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1. ABOUT BOSCH

In India, Bosch is a leading supplier of technology and services in the


areas of Mobility Solutions, Industrial Technology, Consumer Goods, and
Energy and Building Technology. Additionally, Bosch has in India the
largest development center outside Germany, for end to end engineering
and technology solutions.

The Bosch Group operates in India through nine companies, viz, Bosch
Limited, Bosch Chassis Systems India Limited, Bosch Rexroth India
Limited, Bosch Engineering and Business Solutions Private Limited,
Bosch Automotive Electronics India Private Limited, Bosch Electrical
Drives India Private Limited, BSH Home Appliances Private Limited,
ETAS Automotive India Private Ltd. and Robert Bosch Automotive
Steering India Pvt. Ltd. In India, Bosch set-up its manufacturing operation
in 1951, which has grown over the years to include 15 manufacturing
sites, and seven development and application centers. Bosch Group in
India employs over 30,000 associates and generated consolidated revenue
of about ₨.17,022 crores in 2015 of which ₨. 12,100 crores from third
party. The Group in India has close to 14,000 research and development
associates.

In India, Bosch Limited is the flagship company of the Bosch Group. It


earned revenue of over ₨. 10,415 crores (1.4 billion euros) in 2015-16.

Before the 19th century ended, Bosch expanded his operations beyond
Germany. The company established a sales office in the UK in 1898, and
other European countries soon after. The first sales office and the first
factory in the U.S. were opened in 1906 and 1910 respectively. By 1913,

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the company had branch operations in America, Asia, Africa, and


Australia, and was generating 88% of its sales outside Germany. In rapid
succession in the years following the First World War, Bosch launched
innovations for the motor vehicle, including diesel fuel injection in 1927.
In the 1920s the global economic crisis caused Bosch to begin a rigorous
program of modernization and diversification in his company. In only a
few years' time, he succeeded in turning his company from a small
automotive supplier into a multinational electronics group.

From the beginning, Bosch was greatly concerned about promoting


occupational training. Prompted by his awareness of social responsibility,
he was one of the first industrialists in Germany to introduce the eight-
hour work day, followed by other social benefits for his associates Robert
Bosch did not wish to profit from the armaments contracts awarded to his
company during WWI. Instead, he donated several million German marks
to charitable causes. A hospital that he gave to the city of Stuttgart opened
in 1940.

In the 1920s and 1930s, Robert Bosch was politically active. As a liberal
businessman, he sat on a number of economic committees. He devoted a
great deal of energy and money to the cause of bringing about
reconciliation between Germany and France. He hoped this reconciliation
would bring about lasting peace in Europe and lead to the creation of a
European economic area.

The Nazi (National Socialist) regime in Germany brought Bosch’s


peacemaking efforts to an abrupt end. The company accepted armaments
contracts and employed forced laborers during the war. At the same time,
Robert Bosch supported the resistance against Adolf Hitler: together with

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his closest associates, he saved victims of Nazi persecution from


deportation.

Robert Bosch was keenly interested in agricultural issues and owned a


farm south of Munich. He was also a passionate hunter. When he died in
1942, he was survived by four children from two marriages. A son from
his first marriage died in 1921 following a protracted illness.

BOSCH INDIA

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2. PRODUCTS AND SERVICES OF BOSCH

 Injectors
 Spark plug
 Household Appliances
 Pumps
 Filters
 Safety systems
 Professional power tools
 Automotive service solutions
 Energy building solutions

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3. OBJECTIVES

• Reduction in changeover time

• Increases the production efficiency

• To minimize the errors in the given chain of processes on


the production lines

• Increases the production of manufactured part in the


company

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4. FUEL INJECTOR

Fuel injection is the introduction of fuel in an internal


combustion engine, most commonly automotive engines, by the
means of an injector.

All diesel engines use fuel injection by design. Petrol engines


can use gasoline direct injection, where the fuel is directly
delivered into the combustion chamber, or indirect injection
where the fuel is mixed with air before the intake stroke.

On petrol engines, fuel injection replaced carburetors from the


1980s onward. The primary difference between carburetors and
fuel injection is that fuel injection atomizes the fuel through a
small nozzle under high pressure, while a carburetor relies on
suction created by intake air accelerated through a Venturi tube
to draw the fuel into the airstream.

CRDI INJECTOR

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5. TEST LINE LAYOUT

Clamping saddle and Bench 1


DMC check

Laser inscription Bench 2


station

Bench 3
Resistance check unit

EMI station Vision tool station

HD station Packaging

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5.1.1 HD STATION (High Pressure Leak Test)


HD station is just station on the test line. In these station
leakage checking of injector is done by inserting the high
pressurized testing fluid on it. The following parts are
checked during the HD test.
1. Nozzle spray hole
2. Nut(Thread start)
3. IC stud
4. Magnet nut
5. Magnet moulding

5.1.2 EMI Station (Functional Test Station)

EMI Station is called as functional test station. Because in


the EMI all the functional properties of injectors are
checked. The injector is travel from HD station to EMI with
the help of WPC. In the EMI the high pressurized test oil is
inserted into the injector from the IC stud cap.

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5.1.3 RESISTANCE CHECK UNIT


In this unit the resistance check of the injector is checked.
The resistance amount which required for the testing of
injector is too much high. If we use the copper connector test
cable, it does not produced the required amount of
resistance. So that we uses golden connector test cable
which produce high resistance. When the type of injector
changes according to that resistance amount is changes.

5.1.4 LASER INSCRIPTION STATION


In this station the essential data of injector is engraved on
the upper side of injector. The data is engraved with help of
laser technology. Following data is unscripted on injector:
1. Bosch logo
2. Injector type
3. Plant code
4. Manufacturing date and time
5. DMC

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5.1.5 CLAMPING SADDLE AND DMC CHECK


STATION:

In this station clamping saddle is mounted on the upper side


of the injector. The main purpose of this saddle for easy
mounting the injector in the vehicle. Some type of injector
which does not required clamping saddle. In the lasering
station the DMC is engraved on the upper side of injector.
These DMC is checked by DMC check station. In these
station each injector is entering in the station and with the
help of scanner upper engraving is checked. If it is not right
part is rejected.

5.1.6 BENCH STATION:

1. Bench1:

On Bench 1 following operations are done:

(a) Coaxiality check

(b) IC stud visual

(c) O-ring mounting

(d) Production cap assembly

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2. Bench 2:

On the Bench 2 following operations are done:

1. Copper washer assembly


2. Magnet angle check
3. Torque check

3. Bench 3:
On the Bench 3 following operations are done:
1. Visual inspection
2. Clamping saddle check
3. Gauge check

5.1.7 VT STATION (VISUAL TOOL STATION):

VT station is the last station on the test line. In these station there
are number of cameras present and they capture image from
various positions and store the image of each injector. After
checking the component the operator install the BFT cap and
nozzle cap.

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 Parameter check of VT station:


1. Position of DMC
2. Laser inscription
3. IC stud cap
4. Magnet cap
5. O-ring

 OPERATION PROCEDURE:
1. At the start of the shift, login the system with E.No. and
E.Name.
2. If type is already loaded then click start button to start the
operation.
3. If type is not loaded then load the job using the option of
select job.
4. Pick up the part from the pallet.
5. Assemble the magnet and IC stud protection cap.
6. Remove the earlier part from the VT fixture and place the
new part.
7. Assemble the protection cap of nozzle and BFT.

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8. Put the dot mark on the washer if applicable (type


specific).
9. Place the finished injector in the green bin.

5.1.8 PACKAGING STATION:

It is the last station on the test line. After testing of each


injector, if it is passed all the test then it is packed in the
packaging box. In each box there are 24 injectors are placed.

There are 2 types of packing:

1. Corolated packing
2. Returnable packing

In corolated packing, the packing boxes are not returned to the


company. The packing material used for these is directly scrap.
The material used for these is generally card board type. These
materials is easily reused. Whereas on the returnable packing the
material used is plastic material. In the returnable packing the
bins in which injector is packed are returned to company for
further use. Because of returnable packing major amount of cost
saving is done as well as less pollution is formed.

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6. WORK PIECE CARRIERS


WPC means ‘Work Piece Carriers’ which carriers the work piece
from one position to another. Work piece carriers is a type of
holding device like Jigs and Fixtures which holds the work piece
carriers for the required operations. Work Piece Carrier is
available in many shapes and sizes according to shapes and sizes
of the component. Work Piece Carriers is help to carry the work
piece from one station to another station. It should be available
in required quantity.

A WPC primary purpose is to create a secure mounting


point to work piece allowing for support during testing and
increased accuracy, precision, reliability, and interchangeability.
It also serves to reduce working time by allowing quick set up
and by something the transition from part to part. It frequently
reduce the complexity of a process allowing for unskilled
workers to perform it and effectively transferring the skill of the
tool maker to the unskilled worker. WPC also allow for a higher
degree of operator safety by reducing the concentration and
effort required to hold a piece steady. Economically speaking the
most valuable function of WPC is to reduce labour costs.
Without a WPC, operating a machine or processes may require
two or more operations using a WPC can eliminate one of the
operation by securing the work piece.

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CLASSIFICATION OF WPC:
Work piece carriers can be classified in various groups but
mostly it is classified according to their diameters.

There are mostly two types of diameters:

(i) 17 Diameter (ii) 19 Diameter

CONSTUCTION OF WPC:
WPC consists of different components:

1. Test cable

2. Aufhname

3. Aufhname holder

4. Base plate

5. Sensor plate

6. ODU plate

7. Spring

8. Dowel

9. MDT

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WORK PIECE CARRIER

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I . TEST CABLE:

It is a type of wiring arrangement which connects the fuel


injector to the power supply for testing of injector. Test cables is
very important component for testing of part. Inside the test
cables there is gold plated electrical terminal which provides the
power supply to injector. The cost of single test cable is around
12,000 to 18,000. The length of test cable is changes according
to type of injector.

It consists of various type of component:

(a) Plastic connector Assembly Component

(b) Cable and Insulation Assembly Component

(c) ODU Assembly Component

II. AUFHNAME:

It is the most important part in the WPC. An Aufhname is a


hollow cylindrical shape component which are available at
different types of bore diameter i.e 17 or 19 diameters. The
upper part of Aufhname consists of two dowel pins which are
made up of stainless steel. On the side of Aufhname there is no.
engraved which is called as L.K Number.

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Types of Aufhname:

(a) 17 Diameters

(b) 19 Diameters

III . AUFHNAME HOLDER:

It is a component which is used to holder Aufhname. A holder is


also classified according to diameters of Aufhname. It is
cylindrical shape component at bottom of cylindrical shape
there is rectangular plate which consists of four holes of equal
sizes.

IV. BASE PLATE :

It is the bottom part of WPC. It is also called as ‘Antistatic base


plate’. When the four base plate is assemble then a full base of
WPC done. It is generally visualize in black color. The main
purpose of antistatic material is to avoid the static elastic shock
which is produced due to continuous movement of base plate in
line.

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V . SENSOR PLATE:

It is most important part of WPC which is mount on antistatic


plate. The main purpose of sensor plate is to guide the WPC
when it is working on the line. Sensor plate is made up of
stainless steel.

VI. BOLTS:
A Bolt is a form of threaded fastener with an external thread
used to connect the two components. It is generally use to
connect the Aufhname holder to the base plate. There are two
types of bolts used in WPC. They are classified according to
their heights.

VII. DOWEL PIN:

A Dowel is a solid cylindrical rod, usually made from steel


material. In its original manufactured form is called a Dowel rod.
The main purpose of dowel pin is to hold the injector in proper
positioning when it is mounting on WPC.

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VIII. SPRING:

Spring is any of several elastic devices used variously to store


energy to absorb shock, sustain the pressure between contacting
surface and to restrict tensional or compressional stresses. A
spring is an elastic abject used to store Mechanical Energy.
When a spring is compressed or stretched from its resting
position, it exert on opposition force approximately to change in
length.

IX. MDT:

It is a data storing device. When a testing of injector is done, the


data which takes after testing is stored in the MDT. There are
various types of MDT available in market.

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7. PROCESS FLOW FOR WPC REPAIR:


Properly identify the defect
and mark the WPC

Keep the WPC on the WPC repair trolley and bring to “Junior factory”

Not Ok
Check Replace MDT
MDT

Ok

Not Ok
Check
Replace antistatic
antistatic

Ok

Check Not Ok
Replace damaged components
Aufhname

If repairable then repair or else


Check Test Not Ok
replace component
Cable

Ok

Clean the WPC load in the trolley and take it to the test line

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8. FUTURE SCOPE

UNIVERSAL WPC: Generally there are two types of WPC


used on testing line. These may be 17 or19 diameter type. When
the type of Injector is changes according to that WPC changes as
well as Aufhname is also changes. When we uses one WPC for
all types of injector these WPC are called as Universal WPC.

In universal WPC there is certain type of adjust of


sliding plate is done. Due to that it can also used for both 17
diameters or 19 diameters injector type. In the universal WPC
all the part of conventional WPC is kept as it is but the holes
arrangement inside the slighting plate is changed. Since in the
sliding plate there are both types of holes arrangement is present
due to that it can be used for any type of injector.

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9. CONCLUSION:
 Reduction in changeover time.
 Increases the production efficiency
 Increases the production of manufactured part in
the company

10. REFERENCES:
 http://m.boschindia.com/en/our-company-1p.html
 http://m.boschindia.com/en/location-detail
8577.html
 http://www.bosch-home.com/in/products.html
 https://www.boschparts.com/en/auto/diesel -
parts/genuine- oc-injectors

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