Asia Motor Work (AMW) Project

VOCATIONAL TRAINING 2013
AMW
Asia Motor Works
Vocational Training
Project Report
Submitted By:
Abhishek Jumwal
B.Tech. ME
1154337
Guided By:
Mr. Ramesh Sharma
( Workmanager )
ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH
Page 1
ACKNOWLEDGEMENT
I would like to thank the following people for helping
me in completing the vocational training at Asia Motor
Works. Without them it would not have been possible
for me to get practical knowledge.
I am grateful to Mr. Vivek Bhardwaj, Head - Bhagat
Motors (UNA) for giving me the opportunity to
undergo training in AMW (Bhagat Motors).
Mr. Ramesh Sharma (Work Manager), Chintan
Padhiyar (Senior Engineer) - Bhagat Motors who has
guided me throughout my training period.
Page 2
LAYOUT OF AMW WORKSHOP UNA
Page 3
MEMBERS OF AMW WORKSHOP UNA

RAMESH SHARMA
WORKS MANAGER
VIRENDER BANYAL
STORE MANAGER
CHINTAN PADHIYAR
SENIOR ENGINEER
MOHAN LAL
SUPERVISOR
VARUN SHARMA
SUPERVISOR
SHUBAM SHARMA
ADVISOR
BALVINDER KUMAR
ADVISOR
AKHIL CHOUDHARY
MECHANIC
RAKESH KUMAR
HEAD MECHANIC
KARAN SHARMA
HEAD MECHANIC
JASWINDER KUMAR
MECHANIC
MUKESH KUMAR
HEAD MECHANIC
AJAY KUMAR
ELECTRICIAN
DARSHAN LAL
MECHANIC
JAGDISH SINGH
MECHANIC
SHASHI PAL
HELPER
VINOD KUMAR
HELPER
ANKUSH KUMAR
HELPER
Page 4
CONTENTS
o INTRODUCTION
o FACILITY AT WORKSHOP
o OVERVIEW OF WORKSHOP
o INVESTIGATION PROJECT
Page 5
INTRODUCTION
Asia Motor Works Ltd (AMW) manufactures commercial vehicle, auto components, fully
built vehicles and forged components, in India. Founded in 2002. AMW is India's third
largest manufacturer of heavy commercial vehicles, having achieved a unique position in the
country's transportation sector through innovative engineering and customer orientation. We
are the fastest growing truck brand in India with a volume growth of over 100% for the last
three years. Our world class trucks are manufactured at a state of the art, 50,000 units per
annum plant in Bhuj, Gujarat.
AMW's trucks incorporate some of the best automotive technology from around the
world like a 9-speed gearbox and 380 mm power-assisted clutch.
Engineering Excellence
Providing complete solutions from design to delivery
AMWs vision rests on three pillars providing world class quality, delivering on time
and maximizing the economic advantage of large scale. Our integrated
manufacturing facility at Bhuj is built to optimize on all three.
Customer Satisfaction
Delivering customer satisfaction is our number one priority
At AMW, the customer is the focus of our operations, and delivering customer
satisfaction is our number one priority. We aim to do it by delivering products that
score high on safety and quality, so that the customer enjoys a good driving
experience and enjoys a high return on investment.
Social Responsibility
Leading with initiatives on employment
AMW is an active participant in the development of the local communities, leading
with initiatives on employment, community building, health and the environment.
Page 6

AMW PRODUCTIONS:
Tippers
Tractors
Haulage
Transit Mixers
Concrete Pumps
Fully Built Vehicles
Operations
The manufacturing facility of AMW is located in Bhuj, Gujarat, in the western region of
India. The capacity for commercial vehicles is at 50,000 annually. The company has capacity
for tipper bodies, fabricated components, pressed metal and frames for chassis production.
AMW manufactures components for the automotive and general engineering industries.
AMWs capacity of 15 million wheel rims makes it the largest single location plant in Asia.
The company supplies pressed metal components to the worlds auto and white goods
manufacturers. AMW has over 60 touch points across India.
Type
Private company
Industry
Automotive and auto components
Founded
2002
Founder(s)
Anirudh Bhuwalka
Headquarters Mumbai, Maharashtra, India[1]
Key people
Anirudh Bhuwalka
(MD & CEO)
Products
Website
Commercial Vehicles
Auto Components
Road Safety Solutions
Forgings
www.amwasia.com
Page 7
PRODUCTS
Commercial Vehicles
A commercial vehicle is any type of motor vehicle used for transporting goods or
paid passengers. The European Union defines "commercial motor vehicle" as any
motorized road vehicle, that by its type of construction and equipment is designed for,
and capable of transporting, whether for payment or not: (1) more than nine persons,
including the driver; (2) goods and "standard fuel tanks". This means the tanks
permanently fixed by the manufacturer to all motor vehicles of the same type as the
vehicle in question and whose permanent fitting lets fuel be used directly, both for
propulsion and, where appropriate, to power a refrigeration system. Gas tanks fitted to
motor vehicles for the direct use of diesel as a fuel are considered standard fuel tanks.
Contents
1. Commercial classification
In the United States a vehicle is designated commercial when it is titled or registered to a
company. This is a broad definition, as commercial vehicles may be fleet vehicles, company
cars, or other vehicles used for business. Vehicles that are designed to carry more than 15
passengers are considered a commercial vehicle.
A vehicle may be considered a commercial vehicle if it is:
Belongs to a company or corporation

Used for business, but is in an individual's name, such as a sole proprietor
A leased vehicle and in the name of the financial institution that owns it
Exceeds a certain weight or class and therefore is "classified" as commercial even
though it may not be commercially used or commercially owned. A weight rating of
26,001 pounds or more is always consider commercial.
Used to haul any hazardous material
A vehicle can be used for a business, if not exclusively, and remain privately licensed,
depending on the amount of time used for business
Page 8
2. Examples of commercial vehicles

1.Truck
2.Semi truck (articulated lorry)
3.Van
4.Coach
5.Bus
6.Taxicab
7.Trailers
8.Box truck (also known as a straight truck)
3. Commercial truck classification

Commercial trucks are classified according to the Gross vehicle weight rating (GVWR).
The United States Department of Transportation classifies commercial trucks with eight
classes:
Class 1- GVWR ranges from 0 to 6,000 pounds (0 to 2,722 kg)

Class 2- GVWR ranges from 6,001 to 10,000 pounds (2,722 to 4,536 kg)
Class 5- GVWR ranges from 16,001 to 19,500 pounds (7,258 to 8,845 kg).
Class 8- GVWR is anything above 33,000 pounds (14,969 kg)
Page 9
Gross vehicle weight rating
The gross vehicle weight rating (GVWR), or gross vehicle mass (GVM) is the maximum
operating weight/mass of a vehicle as specified by the manufacturer[1] including the vehicle's
chassis, body, engine, engine fluids, fuel, accessories, driver, passengers and cargo but
excluding that of any trailers.[2] The term is used for motor vehicles and trains.
The weight of a vehicle is influenced by passengers, cargo, even fuel level, so a number of
terms are used to express the weight of a vehicle in a designated state. Gross combined
weight rating refers to the total mass of a vehicle, including all trailers. GVWR and GCWR
both describe a vehicle that is in operation and are used to specify weight limitations and
restrictions. Curb weight describes a vehicle which is "parked at the curb" and excludes the
weight of any occupants or cargo. Dry weight further excludes the weight of all consumables,
such as fuel and oils. Gross trailer weight rating specifies the maximum weight of a trailer
and the gross axle weight rating specifies the maximum weight on any particular axle.
POWERED BY PERFORMANCE
Class-leading trucks
Dependability, low operating costs, panoramic visibility, unsurpassed handling, high driver comfort
and easy maintenance. No wonder they are rated as the hardest working trucks on the road today.
Adverse conditions bring out the best in the toughest of trucks. AMW trucks have excellent driving
characteristics even on difficult terrain and in adverse climatic conditions.
The higher carrying capacity of AMW trucks increases operating efficiency and engines comply with
Euro Ill norms. Advanced technology from the worlds most reputed suppliers of components ensures
that AMW trucks are able to deliver better value to customers.
Ideally suited for haulage and special purpose applications.
Engineered to provide higher operating efficiencies, lower fuel costs and world-class
performance.
AMW trucks come with a range of features that ensure best-in-class

performance.
A. Engine
Page 10

Powered by best-in-class 180 HP & 215 HP Cummins engines, AMW trucks easily handle
upward inclines and other tough conditions.
B. Gearbox
AMW trucks come with a technologically advanced gearbox from ZF, Germany and Eaton.
With a gear ratio of 13.1621 enabling a highly improved start-up, even with very heavy loads
and in difficult conditions.
C. Chassis
Page 11

A sturdy frame-in-frame chassis offers high reliability and durability
The chassis of an automobile consist of following components suitably mounted:
1. Engine and the radiator
2. Transmission system, consisting of the clutch, gearbox, propeller shaft and the rear axle
3. Suspension System
4. Road Wheel
5. Steering system
6. Brakes
7. Fuel tank
All the components listed above are mounted in either of the two ways, the conventional construction,
in which a separate frame is used and the frameless or unitary construction in which no separate
frame is employed. Out of these, the conventional type of construction is being used presently only for
heavy vehicle whereas for car the same has been replaced by the frameless type or the monocoque
chassis is manufacture, who still find it economical two use frame.
Chassis are classified as :
1. Conventional control chassis
2. Semi forward control chassis
3. Full forward control chassis
D. Bogey suspension
The unique bogey suspension adds to the vehicles tenacity, and aids comfortable handling even in
the roughest terrain.
Page 12
E. Air-conditioned cabin
AMW trucks provide the most comfortable and safe driving experience for the driver. With a worldclass ergonomic design, energy absorbing steering wheel for safety, and entertainment facilities like a
stereo FM and CD player, these vehicles ensure that the driver is comfortable and therefore able to
give his best.
Page 13
Integrated Manufacturing Facility

The 515 acre plant at Bhuj, Gujarat forms the backbone of the companys truck manufacturing
operations in India. State-of-the-art plants, assembly lines, a specially designed frame shop, a
completely automated paint shop, in-house R & D facilities, and a modern warehouse ensure that
only trucks of international quality roll out from these premises.
FRAME SHOP
AMW builds robust chassis systems, specially designed for Indian roads. The rock-sturdy in-frame
chassis is a fine example. The unique, in-frame structure of each truck chassis improves vehicle
balance, handling, ride characteristics, and maneuverability.
ASSEMBLY LINE
AMW takes pride in providing high quality and value at every stage of the manufacturing process.
After pre-assembly, carriages, bodies, engines and other parts are assembled on a semi-automated
modern assembly line, where the bare chassis is brought in and leaves as a fully integrated AMW
world-class truck.
CAB WELD SHOP

The automated cab welding facility manufactures a wide range of cabs for different trucks. With the
focus on increased productivity and quality, the cab welding shop is an integral part of AMWs
truck manufacturing facility.
FULLY AUTOMATED PAINT SHOP

A fully automated paint shop, designed by Durr, Germany offers superior coating and finish
properties. The paint shop has state-of-the-art coating lines for cabs, with advanced equipment and
coating technology.
Installed Capacity 50,000 vehicles per year
QUALITY
AMW prides itself on employing only world-class technologies and manufacturing practices.
At AMW, meeting and exceeding the expectations of valued customers remains the prime focus at all
times. Quality assurance teams conduct simulated and field trials on every product. AMW has set the
highest standards for quality with TS 16949 ready systems and processes.
SAFETY
Safe manufacturing practices are a high priority at the AMW plant in Bhuj. AMWs safety program
encompasses Health, Safety and the Environment. Engineers and managers constantly bring in
improvements in manufacturing practices and technology to ensure a hazard-free work place. Another
critical aspect of the AMW safety program revolves around the driver who is a key factor in any
transport activity. A safe working environment for the driver means higher productivity and lower
operating costs.
Page 14

VRDE Certification and Testing
AMW trucks go through independent validating tests to verify, validate and certify their performance,
durability and reliability. This includes variants as well as new features and product improvements.
The tests cover all critical parameters such as maximum speed, acceleration through gears, braking
deceleration, stopping distance, steering effort, pass by and in-cab noise, cooling, grade ability, water
wading, stability etc.
On-road fuel consumption tests are carried out as per pre-determined cycles to predict fuel
consumption under a variety of traffic and terrain conditions. AMW has entered into an agreement
with the Vehicle Research and Development Establishment (VRDE), a Government of India
Undertaking, under which validation of the structural durability of vehicles is carried out on the
Belgian Pave and Torture Tracks at VRDE, Ahmednagar.
After-sales Service, Spare parts

AMWs strong dealership network, authorized service centers and spare parts outlets ensure that
vehicles run with maximum up-time and minimum stoppage of work. AMWs dealer network is one of
the fastest growing networks, spread across the length and breadth of the country. Its authorized
service centers and spare parts outlets are strategically placed in almost every city to provide
customers sales, service and spare parts support anywhere, anytime.
Awards
Customer satisfaction is the highest award. Yet, it is satisfying to be recognized by industry experts
and peers. Voted Truck of the year for 2008 by NDTV, AMW leads the way, offering pride of
ownership with unmatched commercial value. AMW also won the Innovation of the year award in
2010. This was for a very long truck, in which four wheels are turned by the steering wheel; an
innovation that enhances maneuverability, eliminating the need for articulation.
Fully Built Vehicles

AMW manufactures a wide range of Fully Built Vehicle Solutions for on-road and off-road
applications.
The chassis is designed for use as Tippers, concrete mixers, mobile cranes and other specialpurpose bodies. The AMW range includes box body and rock body Tippers, Tip-Trailers and Trailers.
TIPPERS
AMW Tippers are manufactured in a state-of-the-art plant, with a robotic welding system. They are
designed for strength, built to high quality standards, and are proven products, ready to meet arduous
challenges.
Page 15
TRAILERS
AMW Trailers are built in a technologically advanced facility and go through stringent quality
processes. Custom-designed to suit varied applications, AMW Trailers are sturdy, durable vehicles,
increasingly sought after by discerning customers. AMW will soon add Transit Mixers, Bulkers and
Tankers to its already large product portfolio in the near future.
For customers, the AMW range of Fully Built Vehicles allows for immediate revenue, as they can be
quickly attached to trucks or prime movers and deployed for work in various areas without any
waiting time for fabrication or modifications.
INSTALLED CAPACITY
Tippers - 12000 per year
Trailers - 4000 per year
Page 16
FACILITY AT WORKSHOP
Bhagat Motors deals with the sales/services/repairs of the vehicle. There are
enough facilities in the workshop. There are many types of repairs of the
components of the trucks can be done within the workshop. The plant does not
only the repair facility but it also has the facility of spares and parts. All types of
useful parts are available in the spares shop. It also sales the new trucks. They
make sure a better service always made available to customer. For the new
workers, laborers, and trainees, a training department has been established. A
quality assurance department is also there along with marketing department
which takes care of the better service provided for the customers.
Repairs facilities at the workshop

i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Engine service
Gear box repair
Differential repair
Axle alignment
Water wash
Denting
Chassis alignment
Body repair
Page 17
INVESTIGATION PROJECT
ENGINE WORKING
A diesel engine (also known as a compression-ignition engine) is an internal combustion
engine that uses the heat of compression to initiate ignition to burn the fuel that has
been injected into the combustion chamber. This contrasts with spark-ignition engines
such as a petrol engine (gasoline engine) or gas engine (using a gaseous fuel as opposed
to gasoline), which use a spark plug to ignite an air-fuel mixture.
The diesel engine has the highest thermal efficiency of any standard internal or external
combustion engine due to its very high compression ratio. Low-speed diesel engines (as
used in ships and other applications where overall engine weight is relatively
unimportant) can have a thermal efficiency that exceeds 50%.
Diesel engines are manufactured in two-stroke and four-stroke versions. They were
originally used as a more efficient replacement for stationary steam engines. Since the
1910s they have been used in submarines and ships. Use in locomotives, trucks, heavy
equipment and electric generating plants followed later. In the 1930s, they slowly began
to be used in a few automobiles. Since the 1970s, the use of diesel engines in larger onroad and off-road vehicles in the USA increased. According to the British Society of
Motor Manufacturing and Traders, the EU average for diesel cars account for 50% of the
total sold, including 70% in France and 38% in the UK.
Page 18
p-V Diagram for the Ideal Diesel cycle. The cycle follows the numbers 1-4 in clockwise
direction. In the diesel cycle the combustion occurs at almost constant pressure and the
exhaust occurs at constant volume. On this diagram the work that is generated for each cycle
corresponds to the area within the loop.
The diesel internal combustion engine differs from the gasoline powered Otto cycle by using
highly compressed hot air to ignite the fuel rather than using a spark plug (compression
ignition rather than spark ignition).
In the true diesel engine, only air is initially introduced into the combustion chamber. The air
is then compressed with a compression ratio typically between 15:1 and 22:1 resulting in 40bar (4.0 MPa; 580 psi) pressure compared to 8 to 14 bars (0.80 to 1.4 MPa; 120 to 200 psi) in
the petrol engine. This high compression heats the air to 550 C (1,022 F). At about the top
of the compression stroke, fuel is injected directly into the compressed air in the combustion
chamber. This may be into a (typically toroidal) void in the top of the piston or a prechamber depending upon the design of the engine. The fuel injector ensures that the fuel is
broken down into small droplets, and that the fuel is distributed evenly. The heat of the
compressed air vaporizes fuel from the surface of the droplets. The vapor is then ignited by
the heat from the compressed air in the combustion chamber, the droplets continue to
vaporise from their surfaces and burn, getting smaller, until all the fuel in the droplets has
been burnt. The start of vaporization causes a delay period during ignition and the
characteristic diesel knocking sound as the vapor reaches ignition temperature and causes an
abrupt increase in pressure above the piston. The rapid expansion of combustion gases then
drives the piston downward, supplying power to the crankshaft.
As well as the high level of compression allowing combustion to take place without a
separate ignition system, a high compression ratio greatly increases the engine's efficiency.
Increasing the compression ratio in a spark-ignition engine where fuel and air are mixed
before entry to the cylinder is limited by the need to prevent damaging pre-ignition. Since
only air is compressed in a diesel engine, and fuel is not introduced into the cylinder until
shortly before top dead centre (TDC), premature detonation is not an issue and compression
ratios are much higher.
Early fuel injection systems

Diesel's original engine injected fuel with the assistance of compressed air, which atomized
the fuel and forced it into the engine through a nozzle (a similar principle to an aerosol
spray). The nozzle opening was closed by a pin valve lifted by the camshaft to initiate the
fuel injection before top dead centre (TDC). This is called an air-blast injection. Driving the
three stage compressor used some power but the efficiency and net power output was more
than any other combustion engine at that time.
Page 19

Diesel engines in service today raise the fuel to extreme pressures by mechanical pumps and
deliver it to the combustion chamber by pressure-activated injectors without compressed air.
With direct injected diesels, injectors spray fuel through 4 to 12 small orifices in its nozzle.
The early air injection diesels always had a superior combustion without the sharp increase in
pressure during combustion. Research is now being performed and patents are being taken
out to again use some form of air injection to reduce the nitrogen oxides and pollution,
reverting to Diesel's original implementation with its superior combustion and possibly
quieter operation. In all major aspects, the modern diesel engine holds true to Rudolf Diesel's
original design, that of igniting fuel by compression at an extremely high pressure within the
cylinder. With much higher pressures and high technology injectors, present-day diesel
engines use the so-called solid injection system applied by Herbert Akroyd Stuart for his hot
bulb engine. The indirect injection engine could be considered the latest development of these
low speed hot bulb ignition engines.
Fuel delivery
A vital component of all diesel engines is a mechanical or electronic governor which
regulates the idling speed and maximum speed of the engine by controlling the rate of fuel
delivery. Unlike Otto-cycle engines, incoming air is not throttled and a diesel engine without
a governor cannot have a stable idling speed and can easily over speed, resulting in its
destruction. Mechanically governed fuel injection systems are driven by the engine's gear
train. These systems use a combination of springs and weights to control fuel delivery
relative to both load and speed. Modern electronically controlled diesel engines control fuel
delivery by use of an electronic control module (ECM) or electronic control unit (ECU). The
ECM/ECU receives an engine speed signal, as well as other operating parameters such as
intake manifold pressure and fuel temperature, from a sensor and controls the amount of fuel
and start of injection timing through actuators to maximize power and efficiency and
minimize emissions. Controlling the timing of the start of injection of fuel into the cylinder is
a key to minimizing emissions, and maximizing fuel economy (efficiency), of the engine. The
timing is measured in degrees of crank angle of the piston before top dead centre. For
example, if the ECM/ECU initiates fuel injection when the piston is 10 before TDC, the start
of injection, or timing, is said to be 10 BTDC. Optimal timing will depend on the engine
design as well as its speed and load.
Advancing the start of injection (injecting before the piston reaches to its SOI-TDC) results in
higher in-cylinder pressure and temperature, and higher efficiency, but also results in elevated
engine noise and increased oxides of nitrogen (NOx) emissions due to higher combustion
temperatures. Delaying start of injection causes incomplete combustion, reduced fuel
efficiency and an increase in exhaust smoke, containing a considerable amount of particulate
matter and unburned hydrocarbons.
Major advantages
Diesel engines have several advantages over other internal combustion engines:
They burn less fuel than a petrol engine performing the same work, due to the
engine's higher temperature of combustion and greater expansion ratio. Gasoline
engines are typically 30% efficient while diesel engines can convert over 45% of the
fuel energy into mechanical energy.
Page 20
They have no high voltage electrical ignition system, resulting in high reliability and
easy adaptation to damp environments. The absence of coils, spark plug wires, etc.,
also eliminates a source of radio frequency emissions which can interfere with
navigation and communication equipment, which is especially important in marine
and aircraft applications.
The life of a diesel engine is generally about twice as long as that of a petrol engine
due to the increased strength of parts used. Diesel fuel has better lubrication properties
than petrol as well.
Diesel fuel is distilled directly from petroleum. Distillation yields some gasoline, but
the yield would be inadequate without catalytic reforming, which is a more costly
process.
Diesel fuel is considered safer than petrol in many applications. Although diesel fuel
will burn in open air using a wick, it will not explode and does not release a large
amount of flammable vapor. The low vapor pressure of diesel is especially
advantageous in marine applications, where the accumulation of explosive fuel-air
mixtures is a particular hazard. For the same reason, diesel engines are immune to
vapor lock.
For any given partial load the fuel efficiency (mass burned per energy produced) of a
diesel engine remains nearly constant, as opposed to petrol and turbine engines which
use proportionally more fuel with partial power outputs.
They generate less waste heat in cooling and exhaust.
Diesel engines can accept super- or turbo-charging pressure without any natural limit,
constrained only by the strength of engine components. This is unlike petrol engines,
which inevitably suffer detonation at higher pressure.
The carbon monoxide content of the exhaust is minimal, therefore diesel engines are
used in underground mines.
Biodiesel is an easily synthesized, non-petroleum-based fuel (through
transesterification) which can run directly in many diesel engines, while gasoline
engines either need adaptation to run synthetic fuels or else use them as an additive to
gasoline (e.g., ethanol added to gasohol).
Mechanical and electronic injection

Many configurations of fuel injection have been used over the course of the 20th century.
Most present-day diesel engines use a mechanical single plunger high-pressure fuel pump
driven by the engine crankshaft. For each engine cylinder, the corresponding plunger in the
fuel pump measures out the correct amount of fuel and determines the timing of each
injection. These engines use injectors that are very precise spring-loaded valves that open and
close at a specific fuel pressure. Separate high-pressure fuel lines connect the fuel pump with
each cylinder. Fuel volume for each single combustion is controlled by a slanted groove in
the plunger which rotates only a few degrees releasing the pressure and is controlled by a
mechanical governor, consisting of weights rotating at engine speed constrained by springs
and a lever. The injectors are held open by the fuel pressure. On high-speed engines the
Page 21

plunger pumps are together in one unit. The length of fuel lines from the pump to each
injector is normally the same for each cylinder in order to obtain the same pressure delay.
A cheaper configuration on high-speed engines with fewer than six cylinders is to use an
axial-piston distributor pump, consisting of one rotating pump plunger delivering fuel to a
valve and line for each cylinder (functionally analogous to points and distributor cap on an
Otto engine).
Many modern systems have a single fuel pump which supplies fuel constantly at high
pressure with a common rail (single fuel line common) to each injector. Each injector has a
solenoid operated by an electronic control unit, resulting in more accurate control of injector
opening times that depend on other control conditions, such as engine speed and loading, and
providing better engine performance and fuel economy.
Both mechanical and electronic injection systems can be used in either direct or indirect
injection configurations.
Two-stroke diesel engines with mechanical injection pumps can be inadvertently run
in reverse, albeit in a very inefficient manner, possibly damaging the engine. Large
ship two-stroke diesels are designed to run in either direction, obviating the need for a
gearbox.
Indirect injection
An indirect injection diesel engine delivers fuel into a chamber off the combustion
chamber, called a pre-chamber or ante-chamber, where combustion begins and then
spreads into the main combustion chamber, assisted by turbulence created in the
chamber.
Arrow indicates opening from pre-chamber

Main article: Indirect injection
Page 22

This system allows for a smoother, quieter running engine, and because combustion is
assisted by turbulence, injector pressures can be lower, about 100 bar (10 MPa; 1,500 psi),
using a single orifice tapered jet injector. Mechanical injection systems allowed high-speed
running suitable for road vehicles (typically up to speeds of around 4,000 rpm. The prechamber had the disadvantage of increasing heat loss to the engine's cooling system, and
restricting the combustion burn, which reduced the efficiency by 510%. Indirect injection
engines are cheaper to build and it is easier to produce smooth, quiet-running vehicles with a
simple mechanical system. In road-going vehicles most prefer the greater efficiency and
better controlled emission levels of direct injection. Indirect injection diesels can still be
found in the many ATV diesel applications.
Direct injection
Direct injection diesel engines have injectors mounted at the top of the combustion chamber.
The injectors are activated using one of two methods - hydraulic pressure from the fuel pump,
or an electronic signal from an engine controller.
Hydraulic pressure activated injectors can produce harsh engine noise. Fuel consumption is
about 1520% lower than indirect injection diesels. The extra noise is generally not a
problem for industrial uses of the engine, but for automotive usage, buyers have to decide
whether or not the increased fuel efficiency would compensate for the extra noise.
Electronic control of the fuel injection transformed the direct injection engine by allowing
much greater control over the combustion.
Common rail direct injection

In common rail systems, the separate pulsing high-pressure fuel line to each cylinder's
injector is also eliminated. Instead, a high-pressure pump pressurizes fuel at up to 2,500 bar
(250 MPa; 36,000 psi), in a "common rail". The common rail is a tube that supplies each
computer-controlled injector containing a precision-machined nozzle and a plunger driven by
a solenoid or piezoelectric actuator.
Page 23

6 CYLINDER DIESEL ENGINE
A 6 cylinder Engine which produces more power works with two extra cylinders that
create additional piston thrust. The process involves the piston traveling down on the
Intake stroke, up on the compression stroke, down on the Power stroke and up on the
exhaust stroke.
Greater the cylinders more the power, more the horse power and greater fuel consumption.
Internal combustion engines are made from various parts. Each part has its own location and
function for proper working of engine. Some important parts and its function is as described
below.
01) Cylinder Block

In the bore of cylinder the fresh charge of air-fuel mixture is ignited, compressed by piston and
expanded to give power to piston.
Page 24

02) Cylinder Head
It carries inlet and valve. Fresh charge is admitted through inlet valve and burnt gases are
exhausted from exhaust valve. In case of engine, a spark plug and in case of diesel engine, a
injector is also mounted on cylinder head.
03) Piston
During suction stroke, it sucks the fresh charge of air-fuel mixture through inlet valve and
compresses during the compression stroke inside the cylinder. This way piston receives power
from the expanding gases after ignition in cylinder. Also forces the burnt exhaust gases out of the
cylinder through exhaust valve.
Page 25

04) Piston Rings
-It prevents the compressed charge of fuel-air mixture from leaking to the other side of the piston.
Oil rings, is used for removing lubricating oil from the cylinder after lubrication. This ring prevents
the excess oil to mix with charge.
05) Connecting Rod

It changes the reciprocating motion of piston into rotary motion at crankshaft. This way
connecting rod transmits the power produced at piston to crankshaft.
06) Gudgeon Pin

Connects the piston with small end of connecting rod.
Page 26

07) Crank Pin
hand over the power and motion to the crank shaft which come from piston through connecting
rod.
08) Crank Shaft

Receives oscillating motion from connecting rod and gives a rotary motion to the main shaft. It
also drives the camshaft which actuate the valves of the engine.
Page 27

09) Cam Shaft
It takes driving force from crankshaft through gear train or chain and operates the inlet valve as
well as exhaust valve with the help of cam followers, push rod and rocker arms.
10) Inlet Valve & Exhaust Valve

Inlet valve allow the fresh charge of air-fuel mixture to enter the cylinder bore. Exhaust valve
permits the burnt gases to escape from the cylinder bore at proper timing.
11) Governor
It controls the speed of engine at a different load by regulating fuel supply in diesel engine. In
petrol engine, supplying the mixture of air-petrol and controlling the speed at various load
condition.
Page 28
12) Fuel Pump

This device supply the petrol to the carburetor sucking from the fuel tank.
13) Fuel Injector

This device is used in diesel engine only and delivers fuel in fine spray under pressure.
Page 29

Asia Motor Work (AMW) Project

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Asia Motor Work (AMW) Project

Caricato da

Copyright:

Formati disponibili

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

LAYOUT OF AMW WORKSHOP UNA

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

MEMBERS OF AMW WORKSHOP UNA

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Automotive and auto components

Headquarters Mumbai, Maharashtra, India[1]

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Belongs to a company or corporation

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

2. Examples of commercial vehicles

3. Commercial truck classification

Class 1- GVWR ranges from 0 to 6,000 pounds (0 to 2,722 kg)

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Gross vehicle weight rating

Ideally suited for haulage and special purpose applications.

AMW trucks come with a range of features that ensure best-in-class

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Integrated Manufacturing Facility

CAB WELD SHOP

FULLY AUTOMATED PAINT SHOP

Installed Capacity 50,000 vehicles per year

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

After-sales Service, Spare parts

Fully Built Vehicles

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Repairs facilities at the workshop

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Early fuel injection systems

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Mechanical and electronic injection

ASIA MOROR WORKS, BHAGAT MOTORS, UNA,HIMACHAL PRADESH

VOCATIONAL TRAINING 2013

Arrow indicates opening from pre-chamber