Internship Review - I

TubeTech Engineers
By
Aniruddha Balbudhe - 1032202176

Branch: Mechanical Engineering

College Guide: Prof.S.B.Kolekar

Company Guide : Gopal Singh Gusavi
Index

• Introduction
• Problem Statement
• Design Considerations
• WHAT WE DID ?
• List of day - to - day activity
• Results
• Conclusion
AshishAniruddha
PD-07 Yewale, (PD-04),
Balbudhe,
MIT-WPU,
MIT-WPU,
Pune
Pune 30-Nov-23 2
Introduction

The implementation of preventive maintenance for hydraulic power packs is crucial for ensuring the reliability, longevity,
and optimal performance of these components in various industrial applications. Regular maintenance activities involve
scheduled inspections and proactive measures to address potential issues before they escalate. This approach contributes
to increased equipment lifespan, reduced downtime, and enhanced overall reliability. Cost savings are achieved through
the identification and resolution of minor issues during scheduled maintenance, preventing the need for major repairs or
replacements.

Additionally, preventive maintenance improves safety by identifying and rectifying potential hazards, helping businesses
comply with industry regulations. Well-maintained hydraulic systems operate more efficiently, potentially reducing
energy consumption and minimizing the environmental impact. Ultimately, a comprehensive preventive maintenance
program for hydraulic power packs is essential for promoting safety, reliability, and cost-effectiveness in industrial
operations

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 3
Internship Review - II
TubeTech Engineers
By
Aniruddha Balbudhe - 1032202176

Branch: Mechanical Engineering

College Guide: Prof.S.B.Kolekar

Company Guide : Gopal Singh Gusavi
Index

• Introduction
• Problem Statement
• Design Considerations
• WHAT WE DID ?
• List of day - to - day activity
• Results
• Conclusion
AshishAniruddha
PD-07 Yewale, (PD-04),
Balbudhe,
MIT-WPU,
MIT-WPU,
Pune
Pune 30-Nov-23 5
Introduction
Now a day’s many drilling machine are available for drilling purpose, but that it will not full fill some
particular criteria for some kind of special operation which is essential in mass production. Here going to
solve problem of one particular industry which face difficulty in large amount of drilling operation (approx.
12,000 drill per day) with minimum cycle time.

The Client had a manual working drilling machine and required a faster, cheaper and productive to solution
for the same.

Advance factory made CNC drilling may fulfill the requirement of industry, but it is not feasible on small
scale industry as the installation , cost is much higher. The alternative solution is to install a SPM(Special
purpose machine) with required dimensional accuracy and degree of precision with semi or fully automation
to overcome this problem.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 6
Problem Statement

Design a proper hydraulic circuit and powerpack for a special purpose machine(SPM) i.e. a multi spindle drilling machine.
The main criteria for correction:
• More Productivity
• Less Time Consuming
• Affordable
• More Laborious

Parameters In Conventional In SPM

Loading/Unloading time =10 sec/piece 5 sec/piece (At a time 2 piece)

Indexing time 2 sec/piece -

Machining time 45 sec/piece 45sec/2 piece

Total time 57 sec/piece 50 sec/2 piece

Total time for 2400 pieces/day 8 hours 3.33 hours

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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Technical Data & Specification
• Dead weight of machine : 176 kg
• Clamping Force : 0.56 kN/mm2 x 2Tool
• Hydraulic system pressure : 30 bar
• Hydraulic Fluid : SAE 68
• Factor of Safety : 2
• Power at spindle : 4hp
• Feed rate : 2mm/sec
• Cycle time : 50 second
• Assumed efficiency for gear drive : 90%
• Assumed efficiency for belt drive :70%

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 8
Calculations
• PUMP : VANE PUMP “PV2R” Series
Single Pumps

• Directional Control Valve:

4/3 way solenoid Operated DSG01

• Pilot operated check valve: CM0TA-01

• Double acting Check Valve: CSS007

• Relief Vave : RDE 25 860-R

• Flow Control Valve : RPCE-18302

• Unloading Valve : SLA 6 -6R-210

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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What We Did ?

Powerpack Exploded
PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23
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What We Did ?
Here is the Hydraulic Powerpack and Circuit
Part List

Powerpack
PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23
11-Sep-23 11
What We Did ?

1. Fill the Properties:

- Populate essential model properties such as mass, material, and area. This information provides crucial details for
analysis and documentation.

2. Check Fillets and Chamfers:

- Thoroughly inspect and validate all fillets and chamfers on the model to ensure they meet design specifications and do
not introduce unintended issues.

3. Take Necessary Views:

- Capture key views (front, top, side, and ISO) to facilitate clarity on the drawing sheet and avoid confusion during the
drafting process.

4. Provide Accurate Dimensions:

- Apply precise dimensions, tolerances, section and detail views where needed, along with feature callouts and hole
callouts. This step ensures clarity and adherence to design specifications.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 12
What We Did ?
5. Create a Property Table:
- Establish a property table incorporating crucial information such as item number, weight in kilograms, and area. This
table serves as a quick reference for essential model properties.

6. Track Geometric Characteristics:

- Refer to the QC track sheet and calculations to monitor and verify geometric characteristics. This ensures compliance
with quality control standards throughout the drafting process.

7. Generate Bill of Material (BOM):

- Develop a comprehensive Bill of Material for each assembly, listing all components with part numbers and names. This
facilitates accurate assembly documentation and organization.

8. Create Exploded Views:

- Construct exploded views for assemblies, clearly illustrating the spatial relationships between components. Include part
numbers and names to enhance the understanding of the assembly structure.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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List of Day-to-day Activity
● Daily task assigned by the leader on the
excel sheet.
● Daily track sheet update
● Days divided for drafting, calculation
and QC corrections.
● Monday - Wednesday ( Drafting )
● Thursday - Friday ( Corrections and
Model Updates)
● Saturday (Weekly work Delivery and
next week planning)

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 14
Internship Review - III
TubeTech Engineers
By
Aniruddha Balbudhe - 1032202176

Branch: Mechanical Engineering

College Guide: Prof.S.B.Kolekar

Company Guide : Gopal Singh Gusavi
Index

• Introduction
• Problem Statement
• Design Considerations
• WHAT WE DID ?
• List of day - to - day activity
• Results
• Conclusion
AshishAniruddha
PD-07 Yewale, (PD-04),
Balbudhe,
MIT-WPU,
MIT-WPU,
Pune
Pune 30-Nov-23 16
Introduction
AVL is one of the world’s leading mobility technology companies for development,
simulation, and testing in the automotive industry, and in other sectors. Drawing on our
pioneering spirit, we provide concepts, solutions, and methodologies for a greener, safer,
and better world of mobility.

As a global technology provider, our offerings range from simulation, virtualization, and
test automation for product development to ADAS/AD and vehicle software. We combine
state-of-the-art and highly scalable IT, software, and technology solutions with our
application know-how, thereby offering customers extensive tools in areas such as Big
Data, Artificial Intelligence, cybersecurity, and embedded systems.

PD-04 Ashish Yewale, MIT-WPU, Pune 30-Nov-23

11-Sep-23 17
Problem Statement

DESIGN A HYDRAULIC POWERPACK AND CIRCUIT

FOR BED PRESS TO AUTOGUIDE CLAMPING OF
ENGINE FOR TESTS

WORKING PRESSURE : 70 Bar

TESTING PRESSURE : 110 Bar

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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Calculations

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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Technical Data & Specification

• Working Pressure : 70 Bar

• Test Pressure : 105 Bar
• Working Fluid: ISO VG46
• Flow: 20 LPM
• Motor: 3.7kW @ 1000RPM
• Weight: 180 kgs app.
• Efficiency(req.): 90%

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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What We Did ?
Here is the Hydraulic Circuit

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

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What We Did ?

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 22
What We Did ?

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 23
What We Did ?
• Gear pump : AZPW-21-022 RQRXXMB

PARTS LIST • Drain Ball Valve: ½” BSP LOW PRESSURE

• Motor: 3.7kW @1500RPM HZ 415 VOLT IE3

MAKES ARE • Check Valve: S10 A1.0

DISTRIBUTED WITHIN:
• REXROTH • Pressure relief valve: DBDS10 K200
• ATOS
• HYDAC • Directional control Unloading Valve: 4WE6 HA6X/E G24

MOTOR MAKE : BBL • Double Throttle Check Valve: Z2FS6-2-4X/2QV

PUMP MAKE: REXROTH • Pilot operated Check Valve: Z2S6-B1-6X

• Poppet Valve: WSM06020Y-01-C-NN24DG

• Pressure Relief Valve: DBDS6 K100

• Flow Control Valve: DVP-12

• Directional Control Valve: 4WE6J6X/G24 N9K4

• Pressure Reducing Valve: ZDR6DP2-4X/150 YM

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 24
What We Did ?

1. Fill the Properties:

- Populate essential model properties such as mass, material, and area. This information provides crucial details for
analysis and documentation.

2. Check Fillets and Chamfers:

- Thoroughly inspect and validate all fillets and chamfers on the model to ensure they meet design specifications and do
not introduce unintended issues.

3. Take Necessary Views:

- Capture key views (front, top, side, and ISO) to facilitate clarity on the drawing sheet and avoid confusion during the
drafting process.

4. Provide Accurate Dimensions:

- Apply precise dimensions, tolerances, section and detail views where needed, along with feature callouts and hole
callouts. This step ensures clarity and adherence to design specifications.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 25
What We Did ?
5. Create a Property Table:
- Establish a property table incorporating crucial information such as item number, weight in kilograms, and area. This
table serves as a quick reference for essential model properties.

6. Track Geometric Characteristics:

- Refer to the QC track sheet and calculations to monitor and verify geometric characteristics. This ensures compliance
with quality control standards throughout the drafting process.

7. Generate Bill of Material (BOM):

- Develop a comprehensive Bill of Material for each assembly, listing all components with part numbers and names. This
facilitates accurate assembly documentation and organization.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 26
List of Day-to-day Activity
● Daily task assigned by the leader on the
excel sheet.
● Daily track sheet update
● Days divided for drafting, calculation
and QC corrections.
● Monday - Wednesday ( Drafting )
● Thursday - Friday ( Corrections and
Model Updates)
● Saturday (Weekly work Delivery and
next week planning)

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 27
Result

The implementation of the aforementioned practices in the model drafting process, including meticulous
attention to geometric characteristics, adherence to Quality Control standards, and precise calculations
of properties such as mass and area, has yielded substantial improvements in our team's understanding
of Geometric Dimensioning and Tolerancing (GD&T) and intricate calculations. Not only has it helped
in the quality standards but also in the Hydraulics gaining the knowledge of the afore mentioned
calculations and practicing them.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 28
Conclusion

In conclusion, the integration of meticulous drafting practices outlined above has not only facilitated the successful
completion of complex modeling tasks but has also significantly elevated our team's proficiency in Geometric
Dimensioning and Tolerancing (GD&T) and Hydraulics. The comprehensive understanding of GD&T along with
Hydraulics, imparted during our second year, played a pivotal role in guiding our approach to geometric
characteristics, fillet and chamfer validations, and precision in dimensioning. The incorporation of property tables,
Bills of Material, and exploded views underscore the application of GD&T knowledge, contributing to heightened
accuracy and adherence to quality standards. This experience underscores the enduring impact of foundational
teachings from Prof. C. Kohsti on our practical applications and reinforces the importance of a strong educational
foundation in shaping professional excellence.

PD-07 Aniruddha Balbudhe, MIT-WPU, Pune 30-Nov-23

11-Sep-23 29
THANK YOU