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Delphi Noida PVT. LTD .Machine core bulder
1. PROJECT REPORT
ON
―MATRIX CORE BUILDER‖
Undertaken at:
Automotive Systems, Greater Noida
Under the guidance of: Submitted by:
Mr. Sanjay Grover Manoj Kumar
P C & L Department B. Tech 2nd
Year
Delphi, Greater Noida PMCE, Sonepat
(Haryana)
2. ACKNOWLEDGEMENTS
The satisfaction and euphoria that accompany the development
of any task would be incomplete without mentioning the people
who made it possible and whose constant guidance and
encouragement crowned my efforts with success.
I take this opportunity to acknowledge the help I received from
different individuals and place on record my appreciation and
thanks to those who lent me a helping hand in bringing out this
project work.
I would like to express my sincere thanks to Mr. Sanjay Grover for
helping me conceptualize and realize this project. This project
would not have been possible had it not been for his continual
guidance and profound assistance.
I am also indebted to the various team leaders and other
members of the P C&L department for their valuable time and
being extremely cooperative during my interactions with them.
Lastly I would like to express my gratitude to the faculty of PMCE,
(Sonepat) who have been a constant inspiration in my quest for
knowledge and excellence.
Manoj Kumar
B. Tech 2nd
Year
Mechanical Engineering.
PMCE, Sonepat (Haryana).
3. CERTIFICATE
This is to certify that the Project Report titled ―Matrix Core
Builder‖ is the bonafide work of Manoj Kumar, PMCE Sonepat
(Haryana) carried out at “Delphi, Automotive System Private
Limited, Greater Noida” in the year 2012-2013; and this has not
been submitted to any other University or Institution for the award
of any Degree or Diploma.
―Matrix Core Builder‖
Project Guide:
Mr. Sanjay Grover Manoj Kumar
P C & L Department B. Tech 2nd
Year
Delphi Automotive Systems PMCE, Sonepat
Greater Noida . Haryana.
5. ABSTRACT
This project was carried out under the guidance of various
members of the Production Department at Delphi Automotive
Systems, Greater Noida. The purpose of my project was to how
“Matrix Core builder” use for making condenser in Delphi and
save time and effort of workers. Matrix core builder fully automatic
machine which connected with Central Machine which provides
centers to machine for making condenser. Matrix core builder is
use for making condenser of YE3 car (codename) for Maruti
Suzuki. Its biggest machine in Delphi.
6. COMPANY PROFILE
Delphi India
In India, Delphi Automotive Systems Private Limited has been operating
as a wholly owned subsidiary of the parent company since 1995. The
Delphi employees in India are exposed to a diverse culture and rich
history as they help drive tomorrow's technology.
Delphi has four QS 9000 certified manufacturing facilities in the country,
located in Bangalore, Noida and Gurgaon. Delphi„s key customers in
India include Maruti Udyog Limited, General Motors India, Daewoo
Motors, Fiat, Hindustan Motors, Volvo and Telco.
Delphi facilities boast the conveniences and tools necessary to safely
and efficiently produce the high-quality products that help make Delphi a
world leader in automobiles. Delphi India facilities are steadily increasing
product engineering capabilities to keep pace with the increasing
prevalence of electronics in automobiles.
Delphi Automotive Systems is the world„s most diversified automotive
systems and components supplier. Earlier known as the Automotive
Component Group Worldwide (ACG Worldwide) of General Motors, its
operations were restructured and unified into a single identity called
Delphi Automotive Systems in February 1995. Multi-national Delphi
conducts its business operations through various subsidiaries and has
headquarters in Troy, Mich., USA, Paris, Tokyo and São Paulo, Brazil.
Evolution of Delphi :
1988: ACG (Automotive Components Group) Worldwide Group structure
created
7. 1994: General motors established ACG Worldwide as a separate
business sector
1995: ACG Worldwide became Delphi Automotive Systems
1998: Delphi incorporated as a subsidiary
1999: Delphi becomes a fully independent publically held corporation.
2002: Delphi Automotive Systems become ―Delphi
Milestones :
In 2003-2004, Delphi India has been honored by Maruti Suzuki with
three quality awards, one for "Excellence in Quality," "Cost Reduction"
and the prestigious "Outstanding Overall Performance" award.
In 2002, Delphi won the Vendor Performance Award for "Low PPM
Rejections of Incoming Suppliers
In 2001,Delphi Gurgaon earned the Vendor Performance Award for
"Overall Quality."
Products:
Delphi produces a wide range of products at its various facilities in India:
Brazed Aluminum Heat Exchangers
Catalytic Converters
Evap Containers
Front Corner Modules
Half SHAFTS
Heating, Ventilating, and Air conditioning (HAVC) Systems
Oil- Filters
Shock Absorbers and Struts
8. Steering Columns
Electrical/electronic distribution systems
Wire harness
Energy & Chassis Systems
Diesel Engine Management Systems
Gasoline Engine Management Systems
Systems
Fuel Handling & Evaporative Systems
Automotive Batteries
Fuel Cells
Valve train
Sensors & Actuators
Chassis Systems & Module Fuel Cell
Controlled Braking Systems
Complete Brake Systems
Wheel Brake Components
Brake Apply Components
Gen III Wheel Bearings
Suspension Dampers & Modules
Steering Systems
Vehicle Control Systems
o Steering Columns
o Power Steering Pumps and Hoses
o Steering Gear
o Half Shafts, CV Joints
Electric Steering Systems
o Electric power steering
9. Interior Systems
Instrument Panels
Airbag Systems
Door Modules, Trim &
Related Hardware
Thermal Systems
Climate Control Systems
HVAC Modules
Condensers,
Compressors,
Thermal Management Systems
Engine/Transmission Cooling Systems
Radiators,
Oil Coolers,
Engine Cooling Modules
Product and Service Solutions
Vehicle Electronics
Consumer Electronics
Service Technologies
Diesel Products
Electronics and Safety
Sensors & Power Modules
Body & Chassis Electronics
Power train Controllers
Audio & Communications
Driver Information & Controls
About my Project:
I had undertaken to work in the production department. Thus I was
assigned a project on Tooling Management. The project comes under
the P C & L Department.
A brief overview of the department is given in the next unit.
10. PC & L Department (Production, Control
and Logistics)
P C & L stands for
Production
Control (Stores)
Logistics (Dispatch)
Production Planning and Control
Production is a process whereby raw material is converted into semi-
finished products and thereby adds to the value of utility of products,
which can be measured as the difference between the value of inputs
and value of outputs. The main objective of production function is to
produce the goods and services demanded by the customers in the most
efficient and economical way.
Objectives:
o Define production management
o Analyze various factors, which are crucial for designing the
production.
o Explain the design of production system and manufacturing
processes.
o List out the factors influencing the choice of production process.
o Having properly designed production planning, and control system.
Production Management:
Production system is a system whose function is to convert a set of
inputs into asset of desired outputs Production management involves the
managerial decisions regarding design of the product and design of the
11. production system i.e. determination of production processes and
production planning and control.
Steps of Production Planning and Control
- Planning
- Routing
- Scheduling
- Loading
- Dispatching
- Following up
- Inspection
- Corrective action
The most important role in production planning and control is played by
Materials Requirements Planning (MRP).
An MRP system is intended to simultaneously meet three objectives:
- Ensure materials and products are available for production and delivery
to customers.
- Maintain the lowest possible level of inventory.
- Plan manufacturing activities, delivery schedules and purchasing
activities.
Tooling management also has an important role to play in the planning
process in the Production department. Tooling management and its
advantages in manufacturing processes has been discussed in detail in
the later unit of this project report.
12. Another important term we ought to know about is product specification.
Product specification refers to anything which describes how a product
will be manufactured.
Advantages of product specification
- Raw material suppliers know exactly what they need to deliver.
- Production department knows exactly what it needs to produce.
- Raw materials can be controlled, ensuring a quality product.
- Customers can expect a certain standard.
- Testing for quality control is easier.
Logistics
Logistics is basically a business planning framework. It involves the
management of material, capital flows, service and information. All the
increasingly complex information, communication and control systems
which are required in today's business environment are included in it.
Logistics is not the transportation itself, but to streamline and control the
flow through the value adding processes and eliminates non-value
adding ones. Production logistics provides the means to achieve
customer response and capital efficiency.
Production logistics is getting more and more important with the
decreasing batch sizes. In industries such as the cell phone industry,
batch size one is the short term aim. This way even a single customer
demand can be fulfilled in an efficient way. Track and tracing, which is
an essential part of production logistics - due to product safety and
product reliability issues - is also gaining importance especially in the
automotive and the medical industry.
Logistics management is that part of the supply chain which plans,
implements and controls the efficient, effective forward and reverse flow
and storage of goods, services and related information between the
point of origin and the point of consumption in order to meet customers'
requirements. A professional working in the field of logistics management is called a
logistician.
13. Brief Overview of Center Machine And
Matrix Core Builder
There are various machines in Delphi which are used to perform different
operations during the manufacturing processes. These machines have
various types of tooling’s. In this unit, I have documented about the Matrix
Core Builder machine and Center Machine which important machine in
Delphi for making condenser of CodenameYE3.
CENTER MACHINE
BASIC TERMINOLOGIES INVOLVED
Air Centre
The air center is a medium between the outside ambient air and the fluid
that is carried in the tubes. It is a primary part of the heat exchanger and
draws heat from the fluid flowing through the tube with which it is in contact
and loses it to the air flow as it passes through the louvers.
Convolution
Combination of two consecutive fins is called convolution.
Constant
The distance between two consecutive tip radiuses is called
constant.
Margins
Margins are the non-louvered material which is present in center
turnaround and outside edges.
Fin
Fin is one half of a convolution.
Center Length
Center Length = Number of Convolutions X center constant
Height
Height is the distance between the top and bottom tip radius.
Tip Radius
It is the material that connects two consecutive convolution legs.
14. Louver Panel
The combination of the louver banks on a single fin.
Louver Bank
The bank of louvers between the outside margins and middle
margin is known as the louver bank.
Louver Twist
The difference in the measured angle between the louver angles at
top and bottom tip radius and compared to nominal louver angle.
Bulk Transmission
Bulk transmission percentage is the amount of actual light that
passes through the louver slit openings in a panel compared to the
theoretical maximum you could receive.
Raised Outside Margin
Raised outside margin is used to avoid drop centers by holding the
air center in position next to the tube during braze.
Reduced Middle Margin
The reduced middle margin is designed to minimize the barrel
shape of the air center.
Dog Leg
Dog leg refers to the curve in the center over the length of the
center.
Rollovers
Crushed convolutions exiting the pullout rolls are termed as
rollovers.
Lock Up
Lock up is basically the amount of tooth engagement between the
upper and lower form rolls.
Louver Angle
Louver angle is the degree of angle of the louver slit relative to the
flat surface face of the convolution panel. The spring back ie the
elastic recovery of a metal after stressing is greater if the aluminum
material is harder. Greater spring back results in a lower louver
angle as the material attempts to bring the louver slit back to the
natural flat state. Thus 40 degrees may be placed on the cutting
edge of the form discs but the actual measured louver angle is 35
degrees.
Louver angle decreases due to disc wear, aluminum debris in the form rolls and
minimizing the lubrication of the aluminum strip.
15. Automatic High volume Core
Builder(YE3)
The YE3 is a high volume core builder that can produce a range of radiator and condenser
cores. The machine uses servo-based controls to ensure precise core assembly dimensions.
The YE3 can be configured with varying levels of automation. The standard machine (shown
below) includes automatic header and tube loading into the machine from component storage
carts that loaded into the machine. Other optional configurations can include automatic side
support and braze bar loading, as well as automatic braze clip loading/core unloading.
16. ABOUT THE MACHINE
The front side of the center machine is basically the operator side of the
center machine.
The center machine pulls in the individual aluminum strips from the stock
uncoiler by the rotation of form rolls. The center machine tooling creates all
part characteristics in the air center but the overall quality will be influenced
by the condition of the incoming material from the stock uncoiler.
The center machine design concept for each different product family is
identical and only differs on what the height, louver angle, and what the
constant is to be. The sequence of operations for each system is the same.
YE3 Condensor for Maruti Suzuki Alto 800
Machine Matrix Core Builder
Steps for making YE3
1) Matrix core builder
2) Brazing
3) Separator leak test
4) Cosmetic test
5) DBA Assembly
6) End cap press
7) End cap flame Braze
8) Proof test
9) Mass Spectrometer
10) Under water SLT
11) Underwater test (mass
spec)
12) Appearance
13) Final alignment gauge
17. Test On Condensor
--------------------------------------------
Leak testing equipment is a type of nondestructive testing equipment used to
measure the escape of liquids, vacuum or gases from sealed components or
systems. Some configurations require a separate leak detector or sensor as an
input. They are often equipped with various other components such as pumps,
calibrators, gages and cases. A leak is a hole or porosity in an enclosure capable of
passing a fluid from the higher pressure side to the lower pressure side.
There are many basic leak test methods and a few variations. The most familiar
are dunk testing, pressure decay, mass flow, mass spectometer and ultrasonics.
Dunk testing is still the most popular method, with pressure decay and mass flow
rapidly gaining in use. Mass flow is the de facto test method of choice in
automotive applications. An exception is pressure decay testing on a brazing
fixture.
If there is a situation where a no leak application is required, there is only one
choice— mass spectrometer—regardless of cost. This application uses helium and
hydrogen gases as part of its inspection process. The good news is the leakage
may be so microscopic it is rarely detrimental to product performance.
DunkTesting
Dunk testing, sometimes called bubble testing, is used for applications that do not
require high sensitivity. With dunk testing, the part under test is pressurized,
submerged in a liquid—typically water—while the operator looks for bubbles.
Bubbles form at the source of the leak as a result of air pressure, and the amount
of bubbles per minute can signify the size of the leak. Automotive radiators often
are checked for leaks this way. If a leak is present, the bubbles indicate where and
the leak can be repaired. Leak testing works best when speed is not a factor. On a
production line where test time is critical, leak testing is not the best choice.
While the initial cost of a dunk tank is low, in production it is expensive primarily
because the water becomes contaminated, thus producing a hazardous toxic
waste requiring special disposal. Tramp oil on the parts, as well as residual
brazing flux are the main problems. Tramp and brazing flux from the parts leech
into the water causing water contamination and costly special disposal. In one
plant, aluminum condensers—AC radiators—are tested on four lines, six tanks
total. Each operator has 19 seconds to determine if the bubbles represent air
trapped in the fins or an actual leak. The operator is solely responsible for quality
control prior to final mass spec testing. Failure of the operator to find a leak of 3.5
standard cubic centimeters per minute (sccm) or greater can shut the mass spec
line down for hours. In addition to disposal, maintenance of the water for pH,
bacteria and skimming the surface to control skin rashes is a big factor—possibly
18. $30,000 per year for maintenance of each tank. In the above mentioned condenser
plant, each 3- by 3- by 12-feet tank is said to cost $30,000 per year to maintain.
This is an example of a familiar process for low-volume applications and repairs
but an inappropriate use in high-volume applications. High-speed leak testing in a
production line situation hampers the operator’s ability to accurately identify
bubbles. However, dunk testing can be used on fuel tank filler assemblies and fuel
tanks themselves.
One advantage of water dunking is temperature stability. The large volume does
not change temperature, which affects most of the more sophisticated testers.
Pressure Decay
The pressure decay testing method measures the decrease in
pressure in an object. A test object is initially inflated and then
a reference pressure is established. After a designated amount
of time, the pressure is monitored again, and the initial and
final measurements are compared. The change in pressure can
be used to calculate the leak rate given the internal volume of
the device. Pressure decay is able to detect minute changes in
pressure. A drop in pressure signifies a leak; the greater the
pressure drop, the larger the leak. This method is convenient
in that it is easily automated and dry.
Years ago, the operator drew a grease pencil mark on a gage
and came back a while later to see if the gage pointer had
moved. If it had, this meant that pressure decayed. Today,
electronics monitor to 0.00001 psi and the test is fast—the
fastest on small-volume parts. During the past 20 years,
electronics have progressed from a 12-bit analog to digital
converters, which provided a resolution of 0.0012 to 5 psi.
This reduced to 0.0244 psi at 100 psi, far too coarse to be
practical.
One way around this problem was the differential pressure tester. Two sensors,
having a 5-0-5 psi range, could be set up at 100 psi and provide a resolution of
0.0012, which was usable. Presently, 24-bit resolution is available which provides
16,777,215 steps or 0.0000002 psi at 5 psi and 0.000059 psi at 250 psi.
Consequently, differential testing has practically been phased out.
The pressure decay method can be used to test small parts at high speeds. A 0.3-
inch diameter by 1.2-inch long medical filter can be tested to see if the filter is in
place, if it is plugged and if it allows for correct air flow. Test time from clamp to
next clamp is 0.85 second at 15 psi.
Also, a molded vacuum tube connection for the automotive industry is 12 inches of
0.2-inch inner diameter tube with circular molded fitting can be tested. Its test
time is 3.5 seconds, clamp-to-clamp at 15 to 30 psi, depending on part. Each test
result is permanently recorded and traceable if required.
Dry testing a
radiator, this
pressure decay
tester inspects
with a test cycle
time of 16 seconds
at 95 psi. This is
the same tester
that tested the
brazing fixture.
Source: Stewart
Ergonomics Inc.
19. Communication has become a significant quality tool. Sometimes, only a
permanent record of key test parameters and results are sufficient. Other times, a
label is printed out and permanently affixed to the part. Still others apply a
permanent paint spot or stamp a mark. On certain safety-critical parts, a guillotine
destroys a bad part.
Temperature variation is a concern. It is widely believed that pressure testing a
gas tank filler assembly while red hot on the braze fixture is impossible. The part
in the brazing fixture is approximately 1200 F in the brazing area. Room
temperature air fills the part to test pressure, then the fill valve closes. A 30 psi
test would normally be considered incorrect at 29.9 psi. However, the pressure is
rising, not decaying. The pressure will climb to 34 to 35 psi before starting to
decay. It will require at least 15 minutes to reach 29.9 psi and will not be
repeatable enough to be practical. The required test time is 20 seconds maximum.
MassFlow
With the mass flow method, the part is pressurized throughout the test. Any
pressure change measured by a pressure sensor is compensated for by inputting
air into the test part, therefore exact pressure control is critical. The amount of air
entering a part is measured by a flow sensor, directly determining the leak rate of
the part. Leakage flow is directed across a heating element. The temperature
change across a temperature transducer bridge results in an output voltage
proportional to mass flow.
If there is a leak, air will flow into the part. This flow is monitored electronically
and processed directly in sccm. Because the flow of air into the part is equal to the
leak loss, large-volume parts may be tested with relative ease. The problem with
testing large parts is long settle or stabilize time. Because precise pressure control
is critical, any oscillation during testing will compromise the test.
Several types of electronic sensors are available. One has a fine tube through
which air flows to the part. An electric heater at the input heats the air slightly
and that temperature is precisely measured just beyond the heater. The change in
temperature is proportional to the flow of air.
Another application measures the milliampere (mA) of current needed to maintain
temperature. Ambient incoming air temperature will affect the test. Most
production systems are recalibrated every morning, noon and late afternoon.
Large parts, such as truck radiators, are commonly placed in a wooden ―coffin‖ to
protect against air currents from fans and open doors. The slow test with long-
settling time requires protection from thermal changes for repeatability. Mass flow
is the process of choice in many automotive applications such as air conditioning
condensers, radiators and some fuel lines.
20. Mass Spectrometer
The mass spectrometer method involves pressurizing the test
object with a helium mixture and placing it in a snug-fitting
vacuum chamber. The air is then evacuated from the chamber,
creating a pressure gradient between the internal volume of
the part and the vacuum. The helium molecules move out of
the part through any porosity, holes and cracks. A mass
spectrometer then samples the air inside the chamber and
finds individual atoms of helium.
This is the most sensitive test presently available. These
testers are capable of detecting a leak of R600a refrigerant as
small as 0.0028 ounce per year. In use, the helium is usually a
disposable item adding cost, although recovery systems are
now available. Electronic parts often are tested by placing
them in a chamber and pressurizing with helium, then placed
in the vacuum chamber of the mass spectrometer to see if
helium is drawn out. This method also will find porosity.
The initial cost of a snug-fitting chamber is high, requiring
precise machining and extremely tight seals, limiting the
practical part size. A basic operation limitation is that a large
leak—more than 4 sccm—will saturate the vacuum container with helium. This
requires several hours of flushing to lower the helium background to a workable
level. A pre-test can be employed to weed out the gross leakers. As with dunk
testing, a 19-second inspection has proven troublesome and is slowly giving way
to pressure decay testing, with or without permanent recording. Even a condenser
16- to 18-inches high, and 24-inches long can be easily tested to 3 sccm in 12 to
15 seconds at 200 psi. Many air conditioner condensers (radiators) are quite large,
but they still must not leak for 8 to 10 years. For these applications, a wand
testing system has been developed which, while not as accurate as placing the
part in a vacuum chamber, is superior to any other kind of test, and substantially
less expensive than the vacuum chamber system.
Ultrasonics
Ultrasonic leak testers, sometimes called sonic, choked flow or turbulent flow,
analyze the turbulent flow of a fluid across a pressure boundary that creates
acoustic waves. These waves can be transmitted through the medium of the fluid
itself, through the containment structure or through the air surrounding the
containment structure.
A wand testing
system, while not
as accurate as
placing the part in
a vacuum
chamber, is
superior to any
other kind of test,
and substantially
less expensive
than the vacuum
chamber system.
Source: Galileo TP
Inc.
21. Because gas escaping through small holes generates ultrasonic sound, an array of
ultrasonic sensors can be placed around the part. Computer control permits leak
detection and, in certain circumstances, exact leak position may also be obtained,
similar to dunk testing. Ultrasonic testing has become so widely used to test
bearings, gearboxes and general mechanical inspection wear trends over time that
it is often overlooked in leak detection. Part size is usually not a problem, nor is
thermal variation. Arrays of sensors are used to pinpoint a leak. In some
instances, pressure decay testing and mass flow testers have been integrated with
ultrasonics to provide increased sensitivity. While this method has not been widely
used, it has potential for larger parts.
In the future, leak testing will experience faster cycle times, improved reliability
and validation. Leak testing will continue to be integrated into the assembly
process and its accuracy and sensitivity will become higher. NDT
Brazing On Furnace
When condenser completed on matrix core builder its goes for brazing on furnace
on High Temperature. Furnace is divided in four parts
Flexor
Dryer
Brazer
Cooling chamber and Final cool
Separator Leak Test
Parameters
Test Pressure—25to26psi (pressure sqr inch)
Reject level – 1.13 psi
Test Time—5 sec
Dump time – 0.0 sec
Cosmetic Inspection
Fitting Rubber caps in the core Or condenser.
22. DBA Assembly (Desiccant Bags assembly)
At this , desiccant bags insert in RD tank . An adsorbent package is provided for use
within the sealed canister of a fluid flow tube of an air conditioning system. The adsorbent
package includes a desiccant bag formed of a pouch having a sealed first end and a substantially
cylindrical second end. A filter cap is slidably and sealingly received within the second end of the
pouch. The cap includes a resilient sealing ring formed proximate a porous end wall. The sealing
ring slidably and sealingly engages an inner surface of the canister. The package is constructed
of a non-woven spun bonded nylon and can therefore be snugly received within the tight confines
of fluid flow tube or canister sections of an integrated condenser receiver.
End cap pressure
Air pressure – 2 to4 bar
End cap flame braze
Down heater—550 25 centi sec.
Up heater -- 1200 50 centi sec.
Soft heater -- 500 40 centi sec.
Air cooling – 2500 125 centi sec.
Air pressure – 4-6 kg/cm
2
LPG pressure – 1-2 kg/cm
2
Chillet temp. – 10-12 def.c
Air Flow – 0.9 LPM
LPG – 0.22 LPM
Proof Test
Apply nitrogen gas pressure at 500 -550 psi. for 5 second.
Mass spectrometer test
23. Air pressure – 75-85 psi
Helium tank pressure – 120psi
NOTE____:
Under water SLT and Under water test performed after rejection of condenser at mass
spectrometer Test. If Part not reject at mass spectrometer . Its will go to next test
appearance and Final Alignment Gauge Test.
Quality Parameters For YE3 condenser
No. of convolution -- 114 2
Center Height – 6.90 0.08mm
Lower angle – Avg. 24+5 /-2
Bulk transmission – Min. 65%
No. of lowers – should not be less than 6
Center length – 325 to 335 mm
Note –
Gap btw RD tank and Header HDR should be uniform and not exceed
3mm.
Clinching – At this place, brackets insert in Reinforcement
Upper and Lower Bracket at 0.5 bar
Hydraulic Pressure -- 60 to 70 kg/cm2