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PLC & PANEL UPGRADATION OF NAGEL HONING MACHINEPLC & PANEL UPGRADATION OF NAGEL HONING MACHINE

TATA MOTORS

Company Profile

• Tata Motors Limited is India’s largest automobile company, with consolidated revenues of INR 2,32,834 crores (USD 38.9 billion) in 2013-14. It is the leader in commercial vehicles in each segment, and among the top in passenger vehicles with winning products in the compact, midsize car and utility vehicle segments. It is also the world's fifth largest truck manufacturer and fourth largest bus manufacturer.

• The Tata Motors Group’s over 60,000 employees are guided by the mission “to be passionate in anticipating and providing the best vehicles and experiences that excite our customers globally.''

• Established in 1945, Tata Motors’ presence cuts across the length and breadth of India. Over 8 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company’s manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka).

Tata Motors Jamshedpur

• The Jamshedpur facility, Tata Motors' first, was established in 1945 to manufacture steam locomotives. It led the company's foray into commercial vehicles in 1954. It has been modernized through the decades, with a particularly intense scale in the last 10 years and has led the company's evolution into a manufacturer of global repute.

• This world-class facility is equipped with:• State-of-the-art equipment and assembly lines to produce a truck every 5 minutes• Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers, mixers and

special application vehicles, catering to civilian and defence requirements• 3D visualization of new models• Engine assembly shop, capable of supplying upto 200 engines per day• Modern testing facilities• The plant manufactures Tata Motors' entire range of medium and heavy commercial

vehicles, including the Tata Prima, both for civilian and defence applications - over 200 truck variants, ranging from multi-axle trucks, tractor-trailers, tippers, mixers and special application vehicles. Besides India, these vehicles are sold in South Africa, Russia, Myanmar, the SAARC region and the Middle East. On February 19, 2013, Jamshedpur Plant rolled out its two millionth truck.

Contents1) ACKNOWLEDGEMENT2) What is a Honing ?3) What is a Honing M\C?4) Why Honing M\C required?5) Principle of Honing M\C6) Where Honing M\C used?7) PLC & Panel up gradation in Honing machine.8) Applications of Honing M\C9) Conclusion.

What is a Honing ?• Honing is an abrasive machining process that produces a precision surface on a

metal work piece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture.

• Honing is used in:• Track/Raceway honing• Spherical honing• OD through-feed honing (taper and straight)• Flat honing• Bore honing

ORHoning is a cutting process where multi-edge tools coated with particles withcontinuous surface contact between the tool and work piece are used to optimize thedimension, form and surface of pre-machined work pieces. Between tool and workpiece a change in direction of the longitudinal movement takes place. The finishedsurfaces are characterized by a cross-hatch pattern on the surface.

What is a Honing M\C?• A Honing machine is used to material, grind, or finish a work piece.• Tool wear caused by the friction of grinding. • A rough edge remaining on metal after it has been cut or perforated.• A small particle of material that is removed during grinding, cutting, or abrasive

processes.• A clamping device that grips the post or shank of a mounted grinding tool.

Why Honing M\C required?

Typical applications are the finishing of cylinders for internal combustion engines, air bearing spindles and gears. There are many types of hones but all consist of one or more abrasive stones that are held under pressure against the surface they are working on.

Principle of Honing M\C• The work process with honing is a combination of stroke and rotation movement of an

expandable honing tool with inserted honing stones or diamond sticks. The result is the surface structure with cross-hatch pattern generated by the honing process. The timing of the honing is defined by quick cutting of the peaks of the pre-machined bore surface. This rapidly achieves a smoothing of the surface.

Where Honing M\C used?

• Engine: Cylinder Bore, Cylinder Liner, Crank Bore, Connecting Rod, Diesel fuel injection components, Crankshaft Pulley, Rocker Arm, Turbo Charger Valve, Roller Lifter, VVT components.

PLC & Panel up gradation in Honing machine

• Nagel machine operation, Make: Nagel• Understanding project requirement• Project frame work- sheet• Electrical Drawing renewal• Identifying BOM • Offline Electrical wiring in new panel• S7-300 PLC program• Interfacing with Nagel Controller• Nagel PC, Base card, DI/DO card, analog cards, Stepper cards map

ping with new PLC• Installation of panel in machine• Panel commissioning• Machine manual function check• Machine Auto mode trial• Job prove out

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Working of Nagel Honing M\C

• Nagel machine structure.• Nagel Honing principle.• Nagel controller Block diagram.• Nagel controller functioning.• Nagel Interfacing with PLC.

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Nagel machine structure:

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Nagel Honing principle

• Honing is done to remove the ovality & taper.• A transfer bar is there to put the cylinder block from loading position to fixture position, then

diamond moves into the bore & there is a pneumatic gauging system which senses the air pressure in the bore & the sensor sends the data to the PLC then PLC will decide the stroking expansion time then accordingly it will perform the operation. The air pressure should be between 1.5 to 3 bar.

697 497

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Nagel controller Block diagram

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Nagel controller functioning• Industrial PC: MSU-3 soft ware used1) Interface between operator and machine.2) Honing program.3) Parameter editable.4) Gauging function.• PLC: S7-300 used1) Hardware configuration Automata Gateway.2) Interfacing with Automata\Nagel card.3) Machine program (blocks).• Profibus\Automata gateway.1) Interface between PLC & Nagel Cards.2) Protocol CAN.3) Interfacing signals.

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• NAGEL cards:a) Base card:1) Spindle speed measure.2) Expansion proportionate valve.3) Break release servo valve ( not used).4) Air valve in process.b) Digital i\o card:1) Stroke forward.2) Stroke reversal.3) Counter holding valve.4) Finish stone worn-out.5) Finish honing pressure.6) Spindle at top.c) Analog i\o card:1) Movamatic in process sizing.d) Stroking card:1) Stepper motor for H+L valve spindle-1.2) Hard\Soft reversal.3) Spindle 1 work valve.4) Spindle 1 Returned.5) End restrict up.6) End restrict down.e) Expansion card:1) Pulse generator expansion (encoder).2) Stepper motor expansion.

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Nagel interfacing with PLC

M50-455

INPUT FROM NAGEL GATEWAY TO PLC

I67.5 ROUGH HONING STARTED

I67.6 FINISH HONING STARTED

I67.7 SP RETURN

I68.0 SP ADVANCE

I68.1 FINISH HONING FINISHING

I68.6 SP CCW

I68.7 SP CW

I69.0 CLNT ON

I69.1 EXPANSION HOME

I67.0 SPINDLE READY

I67.2 SP HOME POS

I67.1 SP IN OPERATION

I67.3 SP SFTY SP SAFETY POS

M50-455

OUTPUT TO NAGEL GATEWAY FROM PLC

Q66.0 SP TYPE 1 MSU

Q67.0 HYD ON

Q67.1 LOAD ON

Q67.2 AUTO SELECTED

Q67.3 SP RELEASE

Q67.4 COMP PRESENT

Q67.5 COMP CLAMP

Q67.6 RESET HONING FINISH SIGNAL

Q67.7 START HONING

Q68.4 FAULT RESET

Q68.1 EMG STOP

Q68.2 SP RETURN

Q68.3 TOOL CHANGE POSBack

Control Panel of Nagel

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Limit switches

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Programmable Logic Controller

• A PLC is a industrial computer. A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is an example of a hard real-time system since output results must be produced in response to input conditions within a limited time, otherwise unintended operation will result.

Variable Frequency Drive

A variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-speed drive, AC drive, micro drive or inverter drive) is a type of adjustable-speed drive used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage.

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Different control cards used are:• Base Card.• D i\o Card.• A i\o Card.• Stepper stroke card.• Stepper expansion card.• In this M\C Siemens S7-300 series PLC is used.

Outer\Field Parts of Nagel

Hydraulic Motor Spindle motor Lubrication motor Coolant return motor Hydraulic motor-2 Loading conveyor motor Unloading conveyor motor Table motor Table motor break Coolant & Hydraulic chiller supply NEXT

Field Description• Hydraulic Motor: A hydraulic motor is a mechanical actuator that converts

hydraulic pressure and flow into torque and angular displacement (rotation). The hydraulic motor is the rotary counterpart of the hydraulic cylinder.

• Spindle motor: A spindle motor is a small, high-precision, high-reliability electric motor that is used to rotate the shaft, or spindle, on which the platters are mounted in a hard disk drive (HDD).

• Lubrication motor: A lubricant is a substance introduced to reduce friction between moving surfaces. It may also have the function of transporting foreign particles. The property of reducing friction is known as lubricity. (Slipperiness). One of the single largest applications for lubricants, in the form of motor oil, is protecting the internal combustion engines in motor vehicles and powered equipment.

• Coolant return motor: The coolant temperature sensor is used to measure the temperature of the engine coolant of an internal combustion engine. The readings from this sensor are then fed back to the Engine control unit (ECU). This data from the sensor is then used to adjust the fuel injection and ignition timing. On some vehicles the sensor may be used to switch on the electronic cooling fan. The data may also be used to provide readings for a coolant temperature gauge on the dash. The coolant temperature sensor works using resistance. As temperature subjected to the sensor increases the internal resistance changes. Depending on the type of sensor the resistance will either increase or decrease

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• Conveyor: A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt conveyor). A belt conveyor system is one of many types of conveyor systems. A belt conveyor system consists of two or more pulleys(sometimes referred to as drums), with an endless loop of carrying medium - the conveyor belt - that rotates about them. One or both of the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler pulley. There are two main industrial classes of belt conveyors; Those in general material handling such as those moving boxes along inside a factory and bulk material handling such as those used to transport large volumes of resources and agricultural materials, such as grain, salt, coal, ore, sand, overburden and more.

• Coolant & Hydraulic chiller supply: A chiller is a machine that removes heat from a liquid via a vapor-compression or absorption refrigeration cycle. This liquid can then be circulated through a heat exchanger to cool air or equipment as required. As a necessary byproduct, refrigeration creates waste heat that must be exhausted to ambient or, for greater efficiency, recovered for heating purposes. Concerns in design and selection of chillers include performance, efficiency, maintenance, and product life cycle environmental impact.

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Conclusion• With the active help and support of all the employees in the Electronics

department of the Engine Factory, I was able to complete my project and I am extremely grateful to them while doing this project I got an insight of the application of my branch in this factory. Unless one undergoes practical training it is difficult to relate to all that is being taught in theory. Moreover one gets the feel of working in a factory.

• The next important thing that one learns in the training is how to relate himself to his colleagues, his seniors and the employees of his division. Until and unless a person interacts actively with his co-workers, he will not be able to dispel his duties well because in an organization an individual alone, isolated from his workforce cannot complete a job.

• Finally I would like to thank Mr. SANDIP B RAVAN for their constant guidance and help without their support it would not have been possible. I would also like to thank the administration of TATA MOTORS for providing me with this wonderful opportunity of completing my training here.

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• 20april-25may- Nagel PLC and panel up gradation

• 26may-5june- Engine test bed smoke meter up gradation

• 6june-till date- PLC up gradation in SPM machine

Understanding project requirement• Existing Process • • • Control panel condition is very critical. It’s very tedious for fault finding. • • Existing Problems- Control Panel wiring fault • Panel wiring fault MTTR = 2 hrs• • Machine MTBF=24 hrs, MTTR= 2 hrs• • Machine production losses on daily basis• • Existing PLC is obsolete and also diagnostics tool is not available• • No service and spare support for existing PLC• Proposed process• • Main Control and Operator Panel up gradation.• • Replacing Existing control panel wiring with new Generation switch gears.• • Replacing existing PLC with new generation PLC (S7-300)• • Introduction of new generation system will results into life of the machine.• • Removal of obsolete control system & critical panel wiring will results into overall

Equipment effectiveness (OEE)• • Introduction of new generation will assured for service and spare support in future.• • Better Equipment utilization.

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APPLICATION

• Nagel machine is used for “Honing of 697 and 497 Cylinder Block” in Engine Division.

• Below are the control details:

PLC S5 SIEMENS (Obsolete)• Existing control panel wiring is very critical and

complicated for fault finding.

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PANEL COMISSIONING

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OLD PANEL CONDITION

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NEW ELECTRICAL DRAWING

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OLD ELECTRICAL DRAWING

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Thanks.