"Study On Diesel Engine Parts": Submitted
"Study On Diesel Engine Parts": Submitted
"Study On Diesel Engine Parts": Submitted
Submitted
In partial fulfillment for the award for
DIPLOMA IN MECHANICAL ENGINEERING
Submitted by:-
Name:Nadeem taj.N. Mulla
Reg no:580ME17049
Duration of time: From 9-12-201 to 19-12-2019
.
PES&T’s
SHAIKH COLLEGE OF ENGINEERING & TECNOLOGY 2nd
SHIFT DIPLOMA
CERTIFICATE
Certified that this internship report entitled “STUDY ON DIESEL ENGINE
PARTS” is bonafide work carried out by “NADEEM TAJ MULLA” in fifth
semester for partial fulfillment of the Diploma in Mechanical Engineering of
Board of technical Examination Bengaluru, Govt. of Karnataka during the year
2019-2020. It is certified that all correction/suggestions indicated for internal
assessment have been incorporated in the report and one copy of it being
deposited in the library
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ACKNOWLEDGEMENTS
It is my proud privilege and duty to acknowledge the kind help and guidance
received from several persons in preparation of this report. It would not have
been possible to prepare this report in this form without their valuable help,
cooperation and guidance.
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CONTENTS
Chapter 1 Page No
1. About the company
1.1 Historical Background 7
1.2 Mission, Vision and Values 8
1.3 Operation of the Company 9
1.4 Accreditations 9
1.5 Environmental Practice and Initiatives 9
1.6 Role in Emission Cheating Software 10
Chapter 2
2. About the department
2.1 Administration department 11
2.2 Raw material department: 11
2.3 Maintenance department 11
2.4 Inspection and Quality control departments 11
2.5 Engineering department 11
2.6 Purchase department 11
2.7 Finance department 11
2.8 Marketing and Sales department 12
2.9 HR department: 12
Chapter 3
3. Safety Measures
3.1 Accident 13
3.2 Cost of Accident 13
3.3 HR Polices and Administration 14
3.4 Factories Act 1948 14
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3.5 Code of Conduct 15
3.6 Conflict of Interest 15
3.7 Safety Rules 15
3.8 Fire Hazards 15
Chapter 4
4. Company Operations
4.1 Diagnosis of automobile 16
4.2 Common Rail Direct Injection (CRDI) 18
4.3 Fuel injection system 20
4.4 Injectors 21
4.4.1 Mechanical Injectors 22
4.4.2 Electronic Injectors 23
4.4.3 Piezo Injectors 24
Chapter 5
5. Specific outcomes
5.1 Conclusions 25
5.2 Comments and suggestions 26
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CHAPTER 1: -
ABOUT THE COMPANY
From 1897, Bosch started installing better-designed magneto ignition devices into
automobiles and became the only supplier of a truly reliable ignition within the industry. In
1902, the chief engineer at Bosch, Gottlob Honold, unveiled the high-voltage magneto
ignition system with spark plug. This product paved the way for Bosch to become a leading
automotive supplier.
The first factory was opened by Bosch in Stuttgart in 1901. In 1906, the company produced
its 100,000th magneto. In the same year, Bosch introduced the 8-hours day for workers. In
1910, the Feuerbach plant was founded and built close to Stuttgart. In this factory, Bosch
started to produce headlights in 1913.
Until 2000
After the second world war, Bosch established a partnership with the Japanese company
Denso.
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In 1964, Robert Bosch Stiftung was founded. Bosch founded a new development center in
Schwieberdingen in 1968, and the headquarters moved to Gerlingen in 1970.
The most relevant inventions of the company until 2000 were the oxygen sensor (1976), the
electric motor control (1979), the traction control system (1986), the xenon light for cars
(1991), the electronic stability control (1995), the common rail direct fuel injection (1997),
and the direct fuel injection (2000).
In 2000, Bosch sold the Private Networks area (nowadays, Tenovis and Avaya, respectively).
21st century
In 2001, Bosch acquired the Mannesmann Rexroth AG, which they later renamed to Bosch
Rexroth AG. In the same year, the company opened a new testing center in Vaitoudden, close
to Arjeplog in north Sweden. A new developing center in Abstatt, Germany followed in
2004.
In 2002, Bosch acquired Philips CSI, which at the time was manufacturing a broad range of
professional communication and security products and systems including CCTV, congress
and public address systems.
Important inventions in these years were the electric hydraulic brake in 2001, the common
rail fuel injection with piezo-injectors, the digital car radio with a disc drive, and the cordless
screwdriver with a lithium-ion battery in 2003.
China has developed into an important market and manufacturing base for Bosch. In 2012,
Bosch had 34,000 employees and a revenue of 41.7 billion Yuan (about 5 billion Euro) in
China.
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2015 – Bosch takes over 100% of the shares of the former ZF Lenksysteme (Steering
Systems) GmbH joint venture (was 50/50 with ZF Friedrichshafen)
2015 – Bosch purchases Seeo, Inc, a start-up working on solid state lithium ion
batteries.
Mission: -
To relentlessly pursue the creation of superior shareholder value, by exceeding customer
expectation profitably, unleashing employee potential, while being a responsible corporate
citizen, adhering to our values.
Values: -
Integrity: - Honesty in every action.
Commitment: - On the foundation of integrity, doing whatever it takes to deliver, as
promised.
Passion: -Missionary zeal arises out of an emotional engagement with work.
Seamlessness: -Thinking and working together across fictional, hierarchy levels,
business and geographies.
Speed: -Responding to stakeholders with a sense of urgency.
Bosch entered India in 1922, when allies & Company set up a sales office in Calcutta. For
three decades, the company operated in the Indian market only through imports. In 1951,
Bosch set up its first manufacturing plant in India.
Currently, Bosch India has a turnover of over $3 billion and over 31,000 employees spread
across 10 locations and 7 application development centers. 84% of Bosch India revenues
come from its automotive business, with the remaining 16% split between its non-automotive
businesses that include packaging, energy and building solutions, power tools and consumer
retail. Bosch also has an R&D facility in Coimbatore and Bangalore, India. This is Bosch's
largest R&D facility outside its home market of Germany. In September 2014, Bosch
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announced the launch of a locally developed eye-care solution in India. The company's new
eye screening and detection system offers a combination of hardware and software and
provides affordable eye care.
Bosch India is listed on the Indian stock exchanges and has a market capitalization of over
$12 billion.
1.4 Accreditations
Almost all Bosch locations are both ISO 9001 (quality) and ISO 14001 (environmental
protection) certified. In addition to that, their management is compliant with OHSAS 18001.
In May 2019, Bosch said it plans to be “fully carbon-neutral” by 2020 — a decade or more
earlier than most of its rivals — thanks to big investments in clean electricity and an
ambitious carbon offset programed.
In 2006, Volkswagen executives asked Bosch for help in developing software for their
emission defeat devices. Volkswagen is one of Bosch's biggest customers. Volkswagen
engineers provided detailed specifications to Bosch, which wrote the necessary code. Bosch
was apparently concerned about the legality of software and asked Volkswagen to assume
responsibility if the fraud was discovered, but Volkswagen refused.
On 1 February 2017, Bosch agreed to pay consumers in the United States $327.5 million as
compensation for its role in devising the software.
Bosch also provided emissions software for Fiat Chrysler's 3.0 L V6 diesel engine used in
100,000 model year 2014–2016 Grand Cherokee SUVs and Ram trucks and agreed to pay
affected consumers $27.5 million as part of a broader settlement in January 2019.
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CHAPTER 2: -
VARIOUS DEPARTMENTS:
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Prepares annual calibration plans. Maintains all quality records pertaining to the area of
working, and evaluates the design given by suppliers. Follow up with calibration agency and
maintaining records.
2.9 HR department:
Motivates and develops the workers in technical, managerial skills to achieve the
organization goals. Identifies training requirements. It checks the workers needs and
requirements.
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CHAPTER 3: -
ABOUT THE DEPARTMENT
3.1 SAFETY: -
3.2 ACCIDENT: -
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Accident is unplanned, unexpected event or sudden miss-happening resulting in temporary or
permanent disablement of employees and involves heavy losses resulting from wasted
machine hours, man hours, compensation amount, training etc…
Indirect Cost: -
Indirect Cost involves cost of damage to the equipment, material and plant, cost of
reduction in efficiency of the injured workers, cost of replacing the injured employee.
Mr. Henrich is known as the Father of Safety.
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The Factories Act, 1948 (Act No. 63 of 1948), as amended by the Factories (Amendment)
Act, 1987 (Act 20 of 1987)), serves to assist in formulating national policies in India with
respect to occupational safety and health in factories and docks in India. It deals with various
problems concerning safety, health, efficiency and well-being of the persons at work places.
The Act is administered by the Ministry of Labor and Employment in India through its
Directorate General Factory Advice Service & Labor Institutes (DGFASLI) and by the State
Governments through their factory inspectorates. DGFASLI advices the Central and State
Governments on administration of the Factories Act and coordinating the factory inspection
services in the States.
The Act is applicable to any factory whereon ten or more workers are working, or were
working on any day of the preceding twelve months, and in any part of which a
manufacturing process is being carried on with the aid of power, or is ordinarily so carried
on, or whereon twenty or more workers are working, or were working on any day of the
preceding twelve months,
And in any part of which a manufacturing process is being carried on without the aid of
power, or is ordinarily so carried on; but this does not include a mine, or a mobile unit
belonging to the armed forces of the union, a railway running shed or a hotel, restaurant or
eating place.
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3.8 Safety Rules: -
⮚ You are responsible for your own safety and safety of others.
CHAPTER 4: -
COMPANY OPERATIONS
4.1DIAGNOSIS OF AUTOMOBILE: -
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WHAT IS CAR DIAGNOSTIC TEST?
Of all the technological advances in the automotive sector over the decades, one of
the most beneficial to consumers and auto technicians alike has been the
computerization of the car’s components. Using specialized software, car
diagnostic tools quickly and accurately point to problem areas in a car’s engine or
elsewhere, thanks to built-in processors, microchips and sensors.
Diagnostic tests can reveal problems within a car’s engine, transmission, exhaust
system, brakes, and other major components, as well as performance issues with
the fuel injector, air flow and coolant, ignition coils, and throttle.
Before the emergence of car diagnostic tests, identifying problems was time-
consuming and expensive, especially considering car owners only brought their
cars to mechanics after a breakdown or other severe malfunction. Now,
computerized car components can detect problems long before they cause a
breakdown. Diagnostic tools can also check a car’s computer system for
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manufacturer notifications and stored information about the car’s history, giving
technicians a complete picture in order to perform the best repair possible.
You don’t have to wait for the check engine light to get a car diagnostic test. If you
hear or feel something “off,” mechanics can use diagnostic testing to uncover the
problem. However, many technicians recommend taking your car in for a
diagnostic check at least once a year, which will uncover minor problems that can’t
be seen or heard (and that won’t trigger the check engine light).
Diagnostic testing is also a useful tool when you’re checking out a used car. Both
private sellers and professional car dealers should agree to a diagnostic test before
you commit to buying, and if they don’t, that’s a sign you should walk away from
the deal.
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Most modern engine's fuel systems use an advanced technology known as CRDi or
Common Rail Direct Injection. Both petrol and diesel engines use a common 'fuel-
rail' which supplies the fuel to injectors. However, in diesel engines, manufacturers
refer to this technology as CRDi whereas Petrol engines term it as Gasoline
Direct Injection (GDI) or Fuel Stratified Injection (FSI). Both these technologies have
a similarity in design since they consist of “fuel-rail” which supplies fuel to injectors.
However, they considerably differ from each other on parameters such as pressure &
type of fuel used.
In Common Rail Direct Injection, the combustion takes place directly into the main
combustion chamber located in a cavity above the piston crown. Today,
manufacturers use CRDi technology to overcome some of the deficiencies
of conventional diesel engines which were sluggish, noisy and poor in performance
when implemented, especially in passenger vehicles.
The CRDi technology works in tandem with the engine ECU which gets inputs from
various sensors. It then calculates the precise quantity of fuel and timing of injection.
The fuel system features components which are more intelligent in nature and controls
them electrically / electronically. Additionally, the conventional injectors are replaced
with more advanced, electrically operated, solenoid injectors. They are opened by
an ECU signal, depending upon the variables such as engine speed, load, engine
temperature etc.
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A Common Rail system uses a ‘common-for-all-cylinders’ fuel-rail or in simple
words a 'fuel distribution pipe'. It maintains optimum residual fuel pressure and also
acts as a shared fuel reservoir for all the injectors. In the CRDi system, the fuel-rail
constantly stores and supplies the fuel to the solenoid valve injectors at the required
pressure. This is quite opposite to the fuel injection pump supplying diesel thru’
independent fuel lines to injectors in case of earlier generation (DI) design.
WORKING: -
A high-pressure pump supplies pressurized fuel. The pump compresses the fuel at the
pressures of about 1,000 bar or 15,000 psi. It, then, supplies the pressurized fuel via a
high-pressure pipe to the inlet of the fuel rail. From there, the fuel-rail distributes the
fuel to individual injectors which then inject it into the combustion chamber.
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primarily the same across the board. However, its performance depends mainly on the
combustion chamber design, fuel pressures and the type of injectors used.
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Injection pressures during the whole process should be above 1000–1200 bar for a
good spray formation and air–fuel mixture; a tendency in practice to 1600–1800 bar
and higher is noted.
Total nozzle area should be as small as possible in relation to cylinder diameter for
good combustion, particularly at part load.
Total injection duration should be 20° of crank angle or less for achieving a minimum
burning time in order to exploit retarded combustion for reduced NOx emissions
without loss in efficiency. A high compression ratio is desirable.
4.4INJECTORS: -
Injectors are divided into 3 types (depending on operating mechanism)
1. Mechanical injectors
2. Electronic injectors
3. Piezo injectors
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1. MECHANICAL INJECTORS: -
The needle valve is controlled precisely by a pressure-sensitive spring. It lifts off its
seat while spraying the diesel into the cylinder in highly atomized or mist form. The
moment the pressure drops, the needle valve comes back to its seat which causes the
injection to stop. The injection nozzle has extremely critical tolerances. The clearance
between its moving parts is barely 0.002 mm or 2 microns.
Modern-day injector unit forces the diesel through a small opening in the nozzle of
merely 0.25 mm² size. The injected fuel quantity can vary from 1 mm³ to 350 mm³.
Conventional injectors open and close hydro-mechanically. They have average nozzle
opening pressures ranging from 140 to 210 kg/cm2. A modern-day Bosch-unit sprays
the diesel at the speed of up to 2,000 km/h. Bosch and Lucas are world's leading
manufacturers of diesel nozzles.
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2.Electronic injectors: -
3. Piezoelectric Injector:
The most advanced type of injector is, undoubtedly, the ‘Piezoelectric-Injector’. They
not only provide increased precision for the latest generation of CRDi engines but
also create fuel pressures up to 3,000 bar or 44,000 psi. Besides, these modern-day
fuel-injectors work on ‘Piezo’ principle. The word ‘Piezo’ comes from the Greek
word ‘piezein’ which means to squeeze or press.
A Piezo actuator consists of hundreds of ceramic wafers which are stacked one above
the other in the injector. When electrically charged, Piezo crystals can change their
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structure in just a few thousandths of a second by expanding slightly. This expansion
of the stack results in its linear movement. It is then transmitted directly to the injector
needle without any mechanical linkage between them. As a result, the injectors
open/close within a few milliseconds (thousandth of a second). Consequently, it can
inject a very small amount of fuel, weighing less than one-thousandth of a gram and
also distribute it finely.
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CHAPTER 5
As students, we need to use the things we have learned in school and put it in practice.
This is also a good chance for us to get to know our future jobs and to find our
strengths.
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Many college students do internships to gain relevant experience in a particular
career field as well as to get exposure to determine if they have a genuine interest in
the field.
Internships are an excellent way to begin building those all-important connections
that are invaluable in developing and maintaining a strong professional network for
the future.
Internships give students an opportunity to: Find out what it is like to work in a
specific field Make contacts with the professionals in the field.
Gain academic credit. Student must work with a faculty sponsor and register in
advance to.
5.2 CONCLUSION
The Internship program was very useful to me because I got more experience and
knowledge about the actual working in an industry. I also got the exposure to
industrial culture and environment and got to know some highly advanced
technologies that the company is using. The friendly welcome from all the employees
is appreciating, sharing their experience and knowledge which they have gained
during their long journey of work. I believe that this experience will surely help me in
my future and also in shaping my career.
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