Training Report - Senok Trade Combine (Pvt) Ltd - Weliveriya

Abstract This report on In-Plant training contains the training experiences and knowledge that I have earned within the twelve weeks of training period at Senok Trade Combine (Pvt) Ltd at the Division of Construction and Heavy Machinery maintenance division in Weliveriya, Sri Lanka from 29th of September 2014 to 26th of December 2014. The report mainly contains three (3) chapters that are according to, as Introduction to the training establishment, Training Experiences and Conclusion regarding to the In-Plant Training that I gathered within all the twelve weeks in Senok Construction and Heavy machinery maintenance division. Chapter one (1), Introduction to the training establishment describes the details of the company such as company profile, the organizational structure, Facilities and Services available, present performance, profitability, Strengths and Weaknesses and usefulness to the Sri Lankan society. Chapter two (2), Training experiences describes my experiences and knowledge that I gained among the In-Plant Training. Details of work sites and workshops I visited, studied systems and functions during the in – Plant training period are included. Also the problems that I encountered during the training and founded solutions are discussed in this chapter. Chapter three (3), Conclusion of the In – Plant training that I gained at Senok Trade Combine (Pvt) Ltd which includes the positive and negative aspects according to my point of view as an Engineering undergraduate. I have included my suggestions that I believe would be beneficial for relevant parties to make decisions to improve the current training program.

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Acknowledgement First of all I would like to be thankful to the Training coordinator of SLIIT, Mr M. Kalyanapala and my University Sri Lanka Institute of information technology (SLIIT) for giving me this sterling opportunity and facilitate to undergo an In-Plant Training of 12 weeks. Also Dr. Samantha Wijewardana who is the training coordinator of Department of Mechanical Engineering for showing us the correct path to the industrial world.

Then I would like to be thankful to Mr. Prasanna Jayasinghe, the General Manager (Technical) of SENOK construction and heavy machinery Division for providing facilities of training in his place.

Also I would like to thankful to Mr. Ananda Rathnayaka, the training manager of Senok construction and heavy Machinery Division.

And I also thankful to 

Mr. Thilanka Rathnayake - Kobelco Section Service Manager



Mr. Chamila Nissan Thisera - Kobelco Section Service Engineer



Mr. Thusitha Wijerathna - VOGELE/ HAMM Section Service Engineer



Mr. Udayanga Yapa Bandara - VOGELE/ HAMM Section Service Manager/technical officer



Mr. Shiranka Perera - VOGELE/ HAMM Section technical officer



Mr. Udesh Ganepola - JCB Section Service Engineer



Mr. Anura Nandana - UD Nissan Section Service Engineer



Mr. Nandana Gunasekara – UD Nissan Section Service Manager



Mr. Hisne Nazim - ISO Manager



Mr. Sharada Udakanda – IT Officer



Mrs. Stella Wijesingha - Administrative Executive

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And all the administration staff members.

Mr. Chamara Udayanga (Lathe Machine Operator) and Mr. Sajeewa Kakulandara (Welder) and mechanical staff of the company who gave me massive support to make my training session a successful, knowledgeable and enjoyable one.

Especially I would like to thank my Senior Batch mates Buddhi Kalubovila and Sahan Pothupitiya who gave me advices and shared their experiences prior to the commencement of my In – Plant Training in order At Last but not least I would be very thankful to my colleague Dheemantha Fernando who had the training session with me for 2 months in the same place, Senok Construction and Heavy Machinery maintenance division for giving me a good support.

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Contents Abstract ................................................................................................................................................... 1

Acknowledgement................................................................................................................................ 2 List of Figures .......................................................................................................................................... 6 List of Tables ........................................................................................................................................... 7

1.0 Introduction to Senok Group ............................................................................................................ 8 1.1 Senok Group of companies ........................................................................................................... 8 1.2 Senok Vision and Mission .......................................................................................................... 10 1.2.1 Vision.................................................................................................................................... 10 1.2.2 Mission ................................................................................................................................. 10 1.3 Managerial Hierarchy of Senok Trade Combine (Pvt) Ltd ......................................................... 11 1.4 Main functions and services of the Senok Construction Machinery maintenance Division ....... 12 1.5Main Functions of the Sections.................................................................................................... 13 1.5.1 Kobelco Section .................................................................................................................... 13 1.5.2 JCB Section ........................................................................................................................... 14 1.5.3 VOGELE / HAMM Section ..................................................................................................... 15 1.5.4 UD Nissan Section ................................................................................................................ 16 1.5.5 Machining Shop ................................................................................................................... 17 1.5.6 Painting and tinkering Section. ............................................................................................ 18 1.5.7 Main Stores (Machinery Parts) ............................................................................................ 18 1.6 Senok Safety Methods ................................................................................................................ 19 1.7 Senok International quality certificates....................................................................................... 20

2.0 Training Experiences ....................................................................................................................... 22 2.1 Pre Delivery Inspection Process (PDI) ....................................................................................... 22 2.2 Steps of General Repair .............................................................................................................. 24 2.3 Repair of a Swivel Joint of kobelco SK200-8 excavator ............................................................ 25 2.4 Assemble an Engine. ................................................................................................................... 27 2.5 Participate to a Training by KISCO ............................................................................................ 31 2.6 Training in the machine shop ...................................................................................................... 32 2.7 Problems encountered and approach of solving.......................................................................... 37 2.7.1 Equation for dividing head to cut gear wheels without indexing plates ............................. 37 2.7.2 Found a cutting angle for washer of the shaft of winding lifting drum of a Kobelco crane 40

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3.0 Conclusion ....................................................................................................................................... 43

Abbreviations ........................................................................................................................................ 45 References ............................................................................................... Error! Bookmark not defined. Appendices............................................................................................................................................ 47

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List of Figures Figure 1-Senok Group of Companies ..................................................................................................... 9 Figure 2-Managerial Hierachy of Senok trade combine (Pvt) Ltd ....................................................... 11 Figure 3-Managerial Hierarchy display at Senok Trade Combine (Pvt) Ltd ....... Error! Bookmark not defined. Figure 4-Kobelco Section ..................................................................................................................... 13 Figure 5-JCB Section ............................................................................................................................ 14 Figure 6-VOGELE / HAMM Section ................................................................................................... 15 Figure 7-UD Nissan Section ................................................................................................................. 16 Figure 8-Machining Shop ..................................................................................................................... 17 Figure 9-Painting and Tinkering Shop .................................................................................................. 18 Figure 10-Fire Extinguisher .................................................................................................................. 21 Figure 11-Label of Fire Extinguisher.................................................................................................... 21 Figure 12-Kobelco SK200-8 Excavator ................................................................................................ 23 Figure 13-VOGELE 1600-3 Paver ....................................................................................................... 23 Figure 14-Pre Delivery inspection form ............................................................................................... 24 Figure 15-Repairing a swivel Joint ....................................................................................................... 25 Figure 16-Swivel Joint in the Shop Manual.......................................................................................... 26 Figure 17-Specifications ....................................................................................................................... 27 Figure 18-Cleaning the Engine block ................................................................................................... 28 Figure 19-Cylinder Block ..................................................................................................................... 29 Figure 20-Moving Parts of the Engine .................................................................................................. 29 Figure 21-Grinding Paste ...................................................................................................................... 30 Figure 22-Making rough the valve........................................................................................................ 30 Figure 23-Tuning the Engine ................................................................................................................ 31 Figure 24-Theory Session ..................................................................................................................... 32 Figure 25-Theory Session ..................................................................................................................... 32 Figure 26-Lathe a shaft according to the given bearing size ................................................................ 33 Figure 27-A lathe machine at Senok ..................................................................................................... 33 Figure 28-Arc Welding ......................................................................................................................... 34 Figure 29-Plasma Cutting ..................................................................................................................... 34 Figure 30-Speed of the hand causes for a good weld............................................................................ 34 Figure 31-Milling Machine ................................................................................................................... 35 Figure 32-Drilling the brass cylinder .................................................................................................... 35 Figure 33-teeth cutting .......................................................................................................................... 36 Figure 34-Sleeve cutting ....................................................................................................................... 36 Figure 35-Indexing Plate and sector arm .............................................................................................. 36 Figure 36-Dividing Head ...................................................................................................................... 36 Figure 37-Completed warm wheel (II) ................................................................................................. 36 Figure 38-Completed warm wheel (I) ................................................................................................... 36 Figure 39-Dividing head scale .............................................................................................................. 39 Figure 40-winding lifting drum of a Kobelco crane ............................................................................. 41 Figure 41-Kobelco Crane ...................................................................................................................... 42

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List of Tables Table 1-Training Schedule .................................................................................................................... 22

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1.0 Introduction to Senok Group Since 1979, Senok has been a pioneer in the construction machinery industry in Sri Lanka. Over the years, Senok has diversified and grown to encompass a wide variety of products and services including automobiles, energy, travel, mining and more. According to the company profile of Senok, it says, “SENOK today is staffed with some of the best-trained and observant minds in the country. They offer incredible support to the many varied brands SENOK represent Varying from Tea to the world's most prestigious brands of construction equipment, from automobiles to travel, from Jewelry to Haulage, from Mining to Hydropower and aviation.”

For the last three decades, their success has been attributed to the superior products and service that Senok represents. Senok is associated with some of the world's leading companies, contractors and specialized manufacturers that enable us to meet their customers' expectations. Looking ahead, Senok's commitment to innovate its business model will set us apart and ensure their success in the future.

1.1 Senok Group of companies Since its establishment in 1979, Senok has grown to be one of Sri Lanka’s top business groups (Figure 1) with nearly 1000 employees. This remarkable success can be attributed to its spirit of creativity and desire to create a better future by embracing new opportunities. Along with its core business in the Construction Machinery, Automobiles and Trading areas, Senok has now established a strategic business portfolio into Aviation, Energy, Hospitality, Construction and Property Development and Automobile Assembly. Senok regards its employees as its most important asset and attribute its success to the committed work force.

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Figure 1-Senok Group of Companies

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1.2 Senok Vision and Mission 1.2.1 Vision

VISION To provide efficient and personalized services to all spheres of industry whilst ensuring customer and employee satisfaction with the ultimate goal of effectively contributing towards our national objectives

1.2.2 Mission

MISSION To be a caring corporate citizen with a firm resolve to make a significant contribution to the nation’s growth while achieving our own corporate objectives

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1.3 Managerial Hierarchy of Senok Trade Combine (Pvt) Ltd

The Managerial Hierarchy of Senok Construction and Heavy Machinery maintenance division shown in Figure 2 and the displaying chart at Senok shown in Figure 3.

Figure 2-Managerial Hierarchy of Senok trade combine (Pvt) Ltd

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1.4 Main functions and services of the Senok Construction Machinery maintenance Division

Senok construction Machinery Service Centre is located approximately 30km from Colombo port, off new kandy Road at No: 01, Wilimbula, Henegama, Weliveriya. The service Centre is situated on a large extend of land, 38 acres equipped with all required equipment, special tooling and facilities that are for undertaking any kind of services and repairs. The service yard ensures high quality standards and is an ISO 9001:2008 certified in Pre Delivery inspections of plant, Machinery and trucks. Warranty services and repairs, General Repairs, maintenance of machinery and trucks and steel fabrication works. It employs over 200 personnel ranging from Mechanical Engineers, Service Managers, Technical Officers, Foremen, Technicians, Mechanics, Painters, Welders and electricians etc. Their customer oriented service facilities have expanded to locations in Matara and Vavuniya in order to offer more – convenient and quicker service for machinery owners. Their service departments also offers on-site maintenance and repairs with our fleet of mobile service vehicles. They also provide haulage of large special equipment with our fleet of Low Bed Trailers, SelfLoading Trucks etc. Mainly This division has seven sub sections 1. Kobelco Section 2. JCB Section 3. VOGELE / HAMM Section 4. UD Nissan Section 5. Painting and Tinkering Section 6. Machining and welding Shop 7. Main Stores

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1.5 Main Functions of the Sections 1.5.1 Kobelco Section

Figure 3-Kobelco Section Kobelco section (Figure 4) of Senok Construction and Heavy machinery division is the section that deals with Hydraulics. Senok Has been representing Kobelco Construction machinery company Ltd of Japan for over 30 years and also the dealer of Sri Lanka and Maldives. 2.0 ton capacity Hydraulic Excavators, Rough Terrain and crawler cranes are imported and retailed by this Kobelco section. Kobelco section of Senok has Latest technology and they have good well experienced mechanical staff. Always they try to give good and quality service to their customers. Their most popular and most marketing machine in Srilanka is Kobelco excavator. Latest Excavators models are Geo spec Kobelco SK200-8, SK330-8 Heavy Hydraulic Excavator and SK35, SK40 and SK115 Mini Excavators.

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This section is under the supervision of Service Manager Mr. Thilanka Rathnayake and Service Engineer Mr. Chamila Thisera.

1.5.2 JCB Section

Figure 4-JCB Section Senok has been proudly representing JCB in Sri Lanka since 1994. They have been serving all sectors, which includes Government institutions, Local and foreign contractors and Rental companies etc. Among most common machinery they import, JCB 3CX Backhoe Loaders (British), JCB 3DX Backhoe Loaders (Indian), JCB JS 200 Excavators, JCB JS 140 Excavators, JCB 426ZX Wheel Loaders are the most popular machineries in Sri Lanka. But also if the customer requires away from these models, Senok import any kind of JCB product like crawler excavators, wheeled excavators, telescopic handlers, wheel loaders, dump trucks, rough terrain fork lifts, Industrial fork lifts, mini/ midi excavators, skid steer loaders, tractors and compaction equipment.

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JCB section (Figure 5) also have wide range of machinery repair section under supervision of service engineer Mr. Udesh Ganepola. They do any repair of the machine after sold and they import original spare parts also

1.5.3 VOGELE / HAMM Section

Figure 5-VOGELE / HAMM Section In the VOGELE / HAMM section (Figure 6), many kinds of machineries such as VOGELE, HAMM and Mitsubishi are repaired. VOGELE (German) pavers are the most remarkable machinery that import and repairing. It is used to lay carpet on the roads. Also it is operating with very complex electronic circuits. It is a huge mechatronic application. VOGELE / HAMM section imports all kind of Mitsubishi, HAMM, VOGELE and mini compaction machines (Rammers) and takes responsibility of maintenance and repairs after selling. This section is controlled under the supervision of service engineer Mr. Thusitha Wijerathna.

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1.5.4 UD Nissan Section

Figure 6-UD Nissan Section UD Nissan section (Figure 7) import sell and repair all type of Nissan UD trucks. Not only Nissan trucks this section also imported and maintain Eicher Trucks and busses also because UD trucks are very expensive in cost. Customers have more favor in buy Eicher vehicles than Nissan. But in the government sector most of the time they tend to buy Nissan vehicles because their long life time with advance technology. Senok has been representing Nissan diesel in Sri Lanka and Maldives since 1990. Nissan Diesel trucks and bowsers are extensively used by the Ceylon Electricity board, Ceylon Petroleum Corporation and Sri Lanka ports authority. Reason for that in other and the UD brand name has been synonymous with driving comfort superior performance and durable reliability. Not only that Eicher trucks are designed for superior performance with better fuel economy, higher rated payload and faster turnaround. Hence these trucks have low operating cost and high reliability leading to higher profits.

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This section control under supervision of Service manager Mr. Anura and Service manager Mr. Nandana. 1.5.5 Machining Shop

Figure 7-Machining Shop Machining Shop (Figure 8) is the most important section of the company. Because this section provides its service to all other sections in the company. They have 3 lathe machines, Welding plants with new technology (Arc welding, MIG, TIG, Plasma) etc. They do Lathe works for fulfill other sections requirements like lathe out nuts and bolts, varies types of iron blocks, etc. Especially they repair track belts, buckets of excavators, booms of cranes and many parts coming from each and every section. This section is under the supervision of Mr. Nandana and one service advisor.

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1.5.6 Painting and tinkering Section.

Figure 8-Painting andTinkering Shop

This section (Figure 9) also stands for fulfill the needs and equipment of any vehicle under the senok responsibility. They do tinkering works, painting, cut 7 polish, service vehicles etc. In the pain shop have 2 booths with new technology to fulfill the customer needs fast and better. Both sections have well experienced workers to offer quality service to senok customers. This section is control under the supervision of one service advisor. 1.5.7 Main Stores (Machinery Parts) Senok Trade combine (Pvt) Ltd main spare parts department is situated in Grand Pass, Colombo. But all the senok machinery maintenance branches in Sri Lanka have spare parts stores inside the branch. Because when they repair the machines they want to replace parts and give their

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good service for customers. Senok maintains spare parts stores in Weliveriya service division also. In this section the staff are experienced and well trained handling multi-franchised products. Almost all essential spare parts are continuously stored in stock, while any item immediately unavailable could be air freighted within a period of 3 to 5 days. This is in keeping with their company policy of keeping the down time on customer equipment to a bare minimum, thus ensuring maximum productivity. They are selling only genuine spare parts. Ensuring best value for money, by virtue of durability and minimal down-time of machines.

1.6 Senok Safety Methods Senok construction machinery division always thinks about their labors safety, because working with these type of heavy machineries are risky for their life. Always they work with heavy equipment, tools and high pressure hydraulic tools. In the Machining shop, they work with three phase electricity. (Welding plants, Lathe and milling machines are work with three phase currant) and fire (acetylene and plasma cutting) Senok construction machinery division on risk to occur fire in anytime. Because these people always work with high inflammable fuel like petrol, diesel and hydraulic oil. To avoid that risk senok provides fire extinguishers inside the company and they train their staff, how to response when these type of incident occurs. For ISO quality assurance, fire safety is a very important thing. During the working period in the company or when go on outstation services through the company, workers must have wear their safety overall, helmet and safety shoes. If anyone works without having safety methods, senok takes actions for them according to the company constitution. Safety overalls are categorized into 4 classes considering their patterns and colour. They are; Training Mechanics

- Light Blue

Mechanics

- Dark blue

Supervisors / Service advisors- Sky blue Technical officers

- White

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Safety helmets also divide into two categories by its colour. Yellow – Training mechanics, mechanics. White – Service advisors / Supervisors.

1.7 Senok International quality certificates Senok construction machinery maintenance division is qualified under the ISO 9001:2008 certificate. ISO official web site define it as follows, “ISO 9001:2008 specifies requirements for a quality management system where an organization o Needs to demonstrate its ability to consistently provide product that meets customer and applicable statutory and regulatory requirements, and o Aims to enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable statutory and regulatory requirements.

All requirements of ISO 9001:2008 are generic and are intended to be applicable to all organizations, regardless of type, size and product provided. Where any requirement(s) of ISO 9001:2008 cannot be applied due to the nature of an organization and its product, this can be considered for exclusion. Where exclusions are made, claims of conformity to ISO 9001:2008 are not acceptable unless these exclusions are limited to requirements within Clause 7, and such exclusions do not affect the organization's ability, or responsibility, to provide product that meets customer and applicable statutory and regulatory requirements.”

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ISO officers audit the company every year and they check whether company runs under their qualities and conditions. Their main target of auditing is to check whether the company gives its maximum service to the customers, company runs under the energy saving concepts and safety condition of the workers. Under that they, o Check 5S concept running inside the company o Check stores and section works with the recorded data (books or computers) o Check all measuring equipment with master instrument whether they correct or not

(E.g.: Check all millimeter, clinometers with master meters)

o Check about the fire safety conditions I.

Water lines, gas lines, air lines, electrical wire lines must be label in appropriate colour.

II.

All the mechanics wear their safety kit (overall, helmet, safety shoes)

III.

Fire extinguishers (Figure 10) must provide inside the company with appropriate label (Figure 11) for which kind of fire they should use)

Figure 9-Label of Fire Extinguisher

Figure 10-Fire Extinguisher

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2.0 Training Experiences In the Senok Trade combine (Pvt) Ltd, the Construction and Heavy machinery maintenance division most of their works are related to Mechanical Field. Mainly on maintenance works. Maintenance on Hydraulic systems, Mechanical Systems are mainly done in this division. Also making simple parts and steel fabricating in the machining shop. Also there is mechatronic applications, Most of them are in the VOGELE, HAMM and Kobelco machines. The schedule of the training of 12 weeks in 3 workshops shown in Table 01.

Table 1-Training Schedule

Section

Summary of Training

Kobelco

Hydraulic

and

Duration

mechanical 5 weeks

maintenance training Machining Shop

Lathe, milling and welding 5 weeks processes training

VOGELE / HAMM

PDI and management training

2 weeks

2.1 Pre Delivery Inspection Process (PDI) The Senok Trade combine (Pvt) Ltd is a specialist in PDI processes. The company is granted by ISO 9001:2008 standard for PDI Operations. PDI is inspect and make a report before selling any kind of machine that imported from abroad. During the period of the training 2 PDI processes were done. One in Kobelco SK 200-8 excavator machine (Figure 12) and other one is VOGELE 1600-3 paver machine (Figure 13). In Senok, there were Pre-prepared PDI forms (Figure 14) for each machine which they are deal with. The form was included with all the mechanical and electronic functions of the particular machine.

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Company was followed with few steps to complete the PDI process 1. Get the vehicle Inventory 2. Make a PDI Job card 3. Inspect the machine and fill the form 4. Send the invoice for PDI process to the marketing Department In pre delivery inspections mechanics were checked in many things such as, a. General condition b. Visual check c. Controllers d. Engine e. Break System f. Transmission System

Figure 11-Kobelco SK200-8 Excavator

Figure 12-VOGELE 1600-3 Paver 23

Figure 13-Pre Delivery inspection form

2.2 Steps of General Repair Senok have earned the ISO 9001:2008 standard for General Repairs and Services. In General repairs they were followed some steps for the process. The process was followed any vehicle or machine which came for the repair. 1. Job requisition form 2. Get the job number 3. Income inspection/ Make Inventory 4. Send inventory form to the customer 5. Open a job card 6. Check all the troubles in machine or vehicle 7. Make an Estimate and send to the customer

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After the 7th step Customer decides whether the repair is doing or not. If it is not the customer should pay only for the estimation. If the customer approves the estimation, the job will continue. The steps are shown in below

8. Repair 9. Final Inspection with customer 10. Invoice send to the customer

2.3 Repair of a Swivel Joint of kobelco SK200-8 excavator A Kobelco SK 200 Mark 8 series excavator was fully repaired. Training was done in repair the swivel joint (Figure 15) of the machine. Excavators are always working in rough, Muddy and wet environments. The trouble of the machine which was repaired is mud has gone inside of the swing areas, swivel joint and crawler system.

Figure 14-Repairing a swivel Joint The oil flow of the machine never shuts off due to the rotation. If it happens the total excavator machine will fail. The swivel joint was designed for that reason. The continuous connection of hydraulic lines was kept by the swivel joint. Therefore the excavator could work in a huge range.

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Due to the effect of mud all the hydraulics paths were blocked. Therefore all the paths have cleaned. First the parts were cleaned with high pressure water to remove mud. After that with kerosene to remove water and after that dried by high pressure air. There were standard specifications (Figure 17) should be in the swivel joint according to the Shop Manual of Kobelco SK 200-8 machine (Figure 16).

Figure 15-Swivel Joint in the Shop Manual

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Figure 16-Specifications

The ports of the swivel joint were adjusted to the specified levels in the shop manual. So that all the Seals and O-rings were newly replaced. Then the swivel joint was assembled and inserted the lubricants. Then was mounted to the machine and connected the hydraulic lines. Then the specified pressures of the each ports by screwing the bolts in the connecting lines were adjusted.

2.4 Assemble an Engine. Kobelco SK200 – 8 excavator which had a repair in the Engine was brought to Senok. The machine was full of mud and many damages to the body due to a tumble. The engine of the Kobelco SK 200-8 machine was a HINO J05E-TA common rail diesel engine. Common rail direct fuel injection system was included in many of Kobelco machine engines.

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The engine was dismounted and cleaned with water, kerosene, degrease solution (Figure 18) and dried by high pressured air. Then the assembling the engine was started.

Figure 17-Cleaning the Engine block

Firstly the cylinder block (Figure 19) was assembled. There were three main parts. a. Cylinder block (Part 11401) b. Cooling Jet (Part 11408) c. Cylinder liner (Part 11467) When the cylinder liner was assembled to the cylinder block in there,the special tool cylinder liner puller was used and the tightening torque would be 9.8 N.m (7 lb. Ft) in the torque wrench. Then the cooling jet was assembled to the cylinder block. The tightening torque for that was 22N.m (16 lb. Ft).

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Figure 18-Cylinder Block Then the timing Gear cover and the Fly wheel housing were assembled. After that Front oil seal retainer, Fly wheel housing and End Plate were assembled. Then the crank shaft front and rear oil seals were assembled. For that job they were used a special tool called Oil seal press tool. After that the main moving parts (Figure 20) were assembled such as Connecting rods, Crank shaft, Fly wheel assembly, Piston and piston ring set etc. After them assembled the cam shaft and Idler gear.

Figure 19-Moving Parts of the Engine

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Then the timing gears were installed. The timing gears were used for timing the valve operations. Then the valve system on the cylinder head was installed. Before the installation new valves were grinded and made rough (Figure 22), because the fuel mixture could be leaked through new valves. For the grinding process technicians were used Grinding paste (Figure 21). Grinding paste was a kind of rough material paste. Most of the time the paste were used where the rough papers could not reach. Small rough areas were made in the valve head. The Rough area was prevented the fuel leak into the combustion chamber.

Figure 21-Making rough the valve

Figure 20-Grinding Paste

Technicians were checked out the roughed valves and valves were assembled. Then the cylinder head and the cylinder block were assembled with 21 bolts (appendices). After that the valve springs were installed. Then the valve clearance was adjusted and the valves were closed by the cylinder head cover. After that all manifolds, Turbo charger, cooling system, Starter motor, Oil Pan, Alternator, Air compressor etc. were installed.( appendices) Finally the engine was mounted in the Kobelco SK200-8 machine for checking and tuning. The Specialty of this engine was the engine could not start out of the machine. Because an ECU system was installed in the machine to control the Engine. The engine was full of electronic sensors and all the details were gathered by the ECU system. Then the system decides and control the diesel levels, rpm levels each and every operations done by the engine. Also the tuning of the engine was done by using a computerized system software (Figure 23). A port for connect the computer to the machine was inside the cabin. Through that port technicians were tuned the engine.

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Figure 22-Tuning the Engine

2.5 Participate to a Training by KISCO A training session held by Mr. Clarance Leong, a Mechatronics engineer at KISCO (Kobelco International Singapore Corporation) was held at Senok Henegama yard. The training was held in two days and each day had two sessions, Theory session and practical session. The training was about newly imported machine to Sri Lanka, Kobelco SK 35P mini excavator machine. In the first day the training was started with the mechanical side of the machine. In the morning session the theory parts were discussed. In the theory session (Figure 24) the trainer were supplied by the hydraulic circuit diagrams of the machine and discussion and explanations were done by Mr. Leong. After the theory session the practical session (Figure 25) was started. All the trainees were observed all the function that were in the diagram are worked or not in the machine. Trainees were checked all the functions such as boom up, traveling, swing etc. In the second day the electrical part of the machine was discussed. The training was same as the previous day schedule. The electrical theories were discussed in the morning and trainees were provided circuit diagrams. In the evening session the practical part was done with machine. After that the training was concluded with the knowledge of maintain the Kobelco SK 35P mini excavator machine.

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Figure 23-Theory Session

Figure 24-Theory Session

2.6 Training in the machine shop The training manager of senok was sent me to the machining shop after 5 weeks of training in kobelco section. In the machining shop there was 2 main parts. 1. Machines part 2. Welding part The machine part there were 3 lathe machines, 1 milling machine and a drill. In the welding part there were many welding plants such as MIG welding, TIG welding, Arc Welding, Plasma cutting etc. The machining shop was made parts for the all the sections in Senok Weliveriya yard such as filling and grind the hydraulic rams, cutting gear wheels and other essential wheels and gears, Nylon lathing, making buckets of excavators, Repairing buckets of excavators, cutting metals, making roofs for construction machineries, repairing crane booms, All the welding works and making internal facilitate items of the company such as gates, metal doors etc. In the lathe machines (Figure 27) many operations such as turning operations, facing operations, Boring operations etc. were practiced. After that lathing a shaft according to the given Bearing size (Figure 26) was practiced. Firstly the bearing was measured by a Vernier caliper. Then the work piece was mounted in the chuck and was turned the shaft. But in the first time was not successful. Then the lathe operator was advised how to turn correctly. In the next time the operation was successful.

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Figure 25-Lathe a shaft according to the given bearing size

Figure 26-A lathe machine at Senok

Also Welding works were practiced. The welder was given instruction about welding, safety and technical strategies that are using in the industry. Also Arc welding (Figure 28), Plasma cutting and grinding were practiced. Some welders were used arc welding to cut thin metal plates with high Amperage (more than 100A). Normally for metal cutting, Plasma cutting is used. (Figure 29).

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Figure 28-Arc Welding

Figure 27-Plasma Cutting

Concentration is very important in the welding. Because if the concentration lost, the welding will fail. Also the speed of the hand causes for a good weld (Figure 30).

Figure 29-Speed of the hand causes for a good weld

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The processes of making a worm wheel was studied in the milling machine. The worm wheel was a UD boom truck’s swing reduction motor. The worm wheel was crashed and there were no any drawings for the worm wheel. Therefore the milling machine operator was reverse engineered the worm wheel. The measurements was taken using measuring tools such as Vernier caliper, bore gauge and micro meter screw gauge. A cylindrical brass piece was given for the job. The brass piece was roughly shaped into the measurement using lathe machine and drilled (Figure 32). Then cutting of warm wheel was started using the milling machine (Figure 31). Firstly sleeve was cut in the drilled hole. (Figure 34) Then cutting the tooth was started (Figure 33). There was a special part of the milling machine to cut gear wheels called dividing head or indexing head. Two wheels were in the dividing head. One was for hold the work piece called spindle or chuck and other one for adjust the angle of particular wheel called sector arm or sector (Figure 35). The dividing head (Figure 36) was used to cut the standard number of teeth. There were special plates called indexing plates (Figure 35) for cutting standard number of teeth. Dividing plates were interchangeable. The operators were selected the number of teeth from that plates and started to cut teeth, then the next tooth was cut by turning the sector arm once and selected the next place. Operators were cut teeth one by one like wise. In the warm wheel, the teeth were not parallel to the bed. There were 5 degrees of angle to the bed. The milling machine was designed with an adjustable bed to recover that problem. Teeth were cut one by one and in 2 days the job was completed. (Figure 37 and Figure 38).

Figure 30-Drilling the brass cylinder

Figure 31-Milling Machine

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Figure 33-Sleeve cutting

Figure 32-teeth cutting

Figure 35-Dividing Head

Figure 34-Indexing Plate and sector arm

Figure 36-Completed warm wheel (I)

Figure 37-Completed warm wheel (II)

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2.7 Problems encountered and approach of solving 2.7.1 Equation for dividing head to cut gear wheels without indexing plates A job of cutting a gear wheel that have 127 teeth was done in the machining shop. There was no indexing plate for index the wheel into 127 parts. There was a gear ratio between sector arm and the chuck of dividing head. Gear ratio was noticed as 1:40 in the dividing head. When the sector arm turns in 40 rounds, the chuck or spindle (Interchangeable parts) turns 1 round. Also it was noticed that when the sector arm turns 1 round, the spindle or chuck turns 9 degrees. Also in the sector arm side there was a round scale. The number of degrees should turn the sector arm to select the next cutting point could find using the round scale. The number of degrees should move on the sector arm for dividing a gear wheel into 127 on spindle was calculated. 360 127

= 2.834646

The value was rounded off to two decimal places because the machine could not cut that much of precisely. Therefore the answer was 2.83 degrees. The round scale (Figure 39) at sector arm could measure degrees as well as minutes. The scale was divided in to 9 and each of those divisions was divided in to 60 parts. The output correction was one minute. The number of degrees and minutes should turn to get the output of 2.83 degrees on the spindle was calculated. The two degrees was got easily from the scale. But the values with decimal places could not get by directly. Because decimals should converted into minutes. So that I converted 2.83 degrees in to minutes. But after the decimal part should only converted into minutes. The answer was separated into two parts. 2.83 = 2 + 0.83

Degree part

Decimal part. Not the actual Minutes

This equation will use by an operator or a mechanic. Therefore it should be user friendly. The operators or mechanics were not experts in logical and solving mathematics equations. Therefore the system should not be complex.

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The decimal part was converted into minutes. 0.83 × 60 = 49.8 The answer was 49.8 minutes. The machine was not designed to give smaller output than 1 minute. Therefore despite the decimal value and was rounded into nearest minute. Therefore the answer was 50. The full answer was 2 degrees and 50 minutes. The operator was instructed to start the cutting and then the operator was given 2 degrees and 50 points by the dividing head scale for select the next cutting point. After that the equation was checked with some random numbers whether the equation is valid for all the gear wheels. The equation was not depends on the radius of the gear wheel. Therefore a simple equation was created for operators as follows. The operators were tried the equation few times and certify that the equation can use in any gear wheels that have any number of teeth.

360 = 𝐴. 𝐵𝐶 𝑍

1

0. 𝐵𝐶 × 60 = 𝑌

2

A = Degree part B, C = Decimal part Y= Minute part Z = Number of teeth The answer was “A” degrees and “Y” minutes.

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Figure 38-Dividing head scale

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2.7.2 Found a cutting angle for a washer of the shaft of winding lifting drum of a Kobelco crane

The Kobelco section was needed to make a washer for a winding lifting drum of a Kobelco crane (Figure 40 and Figure 41). The measurements were given as follows (fig).

The Kobelco division was needed to cut in range of 9.3 mm to 9.4 mm width teeth around the circle. The number of teeth were not specified.

Step 1 𝐶 = 2𝜋𝑅 𝐶 = 2𝜋 × (

136.8𝑚𝑚 2

)

C= 429.77mm

Step 2 429.77mm/ 9.4mm = 45.72 Finding the number of divides in the circle was tried in this step. The answer was 45.72. But the number of divisions must be an absolute number. Therefore the answer was rounded to find the number of divisions. If the answer rounded into 45 the width of a tooth become more than 9.4 mm. The answer was out of range. Therefore the answer rounded into 46. According to the equation the answer was in the range. 40

Step 3 429.77mm/46 = 9.34mm Then the width of a divide was found as 9.34mm. The answer was in the given range. Step 4 Using 𝑆 = 𝑅𝜃 9.34 = (136.8/2) *𝜃 𝜃 = 0.137 𝑟𝑎𝑑 𝜃 = 7.82 Degree Therefore to cut the washer marks were put in every 7.82 degrees. After the cut, there was 23 teeth and 23 coverts (Figure 40).

Figure 39-winding lifting drum of a Kobelco crane

41

Figure 40-Kobelco Crane

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3.0 Conclusion As an undergraduate student of 2nd year who finished the first industrial training of three months, my opinion on the Industrial Program by Sri Lanka Institute of Information Technology is very much positive. I strongly believe that industrial training is one of the key module that an undergraduate can make his or her future career. The period of past three months is the best learning experience I ever had in the university life, in terms of applying theoretical knowledge to solve real world problems. During the training period, I got the opportunity to get to know about many fields in Mechanical Engineering. Considering about the overall training program at SENOK construction machinery Division in Henegama from 29th of September 2014 to 26th of December 2014 I have gathered much knowledge than in the lecturing period and it is really enthusiasm to have that kind of practical experience. The Faculty of Engineering of Sri Lanka institute of information technology has provided the opportunity to every engineering undergraduate to undergo Industrial Training at places which they like to attach and work as the trainee. I see it as a sterling offer that we got whereas only engineering undergraduates of the university get that privilege. (Considering with other faculty students undergraduates). SENOK construction machinery Division is the one of best industrial training placement for trainees who is interested in Mechanical and mechatronics. These places they always deal with heavy machineries. That means hydraulic, Mechanical and mechatronic things. As an undergraduate mechanical engineering, there is no clear idea about electrical and electronic stuffs for me. But when I was in repairing teams such as Engine assembly team, I felt that I must have some knowledge of electrical and electronic things also. If not I will not understand the whole machine. That is the main problem I faced in the training period, less knowledge of electrical and electronics. Senok is a place with electrical and electronics also. Service Engineers, advisors, electricians always help me to gain my knowledge in those stuffs. Sometimes they described me about electronics things such as Sensors, ECU systems, Electronic trouble monitoring systems etc. Here all the Service engineers and advisors have very good knowledge and they treated me very friendly manner. Training manager, Mr. Ananda Rathnayaka who conducts SENOK training programmes is a very friendly person and he always help me to gain my knowledge

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about electronics and hydraulics. So I recommend SENOK construction machinery Division is an ideal place to be visited by all undergraduates in his/her Industrial Training period. I am really thankful to Mr. M. kalyanapala who is the training coordinator of faculty of engineering to conduct this training program more effectively and efficiently for undergraduate students and Also Dr. Samantha Wijewardana who is the training coordinator of SLIIT for showing us the correct path to the industrial world and Mr. Mihiran Pathmika who is the mechanical engineering lecturer at SLIIT for advising us in many ways about the industry. Finally I would like to mention that the industrial training of 12 weeks was a knowledgeable period for me as an engineering undergraduate. I was able to meet with my expectations of the training during the period. The exposure I got through the In-plant Training will definitely be effective for my future career as an engineer. I hope that SLIIT, faculty of engineering will conduct this training programme even more effectively and efficiently. I hope my feedbacks will be helpful in identifying the drawbacks and improving the context of the training program.

De Alwis D.G.S.M Department of Mechanical Engineering, Faculty of Engineering, SLIIT

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Abbreviations SLIIT – Sri Lanka Institute of Information Technology ECU – Engine Control Unit KISCO – Kobelco International Singapore Corporation PDI – Pre Delivery Inspection

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References Anon., 2006. HINO Diesel Engine workshop Manual. s.l.: HINO Corporation. Anon., 2006. KOBELCO Shop Manual SK 200 Series. s.l.: KOBE Steel. Anon., 2014. Mig Welding. [Online] Available at: http://www.mig-welding.co.uk/arc-faults/arc-length-faults-large.jpg [Accessed 24 01 2015]. Anon., 2014. PhotoDivision. [Online] Available at: http://photodivision.gov.in/writereaddata/webimages/thumbnails/59103.jpg [Accessed 24 01 2015]. Anon., 2015. ISO. [Online] Available at: http://www.iso.org/iso/catalogue_detail?csnumber=46486 [Accessed 24 01 2015].

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Appendices

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