Irfan training report 2

Sonalika

Company profile

Sonalika group started its journey of success during 1976 with foundation of small unit to fabricate and assemble wheat-harvesting machines .With passage of time this small initiative taken by Mittals in 1976 turns into a great success due to the continuous efforts of its promoters and thousands of employees who worked unaltered throughout.

The success provided further motivation ultimately in resulting setting up new plant in the name of International Tractors Limited for the production of tractors as the demand requirement of which was growing at good pace. The plant which was setup at village Chak Gujran, Hoshiarpur and is spread over an area of 75 acres(approx.).And obtain the certificate of incorporation on 26 OCT in 1996.

SAVERA GROUP OF INSTITUIONS MOHAMMAD IRFAN HAJAM

Fig No: 1 Parts Manufactured By Company International Tractors Limited was incorporated on Oct 17, 1995.it was established on 1996-97.now Feb.-march, the production rate of tractors 180 per day. The total no. Employees working in ITL are more than 3000.the total no. of dealers of ITL in India and neighbouring countries are 548. ITL was introduced 15 models of tractors .There are 5 regional office in India which are at Delhi, Patna, Ahmadabad, Manipur and Bhopal. Company got ISO 9001- 2000 certificate in April 1999 by ICL. Company is also running its own agriculture equipment making industry, which is producing threshers, disc harrow, wheat harvesters etc. Company also got ISO 14001 – 1996 certificate for environmental safety and ISO TS 16949 for selfmading body parts & plastic parts of tractor. Group vision


finance. Tractor

.ITL Magma

Equipment Farm

Machinery Agricultural

INDUSTRIES SONALIKA AGRO

Engines

Tractor

assemblyTransmission

Cranes

Sets DG

TRACTORS LTD. INTERNATIONAL

SONALIKA GROUP COMPANIES

To become the world leading tractors manufacturing company and major player in automotive products and services.

Company Mission

To translate vision into reality. Success factor

• Quick decision making

• Innovation and strong R&D

• High degree of competency

• Resultant experience

• Fast adaptability to changes

• Product range Di-series (30-60hp)

• Most economical and power tractor

• Fitted with diesel save unit

• Disc brake(OIB option)

• Most balance strong grip • Rx-series (39-60hp)


Fig. No. 2: DI Series Tractor

• Modern tractor

• Available in different option of OIB ,power steering, turbo charger dual clutch DC valve

• Constant mesh gear box,

• Aerodynamic bonnet

• Mobile charger

World track (75-90hp)

FIG.3 WORLD TRACK

• Ultra-modern and powerful • Easy to drive and safe


• Available in option two wheel and four wheel drive

• Fitted with OIB ,power steering, turbo charger dual clutch DC valve 12×12 synchromesh gear box

• Aerodynamic model,

• Mobile charger Group strength

• Cost effectiveness

• Manufacturing strength

• In-house R&D strength

• Strong vendor base

• Marketing capability

• Globa

l contacts

Milestone

1969-model beginning into farm equipment and machinery manufacturing 1997-entry into manufacturing of tractors into market 2000-2003 joint ventures with Renault agriculture, France. Export of tractors to Africa, Asia, sub-continental and Renault branch to develop countries. In- house manufacturing of engines for tractors application 2004-05-joint venture with Yanmar agriculture of Japan for joint manufacturing of tractor in India 2007-08- launch of Rx-series 2009-launch of world track.

Product features:

• Highest torque backup

• Strong and robust tractors-heavy more grip, less slippage, more pulling power and more tyre life

• More front weight and large wheel base-no front lifting and balance tractors

• Ground clearance high

• Powerful hydraulics-1200,1600,1800,2200,2500kg(world track higher hp 75-90)


PLANT VISIT

During the co-op term we were frequently taken for industrial visits with Mr.Rishiraj sir. Each and every part of the industry was explored. During the visits the local workers told us that thirty-three years ago we saw a dream that we have worked to fulfil relentlessly. This dream was 'to make possible the total mechanization of Indian agriculture, so that Indian farmers can also stand on the forefront of the world in terms of productivity and technology. Our dream has been to give them a new future, full of new hopes and challenges. Challenges, that Sonalika will help every farmer meet .It is this inspiration that has encouraged us to achieve a new every moment.

The lush green world of Indian agriculture is not new to Sonalika. The actuality is that Sonalika has spent so much time on Indian farms that it understands the needs and aspirations of the Indian farmer in there.

The saga started thirty-three years ago when Sonalika began manufacturing threshers to help Indian farmers ensure greater productivity through qualitatively superior technology. History stands witness that, since the day of its inception, Sonalika has never needed to look back. Today Sonalika is a well-known name in every household. A great bond of trust has grown between the company and farmers. Over the years, this trust grew to such an extent that the farmers soon put forth the demand that Sonalika should also manufacture a high-technology tractor. For quite some time, the company had also been thinking on the same lines and we took a bold step forward by beginning the tractor production in 1995.

“Excellent Design" of Sonalika Tractor is prepared by Govt. of India's Central Mechanical Research Institute. The design of Sonalika Tractor has been prepared by Central Mechanical Engineering Research Institute (Durgapur), the premier design institute of the Government of India's Research and Development department. The institute, which has also prepared the design of Swaraj Tractor, is known for its three decades of designing experience.

The Technical Collaborators of I.T.L is with the Renault Agriculture, France. It has always been the Sonalika's endeavour to offer Indian farmers international quality equipment, to enable them to march in step with the developed world towards a brighter tomorrow.

World-class technology not only gives tractors greater power, but also helps in reducing the consumption of diesel and making the tractor's engine environmentfriendly. With these aspects, and the needs of the Indian farming community in mind, Sonalika entered into a technical collaboration agreement with world leaders, Renault Agriculture of France. As a result of this joint effort, Sonalika has developed the world class Euro-ii range at its fully automated plant at Hoshiarpur.

The inspiring objective has been to take Indian agriculture to the threshold of a new beginning and empower the Indian agriculturist with the glory of a lush green new era.

Production Process

Every Sonalika tractor, manufactured at Sonalika’s ultra-modern plant at Hoshiarpur, is an example of unmatched workmanship. At every stage of production experts keep a constant eye on


the minutest manufacturing details to ensure faultless quality control, by applying the most stringent international quality-check standards to produce tractors that are unbeatable in their category. Each part of every tractor is tested for operational excellence at the Hoshiarpur plant.

Sonalika Engine Production

This is where the top quality, smoke-free engines of Sonalika tractors are produced. The engine is the most vital component of a tractor and therefore only the latest imported equipment is used at the plant to ensure that the engine of every Sonalika tractor is of truly world class standard.

It is this attention to detail that enables Sonalika engine to lead the way, when it comes to fuel-economy and power' To maintain quality levels, every engine is also thoroughly tested on computerized machines after being manufactured.

Gear Manufacturing Process

Only the finest technology and equipment is used to manufacture international quality gearboxes at Sonalika fully equipped gear manufacturing unit. One of the most modern units of its kind, it uses equipment that has been especially imported from France, Germany and Russia to provide gears extra strength and operational efficiency.

Quality Check of Gear Boxes

Every gearbox of Sonalika is intensively tested for quality during the manufacturing process itself. Done by using the latest computerized equipment, the quality control system ensures that every gearbox is manufactured according to internationally accepted quality standards.

Quality Check

To guarantee that Sonalika tractors match the most stringent international quality norms, the Quality Control Unit of the plant checks the production process and every component used in production, most intensively. No room is left for even the smallest error. The precision tests have the capacity to do a quality scan on an area as small as a

1000th part of 7mm. This is the reason why every Sonalika tractor is an example of world class quality' Working in the assembling line

After all this hard work done in the workshop and the field trips, we were moved into the assembling line where the new tractors were assembled. We spend nearly one hour in the assembly line of I.T.L. One thing that we came to know that perfection does not come in a day


you will have to work and work hard for it. Seeing the workers move their hands we were astonished as they were moving them very fast as if the position of the target was fit in their mind like a machine. Overall I had good time assembling tractors in the assembly line.

What is a Tractor?

• The word Tractor is derived from the word Traction Motor.(tract+or=tractor). Traction is the force in the direction of travel developed by the traction medium (soil) & is transferred to the tractor.

• A Tractor is a vehicle specifically designed to deliver a high pulling force at slow speeds, for the purpose of hauling a trailer or an implement used in agriculture.

• The power developed by the engine, finally goes to the tractor wheels, which moves the tractor with or without load.

• Torque is more important for the functioning of Tractor.

• Speed is secondary factor.


GROWTH OF TRACTOR


FIG. 4CONVENTIONAL FARMING WITH BULLOCKS

FIG. 5 Early Tractor with steam engine

FIG.7 Beginning of All-rounder Sonalika tractors

FIG.6 Tractor in late 1950’s

ENGINE Introduction -Heat engine is set of box which convert chemical energy into heat energy and further heat energy converted into mechanical energy (useful work).Heat engine is of two types –

1) External Combustion Engine

2) Internal Combustion Engine

External Combustion Engine- The combustion uses heat in form of steam, which generated in a boiler, placed entirely separate from the working cylinder.

Internal Combustion Engine- The combustion of fuel takes place inside the engine cylinder & heat is generated within the cylinder of the engine .There are two ways in which combustion takes place in the cylinder-

1) By rapid explosion of the air-fuel mixture within the cylinder when it is ignited by a spark is called Constant Volume Combustion (C.V.C.).

2) Combustion takes place by slow burning when the fuel is injected into highly compress heated air contained in the cylinder, this is called Constant Pressure Combustion (C.P.C.).Because when the combustion takes place, the pressure in the cylinder is almost constant.

Principles and working of I.C. Engine

Principle-

A mixture of fuel with correct amount of air is exploded in an engine cylinder which is closed at one end. As a result of explosion, heat is released and this causes the pressure of burning gasses to increase. This pressure increase, forces a close fitting piston to move down the cylinder. This movement of piston is transmitted to a crankshaft by a connecting rod so that the crankshaft turns a flywheel. To obtain continuous rotation of crankshaft this explosion has to be repeated. Before this can happen, the used gasses have to be expelled from the cylinder, the fresh charges of fuel and air must admitted and the piston must be move back to its starting position .This sequence of events is known as working cycle.

Working-

I.C. converts the reciprocating motion of piston into rotary motion of crankshaft by means of connecting rod. the piston which reciprocates in the cylinder is very close fit in the cylinder. Rings are inserted in the circumferential grooves of the piston to prevent leakage of gasses from sides of pistons .Usually a cylinder is bored in a cylinder block and a gasket, made of copper seat are asbestos is inserted between cylinder and cylinder head. The combustion space is provided at the top of cylinder head where combustion. There is rod called connecting rod for connecting the piston and crankshaft. A pin called Gudgeon Pin or Wrist Pin, is


provided for connecting the piston and the connecting rod of engine. The end of the connecting rod which fits over the gudgeon pin is called small end of connecting rod. The other end which fits over the crankpin is called Big End of Connecting Rod. The crankshaft rotates in main bearing which are fitted in the crankcase. A flywheel is provided at one end of the crankshaft for smoothening the uneven torque, produced by a engine. There is an oil sump at the bottom of the engine which contains lubricating oil for lubricating of different parts of the engine. Mechanical cycles of internal combustion engine can be completed in two ways-

1) When the cycle is completed in two regulation of the crankshaft it is called four stroke cycle engine.

2) When the cycle is completed in one regulation of the crankshaft it is called two stroke cycle engine. Engine Function: To provide power for functioning of all the aggregates of tractor.


FIG.8 DIRECT INJECTION & INDIRECT INJECTION

Advantages of DI Engine:

• Burning is more uniform


Indirect Injection Direct Injection

Compression Ignition Spark Ignition

Classification of Engines

Engine External Combustion (2)

Combustion ) Internal (1

Direct Injection

Indirect Injection

• Power developed is high

• Efficiency is high

• Low smoke value

FOUR STROKE CYCLE ENGINE

FIG. 9 FOUR STROKE CYCLE In four stroke cycle engine, all the events taking place inside the engine cylinder are completed in four stroke of the piston. This engine has got valves for controlling the inlet of charges and outlet of exhaust gases. The opening and closing of the valves is controlled by cams, fitted on the crankshaft. The camshaft is driven by crankshaft with the help of suitable gears and chains. The camshaft at half the speed of the crankshaft. The events taking place in the IC engine are as follows:

1) Air or air-fuel mixture (charge) is taken in the cylinder.

2) The charge is compressed in the cylinder by the piston.

3) If charge is only air, the fuel is injected at the end of compression.

4) The charge is ignited at predetermined time under specified pressure inside engine cylinder

5) The power developed due to expansive forces of gases inside the cylinder is transferred to crankshaft through the connecting rod.

6) Exhaust gases go out of the cylinder at regular interval of time.

The complete cycle covers all these events in systematic manner. The four stroke of piston are; 1) Suction Stroke


2) Compression Stroke

3) Power Stroke

4) Exhaust Stroke

1)Suction Stroke- During suction stroke, only air are mixture of air & fuel are drawn inside the cylinder. The charge enters the engine through the inlet valve which remains open during admission of the charge. The exhaust valve remains close during this stroke. The pressure in the engine cylinder is less then atmospheric pressure during this stroke.

2)Compression stroke- The charge taken in the cylinder is compressed by the piston during this stroke. The entire charge of the cylinder is compressed to a small volume contained in the clearance volume of the cylinder. If only air is compressed in the cylinder (as in case of diesel engine), the fuel is ignited at the end compression stroke. The ignition takes place due to high pressure and temperature. After ignition tremendous amount of heat is generated causing very high pressure which pushes the piston backward for useful work. Both valves are closed during this stroke.

3)Power Stroke- During power stroke, the high pressure developed due to combustion of fuel causes the piston to be forced forward or backward at regular intervals. The connecting rods with the help of crankshaft transmit the power to the transmission system for useful work. Both valves are closed during this stroke.

4)Exhaust Stroke- Exhaust gases go out through exhaust valves during this stroke .All the burnt gases go out of engine and the cylinder becomes ready to receive fresh charge. The inlet valve is closed and exhaust valves remains open.

Thus it is found that out of four stroke, there is only one power stroke three idle strokes. The power stroke supplies necessary momentum for useful work.

TWO STROKE CYCLE ENGINE-

In such engine, the whole sequence of events i.e. suction, compression, power & exhaust are completed in two strokes of the piston and one complete revolution of the crankshaft. There is no valve in this type of engine. Gas movement takes place through holes called ports in the cylinder. The crankcase of the engine is gas tight in which crankshaft rotates.

1) First stroke (Suction + compression) – When the piston moves up the cylinder it covers to of ports, the exhaust port and the transfer port which are normally almost opposite to each other. This traps a charge of fresh mixture in the cylinder and further upward movement of the piston compresses this charge. Further movement of piston also uncovers a third port in the cylinder suction port .More fresh mixture is drawn through this port into the crankcase. Just before the end of this stroke the mixture in the cylinder is ignited as in the four stroke cycle.

2)Second Stroke (Power + Exhaust) - The rise in pressure in the cylinder cause by the burning gases forces the piston to move down the cylinder. When the piston goes down it covers and closes the suction port, trapping the mixture drawn into the crankcase during previous stroke then compressing it. Further downward movement of the piston uncovers first the exhaust port


and then transfer port. This allows the burnt gases to flow of through exhaust port and also fresh mixture under pressure in the crankcase is transferred into the cylinder When the piston at the top of its stroke, it is said to be at the top dead centre(TDC).When the piston is at the bottom of its stroke, it is said to be at its bottom dead centre(BDC).

SCAVENGING- The process of removal of burnt or exhaust gases from the engine cylinder is known as scavenging.

Diesel Engine (Compression Ignition Engine)-

Special Features-

1) Engine has high compression ratio ranging from 14:1 to 22:1

2) During compression stroke the engine attains high pressure ranging from 30 to 45

kg/cm2 and high temperature of about 500°c.

3) At the end of compression stroke, fuel is ignited into the cylinder through injectors

(atomisers) at a very high pressure ranging from 120 to 200 kg/cm2 .

4) Ignition takes place due to heat of compression only.

5) There is no external spark in diesel engine.

6) Diesel engine has better slogging or lugging ability i.e. its maintains high torque for a longer duration of time at a lower speed. Engine Components –

Internal combustion engine consist of a no of parts which are given below:

1) Cylinder – it is a part of engine which confines the expanding gases and forms the combustion space. It is basis part of engine. Cylinder is usually made of high grade cast iron.

2) Cylinder Block – it is a solid casting which include the cylinder and water jackets (cooling fins in the air cooled engines).

3) Cylinder Head – it is a detachable portion of an engine which covers the engine and includes the combustion chamber, spark plugs and valves. 4) cylinder Liner Or Sleeves- it is a cylindrical lining either wet or dry which is inserted in the cylinder block in which the piston slides. Cylinder liners are fitted in the cylinder bore and they are easily replaceable. Liners are classified as:

i) Dry liners makes metal to metal contacts with cylinder block casting.

ii) Wet liners come in contacts with the cooling water.


5) Piston- it is cylindrical part closed at one end which maintains a close sliding fit in the engine cylinder. It is connected to connecting rod by a piston. Cast iron is used for making piston.

Head (crown) of piston – it is the top of piston.

Skirt- it is that portion of the piston below the piston pin which is designed to absorb the side movements of piston.

6) Piston Ring – it is a split expansion ring, placed in the groove of the piston. Piston ring is fitted in the grooves, made in the piston. They are usually made of cast iron or pressed steel alloy. The functions of the ring are as follows:

i) It forms a gas tight combustion chamber for all position of piston. ii) It reduces contact area between cylinder wall & piston wall for preventing friction losses and excessive wear.

iii) It controls the cylinder lubrication. iv) It transmits the heat away from the piston to the

cylinder walls. Piston rings are of two types:

a) Compression Ring or Piston Ring

b) Oil Ring (Oil scraper ring)

7) Piston Pins- it is also called as wrist pins or gudgeon pin. Piston pin is used to join the connecting rod to the piston. It is usually made of case hardened alloy steel. 8) Connecting Rod – It is a special type of rod, one end of which is attached to the piston and the other end to the crankshaft .It transmits the power of combustion to the crankshaft and makes it rotate continuously. It is usually made of drop forged steel.

9) Crankshaft- it is the main shaft of an engine which converts reciprocating motion of the piston into rotary motion of flywheel. Crankshaft is made of drop forged steel or cast steel. The space that support the crankshaft in the cylinder block is called main journal, whereas the part to which connecting rod is attached is known as crank journal.

10) Fly wheel - It is made of cast iron. Its main function is as follows:

(a) Its stores energy during power stroke & returns back the same energy during the idle strokes.

(b) It also carries ring gear that meshes with the pinion of the starting motor.

(c) The rear surface of the flywheel serves as one of the pressure surfaces for the clutch plate.

(d) Engine timing marks are usually stamped on the flywheel, which helps in adjusting the timing of the engine.


11) Crankcase- It is that part of engine which support and encloses the crankshaft & camshaft. It provides reservoir for the lubricating oil of the engine. It also serves as a mounting unit for such accessories as the oil pump, oil filter, generator, starting motor, ignition components.

12) Camshaft- it is a shaft which raises and lowers the inlet and exhaust valve at proper time .Camshaft is driven by crankshaft by means of gears ,chains or sprockets. The speed of camshaft is exactly half the speed of crankshaft in four stroke engine. Timing Gear- It is a common the end of the combination of gears, one gears of which is mounted at one end of the camshaft and the other gear on the end of the crankshaft .Camshaft gear is bigger in side than that of crankshaft gear and it has twice as many teeth as that of crankshaft gear. Timing gear controls the timing of ignition, timing of opening and closing of valves as well as fuel injection timing.

13) Inlet manifold- It is that part of engine through which air or air- fuel mixture enters into the engine cylinder.

14) Exhaust manifold- It is that part of engine through which exhaust gases go out of engine cylinder. It is capable of withstanding high temperature of burnt gases.

15) Valve- It is a small mechanical device used for opening & closing the passage leading to the engine cylinder. Main parts are below:

Valve Head, Valve stem, Valve seat, Valve stem guide

16) Tappet- Tappet is also called as valve lifter. Tappet raises or lowers the valves.

17) Rocker arm- It is an arm used to change upward motion of push rod to downward motion for opening an engine valve.

Basics system in An Engine :

1. Air Intake System

2. Exhaust System

3. Cooling System

4. Lubrication System

5. Fuel Injection System

1.) Air Intake System - Function: - To provides clean & requisite quantity of air to engine for better combustion. Types: -

1. Naturally aspirated.


2. Force Feed Intake System (Turbo charging 2.) Cooling System - Objective: - To maintain optimum working temperature of engine i.e. 80 to 90°c.

Type: - The type of cooling system used in ITL engine is pressurized cooling system.

Main components

1) Radiator 2.) Temperature Sensor. 3.) Fan. 4.) Thermostat. 5.) Water Pump. 6.) Coolant

Fig. 10 Radiator

The rubber seal helps in maintaining the correct pressure in the radiator & does not allow the steam to escape.Never peel off the rubber seal or run the engine without cap, it is dangerous for the engine.


Thermostat: - It helps to achieve quickly the working temperature of the engine

Coolant is a mixture of water & antiscaling/ anti-rusting agent .

Pressure Valve

A vacuum valve is provided to allow the fresh air into the radiator to avoid collapsing of radiator during condensation at night, after day’s work.

Lubrication System

Objective: - The main functions of lubrication system are: -

• Oil lubricates moving parts to minimize wear. Clearance b/w moving parts are filled with oil. The parts move on layers of oil to help prevent excessive wear of the parts.

• Parts moving on layers of oil require a minimum power to make them move. The oil minimizes power losses in the engine.

• As the oil moves, it picks up heat. Then the hot oil drops down into the cooler oil pan, the oil gives up some of this heat, thus serving as a cooling agent.

• Clearances b/w bearings & rotating journals are filled with oil. When heavy loads are imposed on the bearings, the oil helps to cushion the loads.

• Oil helps to form a gastight seal between piston rings & cylinder walls, thus sealing the compression pressure.


Fig. 11 lubricating system

• Oil acts as a cleaning agent. As it circulates through the engine, the oil picks up particles of metal & carbon & carries them back down into the oil pan.

FIG. 12 VACUUM VALVE

Fuel Supply System

Objective: It supplies duly filtered fuel to FIP, which in turn pressurizes the fuel and send into cylinders as per firing order & supplies fuel after filtration to different cylinder at specific pressure as per firing order.


FIG.13 ENGINE Main Components

1. Fuel Tank Assy.

2. Water Separator

3. Feed Pump

4. Primary Filter (Cloth element)

5. Secondary Filter (Paper element)

6. Fuel Injection Pump 7. Injectors.

Water Separator: - It functions on the principle of gravity & separates water (which accumulates in Diesel tank due to condensation) from fuel.

Water separator enhances the life of FIP.


Water Separator is available as standard fitment on the entire range of ITL tractors.

Fuel Injection Pump: - Generally two types of FIP Inline or Rotary are used in tractor.

ITL tractor uses Inline FIP manufactured by MICO on account of Simplicity in Design, Low initial Cost, Ease of maintenance & calibration.

FIG. 14 FIP

Injectors: - P - types injectors are used in ITL engines, which inject the fuel at around 250 bars of pressure, atomize the fuel & makes homogenous mixture to get maximum thermal efficiency.


Turbocharger Working

• The turbocharger uses the exhaust flow from the engine to drive a turbine, which in turn drives an air compressor.

• The turbine in the turbocharger spins at speeds of up to 100,000 rotations per minute (rpm) - that's about 40 times faster than engines rpm of 2400.

Adding extra air means extra fuel can be injected into the engine, and thus achieve better combustion.

• Increased engine power output (in the region of 50% increase).

• Improved fuel combustion (improved pressure balance across the engine).

• Improved emissions.

• Consequentially better fuel economy & higher horsepower Altitude compensation. Improved pick up

Precautions:

(1) If turbo charged engine is used after long time, add lubricating oil. (2) Do not stop engine all of sudden. First bring the RPM to idle RPM and run for 30 seconds, then stop

FIG. 15 TURBO CHARGER


Engine HP / Torque

Horsepower: - The rate of doing work. It is responsible for moving the vehicle under normal conditions.

Torque: - It is that force which helps the vehicle start moving. It also provides power when you are hauling items or towing something.

Horsepower is a measurement of the engine's ability to perform work. One SAE horse power (Mechanical horsepower) is the ability to lift 33,000 lbs one foot in one minute. One DIN horse power (Metric horsepower )is the ability to lift 450000 kg one cm in one minute. For the same power the SAE measurement is thus 98.629% of the metric DIN measurement. Torque back up: - It gives an indication of how much the engine torque increases to maximum i.e. it is the ratio of maximum torque over the torque at maximum power.

Hence it is the ability of the machine to keep working as the engine speed pulls down due to increased load requirements over & above the maximum power.

PTO HP: - It is the power available at the PTO shaft. Draw Bar HP: -

It is the power available at Draw bar. RPMs (Revolution per Minute):-

Idle Rpm : No Load + No Accelerator Maximum Rpm : No Load + Full Accelerator Rated Rpm** : Full Load + Full Accelerator Maximum Torque

Rpm : Maximum Load + Full Accelerator Rated RPM - It is the RPM at which the engine produces maximum power Turning Radius : - The tightest turn a vehicle can make is known as turning radius. Factors that determines the turning radius of a vehicle

• Wheel base


• Wheel track

• Axle ( Straight or Bend )

• The steering gear box

Turning radius of DI 730 III is 2.37m with brakes & 3.06m without brakes. Bore: - The internal diameter of liner, usually measured in mm.

Stroke length: - The distance travelled by piston from TDC to BDC

Cubic Capacity: - volume of gasses swept by piston during one stroke.

C.C = π/4 X D² X L

Where, The value of (π) is 3.14 or 22/7 D is bore size in cm.

And L is length of stroke in cm.

Specific Fuel Consumption: -It is the amount of fuel consumed in grams to produce 1 HP per hour. It is measured in gm/bhp/hr.

• – If SFC of a Tractor is 179 gm/bhp/hr, it means it consumes 179 grams of oil to produce 1 Hp for 1 hour.

POWER TRANSMISSION SYSTEM OF TRACTOR Transmission is a speed reducing mechanism, equipped with several gears. It may be called sequence of gear and shaft through which engine power is transmitted to tractor wheels. The system consists of various devices that cause forward and backward movement of tractors to suit different field condition. The complete path of power from engine to wheel is called power train.

Functions of power transmission system

• To transmit power from engine to rear wheel. • To make reduce speed available to rear wheel of tractor. • To alter ratio of wheel speed and engine speed in order to suit field condition. • To transmit power through right angle drive, because the crank shaft and rear axle are normally at right angle to each other. Power transmission system consist of -

• Clutch • Transmission gear • Differential • Final drive • Rear axle and rear wheel It consists of Clutch, Gearbox & Differential Transmission

serves the following functions: -


• Clutch – Engages or disengages transmission from engine.

• Gear Box - Provides different torque & speed combinations.

- Provides reverse & forward motion.

• Differential - Differentiates power equally between both wheels. o Provides speed variations between wheels while negotiating turns


Engine

Hydraulics

PTO

Flywheel

Clutch

Transmission

SAVERA GROUP OF INSTITUIONS Page 27

POWER TRAIN

Clutch

Types of Clutch:

1. Single

2. Dual

3. Double

Single Clutch: - In Single clutch tractor - both transmission as well as PTO are engaged and disengaged simultaneously.

Advantages: - Low initial cost & less expensive to maintain. Single clutch is useful for

Trailers and trailed implements /

Dual Clutch: - Two clutch discs each for PTO & transmission are used enabling operator to start & stop the transmission without affecting the PTO operation.

Advantages: - Simple design, operator friendly, Safety.

Dual clutch is highly beneficial on PTO operated implements and is available as a standard/optional feature on all ITL tractors excluding 30 HP.

Double Clutch: Separate clutch levers are provided for PTO & transmission.

Advantage: - Ease of operation, Maximum Flexibility. It is available only in

higher hp range tractors.


FIG. 16 POWER TRANSMISSION SYSTEM

Drawbar

Types of Clutch Plates

Clutch Size and lining material (organic & Cerametallic) varies according to the applications throughout the entire range of ITL tractors.

In ITL tractors Clutch Size vary from 254mm to 310mm.


FIG.17Organic Clutch Plate

Cerametallic clutch has high co-efficient of friction, which allows high torque transmission with minimum losses. It is little bit expensive but have more life than organic clutch plate

FIG. 18 Cerametallic clutch

Gears

A tractor engine runs on at high speed but the rear wheel of tractors requires power at low speed and high torque. That’s why it become essential to reduce the engine speed and increase torque available at rear wheel of tractors because

2πnTPower, =

60×1000 Where, T=torque in Nm,

n=speed in rpm.

Principle of gearing

Any combination of gears by means of which motion is transmitted from one shaft to another shaft , is called gear train.

Speed of driving gear(Na) No.of teeth on driven gear(Tb)

Speed of driven gear(Nb) = No.of teeth on driving gear(Ta) Types of gear box

There are three types of gear boxes available on tractor

• Sliding mesh gear box

• Constant mesh gear box

• Synchromesh gear box 1) Sliding mesh gear box Most of the indigenous tractors are fitted with is sliding mesh or sliding cum constant mesh type gear box. The housing of cast iron. It is rigid in construction and serves the purpose of the tractor frame.

Usually, the main and counter shaft is parallel to clutch shaft, but there are certain cases where the shaft are transverse. The gear on lay shaft is fixed, where as those on the main


shaft slide to mesh with a suitable gear on the counter shaft.

In this type, lay shaft gears are fixed & movement is provided in main shaft gears during shifting.

1) Constant mesh gear box

The constant mesh transmission has parallel shaft one over the other with gears in constant mesh. The gears on the main shaft are mounted on bushing and are free to rotate along with the counter shaft gear without affecting the main shaft when in neutral.

In this type, lay shaft gears are always meshed with main shaft gears, which are free to rotate on main shaft. Hub sleeves are fixed on main shaft & during gear shifting, shifter sleeve moves toward respective gear for engagement & transfer the same to lay shaft gear.

FIG.19 CONSTANT MESH GEAR BOX

Advantages:

Ease of gear shifting, reduces noise, wear/breakage & leads to better life.

Standard Feature in Rx & DI Series (above 34 Hp Series Tractors)


Advantages:

Bit noisy operation but Consistent performance.

2) Synchromesh gear box

The synchromesh transmission is basically a constant mesh transmission with an extra device called a synchronizer to equalize the speed of the meeting parts before they engage.

The system is very common in automobiles and is very rarely used on tractor transmission.

Different part of the synchronizing unit is used in the tractors. The hub is splined to the and synchronizer sleeve is mounted on the hub. To lock rings hold the shifter plates out against the sleeve. Each bronze- blocking ring has three slots into which the ends of the shifter plates fits. The inner surface of the blocking rings are cone shaped and match the conical shape of the driven gear shoulders which they constant. These cone-shaped surfaces provides the frictional force to synchronize the speed of the main shaft and gear.

It is similar to constant mesh gearbox except synchronizing cones that are provided on its hub sleeves for equalizing the speed of gears.

FIG.20 SYNCHROMESH GEAR BOX

Advantages:

Excellent noiseless performance with ease of gear shifting but a bit expensive

Only in Worldtrac Series.


Differential When wheels are driven positively by the engine, a device is necessary which can make the wheels move at different speeds on turns, whereas the of both the wheels should remain equal when the tractor is following a straight road.

Principle of operation: The gear train used in a differential is an epicyclic gear train in which the axis of rotation of some the gears are not fixed and it is difficult to visualize exactly what happens when motion takes place.

FIG.21 DIFFERENTIAL

The principle is explained below: 1) consider two large bevel gears G1 and G2 mounted on two shaft S1and S2 respectively meshing

with the small pinion P attached to a shaft A which is fixed in casing C. when casing C is rotate about its axis x y, the result is as if shaft A is being pulled forward. Pinion P does not revolve on its axis, but acts as a key between gears G1 and G2 making them rotate on their own axis. Thus shaft S1 and S2 rotate in the same magnitude and in the same direction I in which casing C is being rotated.

2) Now consider that shaft S2 is being held stationary so that its gear G2 cannot rotate while casing C is still rotating in the same direction. As G2 is stationary the pinion P will roll over gear G2. The


reason for faster speed of gear G1 is that while it is rotating on its axis due to the speed of casing C in the same direction, an additional speed has been added due to the relative motion between pinion P and gear G1.

3) Now suppose , shaft S2 is neither held stationary nor it is being relieved , but is allow to sleep slightly so that it moves in the same direction in which casing is rotating. Now pinion P will roll over gear G2 at slower speed. Hence shaft S1 will rotate accordingly lower than the second case because of the speed of casing C plus the relative speed between pinion and bevel gear G1. However, the algebraic sun of the speed of shafts S1 and S2 will remain the same as in case 1&2.

Differential lock:

Whenever one wheel offers less resistance, it turns faster causing a loss of traction. If one wheel gets in the mud or loose soil, the wheel on the solid ground will not be driven while the other spins around due to the differential action. To overcome this problem, all tractors are provided with a locking system known as differential lock.

Brakes

It helps to decrease the speed or to stop the tractor as per operator desire. Three types of Brakes

1. Shoe Brakes ( Still used in TAFE Tractors )

1. Disc Brakes ( Standard fitment in Sonalika Tractors)

2. Oil Immersed Brakes (Available in Higher HP Tractors in Sonalika.


FIG.22 DRY DISC BRAKE FIG.23 DRYDISC BRAKE LINING

OIB (Oil Immersed Brakes) Disc, brake lining & brake plates are immersed in gear oil. The brakes have excellent stopping power & reduce braking effort. Advantages: - Improve liner life, remove excess heat generation by friction, have longer period for adjustments & service.


Final drive is gear reduction unit in power trains between the differential and the drive wheels. Final drive transmits the power finally to the rear axle and the wheels. The tractors rear wheels are not directly attatched to the half shafts, but the drive is taken through the pair of spur gear. Each half shaft terminates in a small gear which meshes with a large gear called bull gear. The bull gear is mounted on the shaft, carrying the tractors rear wheel. The device for final speed reduction, suitable for tractors rear wheels is known as final drive mechanism.

Epicyclical reduction being used in Worldtrac series.

SAVERA GROUP OF INSTITUTIONS MOHAMMAD IRFAN HAJAM

Brake liner & disc plates for OIB

Final drive

Here 3 gears instead of 1 take the total axle load. It is designed to minimize stress & strain on the transmission & differential in order to provide long service life.

PTO ( Power Take off )

Power take off shaft is used to give power for external use from tractors. Live PTO: - A continuously operating system in which the forward motion may be stopped without stopping the rotation of the PTO shaft. This allows for changing the forward speed with the PTO still in motion.

Standard operating speed (540/1000) is achieved at around 1680 ERPM.

Applications:

• Rotavator.

• Combine Harvester.

• Thresher.

• Genset.

• Compressor.

• Water pump.

• Post Hole Digger.

Ground PTO: - Here the PTO speed is governed by the ground speed of the tractor. Applications:

• Grass mowers

• Seed Drills

• Baler

• Sprayers


• Planters PTO standards:

• 6 Spline – 540 RPM

• 21 Spline – 1000RPM TRACTOR HYDRAULIC SYSTEM

• It is a mechanism in a tractor to raise, hold or lower the mounted or semi-mounted equipment by hydraulic means.

• A system where fluid is used as a media to transfer power is calledhydraulic system.

• Hydraulic system with reference to tractor is considered to be a unit responsible for raising, holding & lowering the implement.

• Hydraulic system consists of following components:

• Hydraulic Pump

• Rear Cover Assembly

• Rear Cover

• Control Valve

• Response Valve

• Hydraulic Cylinder

• Rock Shaft Assembly

• Control Sector Assembly.

• Hydraulic Filter Cover assembly. Directional Control valve Assembly

• Three Point Linkage Assembly.


Operations

• The hydraulic pump draws up oil pump the oil reservoir and sent it to the control vale, the oil goes to the hydraulic cylinder to operate piston, which ‘in turn, rise the lifting arms. The hydraulic pump is operated by suitable gears connected with engine.

• Hydraulic system used on Mahindra Tractors is known as fully live hydraulic system or very tough system. The hydraulic pump is directly driven by timing gear because of which hydraulic control system.

• Position control: • In this system, constant depth of ploughing is maintained by automatic

adjustment of draft of tractor. In this system the control valve can be directly operated by driver to raise lower hold and implement, mounted at the linkage at any chosen height.

• Following Implement are used in position control:

• Rotavator

• Mounted Disc Harrow

• Seed Drill

• Reapers • Movers etc.

• Draft control: • In this system, the working depth of any implement can be controlled

contiguously without need for a depth wheel on the implement. If any implement goes too deep its draft increases. The control system then raises the implement until the draft is back to the present level and the implement is at the original depth again using the draft control system.

Following Implement are used in position control:

• Cultivator

• Plough

• Reversible Plough etc.


demand.

1) Mixed control:

• It is a combination of position control and draft control. After lunch break we went for driving in the field.

• Simultaneous use of position control and Draft control lever is called mix control. If the ground is not uniform and has soft

Areas where the implement can sink too deep Then mix control is performed because in the Situation draft control does not function properly.

FIG. 24 LEVER PERIODIC MAINTENANCE & WHEEL TRACK ADJUSTEMENT

a) Every day 8 Hrs. Servicing

1. Clean the tractor

2. Tighten all the nuts and bolts.

3. Grease all the points indicated in the service manual.


4. Check engine oil level

5. Clean recommended oil, if necessary.

6. Check transmission oil level and clean recommended oil, if necessary

7. Check water level in the radiator, add water if necessary

8. Check and keep recommended tire pressure

9. Check the top to the fuel tank after days has over

10. Change air cleaner oil and clean the blow if dirty.

b) Change air cleaner oil and clean the blow if dirty.

1. Carry out 8 hourly servicing.

2. Check water level in battery.

3. Clean air cleaner thoroughly.

4. Clean battery terminals and apply petroleum jelly or Vaseline.

5. Remove engine oil filter and clean with diesel.

6. Check V-belt tension, if belt deflection is more than 12 mm, adjust it.

7. Drain full power.

c) Every 100 Hrs. servicing

1. Carry out 60 hourly serving. 2. Change engine oil

3. Change oil of the pump of fuel injection pump

4. If the tractor is new drain transmission oil and refill it.


5. Remove carbon from exhaust silencer d) Every 2 month or 350 hrs. Servicing.

1. Carry out 100 hourly servicing

2. Clean fuel tank and fuel cork wire mesh filter. Also clean wire mesh filter at the inlet to the fuel lift pump

3. Clean commentator and bearing of the dynamo.

4. Check the clutch paddle fee play, adjust if necessary.

5. Clean suction tube wire mesh after opening the pump.

6. Change pre-filter insert of the fuel system.

7. Check spray of the injectors.

e) Every one year or 1000 Hrs. Servicing

1. Carry out 350 hourly servicing.

2. Decarbonise cylinder head piston.

3. Check valve sheet.

4. Check water pump bearing.

5. Check dynamo and starter bushes.

6. Wash front wheel bearing with diesel, repack with grease.

7. Tappet clearance, adjust if necessary.

8. Change transmission oil clean drain plough.

9. Reset injectors to correct pressure. f) Every two yearly servicing


1. Wash all the lubricating oil pipe and passages.

2. Examine main end connecting rod bearing.

3. Recalibrate fuel injection pump.

MAINTENANCE WHEELTRACK ADJUSTMENT

Objectives:

1. While travelling in hilly area.

2. While inter culturing in field. Track setting

1. Front wheel:

It is adjustable in four inch steps from 48 inch to 80 inch (1219mm to 203mm).

These setting are obtained as follows:

Jack up the tractor and remove to bolts screwing each front axle arm to central and spread axle arm to obtained desired track width. No change in steering axle connection is necessary. Replace bolts leaving at least one bolt between two bolts to give additional support to obtained reversed wheeled discs on 72 tread. Avoid using this wide setting with front end loaded.

2. Rear wheel:

The rear wheel track is adjustable by assembling rings in different positions. At the same time interchanging wheels may be necessary in order to maintain minimum traction. When changing setting 52” to 60” to or from setting 68”, 72”, 76”, interchanging wheels confirm that the wheels are not their correct side by checking that the arrow on the side of the tire pits. In the direction of forward rotation.

STUDY OF TILLAGE IMPLEMENTS

A) Plough

The main implement for primary tillage is plough it is used for ploughing operation. Ploughing operation which is as primary tillage operation, preformed to cut, break and invert the soil partially or completely. Ploughing essentially means opening the upper crust of the soil, breaking the clods and making the soil suitable for sowing seeds. The purpose of Ploughing can be summarized as follows.


1. To obtain a deep seed bed of good texture

2. To increase the water holding capacity of the soil

3. To improve soil aeration

4. To destroy weeds and grasses.

5. To destroy insects and pests

6. To prevent soil erosion

7. To add fertility to the soil by covering it with

TYPES OF PLOUGH

Different types Of Plough are used at different places. They may be classified as

1. Indigenous plough

2. Mould board plough

3. Disc plough Chisel plough

4. Sub soiler

5. Rotary plough

6. Chisel plough Mould board plough

A mould board plough is very common implement used for primary tillage operations. This plough perform several function

Functions

1. Cutting the furrow slice

2. Lifting the soil

3. Turing the furrow slice and


4. Pulverizing the soil

Components

M.B, plough consists of

a) Share b) M.B plough c) Land side d) Land side e) Frog f) Tail piece

Types of share -

Share is of different type such as

1. Slip share

2. Slip nose share

3. Shin share

4. Bar point share

Mouldboard: It is the curved part which lifts and turn the furrow slice

Land side: It is the flat plate which is bear against and transmit the rear side lateral thrust of the plough bottom to the furrow wall.

Frog: it is the part to which other components of the plough bottom are attached.

Tail piece: It is adjustable extension which can be fastened to the rear of a mould board to help in trying.

Plough Accessories

There are few accessories necessary for plough such as

1. Jointer 2. Counter 3. Gauge wheel 4. Land wheel and 5. Furrow wheel

Adjustment of mouldboard Plough

1. Vertical suction: It is maximum clearance under the land side and the horizontal surface when the plough is resting on horizontal surface in the working position. It helps the plough penetrate in to soil to a proper depth.

2. Horizontal suction: It is the maximum clearance between the land side and a horizontal plane touching point of share at its gunnels side and heel of land side. It helps the plough to cut the proper width of furrow slice. It is also known as side clearance.


3. Vertical clevis: It is a vertical plate with a number of holes, at the end of the beam to control the depth of operation.

4. Horizontal clevis: it is a device to make lateral adjustment of this plough related to line of pull.

B) HARROW

A harrow is an implement that cuts the soil to a shallow depth for smoothening and pulverizing, the soil as to cut weds and to mix materials with soil. It is an Implement used to break the clods after Ploughing, to collect trash from the ploughed land and to level the seed bed

HARROWING

It is a secondary tillage operation which pulverizes, smoothens and packs the soil in seeded preparation and or control weeds.

1) Disk harrow 2) Spraying tooth harrow 3) Pike tooth harrow 4) Blade harrow 5) Guntaka 6) Triangular harrow 7) Bodela 8) Zig-zag harrow 9) Bindha 10) Patella harrow 11) Acme harrow 12) Reciprocating power harrow.

Disk harrow

It is harrow which perform harrowing operation by means of a set

Rotating steel disc. Each set being mounted on a common shaft. Dish harrow are of two types depending upon the sources of power.

A) Tractor drawn

B) Animal drawn

A) Tractor drawn disc harrow

Depending upon disc arrangement disc harrow are divided into two classes,

a) Single acting disc harrow

b) Double action disc harrow


Component of disc harrow:

A disc harrow mainly consist of 1)Disc 2)gang frame 3)Beam 4)gang angle mechanism 5)scrapper 6)spacer axle 7)middle tyne 8)baring 9)spacer 10)clevis Disc harrow is used for breaking clods while preparing seed beds. The disc mainly consist of 1)Disc 2)Gang frame 3)Beam 4)Gang angle mechanism 5)Scrapper 6)Baring 7)Spacer 8)Clevis

B) Cultivator:

It is an implement for Inter Cultivation with laterally adjustable tines or disc to work between crop rows. This can be used for seed bed preparation and for sowing with seeding attachment. The lines may have provision for vertical adjustments also. The cultivator can be

i) Disc Cultivator ii) Rotary Cultivator iii) Tine Cultivator

i) Disc Cultivator:-It is a cultivator fitted with discs ii)

Rotary Cultivator:-It is a cultivator with lines.

iii) Tine Cultivator: - It is a cultivator fitted with lines having shovels. The cultivator shovels. The cultivator stirs the soil, and breaks the clods.

The following are a few important functions performed by a cultivator.

I. Intercultural the field.

II. Destroy the weeds fields.

III. Aerate the soil for proper growth of crops.

Classification of Cultivator:-

i) Tractor drawn ii) Animal drawn

i) Tractor drawn cultivator

It may be i) Trailed ii) Mounted

Trailed Type Cultivator:- It is consists of a main frame which carries a number of cross members of which lines

are fitted. On the front side of the cultivator, there is hitch arrangement for hitching purpose.

Mounted Cultivator

Tractors fitted which hydraulic lift an operate the mounted type cultivators. A rectangular frame of angle iron is mounted on three point hydraulic linkage of the tractor. The cross members carry the lines in two staggered lines.


Usually tractor drawn cultivators are of two types

i) Cultivator with spring loaded tines. ii) Cultivator with rigid tines.

iii) Cultivator with spring loaded tines:-

A tine hinged to the frame and loaded with a spring so that it swings back when an obstacle is encrusted is called spring loaded tine.

ii) Cultivator with rigid tines:-

Rigid tine of the cultivators are these lines which do not deflate during the work in the field.

References 1) Farm Tractor Maintenance & Repair by- S. C. Jain & C. R. Rai

2) Elements of Agricultural Engineering by- Dr. Jagdishwar Sahay

3) www.google.com for much of the information and linked sites.

4) www.sonalika.com for the company profile.

5) I.T.L. for giving handouts to write the report.

6) www.wikipedia.com for the photos and other useful information.


Irfan training report 2

Engineering

Transcript of Irfan training report 2