Rsrtc summer training report

Dept. of Mechanical engg.

S S College of Engineering, Udaipur

RAJASTHAN TECHNICAL UNIVERSITY

KOTA

A

Industrial Training Report

On

“Rajasthan Roadways”

SUBMITTED IN PARITIAL FULFILMENT OF THE REQUIREMENT FOR

THE AWARD OF THE DEGREE

OF

BACHELOR OF TECHNOLOGY

In

Mechanical Engineering

Session 2015-2016

Submitted To: Submitted By:

Dept. of Mechanical Engg. Chandan Kumar

Roll No. 12ECOME302

IV Year/ VII Sem.

Department of Mechanical Engineering

S S College of Engineering

S S Hills, Jhamar Kotda Road, Umarda, Udaipur (Raj.)



RAJSTHAN STATE ROAD TRANSPOT CORPORATION

CERTIFICATE

DATE-:15-07-2015

To whom it may concern

This is to be certify that Mr.-: Chandan kumar S/o shree

…Mithlesh jamadar student of S S College of

Engineering , Udaipur has successfully completed

summer training programme from 01 June 2015 to

15 July 2015 in depot workshop RSRTC, Udaipur.

I wish him every success in his future life with best

wishes.

Manager (operation)

RSRTC, Udaipur.



Acknowledgement

I would like to express our gratitude towards all the people who have contributed their

precious time and effort to help me. Without whom it would not have been possible for me to

understand and complete the training.

I would like to thank Mr. Kanhaiya Gautam, Head of Mechanical Department RSRTC, My

Training Co-coordinator Mr. Anand Sinha and my Guide Mr. Raunit Verma and Mr.

Kapil Lohar for their guidance, support, motivation and encouragement throughout. The

period this work was carried out. And I also thank Mr. Anil Chauhan, Head of Department

of Mechanical Engineering, S S College of engineering for this motivational support and

guidance for training.

Their readiness for consultation at all times, their educative comments, their concern and

assistance even with practical things have been invaluable.

.

CHANDAN KUMAR



Abstract

Rajasthan State Road Transport Corporation is also known as RSRTC, and has 1 million

passengers travel by its buses daily. RSRTC’s services are to all important places in Rajasthan and adjoining states of Gujarat, Haryana, Punjab, Delhi, Uttar Pradesh, Himachal pradesh, Madhya Pradesh and Maharashtra.

Today RSRTC has entered into 50th year of business, since its inception and is committed to

providing high quality bus services, consistently and constantly improving the services for the satisfaction of the passenger’s.

To fulfill the commitment, RSRTC has incorporated ordinary, Express, Deluxe, A.G Gandhi Rath, A.C., A.G Sleeper, Volvo-Mercedes, Volvo-Pantry, Volvo-LCD, Volvo-LCD-Pantry bus services in fleet for all category of passengers.

It has 5,000 buses in its fleet and 56 depots across the state and 3 depots outside the state i.e.

Indore, Ahmadabad and Delhi.



CONTENT

Certificate I

Acknowledgement II

Abstract III

Contents

IV

Chapter 1

1.1 Introduction 1

1.2 History 2

Chapter 2

Tyre section

2.1 Type of tyre 3

2.2 Material properties and structure for tyres 5

Chapter 3

Diesel section

3.1 Pump diesel supply 7

3.2 Oil leakage- Diesel leakage 7

3.3 Oil change of Engine- about Engine 8

3.4 F.I Pump Change- About Pump 9

3.5 Engine Change 10

Chapter 4

Mechanical Heavy Work

4.1 Body work 12

4.1.1 Welding & Repair of Body 12

4.1.2 Accidental Vehicle 14

4.1.3 Glass Work 14



4.2 Washing of Bus 16

Chapter 5

Transmission System

5.1 Transmission System (Gear Box) 19

5.1.1 Functions of Transmission 20

5.1.2 Necessity of transmission 20

5.1.3 Types of Transmission 20

5.2 Sliding mesh type of gear box 21

5.3 Constant Mesh Gear Box 24

5.4 Synchromesh Gearbox 25

Chapter 6

Clutches

6.1 Clutches 27

6.1.1 Clutch System 27

6.1.2 System Components 28

6.2 Clutch Components – Flywheel 29

6.2.1 Flywheel Construction 30

6.2.2 Dual-mass Flywheel 30

6.3 Clutch Disc 31

6.3.1 Clutch Disc Construction 32

Chapter 7

Brakes



7.1 Brakes 33

7.1.1 Function of brakes 33

7.1.2 Classification of brakes 33

7.1.3 Requirement for good braking system 33

7.2 Types of Braking Systems 34

7.2.1 Brake system components 34

7.2.2 Brake Action 35

7.3 Brake Linings 36

7.3.1 Types of Linings 36

7.4 Disc and Drum Brakes 37



Chapter 1

1.1 Introduction

As per the syllabus an industrial training for B.TECH. Students are compulsory. So, I have

taken training at “Rajasthan Roadways”.

Present status “.Today RSRTC has entered into 50th year of business, since its inception and is committed

to providing high quality bus services, consistently and constantly improving the services for the satisfaction of the passengers .To fulfill the commitment, RSRTC has incorporated

Ordinary, Express, Deluxe, A.G. Gandhi Rath , A.C., A.G. Sleeper, Volvo-Mercedes, Volvo-Pantry, Volvo-LCD, Volvo-LCD-Pantry bus services in fleet for all category of passengers. It has 5,000 buses in its fleet and 56 depots across the state and 3 depots outside the state i.e.

Indore, Ahmedabad and Delhi. About 1 million passengers travel by its buses daily. RSRTC's services are to all important places in Rajasthan and adjoining states of Gujarat, Haryana,

Punjab, Delhi, Uttar Pradesh, Himachal Pradesh, Madhya Pradesh and Maharashtra.

Fig 1.1 R.S.R.T.C BUS



1.2 History

The corporation has been established by Government of Rajasthan on 1 October 1964 under

the Road Transport Act 1950 with the objective of providing economic, adequate, punctual and efficient services to the traveling public in the state.

Parent Department of Transport, Government of Rajasthan

Founded October 1, 1964; 50 years ago (1964-10-01)

Headquarters Jaipur, Rajasthan, India

Service area Rajasthan and neighboring states

Service type Low floor, Semi low floor, Mini bus, A/C

Stations 52 (Bus Depot) and 11 (Bus Stand)

Fleet 5000 (approx.)

Daily ridership 10,000,00 passengers per day approx.

Fuel type Diesel,

Chairman and Managing

Director Bhaskar A. Sawant (IAS)

Website rsrtc.rajasthan.gov.in

Rajasthan State Road Transport Corporation Hindi RSRTC) is the largest provider of intercity bus transportation in the Indian state Rajasthan. It is headquartered in Jaipur,

Rajasthan

http://rsrtc.rajasthan.gov.in/



Chapter 2

TYRE SECTION

Proper selection of tubes and flaps is essential to ensure proper performance of the tube-type tyre. The tube - made of butyl rubber - is designed to maintain the air pressure in the tyre while the flap protects the tube from chafing with the rim and prevents it from being pushed

under the bead toe. Fitting the tube and flap properly is an essential step in the process.

2.1 TYPES OF TYRE

1. TUBE TYRE

2. TUBELESS TYRE

Fig 2.1 construction comparison between radial tyre and bias tyre



Fig 2.2. - Tyre size detail

w/house location

No. Item no. Item description

Tyre size Tube size Ply rating

Free state 1 11.00-20 1100/20 16

Free state 2 11.00-20 1000/20 14

Free state 3 14.00-20 1400/20 18

Free state 4 18.4-30 15/30 10

Free state 5 17.5-25 TUBLESS 16

Free state 6 315/80R22.5 TUBLESS 16

Free state 7 12R22.5 TUBLESS 16

Free state 8 195R14C TUBLESS 8

Free state 9 9.00-20 900/20 14

Free state 10 8.5R17.5 TUBLESS 10

Free state 11 7.00-16 700/16 10

Free state 12 225-70R15 TUBELESS 8

Free state 13 11R22.5 TUBELESS 16

Free state 14 155/80R13 TUBELESS NPR

Free state 15 185R14C TUBELESS 8

Free state 16 165/80R13 TUBELESS 8

Free state 17 215R15C TUBELESS 6

Free state 18 31-10.5R15 TUBELESS NPR

Free state 19 5.00R12 TUBELESS NPR








Free state 27 215/80R15 TUBELESS 8

Free state 28 205R16 TUBELESS NPR



2.2 Material properties and structure for tyres –:

Tyre – Carcass

Carcass (casing) is the strength element of the tyre. It transfers tensile, brake and

lateral forces to the tyre radial. It is formed of several layers (plies) of rubberized textile,

anchored at the wire rings of the beads. The textile (Fig. 1) is a fabric with the warp made of

threads of cotton, rayon, nylon, polyester, glass fiber, metallic fiber or carbon fiber, which

imparts mechanical strength to the tyre. The weft is rarely spaced and it serves only to

maintain a constant distance between the warp threads.

The fabric is rubberized by calendaring, and the calendared sheets are cut into pieces of

convenient length, under bias angles varying from 45o (standard diagonal ply tyre) to 90o

(radial ply tyre). The plies thus obtained are joined into a continuous band, and interleaved

with a textile lining in order to avoid self-adhesion during storage.

The composition of the rubber compound for carcass can be 70% NR + 30% SBR or PB. In

these compounds, SBR cannot be over 35% and PB over 30%.

The mechanical properties of the carcass depend also on the nature of the fabric

thread. To obtain the fabrics, the following types of threads or cords (2-3 yarned threads) are

employed:

a) Threads of rayon (a-cellulose)

The material is obtained from cellulose by reaction with sodium hydroxide and carbon

disulfide and regeneration (after spinning) with sulfuric acid. The chemical structure is as

follows:

Rayon threads are characterized by a very small deformation d uring tyre utilization and

they have a very good adhesion to rubber. In exchange, moisture absorption is higher than in

the case of synthetic fibers.

b) Polyamide threads

Polyamides 6 or 6, 6, i.e., the polyamide with the chemical structure -[NH-CO-(CH2)4-

CO-NH-(CH2)6]n-, are used. Polyamide threads possess higher breaking, fatigue and impact

strengths and moisture resistance and a lower density than cellulose. They display a larger

elongation under stress and a lower adhesion to rubber by comparison with rayon threads. All

these deficiencies can be partially corrected.

c) Polyamide (aromatic polyamide) threads

These polyamides contain aromatic rings in the molecule, which leads to remarkable



Properties:

High tensile strength and modulus;

Dimensional stability;

Heat endurance;

Good chemical stability;

High degree of crystallinity.

The lower adhesion to rubber can be corrected by using special adhesives. An example of

aromatic polyamide with industrial application is the one obtained from p-phenylenediamine

and terephthalic acid.

d) Polyester threads

Poly (ethylene terephthalate) (see structure below) is used frequently.

It displays the following characteristics:

Hydrophobic and moisture resistant;

High degree of crystallinity;

Small elongation under stress;

The low adhesion to rubber can be corrected with special adhesives.

e) Metallic threads

They are used for obtaining the plies for radial tyres or to manufacture the fabrics for

breaker. They are made of special steel which contains: 0.4-0.7% MN; 0.15-0.30% Si; min.

0.65% C; max. 0.03% S; max. 0.03% P and traces of Cu, Ni, Cr.

The advantages of the metallic threads over the organic ones are: high breaking

strength, resistance to high temperatures, high elongation modulus and high thermal

conductivity.

The following disadvantages can be mentioned as well:

Higher density;

Low fatigue strength (cyclic stress);

Much higher corrosion.



Chapter 3

DIESEL SECTION

3.1 Pump diesel supply

KNOCKING – DAMAGE OF VEHICLE

First some basics

In diesel engines, first air is taken in when piston is moving down from TDC to BDC. And

during the compression cycle the fuel is injected at high pressure. Due to high compression

ratio, the fuel ignites and explodes to give the power stroke.

This is a kind of heterogeneous combustion because the mixture concentration varies from

low to high throughout the combustion chamber.

Now the requirement of this combustion model is that, the highly atomized fuel should start

burning as soon as it is sprayed in the cylinder, producing heat and thus preparing the

chamber for combustion of incoming mixture. The objective is to burn the incoming fuel to

get a long power stroke. But, if the fuel sprayed initially is not able to mix properly due to

variety of reasons, it keeps on concentrating in the combustion chamber.

This increases the concentration of fuel in the chamber and at some point the large quantity of

fuel ignites sending pulses throughout the chamber. This leads to knocking.

3.2 Oil leakage- Diesel leakage

Pay close attention to leaks from your automobile's engine. Running a vehicle that’s

drastically low on a vital fluid can cause severe damage. After you find the source of the leak,

the following information will help you decide whether you can handle it yourself or you

need professional help.

If water is getting into your vehicle’s passenger compartment, check the rubber

gaskets and weather-stripping around the windows, doors, and sunroof.



Fig 3.1 – Oil leakage

3.3 Oil change of Engine- about Engine

Diesel oil change is a regular part of the maintenance required of your diesel vehicle.

Just like a car or truck that runs on gas, diesel engines require the proper lubrication to keep

them in good working order. A synthetic diesel oil change, under the right conditions, can

last a very long time without needing to be drained. Am soil and Mobil 1 are two synthetic

diesel options to look into, but you should never forgo changing your diesel oil just because

you think you can. Consulting with your mechanic is a good idea if you have questions about

how long your synthetic oil will last. There are some basics to a diesel oil change that every

diesel owner should know. Things like cost, drain intervals and brand options are important

to have in mind when you go to get your oil changed. Knowing how to do it yourself helps

too.

In our country Ashok Leyland and Telco are leading Bus manufacturers and their

recommendations

Ashok Leyland with Hino engine

1. for long distance 32,000 kms

2. Local usage 24,000 kms



Telco with Cummins engine

1. Every 18,000 kms.

Eiche Motors

Every 18,000 kms.

Fig 3.2 Oil change

3.4 F.I Pump Change- About Pump

An Injection Pump is the device that pumps diesel (as the fuel) into the cylinders of a diesel

engine. Traditionally, the injection pump is driven indirectly from the crankshaft by gears,

chains or a toothed belt (often the timing belt) that also drives the camshaft. It rotates at half

crankshaft speed in a conventional four-stroke diesel engine. Its timing is such that the fuel is

injected only very slightly before top dead center of that cylinder's compression stroke. It is

also common for the pump belt on gasoline engines to be driven directly from the camshaft.

In some systems injection pressures can be as high as 200 MPa (30,000 PSI).



Fig-3.3 F.I PUMP

3.5 Engine Change

An engine swap is the process of removing a bus's original engine and replacing it

with another.

This is done either because of failure, or to install a different engine, usually one that

is more modern and so more efficient, this may make it more powerful and or economical.

Older engines may have a shortage of spare parts and so a modern replacement may be more

easily and cheaply maintained. Swapping to a diesel engine for improved fuel economy is a

long established practice, with modern high efficiency and torque diesel engines this does not

necessarily mean a reduction in performance associated with older diesel engine swaps. For

the particular application of off- road vehicles the high torque at low speed of turbo diesels

combined with good fuel economy makes these conversions particularly effective. Older non-

electronic fuel injection diesels were well known for their reliability especially in wet

conditions.

An engine swap can either be to another engine intended to work in the car by the

manufacturer, or one totally different. The former is much simpler than the latter. Fitting an

engine into a car that was never intended to accept it may require much work – modifying the

car to fit the engine, modifying the engine to fit the car, and building custom engine mounts

and transmission bell housing adaptors to interface them along with a custom built driveshaft.

Some small businesses build conversion kits for engine swaps, such as the Fiat Twin cam into

a Morris Minor or similar.

https://en.wikipedia.org/wiki/Internal_combustion_engine

https://en.wikipedia.org/wiki/Morris_Minor



Swapping the engine may have implications on the cars safety, performance, handling and reliability. The new engine may be lighter or heavier than the existing one which affects the

amount of weight over the nearest axle and the overall weight of the car - this can adversely affect the car's ride, handling and braking ability. Existing brakes, transmission and

suspension components may be inadequate to handle the increased weight and/or power of the new engine with either upgrades being required or premature wear and failure being likely.

Fig –3.4 Engine Change



Chapter 4

MECHANICAL HEAVY WORK

4.1 BODY WORK

It includes – WELDING & REPAIR OF BODY, ACCIDENTAL VECIHLE, GLASS

WORK ETC.

4.1.1 Welding & Repair of Body

Welding is a fabrication or sculptural process that joins materials, usually metals or

thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal. In addition to melting the base metal, a filler material is often added to the joint to form a pool of molten

material (the weld pool) that cools to form a joint that can be as strong as the base material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld.

Some of the best known welding methods include:

Shielded metal arc welding (SMAW) - also known as "stick welding", uses an

electrode that has flux, the protectant for the puddle, around it. The electrode holder holds the electrode as it slowly melts away. Slag protects the weld puddle from atmospheric contamination.

Gas tungsten arc welding (GTAW) - also known as TIG (tungsten, inert gas), uses a non-consumable tungsten electrode to produce the weld. The weld area is protected

from atmospheric contamination by an inert shielding gas such as Argon or Helium. Gas metal arc welding (GMAW) - commonly termed MIG (metal, inert gas), uses a

wire feeding gun that feeds wire at an adjustable speed and flows an argon-based

shielding gas or a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from atmospheric contamination.

Flux-cored arc welding (FCAW) - almost identical to MIG welding except it uses a special tubular wire filled with flux; it can be used with or without shielding gas, depending on the filler.

Submerged arc welding (SAW) - uses an automatically fed consumable electrode and a blanket of granular fusible flux. The molten weld and the arc zone are protected

from atmospheric contamination by being "submerged" under the flux blanket. Electro slag welding (ESW) - a highly productive, single pass welding process for

thicker materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or

close to vertical position.

Many different energy sources can be used for welding, including a gas flame, an electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding

may be performed in many different environments, including in open air, under water, and in outer space. Welding is a hazardous undertaking and precautions are required to avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to

intense ultraviolet radiation.

https://en.wikipedia.org/wiki/Welded_sculpture

https://en.wikipedia.org/wiki/Metal

https://en.wikipedia.org/wiki/Thermoplastic

https://en.wikipedia.org/wiki/Fusion_welding

https://en.wikipedia.org/wiki/Brazing

https://en.wikipedia.org/wiki/Soldering

https://en.wikipedia.org/wiki/Melting

https://en.wikipedia.org/wiki/Weld_pool

https://en.wikipedia.org/wiki/Pressure

https://en.wikipedia.org/wiki/Shielded_metal_arc_welding

https://en.wikipedia.org/wiki/Electrode

https://en.wikipedia.org/wiki/Flux_%28metallurgy%29

https://en.wikipedia.org/wiki/Slag_%28welding%29

https://en.wikipedia.org/wiki/Gas_tungsten_arc_welding

https://en.wikipedia.org/wiki/Tungsten

https://en.wikipedia.org/wiki/Argon

https://en.wikipedia.org/wiki/Helium

https://en.wikipedia.org/wiki/Gas_metal_arc_welding

https://en.wikipedia.org/wiki/Argon

https://en.wikipedia.org/wiki/Carbon_dioxide

https://en.wikipedia.org/wiki/Flux-cored_arc_welding

https://en.wikipedia.org/wiki/Submerged_arc_welding

https://en.wikipedia.org/wiki/Energy_source

https://en.wikipedia.org/wiki/Fire

https://en.wikipedia.org/wiki/Electric_arc

https://en.wikipedia.org/wiki/Laser

https://en.wikipedia.org/wiki/Electron_beam_welding

https://en.wikipedia.org/wiki/Friction_welding

https://en.wikipedia.org/wiki/Ultrasound

https://en.wikipedia.org/wiki/Underwater_welding

https://en.wikipedia.org/wiki/Outer_space

https://en.wikipedia.org/wiki/Burn

https://en.wikipedia.org/wiki/Electric_shock

https://en.wikipedia.org/wiki/Ultraviolet_radiation#Human_health-related_effects_of_UV_radiation



Until the end of the 19th century, the only welding process was forge welding, which blacksmiths had used for centuries to join iron and steel by heating and hammering. Arc

welding and ox fuel welding were among the first processes to develop late in the century, and electric resistance welding followed soon after. Welding technology advanced quickly

during the early 20th century as World War I and World War II drove the demand for reliable and inexpensive joining methods. Following the wars, several modern welding techniques were developed, including manual methods like SMAW, now one of the most popular

welding methods, as well as semi-automatic and automatic processes such as GMAW, SAW, FCAW and ESW. Developments continued with the invention of laser beam welding,

electron beam welding, magnetic pulse welding (MPW), and friction stir welding in the latter half of the century. Today, the science continues to advance. Robot welding is commonplace in industrial settings, and researchers continue to develop new welding methods and gain

greater understanding of weld quality.

Fig 4.1.1- Welding

https://en.wikipedia.org/wiki/Forge_welding

https://en.wikipedia.org/wiki/Blacksmith

https://en.wikipedia.org/wiki/Arc_welding

https://en.wikipedia.org/wiki/Arc_welding

https://en.wikipedia.org/wiki/Oxy-fuel_welding_and_cutting

https://en.wikipedia.org/wiki/Resistance_welding

https://en.wikipedia.org/wiki/Laser_beam_welding

https://en.wikipedia.org/wiki/Electron_beam_welding

https://en.wikipedia.org/wiki/Magnetic_pulse_welding

https://en.wikipedia.org/wiki/Friction_stir_welding

https://en.wikipedia.org/wiki/Robot_welding



4.1.2 ACCIDENTAL VEHICLE

Accident management is the centralized handling of a motorist’s claim following a road

traffic collision. It is a cost-effective intermediary service which assists drivers in getting back on the

road quickly and in managing the claims process alone. Whilst it is significantly more cost-effective

for the innocent motorist, the service costs significantly more as a result - a cost borne by the insurer

of the 'at-fault' driver.

The term encompasses a whole host of services; which may include 24-hour vehicle

recovery, damage assessment, replacement car provision, arrangement of vehicle repairs, liaising with insurers, uninsured loss recovery, determining fault, personal injury assistance

and help with paperwork.

It is a particularly useful service for vehicle fleet operators, who need to keep downtime to a minimum. An outsourced accident management service can save managers time and

administration costs.

4.1.3 Glass Work:

When car companies run ads on television touting their vehicle's new safety features, they rarely mention the car's windshield or the surrounding windows, but the glass surrounding

you in those vehicles has been designed and manufactured with your safety in mind. Although automotive glass looks the same as any other type of glass, it functions very

differently.

In most homes, the windows in each room are made from a standard type of glass that will shatter into large shards when it breaks. With the exception of a sliding glass door or front door, these home windows don't receive the same amount of strain that an automotive

window does. A car, on the other hand, will encounter many potholes, rocks and fender benders in its lifetime. Because of this, automotive glass is manufactured into two different

types of safety glass to protect both the structure of the vehicle and the occupants inside. The first type of glass is called laminated glass, which is for the windshield. The second type of glass is known as tempered glass, which is used for the vehicle's side and back windows.

Later on, we'll learn how glass makers insert a thin layer of film between two layers of glass

and fuse them together through heat and pressure to make laminated glass. We'll also take a look at how tempered glass gains its strength through a process of heating and rapid cooling.

Without these different styles of manufacturing and strengthening, automotive glass would be little more than a simple barrier between us and the elements outside.

Laminated and tempered glass each have different functions, but together, they keep you inside the vehicle in an accident, shield you from flying sharp glass, retain the roof's rigidity

in a rollover and allow the side air bag to protect you when it's deployed. Let's go on to the next page and learn when these types of glass were first used and why.



Fig 4.1.2 Glass Work



4.2 Washing of Bus

Surface run-off from washing areas can contain high levels of pollutants such as:

detergents

oil and fuel suspended solids

grease .antifreeze.

You must not allow run-off to enter surface water drains, surface waters or ground waters. This will cause pollution and you could be prosecuted.

You should only wash vehicles in defined areas where the wash water and any rainfall run-off can be contained.

If possible, direct the surface run-off from your vehicle washing area to an on-site treatment system. You may be able to reuse the water. This will reduce your water use and your impact

on the environment. You can also discharge surface run-off directly to a foul sewer or combined sewer. Contact your water and sewerage company or authority to find out if you

need authorization before you discharge run-off to a sewer. You must comply with any conditions of your authorization.

Alternatively, you can collect your run-off in a sealed unit and send it to an authorized disposal site. Check that anyone who takes your waste away from your site is a registered

waste carrier.

You can use sustainable drainage systems (SUDS) to drain run-off from washing areas. SUDS slow and hold back run-off from a site, so that pollutants can be broken down

naturally. In Scotland you must use SUDS to drain run-off from all new built-up areas, such as yards.

Using water from surface waters or ground waters

If you use (abstract) water from surface water or ground waters for cleaning vehicles, you

may need an authorization or license from your environmental regulator.

Good practice; Use water efficiently

Use vehicle washing facilities and equipment that filter and reuse water, or set up a wash water recycling system.

Use trigger-operated spray guns. Make sure they have an automatic water supply cut-off.

Treat waste water from vehicle cleaning

Use collection systems to prevent contaminated water entering surface water drains, surface

waters or ground waters, or draining onto the land.



Use settlement lagoons or suitable absorbent material such as flocculent to remove suspended solids such as mud and silt. Before using flocculent, contact your water and Sewerage

Company or authority to make sure that you can still discharge to the sewer.

Use catch pots or silt traps on drains, and ensure that they are in place during cleaning. Empty them at regular intervals.

Remove oil, grease, petrol and diesel from wash water by passing it slowly through an

appropriately sized oil separator. An oil separator will not work effectively if:

it is too small the speed of flow is too great

It is poorly maintained.

Ensure that any discharge containing detergent cannot run to the oil separator, as this will stop it working.

If you use detergents, use a recycling system with no discharge or ensure that any run-off

containing detergents is collected in a sealed unit. Contact your local water and Sewerage Company or authority for guidance on how to dispose of any of these materials to the foul sewer.

Cleaning chemicals

Minimize the amount of cleaning chemicals you use.

If you use detergents, choose biodegradable and phosphate-free products as they are less harmful to the environment.

Only carry out cleaning in a designated impermeable area that is isolated from the surrounding area by a roll-over bund, raised kern, ramps or stepped access, for example.

Store all cleaning chemicals safely and in an area where you can contain spills. This should

be within a secondary containment system (SCS) such as:

an impermeable bounded area a bounded pallet or spill pallet

A bounded storage unit.

Train your staff

Train all staff to follow your vehicle cleaning procedures. Display details of the procedures in the work area so staff can check them easily.



Fig 4.2 – Bus Washing



Chapter 5

TRANSMISSION SYSTEM

The mechanism which transmits the power developed by engine to drive the

automobile is known as transmission system OR power train. The complete transmission

system consists of engine, a clutch, a gear box, propeller shaft, rear axial and differential and

rear wheels and tyres.

5.1 TRANSMISSION SYSTEM (GEAR BOX):

Gear box: Necessity for gear ratios in transmission, Synchronous gear boxes, 3, 4 and 5

speed gear boxes, Free Wheeling mechanism, Planetary gears systems, over drives, fluid

coupling and torque converters, Epicyclical gear box, principle of automatic transmission,

calculation of gear ratios.

Automotive Gears: Gears play an important role in trucks, car, buses, motor bikes and even

geared cycles. These gears control speed and include gears like ring and pinion, spiral gear,

hypoid gear, hydraulic gears, reduction gearbox.

Fig.5.1 Transmission system

Depending on the size of the vehicles, the size of the gears also varies. There are low gears

covering a shorter distance and are useful when speed is low. There are high gears also with

larger number of teeth.



5.1.1 Functions of Transmission:

* To provide the high torque at the time of starting, hill climbing, accelerating and pulling a

load since high tractive effort is needed

* It permits engine crankshaft to revolve at high speed, while the wheels turn at slower

speeds

*Variable torque by set of gears

*Vehicle speed can be changed keeping engine speed same with certain limit

*The transmission also provides a neutral position so that the engine and the road wheels are

disconnected even with the clutch in the engaged position

* A means to back the car by reversing the direction of rotation of the drive is also provided

by the transmission

5.1.2 Necessity of transmission:

* Variation of resistance to the vehicle motion at various speeds

* Variation of tractive effort of the vehicle available at various speeds

5.1.3 Types of Transmission:

Manual Transmission

*Sliding Mesh Gear box

*Constant Mesh Gear box

*Synchromesh Gear box

Automatic Transmission

o Over drive (semi-automatic)

*Fluid drive or Fluid coupling

o Fully automatic

*Epicyclical gear box

*Free Wheeling unit

*Torque Convertor



5.2 Sliding mesh type of gear box :

Fig.5.2 sliding mesh gear box in neutral position

The figure is of sliding mesh gear box in neutral position. It comprises of input shaft with a

gear (Transmission drive gear), main transmission shaft which is splined and gear are

mounted on it, and a lay shaft (counter shaft) with 2 or 3 or move gears which remains in

connected position with the shaft. Speed change lever (which is shown in figure of gear shift

mechanism) is used the change the gears. Drive gear on the lay shaft is constantly meshed

with drive gear of input shaft. On the splines of main transmission shaft two gears are

mounted which can slide on the splines of the main transmission shaft with the help of shift

lever. A reverse idler gear on the shaft is meshed constantly with the counter (lay) shaft

reverse gear. Gear can be connected to their counter parts on the lay shaft.

When gear are in neutral position, Engine is giving power to crankshaft which in turn

revolves input shaft, the drive gear of input shaft which is constantly meshed with drive gear

of lay shaft also revolves .Due to the revolutions of drive gear of lay shaft. Counter (lay) shaft

rotates in opposite direction to that of input shaft .But no gear of lay shaft are meshed with

gears on the main transmission shaft, hence main transmission shaft will not revolve. The

vehicle will remain as it is.

When vehicle is on first gear, the speed change lever is used to move the larger gear on the

splines of main shaft to mesh it with lower or first gear on the lay shaft the direction of

rotation of the main shaft is same as that of input shaft because gear on counter shaft is

meshed with the gear on the main shaft.



Fig.5.3 Gear in 1st position

Similarly, when the gear is change to 2nd or 3rd the large gear is demised from the first or

lower gear. Smaller gear on the transmission shaft is meshed with the second gear on the

counter shaft with the help of speed change lever. Then vehicle is on 2nd gear.

Fig-5.4 Gear in 2nd position



Fig .5.5 Gear in 3rd position

To make the vehicle move on 4th or top gear, use speed change lever to dames the second

gear and connect the transmission shaft with the input shaft. The vehicle will run on top gear.

Fig 5.6 Gear in 4th position



Fig-5.7 Gear in Reverse position

5.3 Constant Mesh Gear Box:

In constant mesh gear box, all the gear on the counter shaft and all the gears on main

transmission shaft are in constant mesh with one another. And all the gear on lay shaft are

rigidly fixed with it. Two dog clutches are mounted on the splines of the main shaft, one

between the on input shaft and second gear and other one between low and reverse gear.

These two dog clutches are free to slide on the main shaft and can also rotates with it.When

the right hand dog clutch is slides to right by speed change lever, it meshes with the reverse

gear and vehicle will move in reverse direction. When the same dog clutch is made to slide

towards left by speed change lever than the vehicle will run on first gear.

Fig-5.8 Constant mesh Gear Box

Similarly when left hand dog clutch is made to slide towards left and right, the dog clutch meshes



With gear on input shaft (clutch) and second gear respectively.

5.4 Synchromesh Gearbox:

*Similar to constant mesh type, because all the gears on the main shaft are in constant mesh

with corresponding gears on the lay shaft.

*The gears on the main shaft are free to rotate on it and that on the lay shaft are fixed to it.

* Avoids the necessity of double declutching.

*The parts which ultimately are to be engaged are first brought into frictional contact which

equalizes their speed, after which these may be engaged smoothly

Fig-5.8 Synchromesh Gearbox

*A: engine shaft.

*Gears B, C, D, E are free on the main shaft and always mesh with corresponding gears on

lay shaft.

*Members F1 and F2 are free to slide on splines on the main shaft.

*G1 and G2 are ring shaped members having internal teeth fit onto the external teeth on

members F1 and F2 respectively.

* K1 and K2 are dog teeth on B and D respectively fit onto the teeth of G1 and G2.

*S1 and S2 are the forks.

*T1 and T2 is the ball supported by springs.



*M1, M2, N1, N2, P1, P2, R1, R2 are the frictional surfaces.

*T1 and T2 tend to prevent sliding of members G1 (G2) on F1 (F2).

*When force applied on G1 (G2) through forks S1 (S2) exceeds a certain value, the balls are

overcome and member G1 (G2) slides over F1 (F2).

*There are usually six of these balls symmetrically paced circumferentially in one

synchromesh device.

Engagement of direct gear in Synchromesh Gearbox

Cones M1 and M2 mate to equalize speeds. Member G1 pushed further to engage with dog k1.

*For direct gear, member G1 and hence member F1 is slid towards left till cones M1 and M2

rub and friction makes their speed equal.

*Further pushing the member G1 to left cause it to override the balls and get engaged with

dog’s k1.

*So the drive to the main shaft is direct from B via F1 and the splines.

*Similarly for the second gear the members F1 and G1 are slid to the right so that finally the

internal teeth on G1 are engaged with L1.

* Then the drive to main shaft will be from B via U1, U2, C, F1 and splines.

*For first gear, G2 and F2 are moved towards left

*The drive will be from B via U1, U3, D, F2 and splines to the main shaft.

*For reverse, G2 and F2 are slid towards right.

*In this case the drive will be from B via U1, U4, U5, E, F2 and splines to the main shaft.



Chapter 6

CLUTCHES

6.1 Clutches:

• Purpose To connect and disconnect engine power flow to the transmission at the

wheel of the driver.

Fig-6.1 Transmission System

6.1.1 Clutch System:

*Clutch systems are used to disengage the engine from the road

*When the clutch pedal is depressed, the clutch (and transmission) is disengaged from the

engine

* With your foot off of the pedal, the clutch is engaged to the engine.

*The pressure plate holds the clutch against the flywheel, allowing power to travel through

the clutch to the input shaft of the transmission...

* The engine power will transfer through the clutch to the road



Fig-6.2 Clutch system

6.1.2 System Components:

Flywheel: Transfers engine power to the clutch

Input shaft: Transfers power from clutch to the transmission

Clutch Disk (clutch): Splined to input shaft; transfers power from engine to the input shaft

Pressure Plate Assembly: Spring pressure tightly holds the clutch to the flywheel.

Release bearing (throw-out bearing): Connected through linkage or hydraulics to the clutch

pedal; provides a way for the pressure plate to release pressure on the clutch

Pilot bearing (bushing): Mounted in the tail of the crankshaft. Stabilizes the input shaft. Not

always used for FWD.

Clutch Fork (if applicable): Slides the release bearing into and away from the pressure plate

assembly.

Clutch Linkage (or hydraulic plumbing): Allows the driver to operate the clutch fork

Clutch (bell-housing) Housing: Encloses the clutch assembly



Fig -6.3 Clutch component

6.2 Clutch Components – Flywheel:

*Mounted on the rear of the crankshaft

*Acts as balancer for engine

*Adds inertia to the rotating crankshaft

*Provides a surface for the clutch to contact

*Usually surrounded by a ring gear for electric starter operation

Fig -6.4 Flywheel



6.2.1 Flywheel Construction:

*Usually constructed of nodular cast iron which has a high graphite content

*The graphite helps lubricate engagement of the clutch

*May also be constructed from cold rolled steel

Fig 6.5 Flywheel Construction

6.2.2 Dual-mass Flywheel:

*The flywheel hub and clutch mating area are two separate components

*Springs are used to dampen engine and clutch engagement oscillation.

Fig -6.6 Dual-mass Flywheel



*Projects from the front of the transmission

*Usually has a pilot which rides in a bearing or bushing in the end of the crankshaft

*The clutch disc is splined to the clutch shaft.

6.3 Clutch Disc:

*Is squeezed between the flywheel and the pressure plate

*Transmits power from the engine crankshaft to the transmission input shaft.

Fig -6.7 Clutch Disc

Rigid - used primarily for industrial/racing applications.

Flexible - most common, everything from grandma’s cruiser to street/strip racing.

Hub flange - in direct contact with the input shaft

Friction ring - in direct contact with the flywheel/pressure plate.

Clutch facing - friction material.

Marcel springs - facing dampener.

Torsional springs - further dampening for clutch application.

Stop pins - limits the torsional spring’s travel.

Rivets -fastens the facing material to marcel (springs).



6.3.1 Clutch Disc Construction:

*Facing manufactured with frictional material

*(may contain asbestos)

*Other surface materials include:

Paper-based

Ceramic

Cotton

Brass



Chapter 7

BRAKES

7.1 Brakes:

When an acceleration pedal of a vehicle is pressed, heat energy of fuel is converted into

kinetic energy with the help of engine which develops a force at the tyre rod surface. To stop

the vehicle, we have to apply brakes. Brakes decelerate the vehicle, which ultimately stop the

vehicle. Reverse of acceleration is braking.

Generally the braking system used in automobile is hydraulic in nature. When the foot

brake pedal is pressed the fluid flows through brake tube which ultimate ly reaches to the

braking mechanism at the wheels. The mechanism apply brakes at the rotating parts of the

wheel to stop the vehicle.

7.1.1 Function of brakes:

1. To stop a vehicle, whenever required.

2. To convert the kinetic energy of vehicle into heat energy and to dissipate the heat

energy.

3. Using hand lever hold the vehicle stationary, even when driver is not present.

4. To control the vehicle when climbing on a slope.

7.1.2 Classification of brakes:

1. Nature of operation

Mechanical Brake

Hydraulic Brake

Vacuum Brake

Air Brake

Electric Brake

Vacuum & hydraulic Brake

2. Nature of application

Service Brake

Parking Brake

3. Nature of braking for

Double acting Brake

Single acting Brake.

4. Power Brake



7.1.3 Requirement for good braking system:

Maximum retarding force should be developed by brake.

Deceleration should be uniform.

Wear of brake component should not affect brake performance.

Vehicle system other than braking system should not be affected due to braking operation.

Assembly of braking system should be light in weight.

Provision for secondary braking system should be there if the main braking system fail

secondary brakes can be used.

7.2Types of Braking Systems:

Service brakes. It’s the primary braking system using a pedal connected to a

hydraulic system causing it to operate.

Parking brakes. It’s mechanically applied by a lever or pedal

Fig 7.1 Braking System



7.2.1 Brake system components :

Fig 7.2 Brake System Component

Friction is the resistance to motion between two objects in contact with each other.

• Dry friction (Brakes)

• Greasy Friction (Wheel bearings)

• Viscoubearings) s (Crank main

• Friction varies with the roughness of the surfaces.

• Kinetic (Motion) Friction

• Static (Rest) Friction

7.2.2 Brake Action:

When the Brake pedal is pressed, brake fluid travels from Master

Cylinder to the Caliper or Wheel cylinder, pushing the pistons out.

In turn this action pushes the shoes against the drum or

The pads against the rotor



Fig 7.3 Brake Action

7.3 Brake Linings:

These are the friction materials that a vehicle uses.

They can be bonded (glued), riveted, and injection molded to the backing pad or

shoes.

Fig 7.4 Brake Lining

7.3.1 Types of Linings:

• Asbestos

• Organic

• Semi-metallic

• Ceramic

• Carbon/Kevlar



Asbestos- these have phased out, very hazardous to breathe the dust.

Organic- mixture of asbestos and organic materials with a resin binder

Semi-metallic- organic mixed with metal shavings, last longer and very good at dissipating

heat.

Ceramic- low dust output, provide exceptional braking performance

Carbon/Kevlar- Motor sports application, not used on road vehicles because of cost and they

take time to warm up.

7.4 Disc and Drum Brakes:

Disc brakes are found on almost all vehicles now.

Older cars and trucks had a combination of disc and drum brakes.

At one time vehicles came with drum brakes only (1970 and older)

Disc brake consists of metal disc or rotor with flat, lined shoes or pads. These pads rub

against the rotating disc to apply brakes. Brake shoes or pads are held in calipers with one or

more pistons. When pedal is pressed hydraulic pressure pushes the piston outwards. This

results in rubbing of pads with the disc.Due to the frictional force at the point of contact the

vehicle slowdown or stops.

Fig 7.5 (a) Disk Brake 7.5 (b) Drum Brake

In brake drum the break assembly at each wheel is enclosed by a metal brake drum. Brake

shoe having T-section and curve expand outwards. These brakes shoes are riveted with the

brake lining and synthetic adhesive is used to the attach the brake lining to the brake shoes.

Brake assembly is attached to steering knuckle and axle housing.

Rsrtc summer training report

Automotive

Transcript of Rsrtc summer training report