sudhir gensets training file

8/16/2019 sudhir gensets training file

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CHAPTER-1

ABOUT THE ORGANIZATION

1.1 About sudhir Gensets:

Sudhir is a name synonymous with Power . An Industry leader in the field of settingup Diesel base Captive Power Plants up to !"# having its $orporate offi$e inGurgaon % revenue of over &!! "illion 'SD( it stands tall in the Indian Power Generation Se$tor( providing $omplete turn)ey *le$tri$al solutions from" G*+*,A-I +( DIS-,I/'-I + to *0*C-,I ICA-I +2 .

ounded in 134&( Sudhir Group is $ommitted to new and innovative te$hnology andstrives to develop brea)through produ$ts to meet the ever $hanging need of power industry. -he Company has a wide blue5$hip $ustomer base and operates throughmultiple manufa$turing fa$ilities a$ross India. -he produ$t line fo$uses on 4.678A 9 &!!! 78A Diesel % Gas Generators( 1!! 7# Solar Panels( il % Dry -ype-ransformers( - 1178 % &&78 Panels % 0- Panels( Pa$)aged Substations and-urn)ey *PC $ontra$ts $overing ele$tri$al and me$hani$al servi$es.

Signifi$ant $ollaborations( te$hni$al )now5how support and li$ense agreements withsele$ted industry giants( in$luding Cummins for Generators( S$hneider for Pa$)aged

Sub Stations( S$hneider for - Panels and DuPont for Dry -ype -ransformers( and-esar for Cast ,esin -ransformers have helped Sudhir to a$hieve unpre$edentedgrowth and be$ome a name to re$)on with.

Sudhir has also forayed into otel business by leveraging its relationship withCarlson group and setting up lu;urious property Country Inn % Suites in the fastestgrowing Gurgaon $ity.

/a$)ed by a talent pool of e;perts of over 6!! employees( < state of artmanufa$turing fa$ilities( 1= /ran$h offi$es( international presen$e and dedi$atedtraining % servi$e $enters( Sudhir is $ontinuously serving the width and depth of the

Indian industry with its power solutions.

Indeed( Sudhir have a$hieved and leapfrogged towards this unpre$edented growth.or us( this is >ust another step in our ongoing >ourney to greater goals and broader

hori?ons.

Sudhir Power 0td. stands in the vanguard of progress( in ea$h one of its $hosenspheres. It dominates its segment with best5of5the5breed( silent diesel and gasGensets ranging from 4.6 )8A 9 &!!! 7va( powered by Cummins engine. Sudhir hasforged a formidable &! years partnership with Cummins to be$ome India@s largestGensets manufa$turer.



Sudhir has the distin$tion of being the first Gensets $ompany in the $ountry to$omply with the latest CPC/ II norms for air and noise pollution. -hese are

1

$omplimented by an allian$e with S$hneider *le$tri$ ( ran$e for - 11)8 % &&)8

Panels % 0- Panels and /I SC designed9 Pa$)aged Sub Stations up to = )8 .

Considering the need and large demand for renewable energy solutions in India( andabundant availability of its resour$es( Sudhir is also developing large $ommer$ial %utility s$ale photovoltai$ P8B solar power plants.

ig :1.1

Sudhir inventory at /ari /arahmana %7B

1. About Cummins India pvt. ltd.:

Cummins in India( a power leader( is a group of $omplementary business units thatdesign( manufa$ture( distribute and servi$e engines and related te$hnologies(in$luding fuel systems( air handling( filtration( emission solutions and ele$tri$al

power generation systems. Its te$hnology and pioneering initiatives are bringinginnovative solutions and dependable servi$es at the best possible value to usersa$ross the $ountry. Its high performan$e outloo) is based on $ustomer fo$us(integrity and $apability of its people. Part of the 'S 13. billion Cummins In$.(Cummins in India is a Group of eight legal entities a$ross !! lo$ations in the$ountry with a $ombined turnover of ,s. 3( <6 $rores in !1= and employing $loseto 3(4!! individuals.



Cummins India 0imited , the $ountry@s leading manufa$turer of diesel and natural gasengines is one of the eight legal entities of the Cummins Group in India. Comprisingof four business units 5 Industrial *ngine( Power Generation( Distribution( andAutomotive( Cummins India 0imited is also the largest entity of the Cummins Groupin India.

• -he Industrial *ngine /usiness $aters to the industrial se$tor with its broadspe$trum of diesel engines ranging from E6 P to &6!! P. -he range isdesigned to power varied mar)et segments su$h as Constru$tion( "ining(Compressor( "arine( ,ail( Agri$ulture( Pumps( il % Gas( Power Generationand Defense.

• -he Power Generation /usiness addresses standby and prime power needsthrough the design and manufa$ture of pre5integrated generator sets( transfer swit$hes( paralleling eFuipment and $ontrols.

• -he Automotive /usiness integrates Cummins@ diesel and natural gas engineswith related te$hnologies su$h as filtration( e;haust( turbo( fuel and $oolantsystems and lube oil to serve the $ommer$ial vehi$le segment in India.

• -he Distribution /usiness was a$Fuired in 13E4( with the ob>e$tive of providing produ$ts( pa$)ages( servi$es and solutions for uptime of Cummins

eFuipments. It has sin$e been engaged in the business of sale of engines( and providing after5mar)et support to $ustomers in India( +epal and /hutan.

*stablished in 13<4( leet guard ilters Pvt. 0td. is India s leading manufa$turer of heavy5duty air( fuel( lube and hydrauli$ filters and $oolants for on and off highwayappli$ations.

*stablished in 1331( Cummins Generator -e$hnologies India Pvt. 0imited is amar)et leader in the /rushless A. C. Generator AlternatorB produ$t range. -heCompany has $onsistently set new standards of Fuality and business e;$ellen$e

offering premium Fuality AC generators in the range !.E to !(!!! )8A.

http://www.cumminsindia.com/IBU/ibu_index.html

http://www.cumminsindia.com/PGBU/pgbu_overview.html

http://www.cumminsindia.com/ABU/Home.html

http://www.cumminsindia.com/DBU/cummins_distribution_business_overview.html

http://www.cumminsindia.com/MAIN/fleetguard.html

http://www.cumminsindia.com/MAIN/busines_cummins_generator.html

http://www.cumminsindia.com/PGBU/pgbu_overview.html

http://www.cumminsindia.com/ABU/Home.html

http://www.cumminsindia.com/DBU/cummins_distribution_business_overview.html

http://www.cumminsindia.com/MAIN/fleetguard.html

http://www.cumminsindia.com/MAIN/busines_cummins_generator.html

http://www.cumminsindia.com/IBU/ibu_index.html



&

ig no. 1.

Cummins engine installed in sudhir generators

1.& "ain se$tions in the industry :

1B *ngine se$tion

B Assembly line

&B "a$hine and Pre5treatment se$tion

=B *le$tri$al division

6B Paint se$tion



EB -esting $ell

4B abri$ation se$tion

=

CHAPTER-2

SECTIONS UNDERGONE TRAINING

.1 *ngine se$tion :

Cummins Power Generation is a worldwide provider of ele$tri$al generators and power generation systems( $omponents and servi$es in standby power( distributed power generation( as well as au;iliary power in mobile appli$ations to meet theneeds of a diversified $ustomer base. Cummins Power Generation produ$ts in$ludediesel and alternative5fueled ele$tri$al generator sets from .6 to (4!! )#.

As a mature te$hnology (Cummins $lean and ultra modern diesel powered generatorsoffer )ey benefits:

• ,apid produ$t availability

• Proven reliability and low life5$y$le $ost.

• igh effi$ien$y and operational fle;ibility

• igh Fuality ele$tri$al performan$e.

• #ell established servi$e and fuel supply infrastru$ture.

perational fa$tory5 integrated e;haust after treatments redu$e emissions for highhour use in environmentally sensitive lo$ations



-able no. .1

Spe$ifi$ation of the engine reFuired for the generator of different $apa$ity

6

.1.1 Pro$edure for assembling an engine :

or the beginner( assembling an engine at home is most $ertainly an intimidating prospe$t. -here are plenty of parts that have to fit pre$isely and there are plenty of dimensions that must be $he$)ed and double5$he$)ed and some triple5$he$)edB.-here are all sorts of seemingly Hforeign pie$es that somehow have to wor) in

perfe$t harmony. or the beginner( it seems li)e an impossible tas) to put it alltogether.

*ngine assembly is li)e any other ma>or pro>e$t. -here are various parts andsubassemblies that are $ompleted first( and then ea$h Hbuilds upon the last. /uildingan engine at home is a s)ill >ust about anyone $an learn. Sure you@ll need a good$olle$tion of spe$iali?ed tools we@ll help you with tool sele$tion throughout theentire seriesB( but the reality is that anyone $an assemble an engine. If you ta)e your time and are meti$ulous with your wor)( pretty soon you@ll be rewarded with a

$omplete ready5to5run engine.

Pros for the assembling an engine:

1B A $lean wor)ing environment:

#hile it@s possible to build an engine almost anywhere( a $lean environment is amust. In our garage( we stop any $ar maintenan$e a$tivities that $reate dust and grit.

or e;ample( if another pro>e$t reFuires grinding then we either move the operationto another spot or figure out another time to get it done.

#hen it $omes to using tools( we always $lean them after use. #e@ve found a Fui$) shot of bra)e $leaner aerosolB and a wipe down with a $lean paper towel goes a long

s.no Capa$ity of generator in7vA

Power generated

by engine

+o. of $ylinders of engine

-ype of engine

1 165 6 4.65 6 )# Diesel powered

&!5=! &656!!)# & Diesel powered

& Above 1 6 E!!)#5.4"#

E Diesel powered



way toward )eeping the pro>e$t $lean. It also ma)es it more en>oyable to wor) withthe tools.

B Cleaning the pie$es:

#hen it $omes to assembling an engine( one of the biggest mista)es a novi$e $anma)e is to $ontaminate the $omponents. Any pie$e of grit that turns up during theassembly pro$ess $an and regularly willB s$rat$h internal surfa$es su$h as the$ylinder walls or re$ipro$ating $omponents. #e@re $onvin$ed $ontamination is one of the leading $auses of premature engine failure. /e$ause of this( on$e the parts returnfrom the ma$hine shop obviously something you $an@t do in your own garageB( theymust be thoroughly $leaned and )ept $lean during the entire assembly >ob.

&B Cylinder blo$) preparation

irst things first: ot water and soap is mi;ed into a bu$)et and the pressure washer is hoo)ed to a hot water tap. #e use a $onventional $ar wash s$rub brush for the

E

initial $leaning. n$e that@s done( remove the $ylinder blo$) main $aps and gothrough all of the oil galleries with the /%/ Performan$e brush )it. n$e you thin) everything is $lean( start all over again and res$rub the entire wor)s.

=B After drying :

n$e the blo$) is blown dry( you must oil all of the ma$hined surfa$es. -here are a$ouple of ways to a$$omplish this: A $lean rag soa)ed in $lean light oil for e;ample(1!#5&!B or automati$ transmission fluid wor)s. So does a light mist of spraylubri$ant( followed by a wipe down with a $lean shop towel. Spray lubri$ants willnaturally displa$e water so it wor)s in your favor. #e always $lean the ma$hinedsurfa$es until the shop towels show absolutely no tra$e of dirt. -he preferred towelhere is a$tually a roll or two of paper towels. #e prefer the me$hani$5style blue >obssin$e they don@t tear or shed as easily as )it$hen towels.

6B Plugging the holes

All engine blo$)s are eFuipped with a series of pipe plugs. -hey@ve most li)ely beenremoved during the ma$hining and hot tan)ing pro$ess( and obviously should not be

present during your $leanup. Jou@ll need to repla$e them during engine blo$) preparation. Jour lo$al auto parts store( $ar dealer or ma$hine shop $an help you withthe respe$tive plugs you@ll need. or a $leaner loo)( we prefer A+ aluminumB plugswith internal he;es( but brass plugs will wor)( too. or some appli$ations( a rear $am

plug will have to be installed as well. "ost of these are of the drive5in with ahammerB variety. It@s best to leave the $am plug out until later after the $amshaft has

been installedB. In addition( some engine stand $onfigurations don@t allow a$$ess to

the ba$) of the blo$)( so you won@t be able to install the plug until the engine is off the stand.



.1. -ools used for this part of the assembly

• Dial bore gauge

• Dial indi$ator and magneti$ base

• -wo5third5in$h mi$rometer

• alf5in$h drive torFue wren$h

• -hree5Fuarter5in$h and half5in$h drive so$)ets

• Seven5si;teenths5in$h 1 5point half5in$h driver so$)et

• 0arge pry bar

• Deadblow hammer

4

.1.& Steps for assembling the engine blo$):

1B -he first step in determining bearing $learan$es is to measure the $ran)shaft main >ournal diameter. ere we@re using an outside mi$rometer to get the measurement.-he arti$le te;t offers details on how it@s done and tips on using a mi$ . Che$) all$ran)shaft main bearings and re$ord your figures.

ig .1.1

"easuring rod bearing $learan$es

B +e;t( install the main bearing insert for >ournal number one in the $ylinder blo$). +ote the orientation. -he oil hole in the bearing half aligns with the oil hole in themain bearing.



ig +o. .1.

Installation of main bearing insert

<

&B -he mat$hing bearing insert for the main $ap is installed ne;t. /e$ause of the needfor bearing $rush( the insert will seem marginally too big( and a minute portion of theinsert will protrude past the edge of the $ap the same applies to the insert in the

blo$)B.

ig no. .1.&

Installation of main bearing insert

=B Install the $ap and torFue the main bearing $ap to spe$s. -ypi$ally( we begin withthe inside bolts and wor) outward. In addition( it@s best to use three steps on ea$h of the fasteners in order to Hsnea) up on the final torFue figure.



ig no .1.=

Installation of $ap and torFuering of main bearing

6B #ith the bearing installed in the $ap and the fasteners torFued to spe$ifi$ations(you $an measure the main bearing inside diameter. ere( we@re using a /%/Performan$e dial bore gauge for the measurement. Subtra$ting the $ran)shaft

3

>ournal figure from this measurement provides the bearing $learan$e. ,e$ord allmeasurements and repeat this pro$ess for all bearings e;$ept the rear main.

ig +o. .1.6

"easuring main bearing inside diameter

EB /efore measuring the rear main bearing inside diameter( install the oil pump andtorFue to spe$ifi$ations. -he reason is there is always the $han$e for some distortionof the $ap on$e a heavy oil pump is installed. ere( a huge -itan G5,otor oil pump is

installed and torFued to spe$s.



ig no. .1.E

0owering $ran) into main bearing saddle

1!

4B n$e you@ve $he$)ed all of the main $learan$es and they@re all withinspe$ifi$ationB( you $an install the $ran)shaft. Jou $an use $onventional engine oil for the installation or assembly lube. Apply a light $oating to the lower main bearinghalves.

ig no. .1.4

Appli$ation of assembly 0ubri$ant in $ran) $ase assembly

<B +e;t( the rear main seal is installed. #ith a one5pie$e seal su$h as this( it must beslipped over the rear of the $ran) prior to lowering the $ran)shaft into the blo$). -hearti$le te;t offers more detailed info( but in this photo you $an see the installed seal.



ig no. .1.<

"ain seal installation

11

3B #ith all of the lower bearing inserts in pla$e( you $an gently lower the $ran) intothe main bearing saddles. Jou $an reinstall the rear main bearing and $ap along withthe first frontB bearing $ap.

1!B Che$)ing the $ran)shaft thrust dimension is ne;t. Jou@ll need a dial indi$ator setup to read front5to5rear movement on the $ran)shaft. Depending on how you$hoose to perform the >ob( the dial indi$ator $an be set up on the nose of the $ran) or on the rear flange. or this >ob( we have a$$ess to the flange on the engine stand itneeds to be tapped with a hammerB( so we set the dial indi$ator up on the nose. -hete;t offers details on how this >ob is a$$omplished.

ig no. .1.3

Cran) thrust dimension $he$)



11B All of the main bearing $ap bolts or studsB $an be torFued in pla$e. #e use ahalf5in$h drive torFue wren$h for the >ob( and while we have three other torFuewren$hes in our tool $olle$tion( this long handle one ma)es torFuing large numberseasy. -hat way you $an@t forget if you@re $alled away.

ig no. .1.1!"ain bearing studs torFueing $ap bolts

1

1 B "easuring the rod bearing $learan$es is ne;t. ere( the number one and two rod >ournals on the $ran)shaft are measured using a mi$rometer. "u$h li)e the main >ournal measurements( it@s a good idea to $he$) in multiple pla$es around the >ournal.-his determines if the >ournal is in fa$t round. ,epeat the pro$ess on all of the

bearing >ournals and re$ord the measurements.

ig no. .1.11

"easuring rod bearing $learan$es

1&B At this point( the $onne$ting rod bearings $an be installed. +ote the $hamfer onthe bearing is designed to mat$h the $hamfer on the $onne$ting rod. Jou@ll also notethe bearing tangs are ne;t to one another. If the $onne$ting rod and $apB isunmar)ed( this orientation ensures the $ap is installed $orre$tly. #hen assembling

the engine( the $hamfer fa$es the large fillet radius on the $ran)shaft.



ig no. .1.1=

Dial bore gauge determine inside diameter rod bearing

1=

. Assembly line

In assembly units different parts of generators are assembled to ma)e a generator.

-he main parts of the generator whi$h are assembled in assembly line are

• *ngine ( radiator (fuel filter ( air filter et$.

• /ase frame

• A8" pad auto vibration moduleB

• Alternator

• uel tan)

• Canopy

• Control panel

• Sensors

• /attery $harging alternator



ig no. . .1

Assembling of engine with the alternator

16

. .1 * - $ranes:

-he most adaptable and most widely used type of power of power driven $rane for indoor servi$e is undoubtedly the three motion * - $rane. It serves a larger area of floor spa$e within its own travelling restri$tions than any other permanent typehoisting arrangement.

As the name implies (this type of $rane is provided with movement above the floor level. en$e it o$$upies no floor spa$e and this $an never interferen$e with any

movement of the wor) being $arried out at the floor of building.

-he three motions of su$h are the hoisting motion and the $ross ravel motion. *a$hof the motions is provided by ele$tri$ motors.

A * - *le$tri$al overhead travellingB $rane $onsists of two distin$t parts :

1. /ridge

. Crab

1./ridge:



ig +o. . .

/ridge of the * - C,A+*

-he bridge $onsists of two main girders fi;ed at their ends and $onne$ted to another stru$tural $omponents $alled the end $arriages. In the two end $arriages are mountedthe main runners or wheels four or moreB whi$h provide the longitudinal motion tothe main bridge along with the length of the wor)shop. -he motion of the

1E

bridge is derived from an ele$tri$ motor whi$h is geared to a shaft running a$rossthefull span of the bridge and further geared to a wheel at ea$h end. In some designseparate motors may be fitted at ea$h $orner of the main bridge. -he wheels run ontwo heavy ails fi;ed above the floor level along the length of the shop on twogirders ( $alled gantry girders.

. Crab:

-he $rab $onsists of the hoisting ma$hinery mounted on a frame( whi$h in turnmounted on at least four wheels and fitted with suitable ma$hinery for traversing the

$rab to and fro a$ross the main girders of the $rane bridge .+eedless to mention thatthe $rab wheels run on two rail se$tions fi;ed on the top of flange of the main

bridge .-hus load hoo) has three separate motions( these being the hoisting( $rosstransverse of the $rab and longitudinal travel of the whole $rane .*a$h motion is$ontrolled independently of the other motion by separate $ontrollers situated in a$ontrol $age or in a suitable position for $ontrolling from floor of the pendent $hains.



ig +o. . .&"ain parts of $rab

14

S.+o. +ame of the part +o. of parts

1*nd $arriage

#heels on bridge

&

-he bridge =

=Crab without au;iliary hoist B 1

6oisting ma$hinery set 1

E#heels on $rab = not less than =B

4/ottom blo$) #ithout

au;iliary hoistB1

<

0ifting hoo) 1

3,ail on the girder for $rane

movement

1!,ail on the bridge for $rab

movement

11perator $abin 1



-ale no. . .1

*ssential parts of *le$tri$al overhead travelling $rane

.& Pre5treatment and ma$hine se$tion:

-here are different type of ma$hine in the ma$hine and pretreatment se$tion . -hesema$hine are operated by different operators . Different types of ma$hines are:

• C+C $utting ma$hine

• C+C lathe ma$hine

• Pre treatment $hamber

• Conveyer

• Painting $hamber

1<

.&.1 C+C $utting ma$hine:

In an 2+C2 +umeri$ally ControlledB ma$hine( the tool is $ontrolled by a $ode system thatenables it to be operated with minimal supervision and with a great deal of repeatability.

2C+C2 Computeri?ed +umeri$al ControlB is the same type of operating system( with thee;$eption that a $omputer monitors the ma$hine tool. -he same prin$iples used in operatinga manual ma$hine are used in programming an +C or C+C "a$hine. -he main differen$e isthat instead of $ran)ing handles to position a slide to a $ertain point( the dimension is storedin the memory of the ma$hine $ontrol on$e. -he $ontrol will then move the ma$hine to these

positions ea$h time the program is run.

-he C+C ma$hine $omprises of the $omputer in whi$h the program is fed for $uttingof the metal of the >ob as per the reFuirements. All the $utting pro$esses that are to be$arried out and all the final dimensions are fed into the $omputer via the program.-he $omputer thus )nows what e;a$tly is to be done and $arries out all the $utting

pro$esses. C+C ma$hine wor)s li)e the ,obot( whi$h has to be fed with the programand it follows all your instru$tions.

"ain parts of C+C $utting ma$hine:

• Computer

• /rea)out board

• "otors

• Power supply unit PS'B



• 0imit swit$hes

ig +o. .&.1

C+C ma$hine in plant

-he $omputer will run your program send the programs signal to the brea)out board(the board will turn those signals into a new signal that will run the motors.

13

-he PS' is there to power your motors and or brea)out board limit swit$hes( and allthe other ni$e stuff you $an mount on the ma$hine. -he limit swit$hes are not areFuirement( but they are ni$e to have( sin$e your ma$hine will then )now when and

where to stop( before it runs in to itself( whi$h may damage the ma$hine

"ain "e$hani$al parts of the C+C $utting ma$hine are:

-he rame :

-he frame of the ma$hine is pretty obvious( it holds all the other $omponents in pla$e( and also gives the ma$hine the stiffness it will need to wor) on ob>e$ts( thetransmission is to transfer movement of the motors to your a;is( this will be $overeda bit later.

-he /earings:

-he bearing )eeps the spindles where it should be( and if you use the right bearingtype( they will even help redu$e strain on the spindles.

Couplers:

Couplers are the a$tual $oupling between motor and spindle.

-he guides

-he guides are for guiding your linear movement and )eep your ma$hine steadywhile it wor)s. Depending on the ma$hine will most $ommonly have &5= a;is to



worry about( an K5( J(5 L5( and C5a;is. It wor)s >ust li)e a $oordinate system whereyou have K to the forward and ba$)wards motion( J to the left( and right motion( Lis for the ups and downs( and if you have the fourth a;is it will $ontrol the rotationsof your wor)ing ob>e$t( as seen in the first pi$ture.

-his is pretty mu$h the basi$s of the C+C ma$hine itself( they may vary a bit fromma$hine to ma$hine( but all this will be $over a bit later.

/asi$ operation of the $omputer:

-his is a bit more $ompli$ated( but in short you will need a program that $aninterpret drawings and generate the $ode needed. -here are different programs$apable of doing this( but what you need to be loo)ing for is something that $angenerate a G5$ode or an "5$ode( this is either done in your drawing program or a

program )nown as a Computer Aided "anufa$turing program CA"B the $ode is

then transferred to your $ontrol software( where it $an be used to run from there.

!

.&. C+C 0athe ma$hine :

-he ma$hine is $ontrolled ele$troni$ally via a $omputer menu style interfa$e( the

program may be modified and displayed at the ma$hine( along with a simulated viewof the pro$ess. -he setterMoperator needs a high level of s)ill to perform the pro$ess(however the )nowledge base is broader $ompared to the older produ$tion ma$hineswhere intimate )nowledge of ea$h ma$hine was $onsidered essential. -hesema$hines are often set and operated by the same person( where the operator willsupervise a small number of ma$hines $ellB.-he design of a C+C lathe varies withdifferent manufa$turers( but they all have some $ommon elements. -he turret holdsthe tool holders and inde;es them as needed( the spindle holds the wor) pie$e andthere are slides that let the turret move in multiple a;is simultaneously. -he ma$hines

are often totally en$losed( due in large part to o$$upational health and safety %SBissues. #ith rapid growth in this industry( different C+C lathe manufa$turers usedifferent user interfa$es whi$h sometimes ma)es it diffi$ult for operators as theyhave to be a$Fuainted with them. #ith the advent of $heap $omputers( free operatingsystems su$h as 0inu;( and open sour$e C+C software( the entry pri$e of C+Cma$hines has plummeted.



ig +o. .&.

peration of C+C 0athe

1

.&.& Pre treatment $hamber :

ere by pretreatment( we mean metal pretreatment as the powder $oating is predominantly applied to metals. Surfa$e preparation in$ludes :

1.B Cleaning 9 me$hani$al or $hemi$al:

"e$hani$al $leaning in$ludes methods li)e s$rat$h brushing and sand blasting. -his by abrasive a$tion not only removes the surfa$e impurities but also eliminatess$rat$hes and surfa$e irregularities. Cleaning is very good( however( $oating must bedone immediately be$ause the $leaned surfa$e is in a highly rea$tive state and$orrosion o$$urs very soon.

.B Appli$ation of $onversion $oating.

-hese are applied for three purposes:

1B Provide temporary in pro$ess $orrosion prote$tion before appli$ation of powder $oating.

B Promote good adhesion of the powder $oating to the substrate.

&B impart under paint $orrosion % thereby improve the life of the powder $oating.-he type of the $onversion $oating used also depends upon the base metal.

&.B ,eason for pre treatment



1B -enden$y of the material:5

Aluminum is )nown for its tenden$y of undergoing natural o;idation forming a thinlayer of aluminum o;ide on the surfa$e.

B +eed of $leaning:5

-o remove oil or lubri$ant from metal surfa$e. Aluminium has a tenden$y to undergonatural o;idation forming a thin layer of aluminium o;ide on the surfa$e. Apart fromthis( $ommonly )nown pro$ess of anodi?ing also leaves layer of aluminium o;ideunder the influen$e of ele$tri$ $urrent. -his is not a good base to apply powder or any other $oating. en$e( it must be removed before powder $oating. Apart fromthis( there may be oil on the surfa$e whi$h may have $ome during fabri$ation

pro$ess. -his must be removed to have proper bonding of powder $oating.

+eed of $onversion $oating :5 -o prevent o;idation of metal surfa$e.-his in$lude :

• Al)aline Cleaning % A$idi$ Cleaning

• Strong al)aline $leaners• "ild al)aline $leaners

-he aluminium material is very sensitive to al)aline atta$). -here for al)aline$leaners are milder for aluminium than for mild steel. owever( if there is anodi?inglayer on aluminium( $austi$ soda based strong al)aline $leaner has to be used.

owever( this leaves bla$) smut on the surfa$e. -o remove this aluminium is dippedin wea) bath nitri$ a$id.

ig no .&.&

Pretreatment $hamber



.&.= Pro$ess of pretreatment:5

• e5greasing Pro$ess

• #ater5,inse

• De5rusting

• #ater rinse

• A$tivation

• Conversion Coating

• #ater rinse

&

ig no. .&.=

-an)s in the pretreatment $hamber

De5greasing Pro$ess:

Chemi$al de5greasing methods used in any parti$ular appli$ation is $losely related tothe nature of the surfa$e being $leaned and the amount and type of $ontamination.

-he various $hemi$al de$reasing pro$esses appli$able to "ild steel( Galvanised Steel

% aluminum substrates( are as follows:



Solvent Cleaning:

1. Solvent #ipe: Solvent $leaning is the $heapest and best method to removeheavy or sti$)y oilMgrease li)e substan$es from any surfa$e. Sin$e all solventsare almost neutral they do not atta$h to the base metal. In this pro$ess( the

parts to be $leaned are wiped with rag of $otton soa)ed in a suitable solventsu$h as 7erosene( /en?ene( +aphtha et$. -he following are the advantagesand disadvantages of solvent wipe method.

Advantages:

• Cheapest $leaning method available in the industry to remove heavy oils(greases or sti$)y press $ompounds.

• S)illed labour and $ostly plant installation is not reFuired.

• Suitable for the smallest >ob $oater as well as for the *" industry.

=

Disadvantages:

• -he pro$ess is labour intensive.

• Sin$e all the solvents are flammable( a greater fire ris) is asso$iated with thesolvent $leaning.

• reFuent $hange of $loth and solvent is essential or otherwise it $an affe$t theFuality of $leaning

• Solvents going into the drainage system $an $ause effluent disposal problems.

8apour De5greasing:

8apour de5greasing is Fuite a sophisti$ated method of $leaning. In this method( aspe$ial type of solvent is used whi$h has the following advantages.

• "ineral % veg. ils removal is faster

• as lower boiling point than water

• +on5to;i$ to human beings

-his pro$ess reFuires a $losed system in whi$h the item to be $leaned is e;posed to

the $ondensing vapours of the solvent. -his method effe$tively removes lightoilsMgreases but $annot remove heavy oils( greases( and sti$)y press $ompounds.



Advantages:

• 8ery good method for $leaning light oils( greases.

• 0ess ris) of fire ha?ard( minimum pollution as it is a $losed system.

• Sin$e the solvent used is a non5to;i$ there is no danger for the operatingwor)er

Disadvantages:

• ,eFuire $ostly plant installation and s)illed labour

• reFuent removal of oil % grease is reFuired or otherwise they in$rease the boiling point of solvent

• -hin sheets having heavy oil grease or sti$)y press $ompounds $an not beremoved by the pro$ess as there is no me$hani$al a$tion on the parts

• Costly pro$ess

6

*mulsion Cleaning:

*mulsion $leaners are popular as they are based on mild Al)alis and hen$e they aresuitable to all substrates Iron( Galvani?ed steel "a?a) et$.B and operate at roomtemperature. *mulsion $leaners are generally based on either )erosene5emulsifier or turpentine5emulsifier. -hese $leaners are generally mil)y in appearan$e. *mulsion$leaners have a limited $leaning tenden$y and they leave a very thin film of solventMemulsifier over the substrate even after water rinsing. en$e( *mulsionCleaning is always followed by Al)ali $leaning. In $ase of spray pro$ess the parts to

be $leaned are suspended in a funnel wherein they are $onstantly e;posed to thespray solution for to 6 minutes at a pressure of 5& 7gsM$m for better results. In the

dip pro$ess( the parts to be $leaned are simply immersed in a bath of the $leaningsolution.

-his pro$ess has the following advantages and disadvantages:

Advantages:

• perates at a lower temperature =656! degrees CB hen$e $onsuming lessenergy.

• Suitable for all the substrates su$h as "ild steel( "a?a)( Aluminium(

Galvani?ed et$.



Disadvantages:

• 0imited $leaning ability as it $annot remove heavy grease( oil et$.

• +ot suitable for higher temp. as the emulsions are based on solvents whi$h

get separated above 4!N from the emulsion phase.

Al)ali Cleaning:

Al)ali $leaners en>oy superior position in the pre5treatment industry due to followingadvantages.

• -hey operate at room temperature

• Simple bath $ontrol

• Costly plant installation is not always reFuired

• igh $apa$ity to absorb oil

• /ath stability is higher $ompared to all other degreasing pro$esses( lowfoaming tenden$y

E

-hese $leaners are based on strong al)alis su$h as Sodium hydro;ide( Sodiumsili$ates( other filters and builders su$h as soda ash et$( surfa$tants and additives. -he

parts to be $leaned are immersed in this bath at a re$ommended temperature andtime. Strong al)aline $leaners are avoided in $ase of "anganese phosphate pro$essas they $an $ause inferior Fuality $oating.

ig no. .&.6

low pro$ess of pretreatment $hamber



Strong al)aline $leaners are also not suitable for non5ferrous substrates su$h as Lin$(aluminum( /rass( Copper( Glass( Galvani?ed Steel( be$ause all of these metalsreadily get atta$)ed by strong al)alis.

De5rusting:

Corrosion is $ommon phenomenon for metals. #hen Iron or steel is e;posed tohumid atmosphere the $orrosion pro$ess is initiated resulting in rust formation. ,ustis the o;ide of iron whi$h is loosely adhered to the substrate and hen$e it is verydangerous if overheated by any surfa$e $oating. ,ust is readily soluble in a$ids su$has ydro$hlori$ a$id( Sulphuri$ a$id( Phosphori$ a$id and hen$e it $an be removed

by a$id $leaning.

De5,usting Pro$ess:

Advantages:• Cheaper pro$ess than blast $leaning or flame $leaning

• Can be done anywhere( no big plant or sophisti$ated eFuipment is reFuired

• ,emove rust( "ills s$ale

• "a)es the surfa$e rea$tive for the ne;t Phosphating stage

4

Disadvantages:

• If ydro$hlori$ a$id or hot Sulphuri$ a$id is used for derusting it $an $reate a$orrosive atmosphere in the plant

• +ot suitable in $ase of spray appli$ation

• Carry over $an $reate problem in ne;t stage i.e.B in phophating bath

De5rusting $an be done with the following a$idsMa$id $ombinations :

ydro$hlori$ a$id Pi$)ling:

ydro$hlori$ a$id is a fuming a$id and is mostly used for Pi$)ling ( as it readilydissolves the mill s$ales formed during the hot rolling operations. ydro$hlori$ a$id

pi$)ling is the $heapest de5rusting pro$ess. -he use of ydro$hlori$ a$id is verylimited in the industry due to the $orrosive nature of the ydro$hlori$ a$id fumeswhi$h $an $reate problems in the $oating plant and se$ondly( the $arryover of

ydro$hlori$ a$id to the ne;t pre5treatment stage i.e.B either a$tivation or phosphating( $an damage the bath permanently.



In the $ase of Pure ydro$hlori$ a$id de5rusting the tan) should be of Stainless Steel.

Sulphuri$ A$id:

Sulphuri$ A$id is a stronger a$id and it is most suitable for heavily rusted

$omponents. Sulphuri$ A$id at an elevated temp. 6!5E! degrees CB gives outstandingresults in a short time. -he use of a hot pro$ess is limited in the industry due to the$orrosive nature of Sulphuri$ a$id fumes. -he use of an inhibitor is a must in hot

pro$ess to avoid the e;$ess atta$) of a$id on the base metal. -he $arryover of Sulphuri$ A$id $an permanently damage the phosphating bath. or Sulphuri$ a$id

based de5rusting( the tan) should be of either stainless steel or "ild steel with leadlining.

Phosphori$ A$id:

Phosphori$ a$id based de5rusting pro$ess is more popular in the finishing inFuiry dueto its following advantages.

• It gives a uniform % fine de5rusting pattern whi$h ultimately gives less$oarser $oating in phosphating

• It has less pitting tenden$y than ydro$hlori$ a$id % sulphuri$ a$id based de5rusting

• It does not emit any $orrosive ha?ardous fumes

<

• Carry over of bath solution does not $reate mu$h problem

Phosphori$ a$id based do5rusting is $ostly as $ompared with ydro$hlori$ a$id or Sulphuri$ a$id. or Phosphori$ a$id based de5rusting( the bath should be of Stainlesssteel.

A$tivation Pro$ess:

-his pro$ess provides fine a$tive $rystal $entres on the surfa$e of the metal whi$hultimately results into tine phosphate $oating 0ayer in phosphating stage. -his

pro$ess helps to attain a uniform phosphate $oating. -here are two types of a$tivation pro$esses:

• A$idi$ A$tivation

• /asi$ A$tivation

A$idi$ a$tivation :



-his is a $heaper pro$ess. ere bath testing and $ontrol is not reFuired. /ath $an be prepared in hard water. -he pro$ess results into $oarser bigger $rystalline $oating. +ot suitable for non ferrous substrates su$h as Aluminium.

/asi$:-his pro$ess is based on titanium based $ompounds whi$h are most suitable for

errous % non errous substrate. It gives more $ompa$t( uniform fine $rystalline$oating having better $orrosion resistan$e.

Disadvantages are:

1. -he bath is unstable -itanium forms $olloids in aFueous solutionsB

. /ath $annot be prepared in hard water

Conversion Coatings:

Phosphating is universal method of metal Pre5treatment. Phosphating $onsist of thedeposition on the metal surfa$e of insoluble metal phosphates whi$h are a$tually$hemi$ally bonded to the substrate( Sin$e this is a $hemi$al rea$tion( it gives goodadhesion for paint film. Phosphating $an be either $rystalline or amorphous.

-his pro$ess provides the following:

• A $lean( greaseMoil free surfa$e

•

A $orrosion inhibitive base for powder $oating

3

• A non5$ondu$tive bond between base metal and powder $oating

• A $hemi$ally inert surfa$e whi$h prevent the rea$tion between the base metaland powderMpaint ingredients

Phosphating pro$ess is divided into types:

• Lin$ Phosphating sub5divided into "ono( Di( -ri Carboni$ Pro$essB

• Iron Phosphating

Lin$ Phosphating:

Lin$ phosphating pro$ess is widely in the automobile( hardware( home applian$eindustry. ?in$ Phosphating bath solution $ontain a saturated solution of phosphori$a$id along with Lin$ phosphate. n immersion of an arti$le in su$h a bath the iron

gets atta$)ed by the a$id $omponent of the bath( by lowering its $on$entration at themetal surfa$e.



After $ertain time within min. "a;imumB the phosphate $rystallites on the metalsurfa$e. Sin$e this is a $hemi$al rea$tion between the metal and the phosphatingsolution( it stops after the formation of $rystalline phosphate layer. It is not advisableto )eep the partsM$omponents in the phosphating bath for more than 1! minutes

be$ause the bath p is a$idi$ between =.< to 6.6( depending on the bath$on$entrationB and at this p the $oating formed gets dissolved slowly therebyleaving the bare metal( whi$h is again atta$)ed by the phosphating solution formingfresh $rystalline layer of phosphating -his pro$ess may go on till the end of the metaland it unne$essarily in$reases the $hemi$al $onsumption.

Lin$ phosphating is sub5divided into & types:

"ono5$ationi$:Cations are positively $harges ions. Lin$ is the basi$ $ation in all $rystalline

phosphating pro$esses. "ono5$ationi$ pro$esses are $omparatively $heaper than di% tri $ationi$ pro$esses. -he bath solution $ontains only ?in$ as a $ation. -hese

pro$esses find a very limited use in the industry as they have a limited $orrosionresistan$e.

Iron Phosphating:

Iron phosphating is of limited use in the pre5treatment industry although this has gotits own segment. Iron prospe$ting do not $ontain any ?in$ li)e $ation. -hey are basedon sodium or dihydrogen phosphate as ama>or ingredient along with a$$eleratorssu$h as molybdate( -he $oating formed is non5$rystalline amorphousB and havingdar) bluish $olour. -he ma>or advantage of Iron phosphating is due to its non5$rystalline natureB iron phosphates parts $an be welded prior to powder

&!

$oating. Iron phosphates parts when powder $oated give outstanding me$hani$al properties.

Conversion $oating for Aluminium: Aluminium $an be pre5treated by the followingways.

• Phosphating tri5atomi$ Lin$B

• Phosphating Green( Jellow or $olourlessB

Phosphating :

Aluminium parts $an be phosphates li)e mild steel( or Alumnium mild degreasing$hemi$als should be used. eavy( strong degreasing $hemi$als $an $ause e;$essiveet$hing to the base metal( De5rusting pro$ess should be avoided in phosphatingseFuen$e( whi$h should be re5pla$ed by permuting pro$ess parts to be dipped in

1!N Causti$ Solution for 1 to minutes B.



Phosphating pro$ess is not popular in Aluminium pre5treatment be$ause Aluminiumions beyond a limit $an $ause poisoning to the phosphating bath.

.= Paint se$tion

-he $anopies of the Gensets are painted with the help of spray painters in a$hamber .-here are & guns in the spray painting ma$hine $hamber and one is themanual gun of solid spray paint. -he surfa$e of the metal sheet is $harged by themeans ele$tri$ $harged and the paint parti$les are $harged opposite so that the paint

parti$les penetrate the metal surfa$e.

-he most $ommon way of applying the powder $oating to metal ob>e$ts is to spraythe powder using an ele$trostati$ gun( or $orona gun. -he gun imparts a positiveele$tri$ $harge to the powder( whi$h is then sprayed towards the grounded ob>e$t byme$hani$al or $ompressed air spraying and then a$$elerated toward the wor)pie$e bythe powerful ele$trostati$ $harge. -here are a wide variety of spray no??les availablefor use in ele$trostati$ $oating . -he type of no??le used will depend on the shape of the wor)pie$e to be painted and the $onsisten$y of the paint. -he ob>e$t is thenheated( and the powder melts into a uniform film( and is then $ooled to form a hard$oating. It is also $ommon to heat the metal first and then spray the powder onto thehot substrate. Preheating $an help to a$hieve a more uniform finish but $an also$reate other problems( su$h as runs $aused by e;$ess powder. See the arti$le 2 usion/onded *po;y Coatings 2

Another type of gun is $alled a tribo gun( whi$h $harges the powder byturboele$tri$B fri$tion. In this $ase( the powder pi$)s up a positive $harge while

rubbing along the wall of a -eflon tube inside the barrel of the gun. -hese $harged

&1

powder parti$les then adhere to the grounded substrate. 'sing a tribo gun reFuires adifferent formulation of powder than the more $ommon $orona guns. -ribo guns

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


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







ig no. .=.1

Paint guns

are not sub>e$t to some of the problems asso$iated with $orona guns( however( su$h

as ba$) ioni?ation and the araday $age effe$t.

Powder $an also be applied using spe$ifi$ally adapted ele$trostati$ dis$s. Another method of applying powder $oating( $alled the fluidi?ed bed method( is by heatingthe substrate and then dipping it into an aerated( powder5filled bed. -he powder sti$)s and melts to the hot ob>e$t. urther heating is usually reFuired to finish $uringthe $oating. -his method is generally used when the desired thi$)ness of $oating is toe;$eed &!! mi$rometres. -his is how most dishwasher ra$)s are $oated.

.6 ven

-he oven is maintained at the temperature of E!5&!! degree Celsius and the$anopies of the generator are heated for &!5=! minutes in it and then it is allowed to$ool up on the $onveyer.

&

.E abri$ation se$tion:

In the fabri$ation se$tion the base frame and the $anopies are welded with the help of following & types of fabri$ation pro$ess:

• "IG "etal inert gasB #elding

• *le$tri$ ar$ welding

• -IG -ungsten inert gasB welding

.E.1"IG welding

https://en.wikipedia.org/w/index.php?title=Back_ionization&action=edit&redlink=1


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


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



-he basi$ te$hniFue for G"A# is Fuite simple( sin$e the ele$trode is fedautomati$ally through the tor$h head of tipB.-he welder must handle a welding tor$hin one hand and a separate filler wire in the other( and in shielded metal ar$ welding(the operator must freFuently $hip off slag and $hange welding ele$trodes. G"A#reFuires only that the operator guide the welding gun with proper position andorientation along the area being welded. 7eeping a $onsistent $onta$t tip5to5wor) distan$e the sti$) out distan$eB is important( be$ause a long si$)out distan$e $an$ause the ele$trode to overheat and also wastes shielding gas. Sti$)out distan$evaries for different G"A# weld pro$esses and appli$ations. -he orientation of thegun is also important it should be held so as to bise$t the angle between the wor)

pie$esO that is( at =6 degrees for a fillet weld and 3! degrees for welding a flatsurfa$e.

-he travel angle( or lead angle( is the angle of the tor$h with respe$t to the dire$tion

of travel( and it should generally remain appro;imately verti$al. owever( thedesirable angle $hanges somewhat depending on the type of shielding gas used with

pure inert gases( the bottom of the tor$h is often slightly in front of the upper se$tion(while the opposite is true when the welding atmosphere is $arbon dio;ide.

&&

ig no. .E.1

"IG welding



"ain pats of "IG welding setup are:

• #elding gun and wire feed unit

• -ool style

• Power supply

• *le$trode

• Shielding gas

ig no .E.

/eads of "IG welding

&=

.E. *le$tri$ ar$ welding

In ar$ welding( the intense heat needed to melt metal is produ$ed by an ele$tri$ ar$.-he ar$ is formed between the a$tual wor) and an ele$trode sti$) or wireB that ismanually or me$hani$ally guided along the >oint. -he ele$trode $an either be a rodwith the purpose of simply $arrying the $urrent between the tip and the wor). r( itmay be a spe$ially prepared rod or wire that not only $ondu$ts the $urrent but alsomelts and supplies filler metal to the >oint. "ost welding in the manufa$ture of steel

produ$ts uses the se$ond type of ele$trode.



ig +o. .E.&

perator performing ar$ welding operation

"ain parts of *le$tri$ ar$ welding:

• Consumable ele$trode

• Power supply

• *le$trode holder

&6



ig +o. .E.=

/eads of ele$tri$ ar$ welding

.E.& -IG welding:

-IG welding reFuires three thing( heat( shielding( and filler metal. -he heat is produ$ed by ele$tri$ity passing through the tungsten ele$trode by $reating an ar$ tothe metal. -he shielding $omes from a $ompressed bottle of gas that flows to theweld area to prote$t it from air. -he filler metal is >ust a wire that is dipped by handinto the ar$ and melted. -he way these three things $ome together is pretty simple.

irst the welder turns on the gas flow( many times by a valve on the -IG tor$h itself.-he gas begins to flow and starts prote$ting the weld area from the air. -he tor$h isheld over the weld >oint >ust far enough for the tor$h not to tou$h the metal. -hen thewelder presses a foot pedal and the -IG tor$hes tungsten ele$trode starts an ar$. n$ethe ar$ is started the two pie$es of metal begin to melt by $reating a puddle of metal.

n$e the puddle is established the welder with the other hand starts filling the >oint by manually dipping a welding wire into the ar$ to fill the >oint. 'ltimately this pro$ess $reates a single pie$e of metal.

&E



ig +o. .E.6

-IG welding

"ain parts of -IG welding:

• #elding ele$trode

• Shielded gas

• #elding tor$h

• Power supply

ig +o. .E.E

-IG welding >oint

&4



.4 -esting $ell:

In testing $ell the engine and the alternator are tested simultaneously and then theGensets are ready to dispat$h . -o verify that installation has been properly done( it isimportant to observe the drive belt or belts to $onfirm that the belts are properlyseated in all the grooves while the engine is running.

1. Conne$t the negative terminal $able to the battery using an insulated wren$h .

. If eFuipped ( $onne$t the battery $harger and turn it on.

&. In order to purge air from the $ooling system ( start the engine and allow it towarm up.

=.8erify that the v5belt are not sFuealing under the pea) load $onditions( andobserver the drive belts to $onfirm that the belts are properly seated.

6. If any of the belts need to be $orre$ted( or a $oolant lea) o$$urs( stop the engineand when it is $ooled down( dis$onne$t the negative terminal lead of the starting

batteries using an insulated wren$h .

ollowing tests are done in testing $ell:

• Sensitivity test

• ,esponse time test

• "a;imum power load $apa$ity test

• uel $onsumption on full load

.4.1 ow to ma)e a "e$hani$al field test of a DG set:

irst round up your >umper wire. -o $he$) the regulator( start the DG set with the-urn the idle speed up to about 1!!! or 11!! rpm. -his is the speed that your generator will begin to $harge( also )nown as the $ut5in speed.B

Start by $he$)ing the ground of the regulator. ne end of your >umper wire will$onne$t to the frame of the regulatorO the other end to a good ground. If things beginto $harge again( you have found your problem55poor ground. -his is Fuite $ommon.B

If you still have a no5$harge $ondition( $onne$t one end of your >umper wire to thefield terminal of the regulator( and the other end to a good ground li)e the inta)emanifold or the engine blo$)B. #hat you are doing is bypassing the regulator to see if the generator is wor)ing.

&<

+ow loo) at your dash gauge. If the dash gauge shows an in$rease in the output( the$han$es are Fuite good that your regulator is at fault. /ut if there is no in$rease in



output( the $han$es are good that your generator is at fault. -o be sure( you $anremove the >umper wire ground from the engine blo$)( and stri)e it against a metalsurfa$e. +o spar)s will $onfirm that the generator is indeed not wor)ing.

-his test should ta)e >ust a few minutes at most( then you will want to remove your >umper wire. -he test you have >ust $ompleted is $alled ull ielding the Generator.#hat you >ust did was allow the generator to $harge at its ma;imum $apa$ity for a

brief time( >ust as if there was not a regulator atta$hed in the $ir$uit( to see if thegenerator was still wor)ing.

.4. ow to $ondu$t ma;imum load $apa$ity test:5

If the generator field terminal was dire$tly grounded( you would get full $harge( if itwas grounded through the resistor( you would get a partial $harge. Sin$e it didn thave any automati$ $ontrol to allow for unusual $onditions( inattention by the

operator $ould easily let the battery get lower and lower over time or worseover$harge and damage the battery.

-he third brush system had one other drawba$). Sin$e the fi;ed position of the third brush was the only limiting devi$e provided to ma)e sure the generator didn t runwild and burn itself out( it $ould not put out full $urrent on high $harge. It would not$harge at all at low ,P" and at high ,P" would dramati$ally drop in its $hargingoutput. -he two5brush generator was applied to tra$tors in the late fifties to over$omethese defi$ien$ies. 'nli)e the three5brush system( the two5brush generator $oulda$hieve its true ma;imum output when the field was grounded. -his meant thate;ternal $ontrols would be reFuired to )eep it from burning itself out. -his wasa$$omplished by pla$ing the $urrent and voltage limiting $ontrols into the regulator.

&3



ig no. .4.1

Capa$ity of engine reFuired for two types of generator

-he two5brush system was designed with a simpler generator by eliminating thethird5brush( its spring( $arrier and its wiring. As stated earlier( without that third

brush( the generator by itselfB had nothing to stop it from produ$ing full voltage atthe $urrent ne$essary to )eep up with diffi$ult demands li)e when you fire up a hard5starting tra$tor at night and immediately turn on the lights. -his high output

$apability sounds too good to be true when $oupled with the fa$t that it had less partsto wear out and was less $omple;. 'nfortunately it isQ -his simpli$ity was more thanoffset by the $omple;ity of the regulator. -he third5brush system had merely a $utoutrelay to prevent battery dis$harge through the generator when it wasn t produ$ingsuffi$ient output. /eside that there was only the light swit$h resistor or a resistor inthe regulator $asing you may have wondered why the regulator was so small on theold systemsB. -he two5brush system needed more relays in the $ase and the wiring of the relays needed to intera$t. 0astly( the relay in the simple regulator on the third5

brush system would o$$asionally )i$) in or out depending on the battery state or

,P" while the voltage and $urrent relays of the two5brush system would open and$lose up to 6! times a minute later third5brush systems o$$asionally had this typeof regulator also but on most tra$tors only a $utout relay was usedB. In general thetwo5brush system $omple;ity boils down to the regulator being less user5friendlythan those used on a three5brush system.

-he two5brush generator was $reated by simply ta)ing the wire $oming from thefield $oils that would normally $onne$t to the third5brush and $onne$ting it dire$tlyto the wire $oming from the brush on the output or A side brush for this reason( it is$alled a shunt generatorB. /y manipulating the ground on the field terminal side

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with relay5operated points( $urrent would flow at full $harge or not at all in rapid$y$les. -hese $y$les in$reased in freFuen$y as $urrent reFuirements dropped. rom avisible wiring standpoint( nothing $hanged. It has a field B terminal and an outputterminal AB. -he field goes to the regulating devi$e and the /attery terminal goes tothe battery by way of the $urrent relay( $utout relay and Ammeter. -he mainnoti$eable differen$e is that the regulating devi$e was now in the regulator and not inthe light swit$h.

n o$$asion( some ma$hines had three generator terminals. -he third is a groundterminal that is provided to allow e;ternal grounding. +ormally the ground for these$ond brush is internal through the generator $asing. Due to the high resistan$ee;perien$ed from the generator mounting $onne$tion rust( dirt and grimeB( using aseparate wire ensured a superior ground. -his was used on high =vB $hargingsystems su$h as those used on large ohn Deere ma$hines and many $rawlers. +ote

that most referen$es will refer to this type of generator as a two5wire even throughthere are three protruding from the $ase.

,egulator:

-he regulator on a two brush system has e;tensive intera$tion between the relays be$ause they help trigger one another s opening and $losing state. +ow the$omple;ity of the two5brush system be$omes evident. It ta)es three seperatefun$tions to ma)e the system wor) to handle first the fully $harged battery( se$ondhaving a load su$h as lights turn on when the battery is up and last having a load and

a dis$harged battery. -o perform these fun$tions there is a Cutout ,elay( a 8oltage,elay( and a Current ,elay. -hese devi$es are all very similar in design beingele$tromagnet relays. Depending on the dire$tion of flow through their windings(they open or $lose. -hough it is possible to $ombine the fun$tions of the Current,elay and the 8oltage ,elay into one relay $alled a two5unit regulatorB( it is best tosee the fun$tions dis$retely and so we well dis$uss the three5unit regulator.

Cutout ,elay:

-he $utout relay is identi$al to that used in our old three5brush systems. It still opens

when generator output drops below battery level to stop reverse dis$harge but inaddition a shunt or wire to the voltage relay $auses it to simultaneously $lose it s points and ground the field wire. -his a$tion $auses the generator to in$rease itsoutput whi$h will theoreti$ally will result in the $utout rea$hing its magneti$

potential and $losing its points again. It is important to reali?e that that shunt is notsuffi$ient to $ause the 8oltage relay to )i$) in. It only helps. -he primary thing thatwill ma)e the voltage regulator )i$) in is dis$ussed below.

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8oltage ,elay:



-he voltage relay( when open( allows the generator to have it s field groundedthrough a resistor. -he $harging rate of the generator is determined by 2how mu$h2the field is grounded. If through a resistor( a 2low amount of ground2 is provided tothe generator and it $harges less. #hen the field is $onne$ted dire$tly to ground( thegenerator starts $harging to its full rate. -he voltage relay depends primarily on thevoltage output of the generator to $ause its points to open and redu$e the ground bygoing to ground through a resistor. -his happens be$ause when the voltage passingthrough the ele$tromagnet rea$hes the preset ma;imum for the windings( the openingof the points $auses it to drop off in voltage until the $utout relay opens helping it toreturn to its $losed state. -his $y$le is the normal one repeated during times when the

battery is up or the load is light.

+ote: -he voltage relay $onne$ts to the terminal of the generator to apply voltageto its windings.

Current ,elay:

/asi$ally( when the $urrent draw is very high su$h as a low battery and high loadB(the voltage will never rea$h the level ne$essary to open the voltage relay points andrelieve the poor generator. As with any 2wide5open2 running( the generator wouldmeltdown. -his is where the $urrent relay $omes in. It s points are wired in serieswith the 8oltage ,elay s points and will handle these unusual times by opening its

points when the $urrent rea$hes a $ertain level. During these load times( the $urrentrelay brea)s the dire$t ground and runs to the resistor in the same way the 8oltage

relay would have under normal $onditions. -his allows the generator to rest whi$h$auses the generator voltage to fall below battery voltage and opens the $utout relay.-he $urrent relay then $loses again $urrent has fallenB and the generator starts)i$)ing itself up again. Jou $an see the the $urrent relay and voltage relay do e;a$tlythe same thing( but do it for different $onditions and never do it at the same time.*ither the voltage relay is wor)ing or the $urrent relay and the points of the one notwor)ing are always $losed.

-he $utout relay is ad>usted as follows. -he air gap is ad>usted by a s$rew or set of s$rews that allow you to move the upper plate up or down. -he points are ad>usted by

bending the upper armature stop and of $ourse must be filed sFuarely with no nipple.-hese two ad>ustments reFuire )nowing and using the proper si?ed feeler gauge. -helast ad>ustment is the $losing voltage. -his reFuires more spe$iali?e eFuipment. Jouwill need an ammeter and voltmeter to determine if the points $lose at themanufa$turer5spe$ified voltage. -he spring or more a$$urately( Armature Spring Postis bent to $ontrol what voltage triggers $losure. -he end result of setting the $utoutrelay is that it will open when the generator output is lower than the battery voltageand $lose when generator voltage e;$eeds battery

=



voltage. -he $utout voltage for $losing will usually be slightly above battery voltagee.g.( one E volt generatorM$utout $ombination I have $alls for the points to open

when generator output falls below E.6 voltsB

-he voltage regulator has two ad>ustments plus ma)ing sure the points are filedsFuarely. -he two ad>ustments are the air gap and voltage setting. -he air gap ismeasured on$e again with s$rew ad>ustments and the feeler gage is inserted with the$onta$t points $losed. -o ad>ust the voltage setting bend the spring away to in$reasevoltage ad>ustment the relay will ta)e more voltage to $lose the pointsB or $loser tode$rease the reFuired voltage. ,emember that de$reasing the voltage means it will)i$) in the ground thus raising the $harging rate sooner.

0i)e the voltage regulator( the $urrent regulator has two ad>ustments( the points andthe $urrent reFuired to open the points. "a)e sure the points are filed sFuarely andad>ust the air gap in the same manner as the voltage regulator $losedB. -he bigdifferen$e is that the $urrent ad>ustment must be made with a dis$harged battery anda load. -his $an be simulated by $ran)ing the engine over without starting su$h aswith the $oil wire removed... don t do this if you have installed an ele$troni$ ignition)it and never more than &! se$ondsB. /y pla$ing an ammeter in between your regulator s battery output( and the battery wire( you $an determine at what $urrent the$urrent regulator is opening. Ad>ust to the manufa$turer spe$ifi$ation by bending thelower spring down to in$rease the point where it opens or up to de$rease it.In$reasing it means it will ta)e more $urrent to limit the $harging.

#ith all these ad>ustments( be $areful not to overdo the settings. -he tenden$y $an beto >ust get your ma$hine $harging but your battery and generator $an easily bedestroyed by too mu$h of a good thing. 0et me repeat this( get the manufa$turersre$ommended settings prior to ad>ustment. It s impossible to shoot from the hip onthis one. If your settings aren t $orre$t( the generator will heat up e;$essively whi$hin turn will melt and spin off the solder. -his will probably mean repla$ement of thegenerator.

All that diffi$ult stuff aside( the most needed information on setting up this type of system is usually the wiring. "ost of us have fun$tional generators and regulators

but when we do our restorations and refurbishments we may have forgot to writedown whi$h wire went where when we pulled it all apart opefully the followingwill help in this $ase. If your generator has no mar)ings as to whi$h is the field andwhi$h is the A terminal( open it up and see whi$h terminal goes to a brush( this onewill be the A or the terminal that provides the output. -he field will go dire$tly andonly to the field $oils. -hat $overed( the following diagram should help with the rest.



ig no. .E.

-wo /rush $harging system

• -he generator windings are inta$t

• -he $ommutator surfa$e is smooth

• -he insulators between the $ommutators are $utba$) to allow the brushes to

ride $orre$tly• -he brushes are in good $ondition and there is material left

• -he wires to the brushes are inta$t and $orre$tly insulated

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CHAPTER-3

DETAILS OF PROJECT

&.1 Pro>e$t title :

Ruality level improvement of engine before the installation of the engine with thealternator

&. : Problem identifi$ation :

1.BSupply of e;tra or less part in part )it.

.B "issing of parts in part )it are the $ommon problem fa$ed by operators in theassembly line.

&.BDue to above problems assembly line gets stop whi$h leads to loss in produ$tion.

&.& : Solution of the problem :

1B Jellow $ard implementation :Jellow $ard is yellow tag whi$h is used in the part)it ?one and engine assembly. It is used to avoid the following two things :

To avoid supplyof extra and lesspart to part kit.missing of partsin part kit.of extra and lesspart to part kit.missing of partsin part kit.• -o avoid supply of e;tra and less part to part )it.• -o avoid missing of parts in part )it

&.&.1 ,ule of yellow $ard:

1.BJellow plate should be used in every stage (whenever there is stop in a line li)e:5lun$h brea)( tea5brea)( shift $hange et$.

.BJellow plate availability should be ensure by group leaderMline in $harge.

&.B In $ase of repla$ement( $onta$t to line in $harge.

=.B 0o$ation of yellow plate should be proper.

6.B Jellow plate should only be used 6mins after the line stopped.

EB *nsure yellow plate availability on your respe$tive stage.

4B If it s not then )eep it on proper lo$ation.

<B 'se when5ever line stop.

3BCross $he$) by group leader.

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&.&. Implementation:

1B perator: Jellow plate has to use( whenever line5stop.

B Group leader: Cross $he$) during line S- P.

&B0ine5in5$harge: Che$) availability and $ondition of yellow plate by hisMher $he$) sheet.

&.&.& /enefits after yellow $ard implementation:

1BAfter implementation of yellow $ard supply of parts are a$$urate.

BProblem fa$ed by operator of missing parts in part )it is solved.

&BProdu$tion of engine assembly is in$reased.

Rejections

Defective parts 60not proper workingappaerance

leakage

ig no .&.1

Chart of the re>e$tions of engine in Fuality test

sudhir gensets training file

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