DR B R AMBEDKAR NATIONAL INSTITUTE OF

TECHNOLOGY, JALANDHAR

INDUSTRIAL TRAINING REPORT ON

MONITORING OF NUMBER OF WELDING SPOTS
AND
ENHANCEMENT OF SAFETY MEASURES ON
AUTOMATED WORK STATIONS

SUBMITTED BY
Anuj Saini
Roll No -15112046
UNDER THE GUIDANCE OF
Mr Mukund Omar
Deputy Manager (WS 1)
1
 CERTIFICATE

This is to certify that this project titled “1. MONITORING OF

NUMBER OF WELDING SPOTS IN OMNI AND EECO
LINES, 2. ENHANCEMENT OF SAFETY MEASURES ON
AUTOMATED WORK STATIONS” is a bonafide record of the
authentic work carried out by Anuj Saini bearing Roll no.
15112046 at Maruti Suzuki India Limited, Gurgaon during 6
weeks industrial training as a student of B. Tech -ME, Dr B R
Ambedkar National Institute of Technology, Jalandhar Under the
guidance of Mr Mukund Omar during 5th June 2018 to 20th July
2018.
Project Guide

Mr Mukund Omar

Deputy Manager (Weld shop 1)

Signature:

Date:

2
 ACKNOWLEDGEMENT

I take this opportunity to express my sincere thanks and deep gratitude to

all those people who extended their whole hearted co-operation and have
helped me in completing this project successfully.

I would like to thank the Head of Training and Placement Office of NIT
Jalandhar Dr S Ghosh for encouraging students to work hard and apply for
internship at best institutes possible to develop our skill set and apply our
knowledge for the betterment of society.

I extend my deepest gratitude to Mr. Sandeep Chandra, and Mr. Mukund

Omar, my mentors who constantly supported and encouraged me,
throughout the project. I would also like to thank Mr. R P Singh who guided
me in understanding the different types of welding and after processes in
welding shop.

Finally, I would want to thank NIT Jalandhar for providing such a wonderful
opportunity to develop my technical skills. I am also grateful to the
supportive department and all the faculty members who have guided me
through every step of my education.

No words can express my deep sense of gratitude for my beloved family

members and colleagues for their support. It is only because of their
affection and motivation that I am at this step of success, because without
them I could not have accomplished my goals.

3
 ABSTRACT

Industrial training is one of the best methods to make students familiar

with the modern techniques, latest equipment & methods used in various
industries. During industrial training, students visit various companies and
make themselves familiar with the practical aspects of the production
method.

This report focuses on the training which I have undertaken in Weld Shop-1
MSIL, Gurgaon Haryana.

The training has provided an unmatched experience and opportunity to

gain practical knowledge which has increased my level of thinking and
taught me art of dealing with different kinds of people in all walks of life.
The training has improved my theoretical and practical concepts of
automotive technology.

The project aim is to ensure to the same quality in every cycle. Quality of
the product is an important concern for the future of company. On the
other hand, safety of worker is also important to make them confident that
they are safe is this working environment. It directly affects the productivity
and the quality of product. During these project, I learn how to face
different problems and the way to tackle them.

4
 Table of Contents
 INTRODUCTION TO THE COMPANY
o MSIL INTRODUCTION……………………………………………………………………....7
o PLANT JARGONS …………………………………………………………………………….13
o FASCILITIES AT MSIL………………………………………………………………………..15
o QUICK VIEW OF GURGAON PLANT………………………………………………….18
o MARUTI PRODUCTION PROCESS AND VARIOUS SHOPS
 BLANKING LINE……………………………………………………………………….19
 PRESS SHOP………………………………………………………………………..…..20
 WELD SHOP…………………………………………………………………………….22
 PAINT SHOP…………………………………………………………………………....25
 ASSEMBLY SHOP……………………………………………………………..……...26
 VEHICLE INSPECTION………………………………………………….……………27
o WHAT IS WELDING………………………………………………………………………….32
o RESISTENCE WELDING…………………………………………………………………….32
o SPOT WELDING……………………………………………………………………………….35
o FUNCTIONS AND SHAPE OF ELECTRODES……………………………..………..36
o TYPES OF WELDING GUNS AND TIPS……………………………………………....37

 PROJECT 1- MONITORING OF NUMBER OF WELDING SPOTS

o OBJECTIVE………………………………………………………………………………..…….40
o WHY TO CHOOSE THIS PROJECT……………………………………………………..40
o REQUIREMENTS ……………………………………………………………………………..40
o METHODOLOGY USED…………………………………………………………………….40
o RESULTS………………………………………………………………………………………….43
o CONCLUSION………………………………………………………………………………....56
o SUGGESTIONS FOR REDUCTION……………………………………………………..56

5
 PROJECT 2- ENHANCEMENT OF SAFETY MEASURES FOR
AUTOMATED WORK STATIONS
o OBJECTIVE……………………………………………………………………………………...57
o WHY TO CHOOSE THIS PROJECT……………………………………………..………57
o CURRENT MEASURES ……………………………………………………………………..57
o RECOMMENDATIONS………………………………………………………………….….58
 BIDIRECTIONAL PERSON COUNTER…………………………………………….58
 PRESSURE SENSING MAT…………………………………………………………..62
 WARNING SINGAL BEFORE STARTING OF ROBOT………………….…..63
 EMERGENCY STOP SWITCH INSIDE THE ROBOT AREA…………….….64
o CONCLUSION……………………………………………………………………………….…65

6
MARUTI SUZUKI INDIA LIMITED
THE DAWN
Maruti Udyog Limited (MUL) was established in Feb 1981 through an Act
of Parliament, to meet the growing demand of a personal mode of transport
caused by the lack of an efficient public transport system. Although the
Indian Car Industry was established in the late forties, there was little growth
or technical progress, as passenger cars were given very low priority in the
scheme of Centralized Economic Planning. In the 1980s, the car industry
was undergoing technological stagnation and was characterized by low
production volumes, high cost and low productivity. The consumer had very
little choice and market was selling just around 30,000 cars per year.

There was a clear need to provide a cost effective, reliable and quality car to
the customers. MARUTI UDYOG LIMITED was incorporated in such a
scenario as a fully owned Government Company on February 24, 1981 with
a resolve to bring about expansion and technological modernization, of the
automobile sector.

Suzuki Motor Company was chosen from seven prospective partners

worldwide. This was done not only due to their undisputed leadership in
small cars but also to their commitment to actively bring to MUL,
contemporary technology and Japanese management practices (which had
catapulted Japan over USA to the status of the top auto manufacturing
country in the world).

A license and a Joint Venture agreement were signed between Govt. of India
and Suzuki Motor Company (now Suzuki Motor Corporation of Japan) in
Oct 1982 And hence named Maruti Suzuki India limited.

INDIA’S LARGEST AUTO COMPANY

With more than 1 new product launched every year and 4 new products
launched last year, for over 15 years now, Maruti has delivered high quality

Products to Indian customers. More than 21 lakh customers in India are

proud to own and drive Maruti cars. Maruti technology is customized to
Indian road conditions and requirements of Indian customers.
Suzuki is a leader in small car technology and Maruti has access to the very
latest technology. To manufacture a compact aluminum (ACE) engine is
something no car manufacturer in India besides Maruti has been able to do.
7
INDIA’s LARGEST SALES, SERVICE AND SUPPORT NETWORK
Maruti reaches its customers through a sales and distribution network across
more than 470 cities – the largest of its kind. And with over 1200 service
stations – it is true that “Wherever you go you will not be far from a Maruti
Service Station”.

MARUTI VISION & VALUES

COMPANY VISION

“The Leader in the Indian Automobile Industry, Creating Customer

delight and Shareholders wealth; A pride of India”.
The above vision is based on

LEADERSHIP
By Market Share
By Brand Equity
By Operational Practices
By People Strategy

CUSTOMER DELIGHT
Value for Money
Quality
Service

SHARE HOLDERS WEALTH

High Profitability & Image
A corporate citizen
Our products
Our People
Our Practices
Our Customer

8
MODEL’S OFFERED BY MARUTI UDYOG LTD
Maruti has introduced the following models:

S.NO. MODELS SPECIFICATION YEAR OF

LAUNCH

1 797cc, hatchback Dec. ’83

MARUTI 800

2 OMNI 796 cc, MUV Nov. ’84

3 GYPSY 970 cc, 4WD off-road vehicle Dec. ’85

4 MARUTI 800 New Model- 796 cc, hatchback Apr. ’86

5 MARUTI 1000 970 cc, 3 Box car Oct. ’90

6 ZEN 973 cc, hatchback car Oct. ’93

7 ESTEEM 1.3L LX 1298 cc, 3 Box car Nov. ’94

8 GYPSY KING 1298 cc, 4WD off-road vehicle Nov. ’96

9 OMNI (E)) 796 CC, MUV, 8 seater Dec. ’96

10 NEW MARUTI 796, hatchback car (Std &Dx) Sept. ’97

800

11 ESTEEM 98 1298cc,3 box car (LX,VX,AX) Oct. ’97

12 NEW OMNI & 796 cc, MUV Feb. ’98

OMNI-E

13 ZEN VX & ZEN 973 cc, hatchback car Jul. ’98

VX AUTOMATIC

14 ZEN D 1527cc diesel, hatch back car Aug. ’98

15 MARUTI 800 EX 796 cc, hatch back car Jan. ’99

9
16 Zen LX 993 CC, hatch back car Jan. ’99

17 OMNI XL 796 cc, MUV, high roof Oct. ’99

18 BALENO 1600 cc, 3 box car Dec. ’99

19 WAGON R 1061 cc Jan. ’2000

20 ALTO LX 800cc, VX 1061cc Sep. ’2000

21 SWIFT LXI, VXI Sep. ’2005

22 ZEN ESTILO LXI, VXI Feb. ’2007

23 DZire 1200cc,4-door sedan 2008

24 Eeco 1196cc, minivan 2009

25 K10 hatchback 2010

26 Ertiga 1400cc, mini MPV 2012

27 Alto 800 543cc, hatchback 2012

28 Celetio 998cc, 5-door hatchback 2014

29 Ciaz 1600cc,sedan 2014

30 Baleno 1400cc,hatchback 2015

31 S-Cross 2000cc,Mini SUV 2015

32 Vitara Brezza 1300cc,Mini SUV 2016

33 Ignis 1500cc,Hatchback 2017

10
11
 MSIL’S GURGAON PLANT

The manufacturing plant, located about 25-km south of New Delhi in

Gurgaon, has an installed capacity of 5,00,000 units per annum. The total
area of the plant is 12,02,256 m2 with a total covered area of 2,95,293 m2.
The average daily production is around 1500 vehicles a day.
The whole production facility has been divided into 3 plants: -
1. Plant I (EECO, Omni, Supercarry, Gypsy, WagonR)
2. Plant II ( Ignis, S-Cross, Ertiga)
3. Plant III (Vitara Brezza, Alto, Ignis)

The other activities include research & development and utilities (captive
power plant, water and effluent treatment plant, compressor house, boiler
house, air washers and incinerator facilities)

12
 PLANT JARGONS

KAIZEN : IMPROVEMENT

PIKA-PIKA : SYSTEM MSIL USES TO ENSURE NO COMPONENT IS MISSED

OR WRONGLY FITTED BY THE OPERATOR ON THE ASSEMBLY
LINE

FUNDOSHI : A SHEET OF PAPER WITH ALL THE DETAILS OF THE PART ON

WHICH IT IS PASTED

VIN : VEHICLE IDIENTIFICATION NUMBER

PSN : PRODUCTION SERIAL NUMBER

PET : PETROL

DSL : DIESEL

MT : MANUAL TRANSMISSION

CVT : CONTINOUS VARIABLE TRANSMISSION

LDI : BASE DIESEL VARIANT

LXI : BASE PETROL VARIANT

VDI : MIDDLE DIESEL VARIANT

VXI : MIDDLE PETROL VARIANT

ZDI : TOP DIESEL VARIANT

ZXI : TOP PETROL VARIANT

13
MSIL Snap Shot
Equity Structure* 56.2% Suzuki, 43.8% with Public

Net Sales* Rs.77,266.2crore(March 2017)

Net Profit* Rs.7,337.7crore(March 2017)

Sales* 14,29,248 units(April2017-March 2018)

Market Share* 48%

Manpower* over 25,000 employees (2017)

Models* 17 models with over 150 variants (July 2017)

Joint Ventures* 20 joint venture for components

Total outlets* 2,043 across 1,676 cities in India (July 2017)

Service Stations* 3,242 across 1,583 cities in India (July 2017)

TABLE 1
*subjected to change without any prior notice. T&C applied. All right reserved under MSIL.

14
FACILITIES AT MSIL:

There are two manufacturing facilities in India, one in Gurgaon and the
other in Manesar, North India.

GURGAON PLANT:-

Gurgaon plant has three fully integrated plants. While the three plants have
a total installed capacity 650,000 cars per year, several productivity
improvements or shop floor Kaizens (improvement) over the years have
enabled the company to manufacture nearly 700,000 cars per year at the
Gurgaon facilities. The entire facility is equipped with more than 150
robots; out if which 71 have been developed in-house. More than 50% of
shop floor employees have been trained in Japan.

15
MANESAR PLANT: -

Manesar facility has been made to suit Suzuki Motor Corporation (SMC)
and Maruti Suzuki India Limited (MSIL) global ambitions. Rated high among
Suzuki best plant worldwide the plant was inaugurated in February 2007.
The plant has several in-built systems and mechanisms to ensure that cars
being manufactured here are of good quality. There is a high degree of
automation and robotic control in the press shop, weld shop and paint shop
to carry on manufacturing work with acute precision and high quality. In
particular, areas where manual operations are hazardous or unsafe have
been equipped with robots.
The plant is designed to be flexible; diverse car models can be made here
conveniently owing to automatic tool changers, centralized weld control
system and numerical control machines that ensure high quality and the
use of network integrated techniques so that no process is missed. The
plant was started with an initial capacity of 100,000 cars per year. This is
now scaled up to 550,000 cars per year.

16
DIESEL ENGINE PLANT: -

Suzuki Power Train India Limited, the diesel engine plant at Manesar is
Suzuki’s first and MSIL’s perhaps the only plant design to produce world
class diesel engine and transmission for cars. The plant is under a joint
venture company, called Suzuki Power Train India Limited (SPIL) in which
SMC hold 70% equity with the rest held by MSIL.
This facility has an initial capacity to manufacture 100,000 diesel engines a
year. This will be scaled up to 300,000 engines per year.
The diesel engines manufactured at this plant will also be exported to SMC
companies across the world. This facility too has a high level of automation.
Final inspection of components is done through automatic measuring and
marking machines, which leads to a uniform and error free production.

FIG 5

R&D Mission:-

To achieve full model development capability for global Suzuki models fully
operational by 2019, a fully-fledged R&D center is being developed at a
total investment of Rs.38000 crore at 700 acre site in Rohtak, Haryana

17
 MSIL (Gurgaon Plant)
MAIN UNITS AT MSIL-M
 Press shop

 Weld shop

 Paint shop

 Bumper paint & injection moulding shop

 Assembly shop

 Vehicle inspection

MARUTI PRODUCTION PROCESS

18
 BLANKING LINE

There are two blanking lines; ROSL (Rotary oscillatory shear line) for
rectangular sheets and the other employing die cutting for irregular shapes.
The rectangular sheets are obtained on ROSL while dies are employed to
obtain the required shape sheets. The sequence of operations on the blanking
line is as follows:-

 Uncoiling
 Cleaning
 Levelling
 Measuring
 Shearing/cutting
 Piling/stacking

19
 PRESS SHOP

Die spotting press M/C-200t

Tandem press line 2-200t
Transfer press line -30
Tandem press line -1200t

20
The press shop can be regarded as the starting point of a car manufacturing
process. The press shop has a batch production system whereas the plants
have a line production system. The press shop maintains an inventory of at
least two days. The weld shop as per their requirement picks the finished body
parts. These may be divided as A, B & C parts. ‘A’ components are large outer
components, example-Roof, door panels, front hood etc. These components
are manufactured in the press shop at Maruti due to design secrecy and huge
investment requirements. ‘B’ and ‘C’ components are manufactured by joint
ventures or brought from vendors. The press shop can be divided into:

 Raw Material Procurement

 Blanking at Blanking Line
 Stamping at Stamping Line

21
 WELD SHOP

 ROBOTS- 139
 AUTOMATION LEVEL- 76 %

The body panels produced in the press shop and other small components are
joined here to give the “white body” or “shell”. In a typical car body about
1400 different components are welded together. The joining process is
resistance spot welding predominantly.

22
WELD SHOP 1 was the department assigned to me.

The weld shop has following facilities:

 Welding jigs
 Spot welding guns
 Hemming machine
 Punching machine

PROCESS OUTLINE
Each line is divided into 5 areas

 Under Body
 Main Body
 Side Body
 Door Line
 White Body

UNDER BODY
Here different underbody panels are welded together. These comprises of rear
under body, central under body, front engine room panel. These under body
panels are prepared on sub line starting from singular components. The sub
lines have specific jigs for each. There are chain hosts for transferring the jobs
from one jig to another on sub lines. Finally these under bodies are put on the
conveyor and welded together to give the under body.

MAIN BODY
The chassis no. is punched on the cowl top and it is welded to the front engine
room panel. As the body moves on the conveyor roof and side body panels are
welded to it to give the main body. The side body panels are prepared on the
sub lines.

SIDE BODY
This consists of right side body & left side body.

WHITE BODY
The doors, hood and back door are attached on the main body with the help of
bolts and screws to the main body to make it a “white body”. The body is
checked for dent, burr and spatter and these defects are repaired. After
inspection and repairs the body is called WBOK.

23
DOOR LINE
This is where all the doors (rear, front both left and right, backdoor and the
hood) are made.

GUNS USED IN THE WELD SHOP

 PORTABLE SPOT WELDING (PSW): Squeezing is done by

compressed air.
 INTEGRATED TRANSFORMER (IT) GUN: These guns are servo-
controlled.

Sealer Application
There are two types of sealer: Hemming Sealer and Spot & Dust sealer. The
brand names are E-56/beta-mate 73300 and Glass Bead. In hemmed parts such
as door, CO2 spots are made at some selected points to prevent hemmed parts
coming out. Spot and dust sealer is applied where spot is not possible. It is also
used for vibration damping.
THREE TYPE OF SEALERS USED

E-56 : It becomes rock hard after baking in PS ovens

-S : It becomes Soft shock absorbing after baking in PS ovens
1548-G : Same as Z 71-S with More viscosity than Z 71-S (Imported)

TYPES OF WELDING AND PRINCIPLE USED

1. CO2 WELDING
Metal Inert Gas Welding.CO2 Works as inert gas shield to metal .0.8mm
Copper coated MS wire is used for welding. This is a welding method to weld
two metal plates together by using the arc heat without applying any pressure,
while blocking off the atmospheric air with carbon dioxide (CO2) gas. The tip
of the welding wire that is melted by the arc heat repeats the short circuiting
droplet transfer to the molten pool of the base metal.

2. SPOT WELDING
98 % of welding done in weld shop is spot welding. This is a welding method to
melt steel plates with heat that is generated by applying electric current to the
electrodes.

3. STUD WELDING
Electric Capacitance Welding

24
4. BRAZING
Gas Welding, External Metal as Filler, Brass Rod is used as filler metal, vapour
flux and plain brass rod or flux coated brass rod are used.
5. SOLDERING
It is same as brazing at less temperature than brazing temperature.
6. PROJECTION NUT WELDING
Projection welding is a type of resistance welding. High current in less time is
its main feature.

PAINT SHOP

 Fully automatic process

 18 Robots with 10 colours

In the paint shop following processes are carried out:-

 Pre-treatment: the body is thoroughly washed to remove dirt and oil

scales.
 ED coat: this is done by electric deposition method. After applying the
ED coat body is baked in ovens.
 Final coat: for metallic coating, double coats are applied and aluminium
flakes provide the shine to metallic paint. This is also done by spray
painting method.
The PBOK i.e. Paint Body OK is sent to the assembly shop.

25
 ASSEMBLY SHOP

There are three assembly shops at MSIL, Gurgaon, namely, Assembly Plant-
Gurgaon A (AS-MA), Assembly Plant-Gurgaon B (AS-MB) and Assembly Plant-
Gurgaon C (AS-MC).

 AS-1: Production of WagonR , Supercarry, omni, EECO.

 AS-2: Production of S-Cross and Ertiga.
 AS-3: Production of Vitara Brezza and Ignis.

26
 VEHICLE INSPECTION

Various tests are carried on the car to ensure optimum quality and customer
satisfaction. Tests carried out are:

i. Toe-in test
ii. Toe-out test
iii. Shower leakage test
iv. Acceleration test or Drum test
v. Headlamp focus test
vi. Brake test
vii. Turning radius test
viii. Final Drive test

27
PRODUCTION ACTIVITIES

 Production
 Quality
 Discipline
 Suggestion/KAIZEN
 Safety
 5S, 3M, 3K

WHAT ARE 5S’s?

5S stands for 5 initials of the following Japanese words:

Seiri = Organization

 To distinguish between necessary things and unnecessary things, and

getting rid of what you do not need.

Seiton = Neatness
 Establishing a neat layout so that you can always get just as much need of
what you when you need it. It is a way of eliminating search.

Seiso = Cleaning
 Eliminating garbage, filth, and foreign matters for a cleaner workplace.
Cleaning as a form of inspection.

Seiketsu = Standardization

SEIRI SEITON SISEO

 Keeping things organized, neat, and clean, even in personal and
environment aspects.

Shitsuke = Self-discipline

 Doing the right things as a matter of course

28
WHAT ARE 3M’s?
 Man
 Material
 Machinery

WHAT ARE 3K’s?

These are 3 types of jobs
 Kitui (demanding)
 Kitanai (dirty)
 Kiken (dangerous)

The Kitui (demanding) jobs, which require carrying heavy

objects, keeping the kneeling position, and draining workers of
strength and energy, may cause problems with safety, as well as work
efficiency.

Improving jigs, fixtures, tools and other factors in the work environment
shall eliminate dangerous work.

A BRIEF INTRODUCTION TO WELD SHOP I

The department allotted to us was Weld Engineering department coming under
Production Engineering division. The department of weld engineering is
directly concerned with all the current and future activities to be carried out in
the three weld shops 1, 2 & 3.
WELDSHOP –1 established in 1983
WELDSHOP –2 established in 1993-94
WELDSHOP –3 established in 1999-2000

CARS WELDED IN
WELDSHOP–1: WagonR, Omni, EECO, Gypsy, Ignis
WELDSHOP–2: YAD (Ertiga), YL8 (S-cross)
WELDSHOP–3: YE3 (Alto), YBA (Vitara Brezza), YJC (Ignis)

29
Weld shop I at MARUTI stands as the fastest and the most productive weld
shops of the three, currently under operation. The shop mainly deals with the
construction and assembling of the main structural body of WAGON-R and
OMNI, EECO the three most sold out variants of MARUTI. It is systematically
divided functioning in the nodal form connected with one main interface which
is assembly. Lines for all three models are totally independent with one another
due to constraints of space and thus divide the working area of the shop into two
equal sections. Production, maintenance, store facility etc. everything is inside
the workshop itself giving it a comprehensive and partially self-sufficient structure.

It uses a combination of human resource and the latest technologies necessary

for a rapid and quality production. Specific purposes are dealt by workers and
robots respectively. Whereas OMNI with a daily production of around 350 has
more of human force on its ends whereas WAGON-R with 540 per day makes
more use of automated welders or robots. ROBOTS used are either
KAWASAKI or FANUK made. On the basis of axis, Weld Shop has three
types of robots:
1) Two axis Robots

2) Three axis Robots

3) Six axis Robots

The major processes carried here are as follows:

1. Welding of front under body.

2. Welding of Rear under Body.
3. Welding of the main floor.
4. Welding of the cowl box.
5. Welding of Side Under Body ( Left and Right)
6. Welding of Roof
7. Welding of the under body.
8. Welding of Main body.
9. Re-spotting
10. Welding of rear, back and front doors.
11. Welding of hood
12. Welding of the white line body.
13. Inspection.

30
The major welding processes done here are resistance spot welding, CO2
welding, projection nut welding and stud welding. Both manual (45%) and
automated (55%) version are currently working. In automation both in-house
automation designed by MARUTI itself and KAWASAKI and FANUK
designed robots up to six degrees of freedoms are used. Lately IT (integrated
transformer) guns have been replacing PSW (Portable spot welding) guns
due to ease of operation and better maneuvering. With over a man-power of
2000 working over 2 shifts and two assembly lines running with highest
efficiencies simultaneously make WELD SHOP III one of the most dynamic
parts of MARUTI plant.

31
WHAT IS WELDING?

WELDING IS THE PROCESS OF JOINING METALS

FILLER MATERIAL

HEAT MELTING JOINING

OF METAL OF METAL

 ELECTRIC CURRENT
NO FILLER MATERIAL
 GAS

2 GAS

3 CHEMICAL
RESISTANCE
REACTION WELDING

In this process, electric current flows through

resistive circuit to generate heat between two
pieces of sheet metal so that molten metal
reaches molten stage. The resistance to the
flow of current is provided by the work piece.
The maximum heat is generated at the point of
maximum resistance.

32
 Resistance welding

H =heat in joule

I = current in ampere

R = resistance in ohm

T = time in second

Resistance & Effect of Pressure

R1&R5 Resistance between tip and sheet

R2 & R4 sheet individual resistance
R3 Surface contact resistance

R1
R2 In welding it is
desirable to have
R3 •R1,R2,R4,R5 low
•R3 high
R4
R5

33
 Resistance welding
Relation between Current and time

A :- WILL HAVE
LESS WORK DISTORTION
Current
A LESS OXIDATION

B GOOD WELDABILITY

C
Time A: Strong current and short time
C: Small Current and long time
B:Medium current and medium time

FOUR MAJOR ELEMENTS OF WELDING

Welding current
Weld time
Pressure
Electrode shape (current density)

Relation between Current and Pressure

No Nugget
Large
Splash
Nugget Dia
Pressure

B - will have
(Strength) d
el Good Weld
W Less Spatters
o d
Small o Explosion Optimum Nugget Dia
G

Current
A:High Current and High Pressure
B:Medium current and medium Pressure
C: Small Current and High Pressure

34
SPOT WELDING

WELD TIME CONTROL FOR

SPOT WELDING
CURRENT

UP SLOPE
SQEEZE

DN SLOPE
WELD

OFF
HOLD

TIME

35
 Weld time control for spot welding
1. SQUEEZE TIME: Time required for the electrode to close on metal
flow and apply proper pressure. It varies with the gap between the
electrodes.
2. UPSLOPE TIME: Time taken for the current to reach from zero to the
peak value.
3. WELD TIME: Time required for peak current to flow and heat the
metal.
4. DOWN SLOPE TIME: Time taken for the current to cut off i.e. from
peak to zero.
5. HOLD TIME: Time taken by the electrodes to hold the sheets together
after the current flow stops. Pressure is still applied to allow the molten
metal to solidify.
6. OFF TIME: Time between the end of one spot sequence to start of next
spot sequence.

FUNCTION OF ELECTRODES

1. Supply sufficient welding current to the required area.

2. Heating during welding and quick cooling after welding.
3. Define the welding zone and maintain correct pressure.

THE MOST COMMONLY USED ELECTRODES SHAPES ARE P AND CR TYPES.

36
 SPOT WELDING DEFECTS

TYPES OF WELDING GUNS

1. According to position of transformer
 External transformer Guns(PSW)
 Internal transformer Guns(IT)

2. According to Motion Of gun arms:

 C Type Guns: One Arm is moving
 X Type Guns: Both Arms Moving.

37
 Stationary Arm Both Arm
Moving

Moving Arm

SPECIAL TYPE WELDING M/C

1. SSW : Stationary Spot Welder

2. MSW : Multi Spot Welder
3. PSW : Portable Spot Welder
4. IT : Integrated transformer

38
TYPES OF TIPS

1.) BEND TIP

Nugget dia

2.) CAP TIP

Nugget dia

Usable limit line

 If the nugget diameter exceeds 10 mm, perform tip grinding.

 After grinding the tips, the nugget diameter shall be 6 mm or so.
 (Minimum 6 mm to Maximum 10 mm)

39
 Project -1
TITLE:
Monitoring of Number of spots on different working positions on EECO and
OMNI lines

OBJECTIVE:
To ensure that on every welding station numbers of spots made are same in
repeated number of cycles.

WHY TO CHOOSE THIS PROJECT:

In a welded car body every spot has its importance for required strength and
perfect quality of the car, so ever a single missed spot can deteriorate the
quality of car.

REQUIREMENTS:
Layout of EECO and OMNI lines, Manpower Distribution on every station for
both the lines.

METHODOLOGY USED:

 First of all we construct the process flow chart for both the lines by
observation.
 Observe the manpower used on every station. There are 20 stations on
OMNI line and 18 stations on EECO line in which 8 and 10 stations are
robot operated respectively.
 There are 54 working positions on OMNI line and 38 working positions
on EECO line. Both the lines have separate door weld sections.
 Some of the stations have spot counters with every welding gun and
others have an indication light attached with the transformer which
blinks every time when a spot is made.
 We monitor 3 cycles for every working position.

40
 LAYOUT OF OMNI LINE

FR
T
O
&
M
RR
NI
Fl
Un
oo
de
r
r
RH bo
Side dy
Body

Ba O
ck LH M
Do Side NI
or Body M
ai
n
LH & RH Bo
Rear dy
Door OMNI
/
EECO
white
RH Body LH
Front Line FRT
Door Door
41
PROCESS FLOW & MANPOWER DISTRIBUTION LAYOUT

42
 RESULTS:
Station No. - 2
Worker A1 A2
No. of Spots in 1st 63 59
cycle
No. of Spots in 63 59 A1 A2
St- 2
2nd cycle
No. of Spots in 63 59
3nd cycle

Worker A1 A2 A3 A4
No. of Spots in 25 31 33 31
1st cycle
No. of Spots in 25 31 33 31
2nd cycle

43
No. of Spots in 25 31 33 31
3nd cycle

Station No. – 3
A3 A4
St- 3
A2 A1

44
 Station No. – 5 A4 A6 A5

St- 5

A1 A2 A3

Worker A1 A2 A3 A4 A5 A6
No. of 35 28 14 22 14 18
Spots in
1st cycle
No. of 35 28 14 22 14 18
Spots in
2nd cycle
No. of 35 28 14 22 14 18
Spots in
3nd cycle

Station No. – 3
A1 A3
St- 4
A2 A4

Worker A1 A2 A3 A4
No. of Spots in 31 58 33 60
1st cycle
No. of Spots in 31 58 33 60
2nd cycle
No. of Spots in 31 58 33 60
3nd cycle

45
Station No. – 12
A1 A2
St- 12
A3

Worker A1 A2 A3
No. of Spots in 1st 7 6 33
cycle
No. of Spots in 2nd 7 6 33
cycle
No. of Spots in 3nd 7 6 33
cycle

Station No. – 19

A1 St- 19 A2

Worker A1 A2
No. of Spots in 1st cycle 59 60
No. of Spots in 2nd cycle 59 60
No. of Spots in 3nd cycle 59 60

Station No. – 20

A1 St- 20 A2

Worker A1 A2
No. of Spots in 1st cycle 9 9
No. of Spots in 2nd cycle 9 9

46
 No. of Spots in 3nd cycle 9 9

Station No. – 13 (Right Side body)

A2 A3
=3
A5 A7

A1

A4 A6

Worker A1 A2 A3 A4 A5 A6 A7
No. of 59 40 24 60 225 66 15
Spots in
1st cycle

No. of 59 40 24 60 25 66 15
Spots in
2nd
cycle
No. of 59 40 24 60 25 66 15
Spots in
3nd
cycle

Station No. – 14 (Left Side body)

A3 A2
=3
A5 A7

A1
47

A4 A6
Worker A1 A2 A3 A4 A5 A6 A7
No. of 58 42 24 60 22 66 15
Spots in
1st cycle

No. of 58 42 24 60 22 66 15
Spots in
2nd
cycle
No. of 58 42 24 60 22 66 15
Spots in
3nd
cycle

OMNI Back Door:

Worker A1

No. of Spots in 1st cycle 44

A1
No. of Spots in 2nd cycle 44

No. of Spots in 3nd cycle 44

OMNI Front Door:

Worker A1 A2

No. of Spots in 30 30
1st cycle RH LH

No. of Spots in 30 30
2nd cycle A1 A2

48
No. of Spots in 30 30
3nd cycle

OMNI Front Door:

Worker A1 A2

No. of Spots in 55 55
1st cycle RH LH

No. of Spots in 55 55
2nd cycle A1 A2
No. of Spots in 55 55
3nd cycle

49
 LAYOUT OF EECO LINE

EE EECO
CO Door
un Line
de
r
Bo
dy

Left
Side
Body
EE
CO
M
ai
n
Right
Bo
Side
dy
Body

Rear
Floor

50
PROCESS FLOW & MANPOWER DISTRIBUTION LAYOUT

51
52
 EECO Line
Station No. 1: A4 A3

St-1
Worker A1 A2 A3 A4
No. of 19 10 10 20
Spots in A1 A2
1st cycle
No. of 19 10 10 20
Spots in
2nd cycle
No. of 19 10 10 20
Spots in
3nd cycle

Station No. 2: A2

Worker A1 A2
St-2
No. of Spots in 34 34
1st cycle
No. of Spots in 34 34 A1
2nd cycle
No. of Spots in 34 34
3nd cycle

Station No. 4: A2

Worker A1 A2
St-4
No. of Spots in 34 34
1st cycle
No. of Spots in 34 34 A1

53
 2nd cycle

No. of Spots in 34 34
3nd cycle
Station No. 6: A1

Worker A1 A2
St-6
No. of Spots in 37 37
1st cycle
No. of Spots in 37 37 A1
2nd cycle
No. of Spots in 37 37
3nd cycle

Station No. 7: A1

Worker A1 A2
St-7
No. of Spots in 9 9
1st cycle
No. of Spots in 9 9 A1
2nd cycle
No. of Spots in 9 9
3nd cycle

Station No. 9:

A5

A3
St-9

A4

A2

St-9

A1 54
 Worker A1 A2 A3 A4 A5

No. of Spots 20 11 40 18 18
in 1st cycle
No. of Spots 20 11 40 18 18
in 2nd cycle
No. of Spots 20 11 40 18 18
in 3nd cycle

Station No. 15:

A3 A4

Worker A1 A2 A3 A4 St-15
No. of 10 5 10 5
Spots in
1st cycle A1 A2
No. of 10 5 10 5
Spots in
2nd cycle
No. of 10 5 10 5
Spots in
3nd cycle

EECO Right Side Body:

A6 A4 A2

JIG 1 JIG 2 JIG 3

55
A5 A3 A1
 Worker A1 A2 A3 A4 A5 A6

No. of 58 9 17 22 36 10
Spots in
1st cycle
No. of 58 9 17 22 36 10
Spots in
2nd cycle
No. of 58 9 17 22 36 10
Spots in
3nd cycle

EECO Left Side Body:

A1 A3 A6

JIG 1 JIG 2 JIG 3

A2 A4 A5

Worker A1 A2 A3 A4 A5 A6

No. of 8 38 21 22 36 10
Spots in
1st cycle
No. of 8 38 21 22 36 10
Spots in
2nd cycle
No. of 8 38 21 22 36 10
Spots in
3nd cycle

56
 Right & Left Rear Door:

Right Left

Outer Inner Outer Inner

A3 A1 A2 A6 A4 A5

Worker A1 A2 A3 A4 A5 A6

No. of Spots 44 28 6 22 44 6
in 1st cycle
No. of Spots 44 28 6 22 44 6
in 2nd cycle
No. of Spots 44 28 6 22 44 6
in 3nd cycle

Right & Left Front Door:

Right Left

Outer Inner Outer Inner

A1 A2 A3 A4

Worker A1 A2 A3 A4

No. of Spots 16 64 16 64
in 1st cycle
No. of Spots 16 64 16 64
in 2nd cycle
No. of Spots 16 64 16 64
in 3nd cycle

57
EECO Back Door:

Outer Inner
Worker A1 A2
No. of Spots 37 9 A1 A2
in 1st cycle
No. of Spots 37 9
in 2nd cycle
No. of Spots 37 9
in 3nd cycle

EECO Hood:

Worker A1
No. of Spots 11
in 1st cycle A1
No. of Spots 11
in 2nd cycle
No. of Spots 11
in 3nd cycle

Conclusion:
The number of spots made on every station is same for every cycle although
there are some thick weld sections which require repeated spots for proper
joining.

SUGGESTIONS FOR IMPROVEMENT:

 There should be a spot counter with every welding gun so that after
every cycle number of spots can be checked by welder.
 There should be separate welding guns for the welding of thick section
so that repeating of a spot may avoided.

58
 Project - 2
TITLE:
Enhancement of safety measures on automated work stations.

OBJECTIVE:
To make the automated work stations more safe for workers during
maintenance.

WHY TO CHOOSE THIS PROJECT:

Safety on a work station where pre-programmed robots are working is a very
important issue as there are some fatal accidents occurred in different
companies during maintenance of robots.

CURRENT SAFETY MEASURES:

o All the automated areas are covered by fencing.
o Only authorised persons are allowed to enter in fenced areas.
o Two safety plugs are present are every entrance door, one is
attached with the door and other one is detachable which is
carried by the person entering in that area.

RECOMMENDATIONS:

1. BIDIRECTIONAL PERSON COUNTER:

A bidirectional person counter counts the number of persons pass
through the door in both the directions. It can be synchronised with the
robot controllers so that robots will not start until the count is zero. This
bidirectional counter can be formed using a microcontroller and some
sensors which are given below: -

59
REQUIRMENTS:
1. ARDUINO UNO:
The Arduino UNO is a widely used open-source microcontroller board
based on the ATmega328P microcontroller and developed
by Arduino.cc The board is equipped with sets of digital and analog
input/output (I/O) pins that may be interfaced to various expansion
boards (shields) and other circuits.

2. LIGHT DEPENDENT RESISTERS (LDR):

A light-dependent resistor (LDR), or photo-conductive cell is a light-
controlled variable resistor. The resistance of a LDR decreases with
increasing incident light intensity; in other words, it
exhibits photoconductivity. A LDR can be applied in light-sensitive
detector circuits, and light-activated and dark-activated switching
circuits.

60
 3. LASER SOURCE:
Laser Sources differ from traditional illumination sources because they
produce coherent light. The illumination spectrum is often narrow band
with line widths as narrow as tens of megahertz and divergence as low as
fractions of milliradians.

4. RESISTERS
5. BREAD BOARD
6. JUMPING WIRES
7. 5 VOLT POWER SOURCE

CIRCUIT DIAGRAM: -

61
WORKING: -
 When a person enter through door first signal A is LOW and B is
HIGH, then signal B is HIGH and a is LOW. So the controller adds
1 to the counter.
 When a person leave through door first signal B is LOW and A is
HIGH, then A is LOW and B is HIGH. So the controller subtracts
1 from counter.

PROGRAMMING CODE: -

#define LDR_1 A0
#define LDR_2 A1
const int LDR_Min=950;

bool LDR1=LOW;
bool LDR2=LOW;

62
int PeopleNumber=0;

void setup() {
// put your setup code here, to run once:
Serial.begin(9600);
}

void loop() {
// put your main code here, to run repeatedly:
if(analogRead(LDR_1)<LDR_Min &&
analogRead(LDR_2)>LDR_Min && LDR1==LOW &&
LDR2==LOW)
LDR1=HIGH;
if(analogRead(LDR_1)>LDR_Min &&
analogRead(LDR_2)<LDR_Min && LDR1==HIGH &&
LDR2==LOW)
{
while(analogRead(LDR_2)<LDR_Min)
{}
PeopleNumber++;
Serial.println("People in room: " + (String)PeopleNumber);
LDR1=LOW;
LDR2=LOW;
}

if(analogRead(LDR_1)>LDR_Min &&
analogRead(LDR_2)<LDR_Min && LDR1==LOW &&
LDR2==LOW)
LDR2=HIGH;

63
 if(analogRead(LDR_1)<LDR_Min &&
analogRead(LDR_2)>LDR_Min && LDR1==LOW &&
LDR2==HIGH)
{
while(analogRead(LDR_1)<LDR_Min)
{}
PeopleNumber=PeopleNumber>0?PeopleNumber-1:0;
Serial.println("People in room: " + (String)PeopleNumber);
LDR2=LOW;
LDR1=LOW;
}
}

2. PRESSURE SENSING MAT: -

Pressure sensor mats detect load changes position accurately even on
larger surfaces. They are only around one millimetre thick and very robust.
these mat consists of a cover film with electrodes, of a base film with
electrodes and of an in-between dielectric layer. The measuring points are
formed at the crossing points of the bottom electrodes with the cover
electrodes. The loadskin electronics in the form of a small printed circuit
board is connected to the loadskin pressure sensor mats. It supplies the
sensor mats with power and calls up the measured data provided by the
sensors at intervals of a few seconds. Each loadskin electronics has its own
IP address and has LAN / WLAN.

64
DIMENSIONS: -

Loadskin pressure sensor mats are custom produced up to a size of 650 x 315
mm² and can be put together to form larger areas. The mats are around one
millimeter thick, not transparent and not flexible. They are mainly used on
solid, smooth horizontal surfaces.

MEASUREMENT PRINCIPLE: -

At the measurement points, the capacitance between the top electrode and
bottom electrode is measured. If a force is applied to the sensor, the distance
between the electrodes decreases and the measured capacitance changes.

These pressure sensor mats detect and measure position accurately the load
changes on surfaces. Consequentially, there are three essential values for the
characterization of the sensors:

(i) In which load range loadskin pressure sensor mats can be used?

The sensitivity of loadskin pressure sensor mats can be adjusted according to

requirements by changes in the layer stack. The currently most widely used
version for shelves in retail can securely detect a load change in the range of a
weight per unit area of 30 to 300 kg / m² for areas of at least 30 x 30mm².

(ii) How fast can a change be detected on loadskin pressure sensor mats?

The duration of the measurement and thus the number of measurements per
unit of time depend on the number of measurement points on the sensor mat.
The duration of the measurement is approximately 3 ms per measurement
point. At largest possible version with 392 measuring points, this results in a
measuring time of 1,176 ms, approximately 1.2 seconds. For safe detection of
a change, 2 measurements are usually required. This results in a period of 2.4
seconds to detect a load change reliably.

65
 (iii) How accurately can the position be detected on loadskin pressure
sensor mats?

The electrode array of loadskin pressure sensor mats consists of a maximum of

14 x 28 rows. This results in 392 crossing points, which represent the
measurement points. The distance between the measurement points can vary
from 10mm to 30mm, depending on requirements.

3. WARNING SIGNAL BEFORE STARTING OF ROBOTS: -

In current safety system, the robots start working as soon as the safety plug
is inserted. So, there may be a chance that some other maintenance worker
is still there in robot area who might got hurt.
There should be some delay in starting of robots after insertion of safety
plug and in the meantime there should be warning alert in the area.

WARNING ALARM: -
An Alarm system alerts, informs and guides an operator regarding an
abnormal situation and helps him to take timely corrective action to bring
back to safe conditions.

TIME DELAY RELAY: -

Time delay relays (TDRs) can provide simple, reliable, and economical
control for various equipment. Adjusting the delay time is often as simple as
turning a knob. Providing time-delayed switching to start a motor, control a
load, or affect a process, TDRs are typically used in industrial applications.

66
EMERGENCY STOP SWITCH INSIDE THE ROBOT AREA: -
Emergency stop switches are devices that users manipulate to initiate the
complete shutdown of a machine, system, or process. Unlike regular stop
switches, emergency stop switches are not solely dependent on springs.
Instead, they generate electrical signals that latch the actuator. Several types
of emergency stop switches are available.

CONCLUSIONS: -
By using the above methods, the automated stations can be made safer for
human machine interface during maintenance and normal working of robots.

67
 Project- 3
TITLE: Formation of Maruti Operation Standards (MOS) for checking of number
of spots on gypsy line.
OBJECTIVE: To establish standards for checking of number of welding spots.

REQUIREMENTS: Layout of gypsy line, Manpower distribution chart.

METHODOLOGY USED:
 Every hour number of spots welded by a worker are checked.
 Some of the spots are checked on alternating hours and some of the
spots are checked every hour which are called MARU-A spots.
 For the formation of MOS sheets pictures of different parts of body at
different jigs are clicked and arranged in a sequence.
 Number of spots are marked on every picture by a single circle.
 MARU-A spots are marked by double circles.
 All the pictures of one jig are placed in standard MOS format and total
number of spots are written on every picture.

RESULTS:

S.no. Station Number of spots

1 Underbody Jig #1 147
2 Underbody Jig #2 235
3 Underbody Jig #3 117
4 Underbody Jig #4 39
5 Underbody Jig #5 219
6 Left Side Body 126
7 Right Side Body 145
8 Left Fender 235
9 Right Fender 213

68