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SUMMER INTERNSHIP REPORT

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About Hero Moto Corp● Hero Moto Corp Ltd., formerly Hero Honda, is an Indian motorcycle and scooter manufacturer based in New Delhi, India. ●Hero Honda started in 1984 as a joint venture between Hero Cycles of India and Honda of Japan. The company is the largest two wheeler manufacturer in India.●The 2006 Forbes 200 Most Respected companies list has Hero Honda Motors ranked at #108●It has three plants in Dharuhera Gurgaon and Haridwar

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About Hero Moto Corp Contd.

●In 2010, when Honda decided to move out of the joint venture, Hero Group bought the shares held by Honda. Subsequently, in August 2011 the company was renamed Hero MotoCorp with a new corporate identity●Brij Mohanlal Munjal is chairman and Pawan Munjal is MD & CEO of Hero Moto Corp●The Company has Technical Collaboration with EVR America and EEE Italy●As on March 31, 2012 the total numbers of employees on the records of the Company were 6,106

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ProductsO Passion And it’s variants O Glamour And Glamour FIO CBZ ExtremeO Karizma And Karizma ZMRO HunkO ImpulseO AchieverO IgnitorO PleasureO MaestroO Splendor And it’s variants

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Capacity•Three globally benchmarked facilities, with a combined installed capacity of 6.35 million units.•Over 41.7 million two wheelers sold•60,000 vehicles a month•125cc motorcycles 75,000 vehicles per month•17 different products across 100cc, 125cc, 150cc, 225cc and scooter category•Team Hero comprises 6,106 motivated people

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Annual Turnover

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Ten Years Performance

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Maintenance’s Distribution

Maintenance

DG House Utility Frame

PlantEngine Plant

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Types of Maintenance

Maintenance

Sustain Activity

Preventive Maintenan

ceBreakdown Maintenan

ce

Kaizen Activity

Corrective Maintenan

ceMaintenan

ce Prevention

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Types of Maintenance

Preventive Maintenance

Time Based Maintenance

Condition Based

Maintenance

Breakdown Maintenance

Planned Breakdown

Maintenance

Emergency Maintenance

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Engine Plant’s DistributionENGINE PLANT

ALUMUNIUM PHASE

CRANK CASE

CYLINDER HEAD

STEEL PHASE

CRANK SHAFT

CYLINDER

CONRODS

GEAR SECTION

GEARS

SHAFTS

HEAT TREATMENT

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RELAY LOGICIT IS HAVING POWER & CONTROL CKT., BY POWER CKT. WE ARE GIVING POWER TO THAT MOTOR & CONTROL CKT. IS BEING USED TO CONTROL POWER CKT.

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Basic Relays● A relay is an electronic control switch used to open or close a mechanical contact whenever a voltage is applied to its coil.●A switch whose operation is activated by an electromagnet is called a "relay"

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Basic Relays● A basic relay usually contains two sets of contacts, normally open and normally closed. The schematic will show the normal contact position for a de-energized coil

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PUSH BUTTON■ A Push Button is a simple switch mechanism for controlling some aspect of a machine or process. It’s examples are Start Push Button, Stop Push Button.■ Start Push Button is used to start any machine’s process. Normally, it is held open by a spring and thus NO(Normally Open) by nature.■ Stop Push Button is used to stop any machine’s process.Normally,it is held closed by a spring and thus NC(Normally Closed) by nature.

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Proximity Switch■ A Proximity Sensor is a sensor able to detect the presence of nearby objects without any physical contact.■ A proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal. The object being sensed is often referred to as the proximity sensor's target. The maximum distance that this sensor can detect is defined "nominal range".■ Types :- Capacitive, Eddy-current, Inductive, Photocell, Radar, Sonar■ Applications :- Parktronic, Roller coasters, Conveyor systems, Mobile devices

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Limit Switch■ A limit switch is an electromechanical device that consists of an actuator mechanically linked to a set of contacts. When an object comes into contact with the actuator, the device operates the contacts to make or break an electrical connection.■ Limit switches are electro mechanical switches.■Types :- lever, roller plunger, and whisker ■ Applications :- A lathe will have limit switches to identify maximum limits for machine parts or to provide a known reference point for incremental motions and in roller coaster’s operation.

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Timer Switch■ A timer switch  is a timer that operates an electric switch controlled by the timing mechanism.■ The mechanism may be mechanical or electronic, with semiconductor timing circuitry and switching devices and no moving parts or electromechanical.■ Applications :- In CNC/PLC machines for timed control lubricant flow, switching any device on or off at desired time and thus saving electrical energy like street lightining,oven,washing machines.

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Motor Control CircuitryControlVoltageReturn

Three PhaseLine

Main Contacts

AuxillaryContacts

Contactor Coil

M

MotorContactor START

STOP

ControlVoltageSource

L1 L2 L3

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DOL Starter Mechanism■ In DOL method the motor is connected by means of

starter across the full supply voltage.■ On pressing the START push button the contactor coil is energized from two line conductors as shown.■ Following the three main contacts and the auxiliary contact is closed and the motor is thus connected to supply. ■ When the pressure on START push button is released, it moves back under spring action but the coil remain energized through auxiliary contact and thus it called as hold-on-contact.■ When STOP push button is pressed ,the supply through the contactor coil is disconnected or is de-energized.■ Thus the main contacts and auxiliary contact are open and the supply to motor is disconnected and thus motor stops.

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Relay Logic Based Machine in HMC Gurgaon

STD. GRINDER

Grinder front view Electrical Control Panel

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PROGRAMMABLE LOGIC

CONTROLLER

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PLC-Definition– PLC: (Programmable Logic Controller) An

industrial control device developed to accept contact closure inputs and to provide outputs that drive relay coils.• The device may be re-programmed with code relating

inputs to outputs• Modern PLCs may allow analog input/output and may

support high level language functions (C, C++, BASIC)

• Programming logic includes simple logic, timing functions counting functions, sequences, and may include complex algorithms (eg. PID)

• Examples: Allen-Bradley, Mitsubishi, Messung,etc.

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CONTENTS OF P.L.C.

POWERSUPPLY

CENTRALPROCESSING

UNIT

INPUTCARD

I0

INPUT CARD

I1

OUTPUTCARD

O2

OUTPUTCARD

O3

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WORKING OF P.L.C.

FROM M/C I/P CARD C.P.U.

O/P CARD TO M/C

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Power SupplyA power supply is needed to provide power to the PLC and any other modules. Power supplies come in various forms:

• Power supply modules that fit into one of the slots in a chassis

• External power supplies that mount to the outside of a chassis

• Stand alone power supplies that connect to the PLC or I/O through a power cable

• Embedded power supplies that come as part of the PLC block.

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Central Processing UnitProcessor, Controller, or CPU

• Stores the control program and data in its memory

• Reads the status of connected input devices

• Executes the control program

• Commands connected outputs to change state based on program execution – For example: Turn a light on, start a fan, adjust a speed, or temperature

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Input Modules●Input modules interface directly to devices such as switches and temperature sensors.●Input modules convert many different types of electrical signals such as 120VAC, 24VDC, or 4-20mA, to signals which the controller can understand.●Input Modules convert real world voltage and currents to signals that PLC can understand. Input Modules include both digital and analog modules.

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Output Modules•Output modules interface directly to devices such as motor starters and lights.•Output modules take digital signals from the PLC and convert them to electrical signals such as 24VDC and 4 mA that field devices can understand.•Output modules take a signal from a PLC and convert it to a signal that a field device needs to operate. Since there are different types of output devices, there is a wide variety of output cards available, including both digital and analog cards.

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COMMON INPUTS & OUTPUTS

■ INPUTS :- LIMIT SWITCH , PROXIMITY SWITCH , PUSH BUTTONS , PRESSURE SWITCH ETC.

■ OUTPUTS :- SOL. COIL , CONTACTOR COIL , CONTROL RELAYS , L.E.D.s ETC.

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PLC Control Panel

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PLC’S ProgrammingEvery PLC has associated programming software that allows the user to enter a program into the PLC.•Software used today is Windows based, and can be run on any PC.•Different products may require different software: PLC5, SLC, and Control Logic each require their own programming software•Before a PLC can perform any control task, it must be programmed to do so. The most popular language used to program a PLC is ladder logic.•Other languages are Function Block, Structural Text, High level languages, Sequential Function Chart.

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Example of Ladder Logic

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PLC Machines in HMC Gurgaon

● About 200 PLC machines are present in HMC Gurgaon and some of them are as follows in tabular form :-

MACHINE NAME CONTROLLER NAME

Widia Machine Messung, MitsubishiLeak Testing Machine MitsubishiWashing Machine Messung, MitsubishiHMT Machine MessungMico Machine MessungHoning Machine Mitsubishi

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WIDIA MACHINE IN HMC GURGAON

WIDIA Front View Electrical Control Panel

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COMPUTER NUMERICAL

CONTROL

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NC & CNC Numerical control (NC) is a method of automaticallyoperating a manufacturing machine based on a code letters, numbers and special characters. The numerical data required to produce a part isprovided to a machine in the form of program, called partprogram or CNC (computer numerical control). The program is translated into the appropriate electricalsignals for input to motors that run the machine. A CNC machine is an numerical control machine with the added feature of an on board computer. The computer is referred to as the machine control unit (MCU).

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CNC System Elements

A typical CNC system consists of the following six elements

Part program Program input device Machine control unit Drive system Machine tool Feedback system

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Types Of CNC Machines

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Tool Movements

Point To Point Continuous Movement

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Loop System For Controlling Tool

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Application Of CNC Machines

● Cutting● Milling● Boring● Spinning● Drilling● Welding● Sewing

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Electrical Panel Of CNC Machine

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Servo DriveO A servo drive is a special electronic amplifier used to power

electric servomechanisms.O A servo drive monitors the feedback signal from the

servomechanism and continually adjusts for deviation from expected behavior.

O A servo drive receives a command signal from a control system, amplifies the signal, and transmits electric current to a servo motor in order to produce motion proportional to the command signal.

O Servo systems can be used in CNC machining, factory automation, and robotics, among other uses. 

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Contactor● A contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings.● A contactor is controlled by a circuit which has a much lower power level than the switched circuit.● Contactors range from those having a breaking current of several amperes to thousands of amperes and 24 V DC to many kilovolts.● Contactors are used to control electric motors, lighting, heating, capacitor banks, thermal evaporators, and other electrical loads.

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MCB & MPCB■ Miniature circuit breakers (MCBs) are fitted as protection units in place of fuses. They have the advantage that they can be manually reset without having to replace wire as in the case of the traditional fuse. The MCB tripping is an indication either that the circuit has been overloaded or that a short circuit has occurred somewhere in the system.■ The Motor Protection Circuit Breakers (MPCBs) provide short circuit protection, overload protection, and motor disconnect functions. The MPCBs may be combined with a magnetic contactor to provide 2 component combination starters and with the addition of an overload relay. They generally provide contacts to indicate position (Trip, Not Tripped). ◄ MCB

MPCB ►

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RelaysO A relay is an electrically operated switch. Many relays

use an electromagnet to operate a switching mechanism mechanically but other operating principles are also used.

O Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.

O  Relays are used to protect electrical circuits from overload or faults.

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SMPS►A switched-mode power supply (switching-mode power supply, SMPS, or switcher) is an electronic power supply that incorporates a switching regulator to convert electrical power efficiently.► SMPS transfers power from a source, like mains power, to a load.►Voltage regulation is achieved by varying the ratio of on-to-off time►This higher power conversion efficiency is an important advantage of a switched-mode power supply.SMPS are smaller in size and lighter in weight.

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CNC Machine’s Basic Programming

Part programming contains geometric data about the part and motion information to move the cutting tool with respect to the work piece. Basically, the machine receives instructions as a sequence of blocks containing commands to set machine parameters; speed, feed and other relevant information. A block is equivalent to a line of codes in a part program. An example of CNC Machine programming as given below :-

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Various Codes ● Preparatory command (G code) The G codes prepare the MCU for a given operation, typically involving a cutter motion.Ex :- G00 rapid motion, point-to-point positioning G33 thread cutting● Miscellaneous commands (M code)Ex :- M00 program stop , M06 tool change● Feed commands (F code)Used to specify the cutter feed rates in inch per minute● Speed commands (S code)Used to specify the spindle speed in rpm.● Tool commands (T code)Specifies which tool to be used, machines with automatic tool changer.

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CNC Machines In HMC Gurgaon

► About 400 CNC machines are present in HMC Gurgaon and some of them are as follows in tabular form :-

MACHINE NAME CONTROLLER NAMEFANUC ROBODRILL MACHINE

FANUC

MICROMATIC GRINDER FANUCAWH GRINDER FANUCMICO MACHINE FANUCWIDIA MACHINE FANUCKIRA MACHINE FANUC

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CNC Machines In HMC Gurgaon Contd.

MACHINE NAME CONTROLLER NAMETOYADA MACHINE TOYADANACHI MACHINE FANUCBROTHER MACHINE BROTHERLIEBHERR MACHINE SIEMENSLORENZ MACHINE SIEMENSMITSUBISHI MACHINE FANUCGLEASON-HURTH FANUC

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AWH Grinder In HMC Gurgaon

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P.L.C. Vs RELAY LOGIC

P.L.C.

O IT IS COMPACTO HAVING LESS WIRINGO EASY FAULT FINDINGO EASY TO MODIFYO LESS PREDECTIVE

MAINTENANCE

RELAY LOGIC

O HAVING BIG PANELO LOT OF WIRINGO TOUGH FAULT FINDINGO NOT EASY TO MODIFYO MORE PREDECTIVE

MAINTENANCE

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P.L.C. Vs C.N.C. P.L.C.

O SPECIFIC PURPOSE MACHINE

O NO FEEDBACK (EXCEPT SERVO DRIVE)

O LOWER ACCURACYO NOT EASY TO MODIFYO PART OF CNC SYSTEM

C.N.C.

O MULTI PURPOSE MACHINE

O FEEDBACK CONTROLLED SYSTEM

O HIGHER ACCURACYO EASY TO MODIFYO ITSELF A SYSTEM

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THANK YOU

MADE BY :- AMRITANSHU KUMAR