“Study On Product Performance Improvement Of Hydro Static Unit Of

Tractor Power Steering”

Carried out by

Ramu Bhardwaj.(4AD12ME071)
Sandesh Shreyas(4AD12ME078)
Sathyanarayana.M.A.(4AD12ME079)
Shreyas.H.S.(4AD12ME085)

DEPARTMENT OF MECHANICAL ENGINEERING

ATME College of Engineering, Mysuru
2015- 2016
Under the Guidance of
Mr.Girish.Y.N. Mr.Sharavanan
Assist.Professor Head Of Production
Dept Mechanical Engineering Rane (Madras).Pvt.Ltd
ATME Mysore Mysore
About Rane(Madras).Pvt.Ltd

Rane (Madras) Ltd is a part of the Rane Group of Companies involved in the manufacture
and distribution of steering and suspension systems.

The main components manufactured by the company include Hydrostatic Steering

units,Hydraulic cylinders,Tractor lock valve, Manual Steering Gear Products (SGP) and
Suspension & Steering Linkage Products (SSLP).

 Automobile companies that use its products include Ashok Leyland, Volvo, M&M, Tafe,
Tata,Eicher,Swaraj Mazda etc..
 INTRODUCTION
 Power Steering is the system for reducing the steering effort on vehicles by using power source to assist the turning the
wheels.

 Most power steering systems work by using a hydraulic system to multiply force applied to the steering wheel inputs to the
vehicle’s steered(usually front)wheels.
 The steering wheel operates valves(HSU) to control flow to the cylinder, The more torque the driver applies to the steering
wheel and column ,the more fluid the Hydrostatic steering unit allow through to the cylinder, and so the more force is
applied to steer the wheels.
 First Time Quality/Zero Defects is a management tool aimed at the reduction of defects through prevention. It is directed at
motivating people to prevent mistakes by doing their job right at the first time of production.
 HYDRAULIC STEERING SYSTEM (HSS)
The main components of hydrostatic steering
system are:

Hydrostatic steering unit

Cylinder

Reservoir

Hydraulic Pump

Steering column

Hose lines.
 PARTS HYDROSTATIC STEERING UNIT
The steering unit is really the heart of the system. It is the most specialized component. It houses the direction control valve
and the metering unit i.e. the gerotor element. It Controls the Fluid Flow rate in the steering system.
 BILL OF MATERIALS
Sl.No OBJECT DESCRIPTION QUANTITY
1 HOUSING MACHINED 1.000
2 DOUBLE LIP OIL SEAL 1.000
3 THRUST BEARING WITH WASHER 1.000
4 VALVE SLEEVE 1.000
5 CROSSPIN 1.000
6 VALVE SPOOL 1.000
7 FLAT SPRING 6.000
8 O-RING DISTRIBUTOR PLATE 1.000
9 DISTRIBUTOR PLATE 1.000
10 CARDEN SHAFT 1.000
11 ROTOR 1.000
12 SPACER 1.000
13 O-RING GEROTOR 2.000
14 CAM 1.000
15 END COVER 1.000
16 WASHER STEEL 7.000
17 SCREW M18*1 6.000
18 SCREW WITH PIN 1.000
19 STEEL BALL 1.000
20 THREADED BUSHING 1.000
21 RELIEF VALVE PLUG 1.000
22 COPPER WASHER 1.000
23 ADJ PLUG 1.000
24 SPRING 1.000
25 PLUNGER 1.000
26 RELIEF VALVE SEAT 1.000
27 O-RING RELIEF VALVE SEAT 1.000
28 CHECK VALVE 1.000
 PROBLEM STATEMENT
The company is dedicated for continuous improvements of the Product quality and production issues by
implementing various solutions for various problems.Among them the percentage of quality of non defective
products produced at the First time of production is a major issue which is to be concerned the most.

Because the amount of non-defective products produced is the important factor in the production of finished
products that has to be delivered to the customer.

There are issues like regarding to performance of HSU due to change in dimensions of parts in the HSU
during various operations in production line which leads to increase the defective Products in the plant.

OBJECTIVE
 We have been assigned to study and conduct our project work on HSU which is one of the Major product
manufactured in the plant.

 The purpose of this study is to increase FTQ Yield of the product upto 100%. (i,e)Hydro Static steering unit
which is the major part of Power steering system.

 This is perhaps One of the first study to investigate and increase the FTQ yield of HSU in the Rane (Madras) Pvt
Lt Assingned to our Team.
 METHODOLOGY
 Study Of Component Process

 Collecting Dimensions Reports

 Assembling of HSU Products

 Inspection of HSU Products by Standard Measuring Devices and Testing through Standard Operating
Techniques

 Collecting Report of Testing and find Defects/Variations

 Depth Investigation of Component Dimensions

 Taking Counter Measures for every problem by finding permanent solutions

 Re-Inspection of Products through Testing and Assuring FTQ yield of Production to Maximum (i,e)
upto100 %
 HSS UNIT PROCESS FLOW
 HSU UNIT

Housin Spool Sleeve

Rotor Stator
g Valve Valve

 HOUSING  VALVE SLEEVE

Radial Drilling Band Saw Cutting

CNC 1st stage Turning Radial Drilling

CNC 2nd stageTurning 1st Stage Turning

Angular Hole Drilling 2nd Stage Turning

Cross Hole Drilling Rough and finish Honing

Lapping Drilling& Reaming

Rough & Finish Honing Sleeve ID Grinding

Ultrasonic Washing Sleeve OD Grinding

Ultrasonic Washing
  VALVE SPOOL  ROTAR  STATOR

Band Saw Cutting

Broaching Broaching
Piercing
Hobbing Drilling
1 Stage Turning
st

Surface Grinding Surface Grinding

2 Stage Turning
nd

Profile Grinding Profile Grinding

Drilling& Reaming

Spool OD Grinding Surface Lapping Surface Lapping

Ultrasonic Washing Ultrasonic Washing

Ultrasonic Washing
 Hydrostatic Steering Unit Assembly Procedure

Press washer & Insert Steel ball in Insert Threaded Insert housing O-ring Insert valve spool Insert 3Flat springs in Insert cross pin & Insert Sleeve&spool
Thrust bearing into check value hole bush(M12*1) in into the valve sleeve one direction another 3 lock spoo l& sleeve sub assembly into
the housing Using check value hole in opposite direction in housing bore.
Specified Tool spool

Check for free Place Distributor Insert Carden shaft in Placer rotor on carden Insert O-ring on Place stator outside Place spacer inside Place end cover over
rotation of spool & plate. housing bore. shaft each side of stator rotor’s lobes rotor the gerotor
sleeve sub assembly

Insert M8*1 Screw Insert M8*1 Screws Torque the bolts to Place O-ring at bottom of Insert RV Plunger, Check for free
with pin in check valve with washers to other 6 10NM,20NM,30NM RV seat and insert into the Spring & adjustable rotation (torque:3-
hole holes and check free rotation housing with a help of plug in RV seat in 5NM) of the
at every levels of press tool housing and tightened Assembled
torquing the relief valve plug hydrostatic steering
unit.
HSS Unit Testing Machine
 HSS Unit Testing
Sl. Characteristics Specifications Method Of Check 1 2 3 4 5
no
1 Oil Temperature 50*C Indicator 50 50 50 50 50
2 Priming Rotation Test Smooth Manual Ok Ok Ok Ok Ok
3 Flow 19-20 lpm Gauge 20 20 20 20 20
Internal Leakage Test
4 Relief Valve Set Pressure 140-145kg/cm2 Gauge 146 140.8 141 150 142.3
5 P-Port Pressure 90kg/cm2 Gauge 90 90 90 90 90
6 Leakage Left 0.9 lpm Gauge 0.4 1.1 0.9 0.7 0.7
7 Leakage Right 0.9 lpm Gauge 0.5 1.2 0.8 0.8 0.8
Neutral Pressure Drop
8 P-Port Pressure - Gauge 7.1 9.5 12.2 9.8 9.8
9 T-Port Pressure - Gauge 0.9 0.9 0.9 0.9 0.9
10 Pressure Difference <=10.30kg/cm2 Gauge 6.2 8.6 11.3 8.9 8.9
Rotation Pressure
11 Clockwise Rotation Pressure Both Side Equal Gauge 23 33 28 21 32
12 Anti Clockwise Rotation Pressure Both Side Equal Gauge 18 21 21 25 21
 Cylinder Sliding
13 Clockwise Rotation Pressure Nil Visual Not Ok Ok Ok Ok Ok

14 Anti Clockwise Rotation Pressure Nil Visual Not Ok Ok Ok Ok Ok

Power on Slippage Test
15 Slippage Left 2<rpm Display 1.2 2.3 2.1 1.8 2.1
16 Slippage Right 2<rpm Display 1.5 2.5 2.3 1.9 2.4
Manual Steering Test
17 Slippage Left <20Nm Display 19 20 18 17 20
18 Slippage Right <20Nm Display 18 19 18 18 20
Measurement of Normal Steering
Torque
19 Torque Clockwise <20Nm Display 22 23 18 22 20

20 Torque Anti Clockwise <20Nm Display 21 26 19 26 18

Verification of External Leakage

21 External Leakage No Leakage Visual Ok Ok Ok Ok Ok

22 Air Leak Test No Leakage Visual Ok Ok Ok Ok Ok
Problem Identified After Testing

5 5 5 5 5 5 5 5 5 5

3 3 3 3
3

2 2 2
2 s
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1 1 po ms
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1 co obl
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Se Le a
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Total Number Of HSU’s Produced in a Shift=18No’s

Total Number of HSU's Produced in a Batch=18

Non-Defective HSU's
Defective HSU's

13

At Present Situation
First Time Quality Yield =73%

TARGET TO BE ACHIVED=Upto 100%

 I. Relief Valve Set Pressure
•Cause Analysis Table
152
Sl causes Standard Measurem Actual Inference
150 no specificatio ent specificatio
(140-145kg/cm2) n technique n
148
146 1 RV tap size M18 ⃰1.5 TG M18*1.5 Not
Significant
Max
144
2 RV tap depth 27.50±0.1 vernier 27.51 Not
142 Significant

140
Min 3 RV bottom Dia 14.42/14.45 Bore gauge 14.47 Significant
138
1 2 3 4 5 4 RV spot face dia 22.7/23.00 Vernier 22.9 Not
Significant

•Possible Causes
1.Relief valve tap size variation 5 RV Seat and 8-12µ Micrometer 9-11µ Not
2.RV tap depth variation plunger Significant
3.RV bottom size variation
4.RV spot face diameter
variation
5.Cleareance Between Relief Valve Seat and RV Plunger
Relief Valve Bottom Diameter Finish Variation
Sl No Bottom Diameter Actual Specifications
1 14.47
2 14.48
3 14.43
4 14.44
5 14.43

Action for CAT findings :RV Bottom Dia Finish Variation

‘Komat Reamer Finishing tool’ was under more Tool Wear
out resulting in less Tool efficiency the tool itself was replaced
as shown in fig.

The Major Advantage of New Tool is that it Can Perform

four Different Operations in one single tool with more
efficiency

Therefore Counter measures where applied .This Resulted in

elimination of RV Pressure defects From next Batch of
Before After Production.
 II. Slippage Left and Right
•Cause Analysis Table
4
Slippage Left & Right (2<rpm) Sl causes Standard Measurement Actual Inference
3.5 no specification technique specification

3
1 Stator Profile Finish 0.7Ra Roughness 0.86Ra Significan
2.5 Variation Tester t

2 2 Rotor Profile 0.8Ra Roughness 0.7 Ra Not

Variation Tester Significan
1.5 t

1
3 Gerotor Height 15-30µ Trimos 22-30µ Not
0.5 clearence Less Significan
t
0 4 Stator Flatness more 3µ Flatness Tester 2-3µ Not
1 2 3 4 5 Significan
t
No of Components
•Possible Causes 5 Rotar Flatness more 3µ Flatness Tester 2-3µ Not
Significan
1.Stator Profile Finish Variation
t
2.Rotor Profile Finish Variation
3.Gerotor Height Clearence Less
4.Stator Flatness more 6 Gerotor Surface No Surface Visual Surface Dents Significan
5.Rotor Flatness more Dents Dent should Frequently t
6.Gerotor Surface Dents Occur Occuring
1. Stator Profile finish variation

6
7
1
2 Stator profile finish variation
3
5 4

Action for CAT findings : Stator profile finish Variation

Stator
Surface Finish
Spec - 0.7 Ra
Actual - 0.86Ra

To achieve Surface finish of 0.7Ra, we introduced match lapping of Stator & rotor by developing an
SPM. Both the stator & rotor are lapped as a set. The process follows relative motion, which is
experienced in actual working.
This resulted in achieving 0.7Ra surface finish Lapping SPM
2.Stator,Rotar Dent Mark Issues
Problem
Component rejection is
very high in Gerotor due
to Handling Damages
Stator & Rotor Counter Measures
Separate Bin’s were
Introduced for Material
Handling with seperators.

Analysis Results
"1. After Operations, 1.Component
Components were Rejection is reduced.
rejected due to Dent mark 2. Handling
issues. Damages are
2. Material Handling was Reduced."
not good.
3. No Separate BIN's are Benefits
provided for Input &
"1.Material Handling Improved.
Finished components. "
2. Quality of the products
Improved."

Before After
3.Leakage From Port Holes During Painting
Problem HSU Port Holes Counter Measures
Oil Leakage from port
holes during testing. Introduced metal caps to
prevent oil leakage

Analysis Results
1. Oil Leakage From 1. Oil leakage
Port Holes stopped
2. Clearence in port 2. Improved paint
holes caps finish
3. Clearence due to wear
Benefits
1.Rework/Rejections reduced

Before After
III. Clockwise and Anti-Clockwise Rotation Pressure
•Cause Analysis Table
Clockwise and Anti clockwise Rotation
Pressure(Both Sides Equal Pressure) Sl causes Standard Measurement Actual Inference
no specification technique specification
14
12 1 Sleeve Spool 8-12µ Comparator 8-12µ Not
Clearance more Stand & Bore Significan
10 Dial t
8 2 Sleeve Surface 1.6μ Finish Tester 1.2μ Not
Roughness more Significan
6 t
4
3 Sleeve outer Dia 3µ Roundness 3µ Not
2 cylindricity more Tester Significan
t
0
1 2 3 4 5 4 Spool slot symmetry 5-10µ Trimos 12-14µ Significan
No of Components
variation t
•Possible Causes
1.Sleeve & spool clearance more
5 Sleeve& spool No Surface Visual Surface Significan
2. Sleeve slot symmetry variation
surface dents more Dent should Dents t
3. Sleeve surface roughness more Occur Frequently
4.Sleeve outer Diameter cylindricity more Occuring
5.Sleeve spool Surface Dent more
2.Sleeve,Spool Dent Mark Issues
Sleeve & Spool Counter Measures
Problem
Separate Bin’s were
Component rejection is Introduced for Material
very high in Sleeve & Handling with seperators.
Spool due to Handling
Damages Results
Analysis 1.Component
Rejection is reduced.
"1. After Operations, 2. Handling
Components were Damages are
rejected due to Dent mark Reduced."
issues.
2. Material Handling was Benefits
not good. "1.Material Handling Improved.
3. No Separate BIN's are 2. Quality of the products
provided for Input & Improved."
Finished components. "

Before After
1.Spool slot symmetry variation
1
Sl Reference point RP 2- RP3- RP4-
no 1-RP2 RP3 RP4 RP1
1 24.85 24.68 24.70 24.83
4 2
2 24.72 24.71 24.70 24.72
3 24.76 24.89 24.77 24.88
4 24.73 24.78 24.74 24.82
3 5 24.76 24.81 24.74 24.78

Action for CAT findings :Spool slot symmetry variation

Due to improper clamping there was a shift in
fixture of spool during operation in drilling machine.

HenceThe position of the fixture has been changed

to hold the spool component .

Hence Symmetry variation problem has been

eliminated .Thus leakage and pressure variation has
been eliminated during assembly
 IV. High Steering Torque
•Possible Causes
1.Clearence Between Housing & Sleeve
2.Clearence Between Sleeve & Spool
3.Gerotor height clearence
4.Mounting bolts torque
5.More springs in the assembly
6.Spring Thickness more
•Cause Analysis Table
Sl no Possible causes Spec Act Validation Remarks
1 Clearance between Housing & Sleeve 8~12µ 9-10µ Air Gauge Not Significant

2 Clearance between Sleeve & Spool 8~12µ 9-11µ Air Gauge Not Significant

3 Gerotor height clearance 10-15µ 12-13µ Digital comparator Not Significant

4 Mounting bolts torque 30N-m 29-30N-m Torque meter Not Significant

5 More springs in the assembly and Spring thickness 6 Due to more Visual and Vernier Significant
more No’s(0.5+0.5+0.5) springs and Caliper
mm thickness.HSU’s
steering torque is
high
 Summary of Test Power on Steering torque:
 The effort required to steer the vehicle in engine on
20
18
18 18 18 condition
16  Higher power on steering torque requires higher driver
No of HSU’s Testerd

14 effort leading to fatigue

12
10 10
8
8
6
6
4
2
0
Day 1 Day 2 Day 3

Total HSU's Tight

Power on Steering torque1.7-2 Specification Actuals Operator Feel

Rane 2.0 – 5.0 N-m 2.8 - 3.5 N-m Tight
Customer Specification 1.7-2 N-m - Smooth

3.5
3-3.5N-m
3
Aim-To Reduce the Power On Steering Torque Target
2.5
Target-2-5 N-m to 1.7-2 N-m
To rq ue in-mN

2 1.7-2N-m
1.5

0.5

0
Present Target
 Centering Springs
Sleeve Spool S/A
Spring - RML design
Spool Function of Centering springs :
Bring back the spool to neutral condition upon
Centering removal of steering effort (Left or right) to block the
Springs
flow path to the steering cylinder.

Sleeve
Curved Springs -0.5mm Thick
3 nos on either side
Material : X10CrNi18-8 (SS)

Spring Report

From the above analysis, we can conclude that spring configuration is the main contributor for achieving the required power on steering torque.
 Correlation of Spring thickness Vs Torque

Two options are identified based on analysis and evaluated

Spring Number Spring Power on Self
Configuration of thickness Steering centering Remarks
Springs torque Steering
(1.7-1.9N- response
m) (0.2Sec
Max)

Torque is less than

2+2 0.5*4 1.65-1.69N- 0.5sec the target, but
Option-1 =2mm m response delay was
noticed.

Targeted torque
(0.5*2+0.35) was achieved but
Option-2 (2+1) + 0.35mm thickness
+ (0.5*2+0.35)
1.7-1.85N-m 0.2sec called for
(2+1) =2.7mm development cost is
increased.

Option -2 design has got huge cost impact & hence not viable.
 Addressed the option1 issues worked out a mathematical table

Spring Total Width of Total Width of spring in

Total spring Stiffness in Difference in Total No of Power on steering
Options Spring Configuration thickness per spring in free compressed condition Preload in kgs
side in mm thickness in mm Kg/mm condition in mm in mm mm Springs torque in N-m

Existing 0.5*3 1.5 3 1.75 10 6.5 3.5 6 36.75 2.5-2.8

1 0.5*2 1 2 1.75 9 6.5 2.5 4 17.5 1.4-1.6

2 (0.5*2)+ 1.35 2.7 1.75 / 0.61 9.68 6.5 3.18 4+2 26.1396 1.7-1.85
(0.35*1)

In the above table it is evident that the preload of option 2 needs to be matched for option1 to achieve the targeted power on steering torque.
 Counter Measure
In order to increase the preload, springs have to be further compressed. Rane
physical configuration
To arrive at the spring configuration and following design was finalized.

Option -3 : Curved Spring and Flat Plate

Spring Number of Spring Flat Plate Spring Preload in Power on Self centering
Configuration Springs thickness thickness kgs Steering Steering
(curved) torque in N-m response
(0.2Sec Max)

1.3 26.6 1.55 0.22

1.3 26.6 1.62 0.22
1.3 26.6 1.53 0.26
1.4 27.3 1.72 0.18
(2)+1+
(2) 1.4 27.3 1.7 0.18
1.4 27.3 1.68 0.2
1.5 28 1.78 0.17
1.5 28 1.8 0.16
1.5 28 1.92 0.16

All the performance requirements were met with combination of springs with flat plate thickness of 1.4mm .
After the changed spring configuration
Steering Torque has been reduced. Modified spring design horizontally deployed to all HSUs
 Activity Table
Sl.No.PERIOD Jan-16 Feb-16 Mar-16 Apr-16
Activities 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

1 Problem identification

Understand the
2
current situation

3 Analysis

4 Counter Measures

5 Check Results

7 Conclusion
Problem reduced After taking counter measures
18 18 18 18 18 18 18 18 18

s
e nt
n
po s
m
co
b lem
1 1 re o
ilu Pr
0 0 0 0 0 0 0 Fa of
No

ur
e ft ht ise ise ur
e
ur
e ft ht
s Le Ri
g w w s s Le Ri
g
es ag
e e ck ck es es e e
tP
r
ag lc o lc o Pr Pr pa
g g
ak ak ti- n n p pa
Se Le qu
e n tio tio Sli i p
lve Le r a ta ta Sl
a to qu
e Ro Ro
fV to
r ise ise
ie
R el ck
w
ck
w
C lo C lo
nti-
A

Total Number Of HSU’s Produced in a Shift=18No’s

 First Time Quality Yield
100%
94%
90% 88%
80% 81%
74%
70%

60%
FTQ Yield
50%

40%

30%

20%

10%

0%
Jan'16 Feb'16 Mar'16 Apr'16
 CONCLUSION
Various Issues Have been addressed and appropriate counter measures have been applied .

Thus eliminating defects from next batch of production of HSU’s .

Thus Increase in Quality Products Has been increased

 After implementing necessary permanent solutions we found that the overall performances were to
the level of satisfaction.
 Smooth rotation , Solid end Stop of steering wheel,Leak free joints.
 Easy Manuarability
 Reduction in Percentage of Defective HSU’s showcased for winning new businesses from M&M
Swaraj, TAFE and TMTL.
 Potential risk of warranty returns have been resolved, resulting in increase of business growth.
 REFERENCES
1. Sharma, Narender (2011-12-16). "Shakehand with Life: Philip Crosby's : Do It Right First Time and Zero Defects".
Shakehandwithlife.blogspot.com. Retrieved 2013-04-22.

2. A Guide to Zero Defects: Quality and Reliability Assurance Handbook. Washington, D.C.: Office of the Assistant
Secretary of Defense (Manpower Installations and Logistics). 1965. p. 3. OCLC 7188673. 4155.12-H. Retrieved
2014-05-29.

3. Halpin, James F. (1966). Zero Defects: A New Dimension in Quality Assurance. New York: McGraw-Hill. p. 11. OCLC

567983091.

4. Library of Rane private limited, Mysore, Hottagali industrial area.

5. Machine catalogue in Rane madras private limited, Mysore.

THANK YOU