
monitored component.
6. Angle Sensors: Essential for equipment with articulating parts, angle sensors measure
the angular displacement of joints or components. They employ technologies like
potentiometers or magnetic encoders to provide feedback on the angle of movement.
7. Inclinometers: These sensors measure the angle of inclination or tilt of the JCB. They
are crucial for ensuring the stability and safety of the machine, particularly on uneven
terrain. Inclinometers often use accelerometers or gyroscopes to determine the tilt angle.
8. Load Sensors: Commonly used in lifting equipment, load sensors monitor the weight or
load being lifted by the JCB. They can employ strain gauges or hydraulic pressure
measurements to determine the load on the lifting mechanism.
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9. Vibration Sensors: Detecting vibrations in various components, these sensors help
identify potential mechanical issues or imbalances. They work by converting mechanical
vibrations into electrical signals, allowing for early detection of abnormalities.
10. Humidity Sensors: In environments where moisture control is critical, humidity sensors
measure the moisture content in the air. They play a role in safeguarding electrical
components and ensuring optimal operating conditions.
These sensors collectively contribute to the JCB's efficiency, safety, and precision by
providing real-time data for monitoring and control purposes.
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3. Skills Acquired and Personal Development
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4. CONCLUSION
Furthermore, the exposure to electrical components within JCB's machinery has provided
a holistic understanding of the intricacies involved in the functioning of construction
equipment. The synergy between Pascal's law and electrical components has broadened my
skill set, allowing me to comprehend the interdisciplinary nature of modern engineering
practices.
This internship has not only equipped me with technical proficiency but has also cultivated
essential soft skills such as teamwork, communication, and project management. As I
reflect on this enriching experience, I am confident that the skills acquired will serve as a
solid foundation for my future endeavours in the field of engineering.
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5. REFERENCES
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