1

CHAPTER 1

INTRODUCTION

1.1 ROBOT SPOT WELDING IN CAR MANUFACTURING COMPANIES:

Spot welding is one of the most mature applications in robotics. The speed,

precision, efficiency, and resulting cost reductions afforded by automated

resistance spot welding are well documented and accepted, particularly in the

automotive industry. However, industry requires that even the most mature

solutions continue to evolve. End users, including experts from the Big Three

automakers, seek ever more speed and economy from their robotic applications.

These engineers want more modular, lighter-weight systems with increased cycle

times and improved end of arm tooling (EOAT), and vendors are answering the

call as new automobile designs require more of their spot welding robots.

Motoman has introduced manipulators specifically for spot welding - the

ES165 and ES200, with 165- and 200-kg payloads, respectively - Fig. 3. These

robots have utilities (air, water, and power) routed in cable harnesses through the

arm and out to the robot wrist. The standard cable harness supports either servo-

controlled or pneumatic guns. The internal harness eliminates the need for supports

and swivels associated with external "dress-out" packages.

"The internal harness for robot motors has been providing years of reliable

service with mean time between failure criteria of 24,000 hours," said Chris

Anderson, Motoman Inc. "Integrating the welding harness provides similar results

and greatly reduces downtime associated with external cables. They wear quicker

due to greater flexing and rubbing on surfaces. Quick connectors facilitate easy

2

changing and it can be scheduled as preventive maintenance with the main robot

motor harness."

Other advantages include reducing teaching time by 20% or more because

off-line programs can be used directly without touch-up due to cable interference,

the cables are integrated in the slim arm profile, allowing better access into

confined spaces, and OEMs like the fact the internal spot harness is covered in the

robot manufacturer's warranty.

FIGURE 1.1 ROBOT SPOT WELDING

The largest source of failure in a robot spot welding cell is the weld gun and

the cabling (robot dress) used to operate the gun. The dynamic action of the robot

motion can fatigue the robot dress, causing downtime, while the spot welding gun

is susceptible to damage from a crash. By putting the weld gun on a stationary

pedestal, the robot dress is minimized as the tool required holding the panel uses

only air and signaling power. The simpler robot dress makes for a more robust

application and more cell uptime, explained Crawford of EOA Systems.

3

1.2 PROBLEM DESCRIPTION:

The Renault Nissan plant was opened on may 2010. This alliance company

started manufacturing cars like Renault fluence, Renault duster, Renault scala,

Nissan terrano, Nissan tiana. These cars are SUV car model. The manufacturing

line and production areas were developed to manufacture like this cars. On June

2012 this alliance company decided to manufacture a car named Nissan micra.

This Nissan micra car is small in size than those suv cars.

In between 2012 – 2015, these three years they are meeting one particular

damage in the car body production that is improper robot spot welding. That is the

spot welding is not placed at a correct area. Due to this problem, the company

meeting a major problem like, waste of time cycle, robot timing, and replacement

cost etc.

FIGURE 1.2 PROBLEM DESRIPTION

4

On Feb 13 2015, senior engineer of the body shop area in Renault Nissan

Company gave us a project to,

Inspect this problem,

Cause and effect of the problem,

How to rectify the problem,

Management theories for analyzing the problem.

Design and fabrication of the problem detecting device.

1.3 AIM

To eliminate roof spot hole.

To eliminate robot waiting time.

To improve Overall equipment effectiveness of the body shop.

To eliminate the body scrap.

To eliminate the body repair time

1.4 OBJECTIVE

Our objective is to inspect and reduce the problem by using both

mechanical engineering theories and management theories to improve

quality and to give the 99.99% of the problem reduction technique.

And our problem detecting device should be in nominal size, less

maintenance, occupying less area, highly accuracy, less cycle time

process, works automatically without manual power.

5

CHAPTER 2

LITERATURE REVIEW

2.1 LASER INSPECTION METHOD FOR WRONG SPOT WELDING:

Laser Projector-Based Spatial Augmented Reality in Industrial Applications

VOLKESWAGEN AND FORD WERE USING THIS METHOD FROM 2012

AUTHOR - JIANLONG ZHOU (DOI 10.1007/978-1-4419-9845-3_13)

SAR in automobile industries:

SAR is used to highlight spot welding to be inspected on an unpainted metal

car part. The use of SAR can help operators to improve the efficiency of spot

welding inspection in an automobile industry. The approach aims to remove the

paper-based operation description sheet from operators’ hands and relieve them

from the heavy tiresome work, in order to improve the accurateness and efficiency

of the inspection of spot welding.

Spot welding inspection in convenient ways:

In the industry of automobiles, the quality of spot welding on car bodies

needs to be inspected in regular intervals. For example, in an automobile company,

a typical car has thousands of individual spot welds. In the process of making the

vehicle, subassemblies are made and these assemblies have around 30–200 spot

welding. The spots have to be checked randomly from one to the next, even if the

same type of part is checked — this has statistical reasons dealing with the

occurrence of false negatives. Operators often do not check all spots on each body.

They only check different certain number of spots on different bodies in a

6

sequence. When all 200 spot welds are checked in a sequence, operators start a

new spot sequence for checking. A variety of different methods are used to check

spot welding: visual inspection, ultrasonic test, and destruction test. The current

procedure that operators use to check spot welding is as follows: the operator has a

drawing of the testing body. The spots to be tested are marked in this drawing.

First, the operator has to find the spot in the drawing. Then he has to find on the

body. After this, he has to choose the corresponding control method to finally

perform the inspection. This manual inspection process has potential problems: the

operator is easy to check wrong locations and wrong numbers of spot welding; it is

also difficult for the operator to remember where to start and where to finish the

checking on the checked body.

Using Laser Projector-Based SAR in Spot Welding Inspection:

SAR benefits to spot welding inspection in the automobile industry. It

facilitates presentation of projected digital AR information onto surfaces in

structured work environments. Specifically, the portable laser projector-based SAR

allows to project visual data onto arbitrary surfaces for the express purpose and

providing just-in time information to users in-situ within a physical work cell. It

enables operators to do the spot welding inspection efficiently and effectively.

In this example, a laser projector mounted on a movable stand is employed to view

and interact with digital information projected directly onto surfaces within a

workspace. SAR provides guidance to operators of the next set of spot welding to

inspect. The data items are projected onto the car body, providing instructions to

operators. This removes the need to constantly refer to the instruction manual such

as the operation description sheet, thus speeding up the operation and reducing

7

2.1.2 ULTRASONIC INSPECTION METHOD FOR WRONG

SPOT WELDING:

Ultrasonic testing of spot-welded joints on coated steel sheets and optimization

of welding parameters

KOREANS AND JAPANEASE MASS PRODUCTION AUTOMOBILE

COMPANIES USING THIS METHOD FOR INSPECTION

AUTHOR - RICHARD KAMINSKI (NO. SD 296)

INFERENCE

The requirement for improved corrosion prevention in today’s automotive

production has led to increased fabrication of galvanized steel sheets. This also

applies in particular to the passenger car type Monde currently produced by

HYUNDAI at Genk (KOREA). The nondestructive ultrasonic testing of spot welds

has been extremely successfully applied by Ford all over Europe, and also in

Taiwan, for many years now. It was at first only used as a supplement to the

classical hammer- and-chisel test method. However, the ultrasonic test method has

meantime proved to be indispensable, especially in connection with galvanized

steel sheets, and in that case mainly in optimizing the parameters of welding

machines for series production. The spots to be tested are marked in this drawing.

First, the operator has to find the spot in the drawing. Then he has to find on the

body. After this, he has to choose the corresponding control method to finally

perform the inspection. This manual inspection process has potential problems: the

operator is easy to check wrong locations and wrong numbers of spot welding; it is

also difficult for the operator to remember where to start and where to finish the

checking on the checked body.

8

PRINCIPLE OF ULTRASONIC TESTING OF SPOT WELDS

A weld spot with an ultrasonic probe positioned on it and transmitting sound

pulses into the weld metal, as well as the echo sequence generated on the screen

display of the ultrasonic instrument. Let us start by assuming that the weld spot

was flaw free. In addition, only one sound pulse is viewed at first this sound pulse

is transmitted from the probe into the weld spot and partially reflected from the

interface between the probe and weld spot. This reflection appears as interface

echo at sound entry (1st indication to the farthest left) on the screen display of the

ultrasonic instrument. The continuous part of the pulse enters the weld spot and is

only reflected from its rear boundary, provided there is no flaw. This reflection is

displayed as 1st back wall echo to the right of the interface echo. The sound pulse

can run several times back and forth between the front and rear end of the weld

spot, and delivers a part of the sound pulse to the probe every time it hits the front

end. This ever decreasing part of sound pulse is displayed as 2nd, 3rd, 4th back

wall echo at the same intervals on the screen. In this connection, the interval

between the individual back wall echoes corresponds to twice the material

thickness (round trip within the material). If there is a flaw in the weld spot, e.g. in

the form of a gas pocket, a part of the sound pulse corresponding to the size of this

flaw is additionally reflected from it. As the flaw is situated between the front and

rear end of the weld spot, the corresponding flaw echoes also occur between the

back wall echoes. In the case of major weld flaws, the flaw echoes are higher and

possibly only recognizable by the fact that the intervals between them are shorter

than those of the back wall echoes.

9

2.1.3 ULTRASONIC TESTING OF SPOT WELDS IN THE

AUTOMOTIVE INDUSTRY

AUTHOR- WERNER ROYE (NO. SD 297)

THE COMPUTER-ASSISTED SPOT WELD INSPECTION

The type of ultrasonic testing of spot welds described above can be carried

out using any portable ultrasonic instrument showing an adequate bandwidth and

consequently also the required resolution of the acoustic signals. With the large

number of spot welds to be inspected, however, it takes quite a lot of time to

document all results by hand. For this reason, many users today make use of the

computer technology in order to automate as many work processes as possible. The

notebook-type ultrasonic instrument USLT 2000 is suitable for the mobile

inspection. It combines all ultrasonic features with the possibilities of state-of-the

art computer technology. The application program Ultra- LOG was especially

designed for the spot weld inspection. It contains the ―live‖ (active) A scan on the

one hand, and the adjustment facilities required for the ultrasonic inspection on the

other hand. Moreover, the Ultra- LOG program features the following functions:

As soon as the inspector has positioned the probe correctly on

the spot weld (it is not yet possible to automate this according

to the state of the art), the A-scan is automatically frozen.

Within the framework of inspection planning, the criteria for

the positions and amplitudes of the first two back wall echoes

are defined for every metal sheet combination.

10

When an echo display has been frozen, the software issues an

evaluation result, in the present example: ―OK‖ since the first

evaluation criterion for the drop in the echo sequence, and also

the second criterion referring to the intermediate echoes which

must not exceed the 10% threshold, are met.

2.1.4 FEATURES AND PERSPECTIVES OF

ELECTROMAGNETIC ACOUSTIC TRANSDUCERS USE FOR

TESTING

AUTHOR- ANDERY A. SAMOKRUTOV (BOOK OF ABSTRACTS. TS3.24.3. P. 88.)

INFERENCE

The methods of electromagnetic acoustic (EMA) excitation and reception of

longitudinal and SH ultrasonic waves with radial and linear polarization with the

Use of constant or pulse magnetizing of signal inductor were researched. The

settings and operation modes for pulse magnetic field were defined, the

magnetizing system was chosen and specifications for the power supply unit for

the electronic unit were developed. The specification for parameters of the EMA

Transducers (EMAT) was defined and the EMATs with apertures from 3 to 10

mm, small in sizes and weights and with high efficiency were developed. The

results of the practical use of EMAT for acoustic thickness measurement and

estimation of the anisotropy level for objects from aluminum alloys, titan, copper,

brass, various carbonaceous and stainless steels are represented. The possibilities

of various EMATs application for assessment of one axial stressed condition at

testing tightening strength of demountable connections and perspectives for testing

of two axial stressed conditions are shown The method of point weld testing of

11

aluminum alloys and various steel plates using EMA devices with pulse magnetic

transducers was considered. Considering that the parameters specifying the

character of the welding process are propagation time, amplitude and bending line

of the echo signal, it is recommended to use devices with EMAT and correlation

signal processing for point welding testing to measure thickness of welding point.

The characteristics of the device with automatic monitoring, when the thickness is

out of the set limits with accuracy up to 0.01mm, allowing automatic control of the

welding points are given The examples of the successful use of EMAT in

aerospace industries and in metallurgic industry are shown, the perspectives of use

in automobile and machine building industries are detailed.

2.1.5 IMPROVEMENTS IN ULTRASONIC INSPECTION OF

RESISTANCE SPOT WELDS

AUTHOR- JOE BUCKLEY

INFERENCE

Resistance welding is an electrothermic process commonly used in Industry

for joining sheet metal, particularly steel, in applications such as automobile bodies

and chassis assemblies. The method is suitable for partial or total automation, and

is very reliable. However, as with any process, problems can occur and inspection

is therefore necessary. Although ultrasonic inspection of spot welds has been used

for many years, the technology still has problems with production rate and

reliability, and is very operator dependent. This paper will look at the analysis of

ultrasonic signals from weld inspection, and present some improvements in both

probe technology and automatic analysis. Together these result in significant

12

improvements in inspection reliability, and allow the inspection to be fully

automated.

2.1.6 A DETAILED STUDY OF DIFFERENT TYPES OF NDT

TECHNIQUES IN INDUSTRIES

AUTHOR - DR. RAJ KUMAR ( TESTING. DIAGNOSTICS. 2003, ¹ 11, PP. 6-8, 13-19.)

INFERENCE

Non-destructive Testing is a very vast field which helps the industries to

check the material they are manufacturing without damaging them. Most of the

industries take up NDT as the premier way to check the products, like Construction

companies, Boiler industry, Automobile industry, Welding setups etc. In different

industries different types of NDT techniques are used like Visual Testing,

Magnetic Particle Testing (MPT), Ultrasonic Testing (UT) and Liquid Penetrating

Testing (LPT) etc. Each technique has its significance and their results may vary,

so we choose the best NDT technique for the product to be tested and in

accordance with the budget. This paper is review papers on different types of NDT

techniques which shows a trend between their working and let the scholars

understand the know-how of latest in NDT.

NDT means Non- Destructive Testing, where any work-piece, product or

material can be tested without harming its integrity. This means if we have

manufactured any product then with the help of any mechanical operation like

welding, forging, casting etc then the strength of that product can be tested without

damaging that product. With the help of NDT we can even check the life of a

product by inspecting its wear and tear and then calculate how long it can be used

13

before getting fractured. NDT is only concerned with the detection and location of

the flaw and after the inspection the defective portions are machined. The need to

use NDT arrived when we could no longer damage our product for the sake of

inspecting it e.g Jet Aircraft, Missiles, Nuclear Energy. Now-a-days NDT is

finding its application in many fields, methods and techniques and it basically

depends upon Material Type, Defect type, Defect Size and Defect Location. Thus

the need and demand of NDT will continue to grow.

Ultrasonic Testing: This method uses ultrasonic waves to detect any type of flaw

within the material. The sound waves are of the frequency of 1MHz to 15 MHz

and usually go up to 50 MHz. The sound waves of such high intensity penetrate

inside the material and are used to detect to internal flaws and disabilities.

Ultrasonic testing is mostly used on metallic structures because it gives high

efficiency, though it can also be used on concrete and wooden elements but the

efficiency reduces to a greater extent and the values obtained are not desirable.

This testing is done with the help of a probe (transducer) which is attached to the

diagnostic machine. A liquid solvent like oil, water etc is added between test

product and the transducer to let the probe move smoothly over the surface of the

product which in turn sends back the signals by reflection or attenuation to the

same probe. More the speed of sound more will be the penetrating effect which in

turn increases the detection strength and accessibility.

14

2.2 DISADVANTAGES OF LASER AND ULTRASONIC

INSPECTION TECNIQUES:

The initial cost of the SPA sensor is high.

There may be chance occurring defect keeping sensor in the helmet.

This inspection occurred only at the final step in the quality area.

This doesn’t reduce cycle time in the company.

If the head of the worker is just deviated, then the inspection area will passed

away.

100% of accuracy is not expected.

This is slow process.

In ultrasonic inspection, it will inspect only two layered sheet in the body,

but the spot occurred in third layer means this ultrasonic waves could not

able to identify the defects.

This inspection is carried out only at the quality area at the end of the

process. Due to this, there will be a waste of time at production and

assembly area.

In lean manufacturing companies, this wastage and time consumption is

playing a major role. So, the quality inspections were not useful for them.

Skilled employees needed to handle this type of inspections.

More time is taken for ultrasonic inspection.

We cannot get 100% defects in these types of inspection.

Due to this inspections, we cannot able to analyses initial step for this defect

arising area, if we find this initial defect area means we easily rectify the

mistake.

15

CHAPTER 3

ALTERNATIVE METHODOLOGY FOR REDUCING THE

DEFECT

3.1 SIX SIGMA METHODOLOGY:

The term Six Sigma originated from terminology associated with

manufacturing, specifically terms associated with statistical modeling of

manufacturing processes. The maturity of a manufacturing process can be

described by a sigma rating indicating its yield or the percentage of defect-free

products it creates. A six sigma process is one in which 99.99966% of all

opportunities to produce some feature of a part are statistically expected to be free

of defects (3.4 defective features / million opportunities), although, as discussed

below, this defect level corresponds to only a 4.5 sigma level. Motorola set a goal

of "six sigma" for all of its manufacturing operations, and this goal became a by-

word for the management and engineering practices used to achieve it.

16

3.2 FLOW CHART:

Defining a problem

in production line

Measuring the dimension of

the system were the problem

is there and design of the

alternative idea should be

generated

The alternative design should be

analyzed here, many parameters is

considered here, like life time of new

device, area covered by device,

accuracy of the device

After installation of the new device,

check the improvement of the

production and to check the working

process

Check our goal got successful

with 99.97% of good defect

fewer products

17

CHAPTER 4

IDENTIFICATION OF SOLUTION METHODOLOGY

4.1 DEFINING THE PROBLEM:

We went to the pallet line were the car body roof got spot welded. Then we

have noticed all the area in the pallet line, that any variation in the seating area.

During the time of discussion we founded that the bottom of the car body doesn’t

properly seated in the clamp of the pallet line. Due to this variation, the top body

roof slightly deviated from its original area. This variation leads to wrong spot

weld. The robot only programmed to weld in the roof area. It does not know that

welding is carried out in the correct area.

FIGURE 4.1 ERRORS IN BODYSEATING

And we have decided to calculate the defects in one day’s production. We

have noticed that every shift i.e. (8 hours), maximum 20 pieces of car body got

defected from this improper seating condition.

18

FIGURE 4.2 ACTUAL SPOT WELDED AREA

FIGURE 4.3 WRONG SPOT WELDING AREAS

And we have referred, latest journals that how they are rectifying this error.

Leading automobile companies, identifying this wrong spot weld error at the

quality area only. By using laser inspection methods and the ultrasonic inspection

method. But in lean in manufacturing for an every wastage is responsible, and they

don’t need an separate area for inspection, because during this time, there will be a

19

waste of time by keeping the robots in off, waiting in assembly section, and

recycling the defect products, at lost this results in increasing in cycle time process.

4.1.1 FISH BONE DIAGRAM (CAUSE AND EFFECT DIAGRAM)

Here, we have decided to design and implement a new device to overcome the this

issue. To do a complete study of the below mentioned factors, have been

completed by brainstorming

20

4.1.2 FACTOR TO BE CONSIDERED FOR OUR NEW DEVICE:

Our inspecting device should be smaller in size.

It shouldn’t disturb the pallet line while inspecting.

Maintenance should be less.

No separate man power needed.

99.9% of accuracy needed.

Cost required for installation is less.

All inspection should be carried out automatically.

Device should cover only less in the production line.

It should be eco friendly.

Less electricity needed to operate.

Less cycle time period..

It should be a combination of electro-mechanical operation.

4.1.3 SELECTING OF AUTOMATION AND MECHANISM FOR

MOVEMENT OF THE DEVICE:

After completing our, we want to give a movement for the device, which

should not disturbs the line and the workers who they are directly involved in the

production process.

We have selected two major mechanisms for the movement for our project,

these mechanisms are experimentally verified in many situations and we have

collected the both advantages and disadvantages of those mechanism and we

finally select a mechanism which should be installed.

21

METHOD 1:

PIVOT MECHANISM

A mechanical linkage is an assembly of bodies connected to manage forces

and movement. The movement of a body, or link, is studied using geometry so the

link is considered to be rigid.[1]

The connections between links are modeled as

providing ideal movement, pure rotation or sliding for example, and are called

joints. A linkage modeled as a network of rigid links and ideal joints is called a

kinematic chain. Linkages may be constructed from open chains, closed chains, or

a combination of open and closed chains. Each link in a chain is connected by a

joint to one or more other links. Thus, a kinematic chain can be modeled as a graph

in which the links are paths and the joints are vertices, which is called a linkage

graph. The deployable mirror linkage is constructed from a series of rhombus or

scissor linkages.

FIGURE 4.5(B) PIVOT MECHANISM SETUP

22

METHOD 2:

SLIDING MECHANISM

Sliding mechanism, arrangement of mechanical parts designed to convert

straight-line motion to rotary motion, as in a reciprocating piston engine, or to

convert rotary motion to straight-line motion, as in a reciprocating piston pump.

The darkly shaded part 1, the fixed frame or block of the pump or engine, contains

a cylinder, depicted in cross section by its walls DE and FG, in which the piston,

part 4, slides back and forth. The small circle at A represents the main crankshaft

bearing, which is also in part 1. The crankshaft, part 2, is shown as a straight

member extending from the main bearing at A to the crankpin bearing at B, which

connects it to the connecting rod, part 3. The connecting rod is shown as a straight

member extending from the crankpin bearing at B to the wristpin bearing at C,

which connects it to the piston, part 4, which is shown as a rectangle.

A slider crank mechanism converts circular motion of the crank into linear

motion of the slider. In order for the crank to rotate fully the condition L> R+E

must be satisfied where R is the crank length is the length of the link connecting

crank and slider and E is the offset of slider . A slider crank is a RRRP type of

mechanism i.e. It has three revolute joints and 1 prismatic joint. The total distance

covered by the slider between its two extreme positions is called the path length.

FIGURE 4.5(B) SLIDING MECHANISM SETUP

23

After making a detailed study about those mechanisms, finally we have decided to

use sliding mechanism for our device movement.

REASON FOR SELECTING SLIDING MECHANISM OVER PIVOT

MECHNIASM:

The installation of sliding mechanism is than the installation of pivot

mechanism kid.

The time cycle of pivot is slower than the slider mechanism.

Some risk is arising in the production line, if we install pivot.

Slider mechanism doesn’t disturb both the line and the workers.

The operation pivot mechanism requires some additional equipment like

springs and compressors

Pivot assembly requires large amount of area in the platform.

Separate lubrication system is required for pivot setup.

Maintenance is required for pivot setup, because even small dust block also

make major defect in pivot mechanism.

A simple linear guide rail is used for the sling mechanism movement.

The economy of installation of sliding mechanism is less than the pivot

setup.

Sliding mechanism can achieve remote operation; facilitate the

implementation of automated casting operations.

The jogging trails that control the motion and hold make the closed door

very secure and ensure that sliding garage openers are amongst the mοѕt

powerful & mοѕt impenetrable systems аbοut. Thеу саn аlѕο be locked іn a

lot of distinct means аnd offer high resistance to wind аnd impact dаmаgе.

24

4.1.4 DESIGNING OF OUR ALTERNATIVE DEVICE:

4.1.4 (A) ROUGH AND PENCIL SKETCH DESIGN:

After finding a problem and factors to be followed, again we went to the line

and we took a measurements that our devices were to be placed and it shouldn’t

disturbs fixed production line.

We have took the measurements like,

1. Basement area of the platform,

2. Measurement of the clamp,

3. Thickness and width of the bottom car body,

4. Distance from platform to clamp,

5. Calculating the time of movement of each car body.

FIGURE 4.6 PENCIL SKETCH DESIGN

25

After finishing the measurements, we have planned to design a device in a

rough sketch manner. And this design should to accurate and must be in clear

manner. Because, we know this rough sketch plays a major role in further

generation of this optimized design.

We have implemented all of engineering graphics skill, here to develop this pencil

sketch.

4.1.4 (B) 3D MODELLING:

After completing our pencil sketch, we again went to the pallet line and we

compare our sketch and real time view. After getting approval from the

engineering department. We have started our designing procedures.

FIGURE 4.7 NX-CAD DESIGN

In nx cad software we can make a design of component to our material which is to

be really used to prepare a material.

26

FIGURE 4.8 LAYOUT OF BSC DEVICE

We have decided to develop design in NX-CAD mechanical software.

Because, nx cad software is user friendly than other software’s like, cero, pro-e,

catia. First we have developed a each component and we have decided to assemble

it separately. Because, if there is any problem in measurement at particular

component, we can change it easy in the part model and we can re-assemble again.

Product and manufacturing information (PMI) is used in 3D CAD and

product development systems to convey design information for manufacturing.

PMI includes information such as geometric dimensioning and tolerance (GD&T),

text annotations, surface finish and material specifications

Sensor carriage block

L- Block component

Guide rail

Base plate

Square tube rod (connecting rod)

27

4.5 COMPONENT DESCRIPTION

4.5.1 TABLE FOR COMPONENT DETAILS:

SL.

NO

COMPONENT USED MATERIAL DIMESIONS

(ALL

DIMENSIONS

IN mm)

NOS

1. L-BLOCK EN8 80×15×80 1

2. SENSOR CARRIAGE

BLOCK

EN8 120×15 1

3. BASE PLATES MS STEEL 300×300×20

120×100×20

200×200×20

1

1

1

4. SQUARE TUBE ROD MS STEEL 80×2000×5 1

5. GUIDE RAIL ALUMINIUM

(GUN

MATERIAL)

2000 LENGTH

WITH TWO

CARRIAGE

2

6. SINGLE ACTING

CYLINDER

_ _ 1

TABLE 4.1 COMPONENT DETAILS

28

4.5.2 REASON FOR USING EN8 MATERIAL AND MILD STEEL

MATERIAL:

EN8 also known as 080M40. Unalloyed medium carbon steel. EN8 is a

medium strength steel, good tensile strength. Suitable for shafts, stressed pins,

studs, keys etc. Available as normalized or rolled. EN8 is supplied as round

drawn/turned, round hot rolled, hexagon, square, flats and plate

EN24 also known as 817m40 comes treated in the T condition to 850/1000 N/mm2

we can offer EN24T in plate from 10mm thick up to 300mm, diameters from

10mm up to 950mm, squares from 20mm to 300mm and flats 20 x 10 up to 3000 x

300mm from stock. AISI 4340, worst-off 1.6565.

ADVANTAGES OF EN8 MATERIAL

EN8 or 080m40 can be tempered at a heat of between 550°C to 660°C

(1022°F-1220°F), heating for about 1 hour for every inch of thickness, then cool

in oil or water. Normalizing of EN8 bright mild steel takes place at 830-860°C

(1526°F-1580°F) then it is cooled in air. Quenching in oil or water after heating

to this temperature will harden the steel.

Chemical Composition of EN8 Steel

Min 0.35 0.60 0.05 0.015 0.015 0 0 0 0

Max 0.45 1.00 0.35 0.06 0.6 0 0 0 0

TABLE 4.2 EN8 CHEMICAL COMPOSITIONS

29

Mechanical Properties of EN8 Steel

Modern EN8 bright mild steel contains a lot less carbon then it use to, this

mean that it is possible to weld pieces up to 18mm thick without preheating using

MIG wire (SG2) or a 7018 electrode. Over 18mm would require a pre-heat of

100°C (212°F) in order to prevent cracking. Anneal afterward is recommended to

prevent breaking.

Condition Yield

Stress

x 106 Pa

Tensile

Stress

MPa

Elongation

%

Normalized 280 550 16

Cold drawn

(thin)

530 660 7

TABLE 4.3 EN8 MECHANICAL PROPERTIES

MILD STEEL MATERIAL

To create MS steels, the austenite that exists during hot-rolling or annealing

is transformed almost entirely to martensite during quenching on the run-out table

or in the cooling section of the continuous annealing line. The MS steels are

characterized by a martensitic matrix containing small amounts of ferrite and/or

bainite .Within the group of multiphase steels, MS steels show the highest tensile

strength level. This structure also can be developed with post-forming heat

treatment. MS steels provide the highest strengths, up to 1700 MPa ultimate tensile

strength. MS steels are often subjected to post-quench tempering to improve

ductility, and can provide adequate formability even at extremely high strengths.

30

FIGURE 4.8 MECHANICAL PROPERTY OF MILD STEEL

4.6 LIST OF MACHINING PROCESS DONE.

The following machining process adopted in BSC device,

Hardening en8 material,

Milling operation,

1. Face milling,

2. Thread milling.

Cutting operation in CNC machine,

Tapping and drilling operation

Grinding operation,

Welding operation,

1. Plasma arc welding operation,

2. Gas welding operations.

31

4.7 INSTALLATION OF BSC DEVICE:

After assembling the component, the device is to be installed in the

production line, before installing the device, the basement area of the platform is to

be measured for removing. Here accurate measure is to be taken, because if excess

amount of material is as been removed, there will be a problem raised in line. So,

we have take measurements easily.

And we also want to keep in mind the, there is horizontal and vertical sensor

placed in the platform, so during the time of installation, those sensors must be in

safer condition. Our device should not damage any important component in the

pallet line.

FIGURE 4.9 INSTALLATION OF BODY SEATING

CONFORMATION DEVICE

Body seating

Sensing device

Car body

Platform

32

4.8 FEEDING THE PROGRAM IN THE SYSTEM:

After installing the device in the line, the program for automation is to be

developed ant it should be coded in the controlling system which is placed in the

quality and production area, there will separate operator will be there to control

this device. Programmable logic controller unit is used to operate this device,

this program were is very easy to develop and it is user friendly.

FIGURE 4.10 PLC LADDER DIAGRAM OF CONTROLLING BODYSEATING

CONFORMATION DEVICE

33

The input sources convert the real time analog electric signals to suitable

digital electric signals and these signals are applied to the PLC through the

connector rails. These input signals are stored in the PLC external image memory

in locations known as bits. This is done by the CPU The control logic or the

program instructions are written onto the programming device through symbols or

through mnemonics and stored in the user memory.

The CPU fetches these instructions from the user memory and executes the

input signals by manipulating, computing, processing them to control the output

devices. The execution results are then stored in the external image memory which

controls the output drives. The CPU also keeps a check on the output signals and

keeps updating the contents of the input image memory according to the changes in

the output memory. The CPU also performs internal programming functioning like

setting and resetting of the timer, checking the user memory. The operation of a

programmable controller is relatively simple.

The input/output (I/O) system is physically connected to the field devices

that are encountered in the machine or that are used in the control of a process.

These field devices may be discrete or analog input/output devices, such as limit

switches, pressure transducers, push buttons, motor starters, solenoids, etc.

Although not generally considered a part of the controller, the programming

device, usually a personal computer or a manufacturer’s mini programmer unit, is

required to enter the control program into memory. The programming device must

be connected to the controller when entering or monitoring the control program.

34

CHAPTER 5

IMPLEMENTATION AND OBSERVATION OF BSC DEVICE IN

PRODUCTION LINE

5.1 PRODUCTION LINE CONTROLLING UNIT:

FIGURE 5.1 PRODUCTION LINE CONTROLLING UNITS

The above chart explains that, our body seating device is controlled with

statistical evaluation data with computing manipulated. The PLC data is coded in

the production and quality controlled area, this inspects the operation of the device

and it will typically used to see the cycle timing of the inspection. This computer

controlled device mounted in production line A1 and A2.

35

These A1 and A2 line only carried out the hemming and spot welding

operations. So our device is used in this area only. B and C are the testing area, i.e.

if there is any error occurred in line A1 or A2 the workers from these area will

inspect the error occurred and they will rectify these error.

This error information is given from the production department. Because,

our device is installed in production line. In quality area they will control only the

timing operation of the device. So, the wasting of time in quality is reduced by

improving defect less production of material in production area itself.

OPERATION DONE BY B AND C TESTING AREA

In production line, the shop test methods include the shear down test, the

destructive chisel test and the nondestructive chisel test. In the shear down test and

the destructive chisel test, the spot welds are subjected to stress until they break

using simple test means, without recording a measured value. Used as evaluation

criterion is the type of the breakage and the size of the ruptured nugget. The

quantity of test scrap cause considerable cost.

The advantage of the chisel test lies in the fact that it can also be used on a

finished component, e.g. on a shell. However, it is mostly used as a nondestructive

test in these cases, i.e. load is not applied all the way up to the breakage of the

welded joint. The costs for this test are comparably low, but so is also the value of

its test results. This applies in particular to the nondestructive chisel test. It can

only be used for detecting defective spot welds whose strength already lies far

below the permissible minimum value, e.g. so-called ―stick welds‖. Besides, due to

the relatively indefinite test conditions which cannot be kept constant, the test

results vary within wide limits.

36

5.2 DEPLOYMENT OF BSCD IN PRODUCTION LINE

FIGURE 5.2 BODY SEATING CONFORMATION DEVICES

When the car body reaches the area of spot welding, the conformation

device movies forward, and this movement is carried by using linear guiderail,

which is fixed at the base. During time when the body reaches to that area, the

horizontal sensor placed in the platform will give digital pulse to the plc controller,

and it gives signal to the automation system which is connected to the air

compressor. This air compressor supplies air to the single acting cylinder was that

is mounted in the base of the device at carriage on the guide rail. After the setup

moves forward near to the clamp area, the sensor which is placed in the l-block

structure will start to sense the variation, if there is positive result, the normal 0 and

1 signal is send to the controller and the production line moves normally.

If there is any defect or variation in the clamp seating area the sensor will

sense this variation and send reverse signal 1 and 0 to the controller, there the

controller circuit will lock the gate and stops the production line. Until this both

37

quality and production area will control the operation. After detecting the defect

the variation data will send to the production controller, here quality controller

doesn’t receive these data because, these defect is going to rectify in production

area itself.

After receiving these data, production department will send the service or

operating engineer to the line and they will rectify the variation and improper

seating condition.

FIGURE 5.3 PROPER SEATING CONDITION

Actual

seating

position

Car body

38

CHAPTER 6

CONCLUSION

After implementing this device, 99% of the defects were founded and

rectified.

The cycle time of the production rapidly reduced from 15sec to 7sec.

There no separate team to control this device, so manual work stress is

reduced.

FIGURE 6.1 BEFORE INSTALLATION OF BSC DEVICE

FIGURE 6.2 RESULT AFTER INSTALLATION OF BSC DEVICE

Accurate spot

welding after

seating

inspection

39

REFERNCE

[1] Mirosh Y.M., Medushevsky L.S. Providing stability of production quality for

complex products. NDT world. 2001. № 4 (14). Pp. 19-20.

[2] Samokrutov A..A.; Bobrov V.T.; Shevaldykin V.G. and others EMA thickness

gauge for aerospace industry. – XVI Russian scientific-technical conference «Non-

Destructive Testing and Diagnostics», St.- Petersburg, 2002. Thesis of Conference,

abstract 4.5.38, pp. 48.

[3] Samokrutov A..A.; Bobrov V.T.; Shevaldykin V.G.; Kozlov V.N.; Alekhin

S.G.; Zhukov A..V.: Application of EMA thickness gauge A1270 for aluminium

alloy testing, NDT World 2002 № 4, pp. 24-27.

[4] Samokrutov A.A.; Bobrov V.T.; Shevaldykin V.G.; Kozlov V.N.; Alekhin

S.G.; Zhukov A..V.: Anisotropy researches of rolling and its influence on the

results of acoustic measurements, Testing. Diagnostics. 2003, № 11, pp. 6-8, 13-

19.

[5] Samokrutov A.; Alekhin S.; Ivchenko S.; Bobrov V.: The industrial wall

thickness testing of paneling body of ―PROTON‖ rocket. The 3rd International

Conference and Exhibition ―Non-destructive testing and technical diagnosis in

Industry‖(Moscow, 2004). Program and Thesis of Conference, p. 245.

[6] V. Roe Ultrasonic testing of spot welds in automobile industry.

http://www.geinspectiontechnologies.com/ProductLiterature/index.html

40

ANNEXTURE I

COMPANY PROFILE

TYPE Joint venture

INDUSTRY Automotive

FOUNDED May 2010

HEADQUARTERS Chennai, Tamil Nadu,

India

KEY PEOPLE Mr.Sano Toshikhio,

MD & CEO[1]

PRODUCTS Automobiles

PARENT

Renault Nissan

SUBSIDIARIES

Renault India

Private Limited

Nissan Motor

India Private

Limited

WEBSITE www.nissan.in

www.renault.co.in

41

HISTORY

In February 2008, Renault-Nissan Alliance signs Memorandum of Understanding

with Government of Tamil Nadu to set up a manufacturing plant in Oragadam near

Chennai.[2]

Work on the plant began in June later that year and was completed in a

record 21 months. Renault Design India, the first vehicle design studio set up by a

foreign manufacturer in India, was established in Mumbai in September 2008. The

design house is integral to Renault’s success in India as one of its functions is to

monitor customer trends and customise global products for India.

OPERATIONS

In September 2008, Renault India opened its fifth global vehicle design studio in

Mumbai.[3]

In March 2010, Renault India and Nissan India opened a production facility in

Chennai.[4]

Established with an initial investment of Rs 45 billion (US$750

million), the plant has a combined annual capacity to produce 480,000 vehicles.[5]

As of May 2014, Renault India has 130 dealerships in 16 cities across 9 states and

2 Union Territories.[6]

MODELS

Renault sales commenced in May 2011 with the Fluence sedan. This was followed

in September by the Koleos SUV.[4]

In 2012 Renault launched three further

models; the Pulse hatchback in January, the Duster in July 2012, and the Scala in

August 2012. In 2014, aside from the launch of the all-new Fluence and Koleos,

Renault also launched the Duster Adventure Edition.

42

MILESTONES

2008

Renault-Nissan Alliance signs Memorandum of Understanding with

Government of Tamil Nadu to set up a manufacturing plant in Oragadam

near Chennai

The Renault DeSign Studio opened in Mumbai. It is one of the 5 satellite

global design studios for Renault, monitoring customer trends and helping

customize global products for India.[7]

Launch of International Logistics Network (ILN) in Pune handling

components sourced from Indian suppliers for all Renault-Nissan Alliance

production plants worldwide, in particular South Africa & Brazil.

2010

Inauguration of the Renault-Nissan Alliance manufacturing facility in

Chennai (investment of Rs. 4500 crores with a capacity to produce 480,000

cars per year).

2011

Renault launches its first car in India, the Fluence.

Renault – Nissan Alliance manufacturing facility rolls out its 100,000th car.

All new Koleos global launch in India.

Announcement of localization of the Renault K9K diesel engine.

K9K powered Renault Pulse unveiled at the 2011 Indian Grand Prix by

Formula1 drivers Mark Webber and Karun Chandok.[8]

43

2012

Renault launches the Pulse and unveils the Duster at the New Delhi Auto

Expo 2012.[9]

Renault Scala launched in New Delhi.

2013

Inauguration of the new warehouse for the Renault Alliance International

Parts Center (IPC) in Pune.

Renault launched the Gang Of Dusters, the official community for Duster

owners.[10]

Since the launch of the brand in early 2011, Renault has won over 43 awards

till date. The Renault Duster alone receiving 29 awards.

Inauguration of the new warehouse for the Renault Alliance International

Parts Center (IPC) in Chennai as a part of expansion.

MANUFACTURING FACILITIES

Renault Nissan Automotive India Private Limited have their manufacturing plant

in Oragadam near Chennai. The plant has a capacity of 400,000 vehicles per

annum. The capacity is divided equally between Renault India Private Limited and

Nissan Motor India Private Limited.[2]

Renault is constructing a small car powered

by an 800cc engine, to compete with Maruti Suzuki's Alto, Hyundai India's Eon

and Chevrolet's Spark, in the segment, that makes up for about 40-45% of India's

car market. RNAIPL has achieved production target of 5,00,000 lakhs vehicle in

the month of October 2013 in the short span of 40 months after start of production.

RNAIPL is one of the most profitable company which adopts Japanese

manufacturing policy of GENBA KANRI. The company works on the style of

44

maximum productivity with minimum resources. But, in due course this

manufacturing strategy sometimes frustrates its employees. The small car is likely

to be rolled out from the Renault Nissan Alliance plant in Chennai and to hit the

market in 2014-15.[3]

MODELS

RENAULT

1. Renault Fluence (Launched 2011)

2. Renault Koleos (Launched 2011)

3. Renault Pulse (Launched 2012)

4. Renault Duster (Launched July-2012)

5. Renault Scala (Launched 2012)

NISSAN

1. Nissan X-Trail (Launched 2005)

2. Nissan Teana (Launched 2007)

3. Nissan 370Z (Launched 2010)

4. Nissan Micra (Launched 2010)

5. Nissan Sunny (Launched 2011)

45

ANNEXURE II

1. LATEST LASER TECHNIQUES INSPECTION

FIGURE A.1 LASER TECHNIQUE METHOD

FIGURE A.2 CONCEPT ILLUSTRATION OF COMBINING LASER PROJECTOR-

BASED SAR AND HMD-BASED AR FOR COLLABORATIONS

46

FIGURE A.3 VIEW PONT INSPECTION

2. ULTRASONIC INSPECTION TECHNIQUES

FIGURE A.4 MANUAL ULTRASONIC TEST

47

FIGURE A.5 THE INTEGRATION OF DRAWINGS INTO UITRALOG

3. TECHICAL ABBREVATIONS

BSCD - BODY SEATING CONFORMATION DEVICE

SPA - SPATIAL AGUMENTED SENSOR

PLC - PROGRAMMABLE LOGIC CIRCUITS

CNC - COMPUTER NUMERICAL CONTROL

LIM – LASER INSPECTION METHOD

4. BASIC PLC CODINGS USED

M1266 Disable the external control signal input point of HHSC1 reset signal

point (R)

M1267 Disable the external control signal input point of HHSC1 start signal

point (S)

M1268 Disable the external control signal input point of HHSC2 reset signal

point (R)

M1269 Disable the external control signal input point of HHSC2 start signal

point (S)

48

M1270 Disable the external control signal input point of HHSC3 reset signal

point (R)

M1271 Disable the external control signal input point of HHSC3 start signal

point (S)

M1272 Internal control signal input point of HHSC0 reset signal point (R)

M1273 Internal control signal input point of HHSC0 start signal point (S)

M1274 Internal control signal input point of HHSC1 reset signal point (R)

M1275 Internal control signal input point of HHSC1 start signal point (S)

M1276 Internal control signal input point of HHSC2 reset signal point (R)

M1277 Internal control signal input point of HHSC2 start signal point (S)

M1278 Internal control signal input point of HHSC3 reset signal point (R)

M1279 Internal control signal input point of HHSC3 start signal point (S)

M1289 High speed counter I010 interruption forbidden

M1290 High speed counter I020 interruption forbidden

M1291 High speed counter I030 interruption forbidden

M1292 High speed counter I040 interruption forbidden

M1293 High speed counter I050 interruption forbidden

M1294 High speed counter I060 interruption forbidden

M1312 C235 Start input point control

M1313 C236 Start input point control

M1314 C237 Start input point control

M1315 C238 Start input point control

M1316 C239 Start input point control

M1317 C240 Start input point control

M1320 C235 Reset input point control

M1321 C236 Reset input point control

M1322 C237 Reset input point control