SUMMER TRAINING

PRESENTATION

Formerly known as Sona Koyo Steering Systems Ltd.

 PREFACE

THE BASIC idea of the training was to understand the

different child components used in the steering mechanism of
passenger cars of various makes. My total focus was on the
different parts which are later on assembled together to make
the end product ready for installation into the vehicle. Basically
my focus was on Plant I. which manufactures Rack and Pinion
steering assembly. However my report will also be consisting
some extra relevant information as these information are the
part of the whole procedure.In addition I learned about
electrical maintanence and whole power system of the factory
ie. Generation of electricity when the power cuts occour and
how electricity it is controlled and used throughout the factory.
 COMPANY HISTORY

JTEKT was born in January 2006 through a merger of

Koyo Seiko and Toyoda Machine Works.
This merger united the top-class technologies and
passion for monozukuri cultivated by Koyo Seiko, a top-
class bearing manufacturer, and Toyoda Machine Works,
a machine tools manufacturer who possessed world-
class, excellent technologies. JTEKT has developed into a
company with numerous No.1 products and Only One
technologies within the business realms of steering,
drive train parts, bearings, and machine tools and
mechatronics.
 INTRODUCTION
JTEKT is a young company, having formed from a merger 10 years ago from its
predecessors, Koyo Seiko and Toyoda Machine Works, who were established in
1921 and 1941 respectively and who each have their own very long history. The
greatest characteristic of JTEKT is that while it is a machine tool manufacturer that
possesses a steering business, driveline business and bearing business, it is also a
parts manufacturer that has its own machine tools and mechatronics division,
making it a company unique within the world. In other words, JTEKT’s greatest
strength is that it has these several businesses that support its growth, and within
these businesses lay numerous No.1 and Only One products. On the other hand,
JTEKT has expanded globally, with over 130 bases established in 27 countries
throughout the world, and even now with roughly 60 percent of sales and three-
fourths of employees from outside of Japan.
 Sona Koyo Steering Systems Limited (SKSSL) is a technical and
financial joint venture company of Koyo Seiko Company, Japan. With a
Market share of 50%, the company is the largest manufacturer of
steering gears in India and is the leading supplier of:
 Hydraulic Power Steering Systems
 Manual Rack & Pinion Steering Systems
 Collapsible, Tilt and Rigid Steering Columns for Passenger Vans
and MUVs
 PLANT LOCATION

38/6, Delhi-Jaipur Road, NEAR HERO HONDA CHOWK, Gurgaon (Haryana),

India
38 Km from New Delhi,
22 Km from Delhi Airport,
10 Km from Maruti Udyog Ltd.

Total Site Area 56,970 square meters

Total floor Area 14,125 square meters
BRIEF VIEW TO JTEKT
 PLANT -1

PLANT -2
PLANT - 3

PLANT - 4
CUSTOMERS TO JTEKT
 Power Rack and Pinion Steering  Tilting and Collapsible Column
System Assembly
 Clutch Driven Plates  Universal Joints
  Cold Forged Steering Studs
Power Re-circulating Ball Screw
Steering System  Propeller Shafts
 Ball Joints  Cold Forged Ball Studs
 Electrical Power Steering System  Rear Axle Assemblies
 Tie Rod Ends  Cold Forged Case/Socket
 Manual Rack and Pinion Steering  Sub-differential Assemblies
System  Cold Forged Spiders and Yokes
 Suspension Components  Rigid Type Collapsible Column
 Warm forged Synchronizer Rings Assembly
CARRIER DIFFERENTIAL ASSEMBLY
 WORKING OF
CASE DIFFERENTIAL
During Turning
 TYPES OF MANUAL STEERINGS

RACK AND PINION STEERING

(RPS)

RECIRCULATING BALL TYPE

STEERING (RBS)
 In the rack and pinion type steering, the steering main shaft has a
steering pinion at the lower end. This steering pinion meshes with the
steering rack. As the steering wheel is turned, the steering pinion rotates
to move the steering rack to the right or left. The movement of the
steering tack is transmitted to the knuckle arms via the steering rack
ends and the tie rod ends.

The rack-and-pinion gear set does two things:

It converts the rotational motion of the steering wheel into the linear
motion needed to turn the wheels.
It provides a gear reduction, making it easier to turn the wheels.
 STEERING COLUMNS

THE AUTOMOTIVE STEERING COLUMN IS A DEVICE

INTENDED PRIMARILY FOR CONNECTING THE
STEERING WHEEL TO THE STEERING MECHANISM BY
TRANSFERRING THE DRIVER'S INPUT TORQUE FROM THE
STEERING WHEEL.

A STEERING COLUMN MAY ALSO PERFORM THE FOLLOWING

SECONDARY FUNCTIONS:

Energy dissipation management in the event of a frontal collision;

Provide mounting for: the multi-function switch, column lock, column
wiring, column shroud(s), transmission gear selector, gauges or other
instruments as well as the electro motor and gear units .
Offer (height and/or length) adjustment to suit driver preference.
 Steering
columns

Electrical Power
steering
column
Intermediate column shafts
 Spider universal joints

The cross-shaped inner member of a universal

joint is sometimes called a spider. Universal joints (1)The spider (6) ends (3)
allow for a small variable angle between the axis are called gudgeon. Around
of the transmissions output shaft and the the gudgeons there are
axis of the propeller shaft, and between the axis rollers (4) kept in place by
of the propeller shaft and the axis of the input a cap (5), that allows them
shaft of the rear axle to roll freely. The Circlip (7)
fits into the (2) hole in the
yoke and lock the cap.
Steering yoke, clamps & pipes
Steering front and rear axle
 An axle is a central shaft for a rotating wheel or gear. In some cases
the axle may be fixed in position with a bearing or bushing sitting
inside the hole in the wheeler gear to allow the wheel or gear to
rotate around the axle. In other cases the wheel or gear may be fixed
to the axle, with bearings or bushings provided at the mounting
points where the axle is supported.

A straight axle or the front axle is a

single rigid shaft connecting a wheel on
the left side of the vehicle to a wheel on
the right side. The axis of rotation fixed
by the axle is common to both wheels.
Such a design can keep the wheel
positions steady under heavy stress,
and can therefore support heavy loads.
Straight axles are used on trains, for the
rear axles of commercial trucks, and on
heavy duty off-road vehicles. The axle
can be protected and further reinforced
by enclosing the length of the axle in a
housing. Front axle
 In split-axle designs, the wheel on each side is attached to a separate shaft.
Modern passenger cars have split drive axles. In some designs, this allows
independent suspension of the left and right wheels, and therefore a smoother
ride. Even when the suspension is not independent, split axles permit the use of a
differential, allowing the left and right drive wheels to be driven at different
speeds as the automobile turns, improving traction and extending tire life
 Propeller shaft
A drive shaft, driveshaft, driving shaft, propeller shaft, or shaft is a
mechanical component for transmitting torque and rotation, usually used
to connect other components of a drive train that cannot be connected
directly because of distance or the need to allow for relative movement
between them.
Drive shafts frequently incorporate one or more universal joints or
jaw couplings, to allow for variations in the alignment and distance
between the driving and driven components.
here are a couple of key components in power steering in addition to the rack-and-pinion or recirculating-ball mechanism

POWER STEERING
Hydraulic power steering:
THERE ARE A COUPLE OF KEY COMPONENTS IN POWER
STEERING IN ADDITION TO THE RACK-AND-PINION OR
RECIRCULATING-BALL MECHANISM.
PUMP
The hydraulic power for the steering is provided by a rotary-vane
pump (see diagram below). This pump is driven by the car's engine via a belt
and pulley. It contains a set of retractable vanes that spin inside an oval
chamber.
As the vanes spin, they pull hydraulic fluid from the return line at low
pressure and force it into the outlet at high pressure. The amount of flow
provided by the pump depends on the car's engine speed. The pump must be
designed to provide adequate flow when the engine is idling. As a result, the
pump moves much more fluid than necessary when the engine is running at
faster speeds

ROTARY VALVE
A power-steering system should assist the driver only when he is exerting
force on the steering wheel (such as when starting a turn). When the driver
is not exerting force (such as when driving in a straight line), the system
shouldn't provide any assist. The device that senses the force on the steering
wheel is called the rotary valve.
 The key to the rotary valve is a torsion bar. The torsion bar is a thin rod of
metal that twists when torque is applied to it. The top of the bar is connected
to the steering wheel, and the bottom of the bar is connected to the pinion or
worm gear (which turns the wheels), so the amount of torque in the torsion
bar is equal to the amount of torque the driver is using to turn the wheels.
The more torque the driver uses to turn the wheels, the more the bar twists.

The input from the steering shaft forms the inner part of a spool-valve
assembly. It also connects to the top end of the torsion bar. The bottom of
the torsion bar connects to the outer part of the spool valve. The torsion bar
also turns the output of the steering gear, connecting to either the pinion
gear or the worm gear depending on which type of steering the car has.

As the bar twists, it rotates the inside of the spool valve relative to the
outside. Since the inner part of the spool valve is also connected to the
steering shaft (and therefore to the steering wheel), the amount of rotation
between the inner and outer parts of the spool valve depends on how much
torque the driver applies to the steering wheel.
 When the steering wheel is not being turned, both hydraulic lines provide
the same amount of pressure to the steering gear. But if the spool valve is
turned one way or the other, ports open up to provide high-pressure fluid to
the appropriate line.

It turns out that this type of power-steering system is pretty inefficient.

Let's take a look at some advances we'll see in coming years that will help
improve efficiency
 ELECTRICAL power steering:
EPS in modern cars can significantly reduce fuel consumption when
compared to cars using hydraulic solutions. Industry studies have shown
that EPS can save up to 85 percent of the energy normally needed to steer a
vehicle with conventional hydraulic systems. The result is fuel consumption
reductions of up to 0.3 liters per 100 kilometers driven. EPS is so efficient
because the system is only activated when steering support is really needed.
As a result, a permanent engine load is not required.
EPS systems also can help ensure safer driving. The steering torque is
adapted to the vehicle’s speed and optimized for different driving situations.
For example, during low-speed driving maneuvers, such as parking, EPS
provides a higher level of assistance than it does at higher speeds, when
electronic power assist is gradually reduced to enable more direct steering
and better feedback from the road.
 DG. HOUSE (UTILITY)

 In this building all the Diesel Generator ,Air compressor,

LT panels ,etc are installed.
 In this building sound absorbing material is used to absorb the sound
cause by DG and AIR compressor.
 DIESEL GENERATORS

 DG. NO 3
CAPACITY-1500 KVA

 DG. NO 3
CAPACITY-500 KVA
STANDARD OPRATING PROCEDURE (SOP) FOR DG SET

1. Check fuel level into the diesel service tank.

2. Check battery voltage.it should be 23 to 26 volts DC.
3. Check coolant level.
4. Start lubricating pump.
5. To start the engine by turning the key to ‘RUN’ position.
6. Engine will pick up and develop voltage.
7. Check voltage between R-Y,Y-B and B-R . It should be 415 to 420.
8. Check frequency of supply. It should be 49.5 to 50.2 Hz.
9. Check various readings of parameters on panel and note it in the
D.G set monitoring record.
10. The parameters are RPM, lub oil temperature ,Voltage (RY,YB,BR),
Current (R,Y,B), frequency , KWH,KW,P.F .
 SINGLE LINE DIAGRAM OF OLD AND
NEW L/T PANEL(D.G HOUSE)

VACCUM CIRCUIT BREAKER(VCB)

A vacuum circuit breaker is a kind
of circuit breaker where the arc
quenching takes place in vacuum
Medium . The operation of switching
on and closing of current carrying
contacts and interrelated arc
interruption takes place in a vacuum
chamber in the breaker which is called
Vacuum Circuit Breaker.
  THE power supply comes to the step down transformer then after
stepping down the supply is send to the LT panels . Then the
electricity is supplied throughout the company.

STEP DOWN TRANSFORMER 1600KVA/440 V

LT PANELS
LOCK OUT TAG OUT (LOTO)
 Purpose of lock out tag out : To specify the requirements for control
of unexpected start up of stored energy of equipment during
adjustment , maintenence , cleaning or trial.
THANK
you