MAJOR PROJECT

PRESENTATION

ON

JBM Auto Ltd.“ BUS PROJECT ”

Department : Production (Trim + Electrical)

Submitted by : KUNAL RATHOD (VIII Semester)

JBM Motors ltd. makes a Joint Venture with European Bus maker Bredamenarinibus (BMB) to make a true low floor City Buses named CITYLIFE in three Variants namely 230HP CNG, 280HP CNG, and 280HP Diesel buses.

Our detailed market research indicated there was need for a safe, reliable and durable intra-city mode of transport.

The bus has been designed keeping in mind Indian traffic and weather conditions. Some unique features include a monocoque structure to ensure maximum strength and minimum weight.

The bus has been developed on the monocoque body concept which means the chassis is an integral part of the body.

 

USEFULLNESS

It is a true low floor city city bus without having steps as like in other buses.

Both the Doors are Pneumatically Operated. Manual Ramp is their for Handicap Passenger to travel

safely. Full Air Conditioned Sealant Proof Bus, the bus is

having 39 sitting and 59 standing passenger capacity.   The Bus is Equipped with Disc Brake at all Four

wheels, full air system (Pneumatic) with EBS and ABS with EBD.

High Pressure Laminated sheets (HPL) are used to prevent heating inside the bus.

FRP & ABS are the Main internal trimming parts along with Latest Electrical Technology.

PRODUCTION ENGINEERING

Production Engineering is a combination of Manufacturing technology with management science.

Design and application of manufacturing techniques to produce a specific product. It includes activities such as:

1) Planning Specification, and coordination of the use of resources.2) Analysis of producibility, production processes, and Systems.3) Application of methods, equipment and tooling.4) Controlled instruction of Engineering changes.5) Application of cost control Techniques.

In JBM BUS Plant, PRODUCTION has Sub-Department as follows:

1) Trim Line

2) Mechanical Line 3) Electrical 4) Showering

5) Pre Dispatch Inspection (PDI)

TRIM LINETrim line is the Body line where BUS Body is made with the help of different components and parts as follows: 1) FRP (Fibre reinforcement Plastic) 2) ABS 3) Glass Fitment4) Sika Flex Sealant5) Handrails 6) High Pressure Laminating Sheets (HPL)7) GFRP 8) Vinyl Flooring9) Stair Noising10) Seats Fitment 11) Exterior Aluminium Panels12) Front Facia

FRP : Fiber reinforced plastic also known as fibre reinforced polymer. It is a composite material made of polymer matrix reinforced with fibres. The fibres are usually glass, carbon, aramid or Basalt.

Characterstics of FRP : High Strength to weight ratio. Anisotropic in nature. High tensile strength with low modulus of elasticity. Ability to form complex shape.

ABS : Acrylonitrile Butadiene Styrene Three components from which ABS forms are

Polybutadiene, Styrene, Acrylonitrile. ABS can be easily machined using Turning, Sawing,

Die Cutting. It is tough, hard and rigid and has good chemical

resistance and dimensional stability. They also have good electrical properties that are fairly

constant over a wide range of frequencies. ABS properties are little affected by temperature and

atmospheric humidity in the acceptable operating range of temperatures.

HPL : High Pressure laminating sheets is used in interior of a

Bus in both left and right lower side.

HPL is the direct descendent of the original plastic laminate.

It is considered to be one of the most durable decorative surface materials and having properties including chemical, fire and wear resistance.

Common thickness range is 2 mm through 4 mm.

VINYL FLOORING:Vinyl is the covering over wooden floor inside the

bus. Vinyl sheet is pasted over complete interior

wooden plywood with the help of adhesive. Two vinyl is pasted with the help of sealant joint. Then upto 75°C we heat the vinyl sheet from

above, so that it pasted completely.

MECHANICAL LINE : Initially when Bus Structure entered in line one then following assembling process occurs as denoted:

1) Fitment of Engine Mounting2) Base plate mounting 3) Engine mounting with transmission 4) Alternator with starter motor 5) Radiator and its mounting6) Steering gearbox with Universal joint7) Two way Axle with propellar shaft 8) Pneumatic fitment 9) Coolant pipes 10)Mounting of Belts11) Demester Fitment 12)Air tanks & air bellows13) Phasor rod, Jumping rod with relay lever

ELECTRICAL JBM CITYLIFE is Full Electronic Bus operated by

Engine ECU & TCM. JBM BUS is Manufactured as a Multiplex Electronic

System, where On-Board Diagnostic (OBD) is a major Benefit, which shows a trouble code whenever their is an error in a Wiring harness or if any Connection is missed.

The major Electrical Component used is Battery of 200 Ampere, Starter motor which is mounted on Flywheel housing, and Alternator which charge the battery.

Total 6 sensors are used which is used to display on dashboard when Bus is in running condition & also in Idle condition.

1) Driver door Sensor or Driver door limit switch 2) Rear door limit switch 3) Receptical box limit switch 4) Cam sensor5) Rear start stop box sensor 6) Fuel detect sensor7) Crank SensorWhat is Sensor ?A device which detects or measures a physical property

and records, indicates, or otherwise responds to it.What is limit Switch ?A switch that automatically cuts off current to an electric

motor when an object moved by it.

WIRING HARNESS A cable harness, also known as a wiring harness, is an

assembly of cables or wires which transmit signals or electrical power.

System of insulated conducting wires bound together  with 

insulating materials, used in the electrical system . The thing which makes wiring harness function

different is Coupler. Each wire is color coded to represent a specific

electronic feature. It provides one connection point for multiple wiring configurations.

POWER CABLES A power cable is an assembly of one or more electrical

conductors usually held together with an overall sheath.

The assembly is used for transmission of electrical power.

Different types of power cables are used in a Bus to connect mechanical as well as electrical parts.

Power cables use stranded copper or aluminum  conductors.

SHOWER TEST

This is the Second last stage of production process in which we start the high pressure shower test is done.

By this we come to know, is their any leakage in bus from outside.

Defect will be check and monitored by the PDI team.

All Internal, External & Upper side of a bus is checked so that any leakage will be not be their.

PRE DISPATCH INSPECTION

Pre dispatch inspection is the last stage of Production, in which quality engineers check each and every part which is fitted inside and outside of bus.

Quality engineers make Checklist and accordingly, production team verify that points.

Stickers, do’s and don’t’s tags and slips are pasted by PDI Team.

In this stage BUS is completed for dispatch to the

customer.