Mahatma Gandhi Mission’s
College of Engineering and Technology.
Noida, U.P., India
Report on Practical Industrial Training
Carried out at
Motherson Automotive Technologies & Engineering
&
B-135, & 206 , Phase II, Noida 201305.
From 15th June, 2019 to 15th July, 2019
Academic Year 2019 -20
Submitted by: Submitted to:
Name: MOHIT
Class: BT-ME Mechanical Engineering Department,
Univ. MGM’s COET, Noida.
RollNo:1609540017
1
Mahatma Gandhi Mission’s
College of Engineering and
Technology.
Noida, U.P., India
Department of Mechanical Engineering
CERTIFICATE
This is to certify that Mr./Ms. MOHIT of B. Tech. Mechanical
Engineering, Class BT-ME RollNo.1609540017 has completed
partially completed his Industrial Training during the academic
year 2019-20 from 15-06-19 to 15-07-19 at Mate (Motherson
Automotive Technologies & Engineering) & B-135, & 206 ,
Phase II, Noida 201305.
Training Coordinator Head of the
Department
ACKNOWLEDGEMENT
First I would like to thank GM of company, MR. Pramod Kumar (Trainer),
MATE, Noida for giving me the opportunity to do an internship within the
organization. For me it was a unique experience to work in this
organization.
I would like to thank all the people also that works in the
organization. With their patience and openness they created an enjoyable
working environment. Furthermore I want to thank all the engineers and
students, with whom I did the internship. We experienced great things
together and they taught us many more things regarding automobile.
Mohit
ABSTRACT
Motherson Automotive Technologies & Engineering (MATE) is the polymer division of
Motherson Sumi Systems Ltd (MSSL) and was established in 1997. The company is one
of the largest suppliers of moulded parts, assemblies & module supplier to the Indian
automotive industry. MATE manufactures a wide range of plastic components and fully
equipped facilities to support customers in the automotive and the non-automotive
segments. MATE specialises in large size injection moulding, blow moulding,
compression moulding and vacuum forming, which are supported by post moulding
operations.
TABLE OF CONTENTS
Page No.
Contents
CERTIFICATE .....................................................................................
ii
ACKNOWLEDGEMENTS
..................................................................................................................................
iii
ABSTRACT
....................................................................................................................................
v
LISTOFTABLES.
.................................................................................................................................
vii
LISTOFFIGURES.........................................................................................
viii
LISTOFSYMBOLS.................................................................................................ix
LISTOFABBREVIATIONS...................................................................................x
CHAPTER 1 (INTRODUCTION, BACKGROUND OF THE PROBLEM,
STATEMENT OFPROBLEMetc.).
..........................................................................................................................
1
1.1. ................................................................................................................ 5
1.2. ................................................................................................................ 8
CHAPTER2 (OTHERMAINHEADING)
13
3.1. ................................................................................................................. 15
3.2. .................................................................................................................
17
3.2.1. ........................................................................................................
19
3.2.2. .........................................................................................................
20
3.2.2.1. ................................................................................................ 21
3.2.2.2. ..........................................................................................
22
3.3. ................................................................................................................
23
CHAPTER 3 (OTHERMAINHEADING).........................................................24
4.1. ................................................................................................................
36
4.2. ................................................................................................................
39
CHAPTER4 (CONCLUSIONS).........................................................................40
REFERENCES………………………………………………………………………
49
CHAPTER 1
INTRODUCTION
Motherson Automotive Technologies & Engineering (MATE) is the polymer division of
Motherson Sumi Systems Ltd (MSSL) and was established in 1997. The company is one
of the largest suppliers of moulded parts, assemblies & module supplier to the Indian
automotive industry. MATE manufactures a wide range of plastic components and fully
equipped facilities to support customers in the automotive and the non-automotive
segments.
MATE specialises in large size injection moulding, blow moulding, compression
moulding and vacuum forming, which are supported by post moulding operations.
1.1 History
Motherson Automotive Technology & Engineering (MATE) is the flagship company of
the Sumi Motherson group. The Delhi-based Sehgal family initially promoted it as
Motherson Auto Private Limited in 1986 as a single product (wire harnesses) company,
supplying mainly to Japanese customers, namely Maruti Suzuki, Hero Honda, DCM
Toyota etc. In 1986, Sumitomo Wiring Systems (SWS), Japan, which was till then the
technical collaborator, picked up equity stake in MSSL along with Nissho Iwai
Corporation, Japan. Thereafter the company changed its strategy and tied up with other
tier-1 suppliers to cater to the needs of other OEM in India. MSSL became a public
limited company in 1992. The company is a pioneer in integrated wiring harnesses has
over 50 per cent share of the Indian automotive market. It enjoys a privileged status as
the main supplier to a large number of automotive and auto components industries in
India. It offers its customers the complete range of services from design concept to
prototyping, mass production and logistics.
First group company "Motherson" was established in 1975. However, Motherson Sumi
Systems did not come into existence till 1986 when Joint Venture with Sumitomo Wiring
Systems (of Japan) was formulated. Following are the key timelines.
Year Events
1975 Motherson founded
1977 First Cable factory started
1983 Technical agreement with Sumitomo Wiring Systems, Japan for Wiring Harness
1986 JV with Sumitomo Wiring Systems, Japan
1989 Injection Moulding commencement
1992 Cutting Tool Manufacturing
1999 First Overseas office established (Austria)
2000 Representative Office at Singapore
2002 Established wiring harness manufacturing at Sharjah and design centre at Ireland
2003 Offices in USA & UK established, Tool Room at Sharjah
2004 European Headquarters established in Germany
2005 Established fabrication units in Germany
2006 Established fabrication units in UK
2007 Established fabrication units in Australia
2009 Takeover of Visiocorp
2011 Takeover of Peguform
2014 Takeover of Stoneridge Wiring Division
2014 New Plant Start in Noida of Injection Moulding (MAET NOIDA)
1.2 Company Face
Fig.1.1 Moterson Automotive Technology & Engineering(MATE)
CHAPTER 2
Polymer process
Polymers form a very important class of materials: the total volume produced exceeds that of
metals. Used for structural applications, household goods, packaging, fibres ………. Most
engineering polymers (>90% of market) are thermoplastics (i.e. can be melted and resolidify
without damage, do not contain permanent cross-links between chains)
Injection molded plastic parts
The injection machine is a machine that melt plasticize the molding material inside the heating
cylinder and inject this into the mold tool to create the molded product by solidifying inside it.
The injection machine is constructed of a mold clamping device that opens and closes the mold
tool, and device that plasticize and inject the molding material. There are several types in the
injection machine, and the difference is made by how these two devices are arranged.
Plastic Blow Molding Process
Blow molding is a manufacturing process that is used to create hollow plastic parts by
inflating a heated plastic tube until it fills a mold and forms the desired shape. The raw
material in this process is a thermoplastic in the form of small pellets or granules, which
is first melted and formed into a hollow tube, called the parison. There are various ways
of forming the parison. The parison is then clamped between two mold halves and
inflated by pressurized air until it conforms to the inner shape of the mold cavity. Lastly,
after the part has cooled, the mold halves are separated and the part is ejected.
Parts made from blow molding are plastic, hollow, and thin-walled, such as bottles and
containers that are available in a variety of shapes and sizes. Small products may include
bottles for water, liquid soap, shampoo, motor oil, and milk, while larger containers
include plastic drums, tubs, and storage tanks. Blow molded parts can be formed from a
variety of thermoplastic materials, including the following:
Interior & Exterior Trim
We are able to produce plastic parts of many types including painting, chroming, IMD, High Gloss etc.
as to be able to cover most of our Customer needs.
We produce them in various materials, using Flocking, Mucell, Extrusion, Compression and Bimaterial
Injection. Parts are produced in Europe, America, Asia and Africa.
WIRE HARNESS
Wire harness, the wiring and power distribution system for the transmission of electric power
and signals for automobiles, has improved in many important respects in these few years.
Although the increase in the number of circuits as well as the weight and size of wire harnesses
repeatedly occurred at the time of model changes, such advanced technologies as signal sharing
and electrical multiplexing transmission have appropriately dealt with this increase, eventually
realizing the reduction in the quantity and size of wires. In terms of the production process of
wire harness consisting of wire cutting and terminal crimping, manual terminal crimping and
manual cutting, wire intermediate jointing, temporary assembly (sub-assembly), assembly,
electrical tests, and visual inspection, automation of the jointing process and thereafter has
been in delay. On the other hand, social environments have changed to influence wire harness
technology development considerably. For example, young labor has decreased year by year
making improvement of automation and work efficiency in the assembling process inevitable
for car manufacturers. Moreover, wire harness has been one of the most difficult components to
be recycled, because it takes much time to dismount at the time of vehicle dismantling,
resulting in high recovery costs. Against this background, to start the development program of
the wire harness for a full new model land cruiser of Toyota, we undertook to design a novel
wire harness (hereafter called W/H module) doing efforts to improve its
Machine used in wire harness (CNC AUTOMATION MACHINE )
A CNC machine is a motorized maneuverable tool and often a motorized maneuverable
platform, which are both controlled by a computer, according to specific input
instructions. Instructions are delivered to a CNC machine in the form of a sequential
program of machine control instructions such as G-code and then executed. The program
is generated from a graphical computer-aided design (CAD) file. In the case of 3D
Printers, the part to be printed is "sliced", before the instructions (or the program) is
generated. 3D printers also use G-Code.
CNC is a vast improvement over non-computerized machining that must be manually
controlled (e.g., using devices such as hand wheels or levers) or mechanically controlled
by pre-fabricated pattern guides (cams). In modern CNC systems, the design of a
mechanical part and its manufacturing program is highly automated. The part's
mechanical dimensions are defined using CAD software, and then translated into
manufacturing directives by computer-aided manufacturing (CAM) software. The
resulting directives are transformed (by "post processor" software) into the specific
commands necessary for a particular machine to produce the component, and then are
loaded into the CNC machine.
WIRE SPOOL
WIRE spool is a round, drum-shaped object such as a spool used to carry various types
of electrical wires. Cable reel which can also be termed as drums have been used for
many years to transport electric cables, fiber optic cables and wire products. Cable reels
usually come in four different types, each with their own
uses: wood, plywood, plastic and steel
Wire measure
A coordinate measuring machine (CMM) is a device that measures the geometry of
physical objects by sensing discrete points on the surface of the object with a probe.
Various types of probes are used in CMMs, including mechanical, optical, laser, and
white light. Depending on the machine, the probe position may be manually controlled
by an operator or it may be computer controlled. CMMs typically specify a probe's
position in terms of its displacement from a reference position in a three-dimensional
Cartesian coordinate system (i.e., with XYZ axes). In addition to moving the probe
along the X, Y, and Z axes, many machines also allow the probe angle to be controlled
to allow measurement of surfaces that would otherwise be unreachable.
Wire cutting
Electrical discharge machining (EDM), also known as spark machining, spark
eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process
whereby a desired shape is obtained by using electrical discharges (sparks). [1] Material is
removed from the work piece by a series of rapidly recurring current discharges between
two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of
the electrodes is called the tool-electrode, or simply the "tool" or "electrode," while the
other is called the workpiece-electrode, or "work piece." The process depends upon the
tool and work piece not making actual contact.
When the voltage between the two electrodes is increased, the intensity of the electric
field in the volume between the electrodes becomes greater than the strength of the
dielectric (at least in some places), which breaks down, allowing current to flow between
the two electrodes. This phenomenon is the same as the breakdown of a capacitor
(condenser) (see also breakdown voltage). As a result, material is removed from the
electrodes. Once the current stops (or is stopped, depending on the type of generator),
new liquid dielectric is usually conveyed into the inter-electrode volume, enabling the
solid particles (debris) to be carried away and the insulating properties of the dielectric to
be restored.
Wire striping
A wire stripper is a portable handheld tool used by
workers, especially electricians, for removing the
protective coating of an electric wire in order to replace
or repair the wire. It is also capable of stripping the end
portions of an electric wire in order to connect them to
other wires or to terminals. A wire stripper is often
considered an important tool for professional
electricians and other related personnel.
Wire crimping tunnel
Crimping is joining two or more pieces of metal or other ductile material by deforming
one or both of them to hold the other. The bend or deformity is called the crimp. The
metals are joined together via a special connector. Stripped wire (often stranded) is
inserted through the correctly sized opening of the connector, and a crimper is used
to tightly squeeze the opening against the wire. Depending on the type of connector
used, it may be attached to a metal plate by a separate screw or bolt or it could be
simply screwed on using the connector itself to make the attachment like an F
connector.
Wiring harness components
Vertical Integration provides MSSL a competitive advantage. It helps to control
the quality of the products, better cost control, reduced delivery time and reduce
the risk of relying on tier II partners for critical inputs.
Over a period of time, MSSL has established a strong vertical integration for the
critical raw material inputs, engineering design, processes and equipment to
meet customer quality and delivery expectations.
Wires
A wire is a strand of drawn metal used especially in electrical conductors and fencing.
Connectors
An electrical connector is an electromechanical device used to join electrical
terminations and create an electrical circuit.[1] Most electrical connectors have
a gender – i.e. the male component, called a plug, connects to the female component,
or socket. The connection may be removable (as for portable equipment), require a
tool for assembly and removal, or serve as a permanent electrical joint between two
points.[2] An adapter can be used to join dissimilar connector
Fuse Boxes
fuses are a class of fuses used to protect the wiring and electrical equipment for
vehicles. They are generally rated for circuits no higher than 32 volts direct current,
but some types are rated for 42-volt electrical systems. They are occasionally used in
non-automotive electrical products.
Wire Seals
Security seals are mechanisms used to seal shipping containers in a way that
provides tamper evidence and some level of security. Such seals can help to
detect theft or contamination, either accidental or deliberate. Security seals are
commonly used to secure truck trailers, vessel containers, chemical drums,
airline duty-free trolleys and utility meters. Typically they are considered an
inexpensive way of providing tamper evidence of intrusion into sensitive spaces.
Ultrasonic Welding
Ultrasonic welding is a unique method of joining two parts together without using
additional fasteners, adhesives or mechanical features like snap fit or living hinges.
Compared with other welding methods – which include heat staking, hot plate welding,
spin welding, and vibration welding – ultrasonic welding offers advantages in cycle time
and ease of automation. The process uses low amplitude, high frequency vibration to
create friction between the parts to be joined to generate enough heat to melt the plastic at
the interface. The frequencies used are above the range of human hearing, hence the label
ultrasonic. One of the parts to be joined is fixed firmly within a stationary holding jig,
while the mating part is subjected to a sinusoidal-ultrasonic vibration perpendicular to the
desired bond contact area. As a result of the friction between the parts and internal
friction in the parts, heat is generated, causing the polymer to melt at the interface. When
vibration stops, the polymer solidifies as it cools, and forms the bond.
Ultrasonic welding machine component
Generator
Three phase supply
Booster
Snaoted rod
Revolver up/down anvil
Foot switch
