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Industrial Training Report

Jasdev Singh Sandhu Institute of


Engineering & Technology
Kauli (Patiala)

Training At

MALHOTRA MOTORS
Sirhind (Fathegarh Sahib)

Submitted To :-
Submitted By:-
Mechanical Engg. Deptt.
Surinder Singh
Roll
No. 90431175333

Bra
nch Mechanical

PREFACE

This vocational training report on


“Malhotra Motors” Sirhind has been carried out
to undertaken the various machines and
knowledge of automobile parts. In the report on
approach has been mode to understand the basic
information to service of car. I will be thankful
to him. At the end I would like to say that it was
an excellent experience for me.
INDEX

 Tools Used
 Machines Used
 Engine
• Internal Combustion Engine
• External Combustion Engine

 Four Stroke I. C. Engine


 Turbocharging
 CRDI System in Cars
• How does CRDI works

 ABS System
 Working of ABS
 Services of a Car
 Tyre Rotation
 Wheel Balancing
 Wheel Alignment

TOOLS USED
1. Screw Driver
2. L – key
3. T – rod
4. Hammers
5. Pliers
6. Nose Pliers
7. Bench Vice
8. Chisels
9. Spanners
10. Ring Spanners
11. Tappet Gauge
12. Torque Wrench
13. Ring Compressor
14. Hacksaws
15. Oil Filter Clamps
16. Files
17. L Key Set
18. Pipe Wrenches

MACHINES USED

1. Wheel Balancing Machine

2. Hydraulic Crane

3. Car Lift

4. Air Compressor

5. Air Gun

6. Grinder
7. Car Washer

8. Wheel Alignment Machine

ENGINE
An engine is a machine designed to convert
energy into useful mechanical motion. It may also
serve as a "prime mover", a component that
transforms the flow or changes in pressure of a fluid
into mechanical energy. An automobile powered by
an internal combustion engine may make use of
various motors and pumps, but ultimately all such
devices derive their power from the engine. The term
"motor" was originally used to distinguish the new
internal combustion engine-powered vehicles from
earlier vehicles powered by steam engines, such as
the steam roller and motor roller, but may be used to
refer to any engine.
Internal combustion engine
The internal combustion engine is an engine in
which the combustion of a fuel (generally, fossil fuel)
occurs with an oxidizer (usually air) in a combustion
chamber. In an internal combustion engine the
expansion of the high temperature and pressure
gases, which are produced by the combustion,
directly applies force to component of the engine,
such as the pistons or turbine blades or a nozzle, and
by moving it over a distance, generates useful
mechanical energy.

External combustion engine


An external combustion engine is a heat engine
where working fluid is heated by combustion of an
external source, through the engine wall or a heat
exchanger. The fluid then, by expanding and acting
on the mechanism of the engine produces motion and
usable work. The fluid is then cooled, compressed
and reused, or dumped, and cool fluid pulled in (open
cycle air engine).
Four Stroke I. C. Engine

The internal combustion engines in cars, trucks,


motorcycles, aircraft, construction machinery and
many others, most commonly use a four-stroke cycle.
The four strokes refer to intake, compression,
combustion (power), and exhaust strokes that occur
during two crankshaft rotations per working cycle of
the gasoline engine and diesel engine.
The cycle begins at top dead centre (TDC), when the
piston is farthest away from the axis of the
crankshaft. A stroke refers to the full travel of the
piston from Top Dead Center (TDC) to Bottom Dead
Center (BDC).
1. INTAKE Stroke: On the intake or induction
stroke of the piston, the piston descends from the top
of the cylinder to the bottom of the cylinder, reducing
the pressure inside the cylinder. A mixture of fuel
and air is forced by atmospheric (or greater) pressure
into the cylinder through the intake port. The intake
valve(s) then close.
2. COMPRESSION Stroke: With both intake and
exhaust valves closed, the piston returns to the top of
the cylinder compressing the fuel-air mixture. This is
known as the compression stroke.
3. POWER Stroke.: While the piston is close to Top
Dead Center, the compressed air–fuel mixture is
ignited, usually by a spark plug (for a gasoline or
Otto cycle engine) or by the heat and pressure of
compression (for a diesel cycle or compression
ignition engine). The resulting massive pressure from
the combustion of the compressed fuel-air mixture
drives the piston back down toward bottom dead
center with tremendous force. This is known as the
power stroke, which is the main source of the
engine's torque and power.
4. EXHAUST Stroke.: During the exhaust stroke,
the piston once again returns to top dead center while
the exhaust valve is open. This action evacuates the
products of combustion from the cylinder by pushing
the spent fuel-air mixture through the exhaust valve.

Turbocharging
The turbocharger was designed as a part-time
method of compressing more air into the cylinder
head. It consists of a two piece, high-speed turbine
assembly with one side that compresses the intake
air, and the other side that is powered by the exhaust
gas outflow.
When idling, and at low-to-moderate speeds, the
turbocharger is not engaged and the engine operates
in a naturally-aspirated manner. When much more
power output is required, the engine speed is
increased until the exhaust gases are sufficient to
'spin up' the turbocharger's turbine to start
compressing much more air than normal into the
intake manifold.
Turbocharging allows for more efficient engine
operation at low-to-moderate speeds, but there is a
design limitation known as turbo lag. The increased
engine power is not immediately available, due to the
need to sharply increase engine RPM to spin up the
turbo, before the turbo starts to do any useful air
compression.

CRDI System In
Cars
CRDI is an intelligent way of controlling a
diesel engine with use of modern computer systems.
CRDI helps to improve the power, performance and
reduce harmful emissions from a diesel engine.
Conventional Diesel Engines (non-CRDI engines) are
sluggish, noisy and poor in performance compared to
a CRDI engine.
CRDI or common rail direct injection system is
also sometimes referred to by many similar or
different names. Some brands use name CRDe /
DICOR / Turbojet / DDIS / TDI etc. All these
systems work on same principles with slight
variations and enhancements here and there.

How does CRDI works :-


CRDI system uses common rail which is like
one single rail or fuel channel which contains diesel
compresses at high pressure. This is a called a
common rail because there is one single pump which
compresses the diesel and one single rail which
contains that compressed fuel. In conventional diesel
engines, there will be as many pumps and fuel rails as
there are cylinders.
As an example, for a conventional 4 cylinder diesel
engine there will be 4 fuel-pumps, 4 fuel rails each
feeding to one cylinder. In CRDI, there will be one
fuel rail for all 4 cylinders so that the fuel for all the
cylinders is pressurized at same pressure.
The fuel is injected into each engine cylinder at a
particular time interval based on the position of
moving piston inside the cylinder. In a conventional
non-CRDI system, this interval and the fuel quantity
was determined by mechanical components, but in a
CRDI system this time interval and timing etc are all
controlled by a central computer or microprocessor
based control system.
To run a CRDI system, the microprocessor
works with input from multiple sensors. The input
sensors include throttle position sensor, crank
position sensor, pressure sensor, lambda sensor etc.
The use of sensors and microprocessor to control the
engine makes most efficient use of the fuel and also
improved the power, fuel-economy and performance
of the engine by managing it in a much better way.
ABS System

An anti-lock braking system, or ABS is a safety


system which prevents the wheels on a motor vehicle
from locking up (or ceasing to rotate) while braking.

A rotating road wheel allows the driver to maintain


steering control under heavy braking by preventing a
skid and allowing the wheel to continue interacting
tractively with the road surface as directed by driver
steering inputs. ABS offers improved vehicle control
and decreases stopping distances on dry and
especially slippery surfaces. However, on loose
surfaces like gravel and snow-on-pavement, it can
slightly increase braking distance while still
improving vehicle control. On others, it may not
improve control at all.
Since initial widespread use in production cars, anti-
lock braking systems have evolved considerably.
Recent versions not only prevent wheel lock under
braking, but also electronically control the front-to-
rear brake bias. This function, depending on its
specific capabilities and implementation, is known as
electronic brakeforce distribution (EBD), traction
control system, emergency brake assist, or electronic
stability control.
Working of ABS

The anti-lock brake controller is also known as


the CAB (Controller Anti-lock Brake)
A typical ABS is composed of a central electronic
control unit (ECU), four wheel speed sensors, one for
each wheel and two or more hydraulic valves within
the brake hydraulics. The ECU constantly monitors
the rotational speed of each wheel, and when it
detects a wheel rotating significantly slower than the
others, a condition indicative of impending wheel
lock — it actuates the valves to reduce hydraulic
pressure to the brake at the affected wheel, thus
reducing the braking force on that wheel. The wheel
then turns faster.
when the ECU detects it is turning significantly faster
than the others, brake hydraulic pressure to the wheel
is increased so the braking force is reapplied and the
wheel slows. This process is repeated continuously,
and can be detected by the driver via brake pedal
pulsation. A typical anti-lock system can apply and
release braking pressure up to 20 times a second.
The ECU is programmed to disregard differences in
wheel rotative speed below a critical threshold,
because when the car is turning, the two wheels
towards the center of the curve turn slower than the
outer two. For this same reason, a differential is used
in virtually all roadgoing vehicles.
If a fault develops in any part of the ABS, a warning
light will usually be illuminated on the vehicle
instrument panel, and the ABS will be disabled until
the fault is rectified.
Services of a Car
 First service---------------------1000 km
( Oil change, general checking )

 Second services------------------5000 km
( Oil change, air filter and nut bolt checking
and cleaning )

 Third service----------------------10,000 km
( Oil change, Plug & oil filter change, air filter
check and tyre rotation )

 Fourth service----------------------15,000 km
( Oil change, Plug & oil filter change, air filter
checking and cleaning )

 Fifth service-------------------------20,000 km
( Brake oil change, Oil change, Plug & oil filter
change, air filter check and tyre rotation )
Tyre Rotation
Wheel Balancing
Out-of-balance tires will cause a car to vibrate at
certain speeds, usually between 50 and 70 mph. A
tire is out of balance when one section of the tire is
heavier than the others. One ounce of imbalance on a
front tire is enough to cause a noticeable vibration in
the steering wheel at about 60 mph.

To balance a wheel, the technician will mount it on a


balancing machine which spins the wheel to locate
the heavier part. He will then compensate for the
heavy part by attaching a lead weight on the opposite
side. Many people are pleasantly surprised at how
smooth their car drives after balancing all four
wheels.
Most high quality tires will hold their balance fairly
well and go out of balance very gradually. If you
notice a vibration that wasn't there the day before, it
is possible that one of the lead balancing weights fell
off. If you feel the vibration mostly in the steering
wheel, the problem is most likely in a front wheel. If
the vibration is mostly in the seat, the problem is
probably in the rear.
For those of you who are very sensitive about
vibrations and your shop can't seem to get that last bit
of vibration out, check to see if you have locking
wheel lugs. Some locking lugs are as much as 1.5
ounces heavier than the other lug nuts which
translates to about 1/2 ounce at the wheel rim. Try
putting a 1/2 ounce weight opposite the locking lug
and see if it helps.
Wheel Alignment
Wheel alignment consists of adjusting the
angles of the wheels so that they are perpendicular to
the ground and parallel to each other. The purpose of
these adjustments is maximum tire life and a vehicle
that tracks straight and true when driving along a
straight and level road.
To find out if you need an alignment, first
check each tire and look for uneven wear patterns.
At each tire, take a coin and insert it in the tread at
the inside, center and outside.

• If the tread is deeper on the edges


than in the center, the tire is over inflated.

• If the tread is deeper in the center


than the edges, the tire is under inflated.
• If the tread is deeper on one side
than the other, have your wheel alignment
checked soon.

• Run your hand back and forth


across the tread, being careful not to cut yourself
on any debris or exposed steel belt wire. If the
tread is smooth in one direction, but jagged in
the other you have what is called a "saw-tooth"
wear pattern which is caused by a toe-in
problem. Have the alignment checked as soon as
possible as this condition causes rapid tire wear.
The best type of wheel alignment is a four wheel
alignment. Many cars today have adjustable rear
alignment settings, but even for cars without
adjustments in the rear, a four wheel alignment will
allow the technician to identify any rear tracking
problems and compensate for them with adjustments
to the front.
After the wheel alignment is finished, you should
drive the car on a straight and level road and check
that the car goes straight and that the steering wheel
is in the proper position with the spokes level.

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