INDUSTRIAL TRAINING

DONE AT:
MITSUBISHI ELECTRIC
AUTOMOTIVE INDIA PRIVATE
LIMITED
Submitted to:- Submitted by:-
Mechanical Dept Sameer Kumar
Mech. 3rd Year
17001004051
 TRAINING
CERTIFICATE
 Contents
Introduction of Company
Products manufactured
Alternator Current Generator
GMR Sensor
5S Principle
 Introduction of Company
• The Mitsubishi company was founded by Yataro Iwasaki as a shipping firm
in 1870. The Mitsubishi Electric Corporation was founded in 1921, when
Mitsubishi Shipbuilding Co. (now Mitsubishi Heavy Industries, Ltd.) spun
off a factory in Kobe, Japan that made electric motors for ocean-going
vessels.
• It’s operation began in India in mid 1950s and has grown to become one of
the most highly regarded companies in India. It offers a wide range of
innovative and high-quality products for the Indian market, including Air
Conditioners, Visual Information Systems, Power Devices, Photovoltaic
(solar) Solutions, Power Systems, Transportation Systems and industrial
automation machinery.
• Mitsubishi Electric Automotive India Pvt. Ltd. plant is located in
IMT(Manesar) in 21600 m2 area. It employs nearly 500 people.
• Current M.D. of the company is Mr. Yoshito Inaya.
 • Basically, the plant is concerned with manufacturing and assembly process for electronic parts to
cater various automobile needs and demands.
• The plant is divided into various departments:-

Human
Quality Information Sales &
Production Maintenance Resource & Finance
Assurance Technology Marketing
Admin
 Products Manufactured
•Alternator Current Generator: -
Alternators are like A.C. generators
used in automobiles to charge its
battery while the engine is running.

•Electronic control unit/module (ECU):-

An electronic control unit is a device responsible
for overseeing, regulating and altering the
operation of a car's electronic systems.

•GMR sensor: - It is used as crank and

cam positioning sensor to control the fuel
injector in engine.
•Armature: - An armature is the
power-producing component of an
electric machine. The armature can
be on either the rotor or the stator of
the electric machine.

•Electric power steering motor (EPS motor):

-EPS motor helps in power steering of an
automobile.

•Motor control unit (MCU) for EPS motor: -

Motor control unit controls the working of
EPS Motor.
•Purge Control Solenoid Valve: - The purge valve
is the part of the vehicle Evaporative Emission
Control (EVAP) system. The purge valve precisely
controls the amount of fuel vapor that is purged
from the charcoal canister. In modern cars, the
purge valve is an electrically operated solenoid,
that is controlled by the engine computer.
 Alternator Current
Generator
• Alternators are used in modern automobiles to charge the battery and to
power the electrical system when its engine is running.
• The alternator works with the battery to generate power for the electrical
components of a vehicle, like the interior and exterior lights, and the
instrument panel.
• Alternators are typically found near the front of the engine and are driven by
the crankshaft, which converts the pistons' up-and-down movement into
circular movement.
• The power through this circular movement is transferred to pulley of the
alternator to rotate its rotor and generate current.
Working:-

• Alternator works just like an A.C. generator

but the major difference is that in generator
the magnetic field producing part is
stationary and current producing coil rotates
but opposite is the case of alternator.
• The current is generated according to
Faraday’s law of Electromagnetic Induction.
This results in production of A.C. current.
• Then this current passes through the condenser and rectifier and gets converted into
D.C. current. Then it passes through the voltage regulator and attains a constant
voltage and charges the battery.
MODELS PRODUCED

HONDA NISSAN FORD

A005TJ0891ZM
A005TL0191AM A005TZ0781ZM
A005TJ0491ZM
A005TJ0391ZM
A002TJ0291AM A005TZ0782ZM
A005TZ0181AM
CHILD PARTS
 Workstations

Workstations are places in an assembly line where the parts are added in sequence until
the final assembly is produced. By mechanically moving the parts to the assembly work
and moving the semi-finished assembly from work station to work station, a finished
product can be assembled faster and with less labor than by having workers carry parts to
a stationary piece for assembly.
For alternator assembly line these can be summarized into following categories :-
• Press fit machines
• Nut and bolt tightening machines
• Friction check machine
• TIG welding machine
Bearing holder and Bearing is press
Bushes are press Retainer is fitted to
bearing is press fitted to the back Regulator assembly
fitted into rear hold the bearing in
fitted into front end of rotor is prepared.
bracket. front bracket.
bracket. assembly.

Regulator assembly Rotor and pulley are

Rectifier is fitted Silicon is appiled Friction check is
is fitted into rear fitted to front
into rear bracket. inside rear bracket. done on the pulley.
bracket. bracket.

Front and rear

Stator is press Brush pin is inserted
assembly are press Brush holder screws Through bolts are
fitted into rear into the rear
fittted and brush are tightened. tightened.
bracket. assembly.
pin is removed.

Final inspection is
Noise check is Performance check
done and packing is
performed. is done.
done

Assembly procedure(Honda A005TJ0491ZM)

 GMR SENSOR
• Giant Magneto Resistance is a magneto resistance effect observed in multilayers
composed of alternating ferromagnetic and non magnetic conductive layers.
• GMR sensor is used in angle and circular position detection in various applications. Thus,
this type of sensor can be used as crankshaft position (CKP) sensor, camshaft position
(CMP) sensor and automatic transmission (AMT) speed sensor.
• In case of I.C engines the GMR sensor monitors the position and rotational speed of
crank shaft and cam shaft.
• This information is used by engine management system to control the fuel injector or
the ignition system timing and other engine parameters.
MODELS PRODUCED
J5T34371ZM

 J5T34771ZM

 J5T34871ZM

 J5T35072ZM
 Magnet Guide

Base
Holder
assembly

Child Parts Cap Terminal

Plastic
Mould Bush

O-
Ring
 Plastic Mould

Bush Terminal
(inside Cavity)

Cap and holder

O-Ring
assembly
 Workstations
The workstations for GMR sensor assembly process Can be summarised as follows:-
• Moulding machines
• Press fit machines
• Terminal welding machine
• Tie bar cut and terminal bending machine
• Gate cutting and deburring machine
• Terminal height checking machine
• Laser marking and magnetizing machine
• High temperature performance checker
• Pulse checking machine
• O-ring leak checking machine
• Terminal inclination checking machine
• Final inspection table.
Cap and holder are Magnet and guide Cap is press fitted
prepared in are press fitted to Base assembly is to the base Terminal is welded
horizontal injection the holder to press fitted to the assembly to to cap and holder
moulding machine prepare holder holder assembly. prepare cap and assembly
assembly. holder assembly.

Sensor assembly and

Model no. , Company bush are put into mould Tie bar is cut and
no., Lot no., are laser Gates are cut and and housing around it is
Terminal height is terminal is bent to
marked on the gate points are made using injection
assembly and magnet checked moulding in vertical prepare sensor
deburred.
is magnetised injection moulding assembly.
machine.

The assembly is
O-ring is put on the
heated up to Performance check Terminals are Final inspection is
assembly and
135°C(max 155°C) is done at room checked for any done through visual
assembly is checked
and performance temperature. inclination inspection.
for any air leakage
check is done.

Assembly process
 Injection moulding process

• Injection moulding is a manufacturing process for producing parts by injecting molten

material into a mould.
• Raw material under high pressure is injected into a mould which shapes the polymer into
the desired shape.
Horizontal Injection Moulding
Machine
Vertical Injection moulding machine
Machine Equipments:-

• Material tank: It is a container that is filled with new PPS material in the shape of
granules.

• Dehumidifier: A dehumidifier is used to remove moisture content present in raw

material so that mould defects may be avoided.

• Granulator: Granulator is used to grind the sprue and runner part of the moulded part so
that it does not get wasted and reused for moulding.

• Blender: Blender is used to mix the new and ground material.

• Loader: Loader is used to load the material into hopper situated above the tank. Another
loader is used for blending of virgin and ground material.
Mould cleaning process:-

Moulds are cleaned after 4000 shots. The plastic resigns, gaseous particles
and other foreign particles stick to the mould due to its long use. Cleaning is
done in following manner: -
• It is done in a separate mould maintenance area.
• Mould is disassembled into base and blocks.
• Block is disassembled into various inserts.
• These inserts are put into Clipica Ace, a mould cleaning machine.
• After 20 mins they are taken out and kept in water.
• Then they are dried and reassembled.
 5S Principle
5S is the acronym for five Japanese words:-
 Seiri (sort)
 Seiton (systematise)
 Seiso (clean)
 Seiketsu (standardise)
 Shitsuke (self discipline)
THANK YOU