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PROJECT REPORT

PLC & PANEL UPGRADATION OF NAGEL HONING MACHINE


TATA MOTORS
Company Profile






Tata Motors Limited is Indias largest automobile company, with
consolidated revenues of INR 2,32,834 crores (USD 38.9 billion) in 2013-
14. It is the leader in commercial vehicles in each segment, and among the
top in passenger vehicles with winning products in the compact, midsize car
and utility vehicle segments. It is also the world's fifth largest truck
manufacturer and fourth largest bus manufacturer.

The Tata Motors Groups over 60,000 employees are guided by the mission
to be passionate in anticipating and providing the best vehicles and
experiences that excite our customers globally.''

Established in 1945, Tata Motors presence cuts across the length and
breadth of India. Over 8 million Tata vehicles ply on Indian roads, since the
first rolled out in 1954. The companys manufacturing base in India is
spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow
(Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad
(Karnataka).
Tata Motors Jamshedpur


The Jamshedpur facility, Tata Motors' first, was established in 1945 to manufacture steam
locomotives. It led the company's foray into commercial vehicles in 1954. It has been
modernized through the decades, with a particularly intense scale in the last 10 years and
has led the company's evolution into a manufacturer of global repute.
This world-class facility is equipped with:
State-of-the-art equipment and assembly lines to produce a truck every 5 minutes
Over 200 models, ranging from multi-axle trucks, tractor-trailers, tippers, mixers and
special application vehicles, catering to civilian and defence requirements
3D visualization of new models
Engine assembly shop, capable of supplying upto 200 engines per day
Modern testing facilities
The plant manufactures Tata Motors' entire range of medium and heavy commercial
vehicles, including the Tata Prima, both for civilian and defence applications - over 200
truck variants, ranging from multi-axle trucks, tractor-trailers, tippers, mixers and special
application vehicles. Besides India, these vehicles are sold in South Africa, Russia,
Myanmar, the SAARC region and the Middle East. On February 19, 2013, Jamshedpur Plant
rolled out its two millionth truck.
Contents
1) ACKNOWLEDGEMENT
2) What is a Honing ?
3) What is a Honing M\C?
4) Why Honing M\C required?
5) Principle of Honing M\C
6) Where Honing M\C used?
7) PLC & Panel up gradation in Honing machine.
8) Applications of Honing M\C
9) Conclusion.
What is a Honing ?
Honing is an abrasive machining process that produces a precision surface on
a metal work piece by scrubbing an abrasive stone against it along a controlled
path. Honing is primarily used to improve the geometric form of a surface, but
may also improve the surface texture.
Honing is used in:
Track/Raceway honing
Spherical honing
OD through-feed honing (taper and straight)
Flat honing
Bore honing
OR
Honing is a cutting process where multi-edge tools coated with particles with
continuous surface contact between the tool and work piece are used to optimize the
dimension, form and surface of pre-machined work pieces. Between tool and work
piece a change in direction of the longitudinal movement takes place. The finished
surfaces are characterized by a cross-hatch pattern on the surface.



What is a Honing M\C?
A Honing machine is used to material, grind, or finish a work piece.
Tool wear caused by the friction of grinding.
A rough edge remaining on metal after it has been cut or perforated.
A small particle of material that is removed during grinding, cutting, or abrasive
processes.
A clamping device that grips the post or shank of a mounted grinding tool.
Why Honing M\C required?
Typical applications are the finishing of cylinders for internal combustion engines, air
bearing spindles and gears. There are many types of hones but all consist of one or more
abrasive stones that are held under pressure against the surface they are working on.
Principle of Honing M\C
The work process with honing is a combination of stroke and rotation movement of an
expandable honing tool with inserted honing stones or diamond sticks. The result is the
surface structure with cross-hatch pattern generated by the honing process. The timing of
the honing is defined by quick cutting of the peaks of the pre-machined bore surface. This
rapidly achieves a smoothing of the surface.
Where Honing M\C used?
Engine: Cylinder Bore, Cylinder Liner, Crank Bore, Connecting Rod, Diesel fuel injection
components, Crankshaft Pulley, Rocker Arm, Turbo Charger Valve, Roller Lifter, VVT
components.
PLC & Panel up gradation in Honing machine
Nagel machine operation, Make: Nagel
Understanding project requirement
Project frame work- sheet
Electrical Drawing renewal
Identifying BOM
Offline Electrical wiring in new panel
S7-300 PLC program
Interfacing with Nagel Controller
Nagel PC, Base card, DI/DO card, analog cards, Stepper cards
mapping with new PLC
Installation of panel in machine
Panel commissioning
Machine manual function check
Machine Auto mode trial
Job prove out


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Working of Nagel Honing M\C
Nagel machine structure.
Nagel Honing principle.
Nagel controller Block diagram.
Nagel controller functioning.
Nagel Interfacing with PLC.

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Nagel machine structure:

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Nagel Honing principle
Honing is done to remove the ovality & taper.
A transfer bar is there to put the cylinder block from loading position to fixture position, then
diamond moves into the bore & there is a pneumatic gauging system which senses the air
pressure in the bore & the sensor sends the data to the PLC then PLC will decide the stroking
expansion time then accordingly it will perform the operation. The air pressure should be
between 1.5 to 3 bar.
697 497
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Nagel controller Block diagram
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Nagel controller functioning
Industrial PC: MSU-3 soft ware used
1) Interface between operator and machine.
2) Honing program.
3) Parameter editable.
4) Gauging function.
PLC: S7-300 used
1) Hardware configuration Automata Gateway.
2) Interfacing with Automata\Nagel card.
3) Machine program (blocks).
Profibus\Automata gateway.
1) Interface between PLC & Nagel Cards.
2) Protocol CAN.
3) Interfacing signals.
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NAGEL cards:
a) Base card:
1) Spindle speed measure.
2) Expansion proportionate valve.
3) Break release servo valve ( not used).
4) Air valve in process.
b) Digital i\o card:
1) Stroke forward.
2) Stroke reversal.
3) Counter holding valve.
4) Finish stone worn-out.
5) Finish honing pressure.
6) Spindle at top.
c) Analog i\o card:
1) Movamatic in process sizing.
d) Stroking card:
1) Stepper motor for H+L valve spindle-1.
2) Hard\Soft reversal.
3) Spindle 1 work valve.
4) Spindle 1 Returned.
5) End restrict up.
6) End restrict down.
e) Expansion card:
1) Pulse generator expansion (encoder).
2) Stepper motor expansion.

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Nagel interfacing with PLC

M50-455
INPUT FROM NAGEL GATEWAY TO PLC

I67.5 ROUGH HONING STARTED
I67.6 FINISH HONING STARTED
I67.7 SP RETURN
I68.0 SP ADVANCE
I68.1 FINISH HONING FINISHING
I68.6 SP CCW
I68.7 SP CW
I69.0 CLNT ON
I69.1 EXPANSION HOME
I67.0 SPINDLE READY
I67.2 SP HOME POS
I67.1 SP IN OPERATION
I67.3 SP SFTY SP SAFETY POS

M50-455
OUTPUT TO NAGEL GATEWAY FROM PLC

Q66.0 SP TYPE 1 MSU
Q67.0 HYD ON
Q67.1 LOAD ON
Q67.2 AUTO SELECTED
Q67.3 SP RELEASE
Q67.4 COMP PRESENT
Q67.5 COMP CLAMP
Q67.6 RESET HONING FINISH SIGNAL
Q67.7 START HONING

Q68.4 FAULT RESET
Q68.1 EMG STOP
Q68.2 SP RETURN
Q68.3 TOOL CHANGE POS
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Control Panel of Nagel
BACK
Limit switches
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Programmable Logic Controller
A PLC is a industrial computer. A Programmable Logic Controller, PLC or Programmable
Controller is a digital computer used for automation of electromechanical processes, such as
control of machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are
used in many industries and machines. Unlike general-purpose computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is
an example of a hard real-time system since output results must be produced in response to
input conditions within a limited time, otherwise unintended operation will result.
Variable Frequency Drive
A variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-speed
drive, AC drive, micro drive or inverter drive) is a type of adjustable-speed drive used in electro-
mechanical drive systems to control AC motor speed and torque by varying motor
input frequency and voltage.
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Different control cards used are:
Base Card.
D i\o Card.
A i\o Card.
Stepper stroke card.
Stepper expansion card.
In this M\C Siemens S7-300 series PLC is used.
Outer\Field Parts of Nagel
Hydraulic Motor
Spindle motor
Lubrication motor
Coolant return motor
Hydraulic motor-2
Loading conveyor motor
Unloading conveyor motor
Table motor
Table motor break
Coolant & Hydraulic chiller supply




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Field Description
Hydraulic Motor: A hydraulic motor is a mechanical actuator that converts
hydraulic pressure and flow into torque and angular displacement (rotation). The
hydraulic motor is the rotary counterpart of the hydraulic cylinder.
Spindle motor: A spindle motor is a small, high-precision, high-reliability electric
motor that is used to rotate the shaft, or spindle, on which the platters are
mounted in a hard disk drive (HDD).
Lubrication motor: A lubricant is a substance introduced to
reduce friction between moving surfaces. It may also have the function of
transporting foreign particles. The property of reducing friction is known
as lubricity. (Slipperiness). One of the single largest applications for lubricants, in
the form of motor oil, is protecting the internal combustion engines in motor
vehicles and powered equipment.
Coolant return motor: The coolant temperature sensor is used to measure the
temperature of the engine coolant of an internal combustion engine. The readings
from this sensor are then fed back to the Engine control unit (ECU). This data from
the sensor is then used to adjust the fuel injection and ignition timing. On some
vehicles the sensor may be used to switch on the electronic cooling fan. The data
may also be used to provide readings for a coolant temperature gauge on the
dash. The coolant temperature sensor works using resistance. As temperature
subjected to the sensor increases the internal resistance changes. Depending on
the type of sensor the resistance will either increase or decrease




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Conveyor: A conveyor belt is the carrying medium of a belt conveyor system (often
shortened to belt conveyor). A belt conveyor system is one of many types of conveyor
systems. A belt conveyor system consists of two or more pulleys(sometimes referred to as
drums), with an endless loop of carrying medium - the conveyor belt - that rotates about
them. One or both of the pulleys are powered, moving the belt and the material on the belt
forward. The powered pulley is called the drive pulley while the unpowered pulley is called
the idler pulley. There are two main industrial classes of belt conveyors; Those in
general material handling such as those moving boxes along inside a factory and bulk
material handling such as those used to transport large volumes of resources and agricultural
materials, such as grain, salt, coal, ore, sand, overburden and more.
Coolant & Hydraulic chiller supply: A chiller is a machine that removes heat from a liquid via
a vapor-compression or absorption refrigeration cycle. This liquid can then be circulated
through a heat exchanger to cool air or equipment as required. As a necessary byproduct,
refrigeration creates waste heat that must be exhausted to ambient or, for greater
efficiency, recovered for heating purposes. Concerns in design and selection of chillers
include performance, efficiency, maintenance, and product life cycle environmental impact.
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Conclusion
With the active help and support of all the employees in the Electronics
department of the Engine Factory, I was able to complete my project and I
am extremely grateful to them while doing this project I got an insight of
the application of my branch in this factory. Unless one undergoes
practical training it is difficult to relate to all that is being taught in theory.
Moreover one gets the feel of working in a factory.
The next important thing that one learns in the training is how to relate
himself to his colleagues, his seniors and the employees of his division.
Until and unless a person interacts actively with his co-workers, he will not
be able to dispel his duties well because in an organization an individual
alone, isolated from his workforce cannot complete a job.
Finally I would like to thank Mr. SANDIP B RAVAN for their constant
guidance and help without their support it would not have been possible. I
would also like to thank the administration of TATA MOTORS for
providing me with this wonderful opportunity of completing my training
here.
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20april-25may- Nagel PLC and panel up
gradation
26may-5june- Engine test bed smoke
meter up gradation
6june-till date- PLC up gradation in SPM
machine
Understanding project requirement
Existing Process

Control panel condition is very critical. Its very tedious for fault finding.
Existing Problems- Control Panel wiring fault
Panel wiring fault MTTR = 2 hrs
Machine MTBF=24 hrs, MTTR= 2 hrs
Machine production losses on daily basis
Existing PLC is obsolete and also diagnostics tool is not available
No service and spare support for existing PLC
Proposed process
Main Control and Operator Panel up gradation.
Replacing Existing control panel wiring with new Generation switch gears.
Replacing existing PLC with new generation PLC (S7-300)
Introduction of new generation system will results into life of the machine.
Removal of obsolete control system & critical panel wiring will results into overall
Equipment effectiveness (OEE)
Introduction of new generation will assured for service and spare support in future.
Better Equipment utilization.
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APPLICATION
Nagel machine is used for Honing of 697 and 497
Cylinder Block in Engine Division.
Below are the control details:
PLC S5 SIEMENS (Obsolete)
Existing control panel wiring is very critical and
complicated for fault finding.

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PANEL COMISSIONING
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OLD PANEL CONDITION
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NEW ELECTRICAL DRAWING
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OLD ELECTRICAL DRAWING
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Thanks.