DESIGN AND ANALYSIS OF FIXTURE IN HORN ASSEMBLY

PROJECT GUIDE:Mr.K.L.SENTHIL KUMARASSISTANT PROFESSOR(Sr.G)

TEAM MEMBERS: JAYAVIGNESH.J.T (1104027) S.KARTHIC (1104033) N.MURALI (1104047)

INDUSTRIAL GUIDE: Mr .V.SUDHAKARDESIGINATION: ASSOCIATE-PRODUCTION

Roots Industries India Ltd. is a leading manufacturer of HORNS in India and the 11 th largest Horn Manufacturing Company in the world.

Headquarter is at Coimbatore - India, ROOTS has been dominant player in the manufacture of Horns and other products like Castings and Industrial Cleaning Machines.

Since its establishment in 1970 ROOTS has had a vision and commitment to produce and deliver quality products adhering to International Standards.

COMPANY PROFILE

REDUCTION OF OPERATOR INCREASE THE PRODUCTIVITY TIME REDUCTION SKILLED OPERATOR IS NOT NECESSARY SEMI AUTOMATIC OPERATION INTERCHABILITY COST REDUCTION

OBJECTIVE

Two operators are required to operate the two fixtures which involves the assembly of the diaphragm and for measurement of the height of the armature rod

This causes a time delay in the manufacturing because process is done manually .

Combining both the process will increase the efficiency and reduce the work load.

Only skilled operator can operate .

PROBLEM DEFINITION

On account of the time, it takes some extra ideal time such as component movement from one station to another station , loading, unloading.

Since the operation is performed manually ,the labour spend much time to correct the height with the help of dial gauge and screw driver.

These extra time can be eliminated by the proposed methodology.

NEED FOR TIME STUDY

OPREATIONS NO OF OPERATORS

AVERAGE TIME (sec )

DELAY TIME(sec)

SPOOL ASSEMBLY LOCKING , POINT AND TUNING SCREW ASSEMBLY

1 15.16 -

TERMINAL BASE ASSEMBLY TIGHTENING

1 14.53 15

DIAHRAGM ASSEMBLY TIGHTENING 2 20.54 10

HEIGHT MEASURING 1 16.37 23

GASKET ASSEMBLY,PRE CRIMPING AND FINAL CRIMPING

1 23.4 15

AIR GAP MEASURING AND ADJUSTING

1 14.81 9

PRE TUNING AND MOUNTING BRACKET ASSEMBLY

1 15.56 10

HORN TUNING AND TESTING 1 17.83 12

Spool Assembly locking, point holder & Tuning screw Assembly 

Terminal Base Assembly Tightening 

Diaphragm Assembly Tightening

  Gasket Selection & Pre Horn Assembly 

ASSEMBLY LINE

Height measuring

Diaphragm assembly tightening di

EXISITING METHODOLOGYDiaphragm assembly fixture

Height measuring fixture

In the existing methodology , the operator assembles the parts of the diaphragm and then tights the parts with a normal pneumatic gun which doesn’t have accuracy of the height .

The assembly then moves through the conveyor and the next operator manually measures the height of the diaphragm with the help of a manual screw driver with reference to a screw driver .

Existing methodology

Instead of tightening the Diaphragm using an ordinary pneumatic tighter a pneumatic gun with a pre fixed torque is used in order to obtain the required height in the diaphragm of the horn

METHODOLOGHY

When the height is fixed as per the requirement (13.5mm ) it is then placed in the newly designed fixture which consists of a sensor which measures the height of the diaphragm .

The frequency of the horn depends upon on the height which is present in the diaphragm When the height varies the horn sound and efficiency varies .

Torque applied (N/m2 ) Height obtained (mm )

0.5 20.7

0.75 19.8

1 18.6

1.5 17.3

2 15.9

2.25 14.3

2.5 13.6

2.75 12.5

Pneumatic gun torque measurements

LVDT(LINEAR VARIABLE DIFFERENTIAL TRANSDUCER )

• Dial gauge is replaced by a linear variable differential transducer

• LVDT is used to measure the distance between the diaphragm and the armature rod end .

• It give accurate measurement than the dial gauge used before.

FIXTURE DESIGN DIAPHRAGM ASSEMBLY FIXTURE

HEIGHT MEASURING FIXTURE

Diaphragm assembly and height measuring fixture

ANALYSIS

STRAIN

The normal elastic strain is very minimum and deformation rate is also very low when a 500 N pressure applied to the material .

Total deformation

The total deformation obtained for the pressure of 5 bar is very negligible . thus it is very efficient compared to other materials being used .

Redesigning of horn assembly line using ECRS priniples . Authors –Sindhuja.D , Mohandas Gandhi.N , Madhumathi.P

Optimization of assembly line based on work study “Industrial Engineering and engineering management .-Authors – Shauang Lan , Xue Wang

References

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