Design Project

JIMMA UNIVERSITY
JIMMA INSTITUTE OF TECHNOLOGY

DEPARTEMENT OF MECHANICAL ENGINEERING
HOSTING COMPANY – BISHOFTU AUTOMOTIVE
INDUSTRY
DURATION OF INTERNSHIP – 24/2/2014 – 24/6/2014 G.C
DATE OF SUBMISSION 17/10/2014
ACKNOWLEDGEMENT
First and for most we would like to extend our gratitude to our advisor and jimma institute of
technology industry linkage officerAtobalewgizefor his contribution towards the searching
company, advise and further information for internship.
And also our most profound thanks goes company supervisor engineer Saud and metal &
engineering cooperation bishoftu automotive industry work shop workers for their help in the
course of our internship.
Our heart full gratitude for our beloved families for their help in both financially and morally
throughout our school life.
EXCUTIVE SUMMARY
The main objective of internship report is to introduce the students with practical world, in
which machines of different types with different function are present in order then to build the
knowledge we get in classes which is theoretically by the practical one.
Also, it provides the students the opportunity to share knowledge with the workers in the
company who are experienced in practical knowledge.
The report also describe the work ethics that we developed so far from the workers of the
company which may help us in our feature professional ethics for life and practical skills helps
us to upgrading theoretical knowledge.
Also describe the problem we have tried to solve in company by designing automotive
performance test with detailed analysis design.
content
Acknowledgment …………………………………………………………………….. I
Executive summary …………………………………………………………………... II
List of figures ………………………………………………………………………… IV
List of tables …………………………………………………………………………. V
Chapter 1 BACK GROUND
1.1 HISTORY OF BISHOFTU AUTOMOTIVE INDUSTRY……………………………………….
1.2 BASIC CUSTOMER OF ORGANIZATION ………………………………………………………….
1.3 ORGANIZATIONAL STRUCTURE AND WORK FLOW…………………………………………..
Chapter 2 OVERALL INTERNSHIP EXPERIENCE

2.1 HOW WE GET INTO THE COMPANY…………………………………………………………………..
2.2SECTION OF COMPANY WE HAVE BEEN WORKING……………………………………………
2.3 WORK FLOW IN THIS SECTION…………………………………………………………………………..
2.4 WORK PIECE OR WORK TASKS WE HAVE BEEN EXCUTING……………………………………..
2.5 PROCEDURES WE HAVE BEEN USING WHILE PERFORMING OUR WORKS TASKS……
2.6 HOW GOOD WE HAVE BEEN IN PERFORMING OUR WORK TASK……………………………
2.7 CHALLENGES FACING WHILE PERFORMING OUR WORK TASK………………………………..
2.8 MEASURES TAKEN TO OVERCOME THESE CHALLENGES…………………………………………
Chapter 3OVERALL BENEFITS GAINED FROM INTERNSHIP

3.1 IN TERMS OF IMPROVING PRACTICAL SKILLS………………………………………………………….
3.2 IN TERMS OF UPGRADING OUR THIOROTICAL KNOWLEDGE…………………………………..
3.3 IN TERMS OF IMPROVING INTERPERSONAL COMMUNICATION SKILLS…………………
3.4 IN TERMS OF IMPROVING OUR TEAM PLAY SKILL…………………………………………………
3.5 IN TERMS OF IMPROVING OUR LEADERSHIP SKILLS……………………………………………….
3.6 IN TERMS OF UNDERSTANDING ABOUT WORK ETHICS…………………………………………..
3.7 IN TERMS OF ENTREPRENEURSHIP SKILLS……………………………………………………………..
Chapter 4 PROJECTS
4.1 PROBLEM IDENTIFIED AND SOLUTION PROPOSED
4.2 PROJECT SELECTED FOR PRIORITIZED PROBLEM IDENTIFIED
4.3 DESIGN
4.4 DRAWING
RECOMMENDATION
CONCLUSION
REFERANCES
APPENDICES
CHAPTER-1
BACK GROUND OF BISHOFTU AUTOMOTIVE INDUSTRY
1.1 HISTORY OF BISHOFTU AUTOMOTIVE AND LOCOMOTIVE INDUSTRY
Bishoftu automotive and locomotive industry which had started as project 40720 is an
engineering and overhaul complex established in the early 1984 with the main objective of
providing overhaul and maintenances cervices to the military had wares and equipment of the
ground forces of the ministry of national defense.
The project is located in Debrezat, some 45 km to the south east of Addis Ababa, the capital city
of the federal democratic republic of Ethiopia. It occupies at total area of 32.5 hectares, out of
which 87000m x 2area is covered by various building.
Project 40720 is organized under the defense industry and infrastructure sector, DIIS, of the
ministry of national defense, which is highest authority of the project. The general manager,
who is accountable to DIIS, is responsible to ensure that the project is carrying out its operation
efficiently and effectively. The units responsible to perform the core activities are organized
Project 40720 is organized under the defense industry and infrastructure sector, DIIS, of the
ministry of national defense, which is highest authority of the project. The general manager,
who is accountable to DIIS, is responsible to ensure that the project is carrying out its operation
efficiently and effectively. The units responsible to perform the core activities are organized
under the operation and engineering department, while those responsible for supporting
activities are organized as staff units under the General Manager and under the administration
and financial D/G/Manager.
Under the operation and engineering department, while those responsible for support in
activities are organized as staff units under the General Manager and under the administration
and financial D/G/Manager.
1.1.1 Vision
The vision of industrial of the project 40720 phase was to be self- reliant on the providing
maintenance and over all service for the military hardware and equipment of the ground force
and ensure combat readiness of the army.
1.1.2 MISSION
The mission of the industry of the project phase was to ensure the combat readiness of
the army by maintaining and over hauling military hard work and equipment of the ground
force with better efficiency, quality and at lower cost.
To increase manufacturing capacity and capacity for tool, spare part and auxiliary
required for the maintenance and overhaul activities.
1.1.3 CORE ACTIVITY
General maintenance of machinery and equipment that enable it to provide efficient services in
the following specialized areas:-
 Military Automotive and engineering vehicles overhaul and maintenance service

 Tank and APC overhaul and maintenance services
 Armament overhaul and maintenance services
 Communications equipment overhaul and maintenance service
 Generator maintenance
In addition to the machinery and equipment use to accomplished the above mentioned
specialized workers, the project also manufactures spare parts, and provide heat treatment,
collaring and electro platingas well
1.2 BASIC CUSTOMER OF ORGANIZATION
Bishoftu Automotive and Locomotive industry which was founded as Bishoftu motorization
engineering about 20 years ago and the umbrella of the Ethiopia federal democratic republic
minister of deviance ,so that to fulfill the different types of needs of the mission military
equipment to make armies ready for its basic international regional and global mission given by
the peoples of federal democratic republic of Ethiopia and through that of the question of the
international societies specially in the peace keeping missions.
Therefore the basic and sale customer of the industry was the federal democratic republic of
Ethiopia ministry of defense as result if begins to manufacture ,maintain and overhaul different
types of military equipment such as weapons ,military vehicles , and different was mission cars.
Is organized as a multipurpose industry under the branch of metals and engineering
corporation therefore its motives include to make the motion very competent in the global
metal and engineering market as a result the industry being to maintain over haul and assemble
different types of civil and commercial engineering equipment like that of city buses,
construction and locomotive machineries, and different types of field vehicles.
Therefore to include the basic customers of bishoftu automotive and locomotive industry are
federal democratically republic of Ethiopia minster of defiance, federal and regional
government office ,non-governmental organization, private firms and others.
1.3Organizational structure and work flow

Bishoftu Automotive and locomotive industry is organized under eight different factories having
different purpose which are going to express dentally in following manner
A job training for workers based on the demand of bishoftu automotive and locomotive
industry (BALI) factories and other industries.
1.3.1 Design and development

The main function of design and development in Bishoftu Automotive and locomotive Industry
is:
1.3.2 Power train

The main activities of power train production factory are listed in the following manner.
 Over hauling of engine, gear box, propeller shaft transfer case differential.
 Design of power train parts, manufacturing and assemble.
 Overhaul of various commercial vehicles.
 Recondition and grind of crankshaft.
 Service maintains engine blocks.
Fig. no 1 engine head Fig. no 2 engine block
1.3.3Vehicle production factory

The main of vehicle production factory in bishoftu automotive and locomotive industry is-
Assembling of various military commercial vehicles.
, design and others is the other activities of the factory for both military and For example since
last year factory is assembled 500 city buses for Addis Ababa.
Upgrading commercial customer’s needs.
Fig.no 3cross-country bus
1.3.4 Vehicle system production factory

The Assembling main operational activities of vehicle system production factory is
of vehicles injection pump, steering system, cooling system, electrical system and others.
1.3.5 Construction machinery production factory

The construction machinery production factory compresses the following four different
production section
 Dozer, grader, loader, excavator production section
 Currently the construction production factory has been receiving machineries such as
dozer, grader, loader and excavator from different local customers, and performing
repair, assemble as well as well overhaul tasks.
 This factory future intends will be to design and fabricate different types of construction
parts and machinery.
1.3.6 Body and frame production factory.
Overhaul products
Tank hull, tank turret, various vehicles fender, plat form, frame and chassis . Armored vehicle
bodyNewsproductsBusbodies,armoredbodies, heavy truck cab, heavy truck plat form, different
production of sheet metal.Armored personnel carriers vehicles production factory perform
tasks such as
 BROM, BTR armored personnel carriers is BTR commend Personnel carriers’ mission car,
wheeled armored vehicle, special purpose vehicles and others.
1.3.7 Tank production factory

The main operational activities of tan production factory are maintenance, overhauling,
modifying and up grading of various model tanks and tank accessories.
1. Job flow of the industry

Bishoftu Automotive and locomotive industry which is a governmental development
organization is now a profit making industry follow different types of operational job flow cycles
such as
 purchase repulsion
Operational Logistics Purchasing

Factories head admiration department
Market research repulsion for purchase
Factories Head of Market Logistics Purchase

marketing research administrati department
and sales and on
advertiseme
nt
Service repulsion
Operation factories
head
Customer General
Manager
Market and
sales head
CHAPTER - 2
OVERALL INTERNSHIP EXPERIENCE
2.1 HOW WE GET INTO THE COMPANY
By going to bishoftu automotive industry first we contact the military person garden on the get.
Then we told for what and from where we came also we show them ID card and placement
paper.after they saw ID and placement paper they gave direction to go to design and
development office. After going to design and development we also told them for what and
from where we came by giving the placement paper and they take it and told us to come next
day for orientation and to give ID card.
Next day we contact the industry Engineer Mr. Saud gave us orientation and placing us in
different factory also they gave us ID card of the company.
2.2 SECTION OF COMPANY WE HAVE BEEN WORKING

-Bus production factory
-Light production factory
-Tank production factory
2.3 WORK FLOW IN THE SECTION

BUS PRODUCTION FACTORY
Over all work flow in bus production factory
There are four lines in bus production factory. They are
 trim production line

 welding production line
 chassis production line
 painting production line+
Trim production line

There are seven stations in trim production line
Station 1 AC and fuel tanker assembly

At this station materials used are
 Wiper arm
 Wiper motor
 Wiper water tanker
 Front trim lamp
 AC condenser
 AC evaporator
 Sky light
 Fuel tanker
 Air cleaner
 Mud guard
JOB DESCREPTION OF STATION 1
The operation in this station include the mounting of A/C control harness in air duct ,power
wire and earth wire of A/C central control box, compressor harness ,A/C generator harness
capacitor box harness and A/C one way fuse harness.
Important measures should be taken during the operation includes
-The A/C control harness in the dust should be arranged in order and firmly without shaking,
sagging,tension, rubbing.
-The paths were A/C harness pass should be smooth without sharp edge; the harness passing
through the hole should be protected with rubber ring.
-The harness should avoid the high temperature heat source; otherwise, the harness should be
protected according to the process requirements
-Another job done in this station includes the assemble of return air cover of air conditioner
,which includes self-tapping screw fixed PVCreturn air cover of air conditioner and self-tapping
screw fixed aluminum return air cover of air conditioner.
Station 2Play wood assembly

 Heat resister
 AC pipe left/right
 Door rubber
 Door frame
 Fuse
 Water fringe
 Water level switch
 Capacitor
 Ac hose left/right
 Leather patching
 Roof harness

The operation in this section includes assembly of wiring harness in the final assembly
workshop and sealing of harness through holes, protection of electric parts.
Station 3 Decorative assembly

 Side market lamp

 Side turn signal lamp
 Rear tail lamp harness
 Rear foglamp
 License lamp
 Lower side sky light
 Decorative plate of roof side mid roof ac
 Frame roof connector
 Emergency door valve
 Main harness
 Play wood tighten
 Air dust left/right and back; front
 Dash board frame
 Inner roof aluminum frame left/right
 Side wall
-The operation in this station includes the mounting of side marker lamp, side turn
lamps, road bed lamps, locating lamps and deep spot lamps and can be referenced by
similar structures.
-during the assembly process of side wall lamps, the operation of all drill holes and
fastening screw requires the tools such as electric drills and electric screw drivers to be
perpendicular to operated surface.
-various wastes caused during production should be treated according to requirement
on waste management control and be stored at design position according to respective
classification. The main waste generated during the assembly course are;
scrappedscrew, nut and washer, strap scrap, protective film on lamp etc.
Station 4Mirror assembly

 Side wall plate
 Side frame plate
 Electric horn
 Glue
 Rubber back mirror
 Outside mirror
 Radiator grill
 Rear tail lamp
 Aluminum frame
-The operation in this station includes adhering side window and rear wind shield of all models.-
Adhesive sealant application specification of glass, aluminum window frame and rear wind
shield.
Station 5 Floor mat assemblyatthis station material used is
 Laud speaker
 Roof lamp
 Front lamp
 Head lamp
 Accelerator pedal
 Side decorative left/right
 Engine cover
 Pamper
 Radiator cover
 Floor side molding
 Steep molding
 Floor mat
 Plastic welding
 Relays
 Foot break
 Silica flex 265
 String column and cover
The operation in this station includes installation of wood floor or bamboo floor at driving area
n vehicle, large passage way at passenger area and middle passenger way and the like floor at
rear high step area shall be installed be referring requirement of 3292-147 operation
instruction on rear high floor assembly. at present the floor of the bus of the company is fixed
by screw or adhesive.
-During the installation process the operation of all the drill holes and fastening screw
are cared out by electric hand drill and electric screw drivers to be perpendicular to
operated surface.
-The other function of this station is affixing floor leather inside the vehicle. The adhesive
applying method for the internal floor leather of the company can be classified into
scraping and spraying.
STATION 6 Dash board assemblies

 Power supply switch

 Retarder
 Control box
 Hand power master switch
 Luggage holder cover
 Luggage attachment left/right
 Term control switch
 Proper shaft cover
 Driver door cover
 Marsh cover
 Dash board
 Hand break
 In side mirror left/right
-One of the operations in this section includes mounting of head lamp and front grille
-the other job of this section includes the mounting of combined switch and installation
of retarder handle, ignition switch and combined switch cover.
-there is also job of mounting integral tail lamp.
Station 7 Passenger seat assembly
 Electrical control box

 Back side door
 Passenger seat
 Emergency exit plate
 Front mirror assembly
 Wiper
 TV seat
 Complete gauge
 Driver lamp
 Sun rare
-the interior trims mentioned in this section include parts selected by customers such as
safety hammer, pull hook, cup rack, curtain and curtain hook, fire extinguisher bracket,
driver rear trims. The installation method of these parts due to their nearly universal
construction types are the same even though they belong to different vehicles models.
-During the installation process of interior trims all the operation involved with the drill
holes and fastening screw drivers to be perpendicular to the operated surface.
LIGHT VEHICLE PRODUCTION FACTORY

Currently as we have seen the most continuous work is done on this light vehicle production
factory. In this production factory two types of automobile are assembled .They are
1 pick up
2 Huang Hoi Auto are assembled

THIS PRODUCTION FACTORY HAVE SEVEN STATION
Station 1 Frame and axial assembly
Job descriptions or type
-Chassis on line -check left spring front bolt
-Check shekels left and right -check dampening rubber
-check U bolt left and right -check rear axle
-check U bolt cup -check front axle
-check cross stabilizer bar -check rear shock absorber
-check left spring
-check sub-assembly lower swing arm and front shock absorber torsion bar supporting
accessories
-check proportion valve -check rear axle brake oil pipe
-check hand brake line -check fuel tanker
-check all parts visually
Station 2 Wheel assembly
Job description or type
-Spare part inspection -marking for chassis
-Check spare tire filter -check diverter
-Check front, fuel pipe and breaking house -check steering drawing bar
-Check straight bar horizontal pulling bar -assembly of spare tire
-Connect fuel pipe and fuel tank -check inlet and return fuel pipe
-Tire assemble
Station 3Power transition assembly

-Unit and parts inspection
-Check sub assemble of gear box
-Check gear box and engine
-Check universal joint
-Check hosting of engine
-Front/rear propeller shaft
-Check chassis harness
-Check inlet and return fuel hose
-Check positive and negative line
-Check other parts
Station 4 Inspection
Inspection the chassis that means checking all assembling before body
Station 5
-Body and electrical assembly
-Job description or type
-Check car cabin and carriage
-Check rear side indicator light left and right
-Check front side indicator light left and right
-Check rear bumper
-Check sill decoration panel
-Check all seats
-Check four doors,windows, locks and the slider

-Check all lines hose,plugs and pipes
-Check connection of electrical accessories and mechanical parts
-Check decorative cover
-Check inter cooler hose and accessories
Station 6 Despising
Job type or description
-Check level of diesel
-Check level coolant fluid
-Check level of power steering oil
-Check level of brake clutch fluid
-Make shore the engine oil
Station 7 Adjustment
Job description or type -check hand

brake foot bracing wire
-Check wheel alignment
-Check car height
-Check all gage and button are active
-Check all lines
-Check side mirror
TANK PRODUCTION FACTORY

There are three production line in tank production line .They are
1 Zilla production lines
2 T-72 production lines

3 T-89 production lines from tank production factory
we have been working on Zilla production line
1. Accessory production station

4. Left and right side wall welding and grinding station
5. Back wall welding and grinding station
6. Main calling welding and grinding station
7. Dog house or firing house welding and grinding station
8. Window frame welding and grinding station
9. Middle, front and back door welding and grinding station
10. Capsule assembly station
11. Capsule welding and grinding station
12. Capsule final inspection and checking station
13. Capsule After assembly and waiting transportation station
Tools, equipment and machine for each station
Station one :- Accessory production station
- Tools :-
No Tools name Model Quantity Remark

1 Vise- grip 11R 05
2 Vise- grip 6R 05
Machine
No Machine name Model Quantity Remark

1 Mig welding machine Mig L405 01
2 Grinder machine Makita 9554HN 03
3 Host Crane 2-5 tons 01
Station two :- Accessory production station Tools :-

1 Vise- grip 11R 05
2 Vise- grip 6R 05
Machine

3 Host Crain 2-5 tons 01
Station three:- Accessory production station
- Tools :-

1 Vise- grip 11R 05
2 Vise- grip 6R 05
Machine

Station four :- Left and right side wall welding and grinding station
-Tools :-

1 Vise- grip 11R 01
2 Vise- grip 6R 01
3 C-clamp Strong hand 04
um165m
um205m
um125m
Machine

Station five :- Rear wall welding and grinding station

- Tools :-

1 Vise- grip 11R 01
2 Vise- grip 6R -
um165m
um205m
um125m
Machine

Station six :- Main calling welding and grinding station
- Tools :-

1 Vise- grip 11R 01
2 Vise- grip 6R 01
um165m
um205m
um125m
Machine

Station seven :- Dog house or firing house welding and grinding station
- Tools :-

1 Vise- grip 11R 01
2 Vise- grip 6R -
um165m
um205m
um125m
Machine

Station eight :- Window frame welding and grinding station
- Tools :-

1 Vise- grip 11R -
2 Vise- grip 6R 01
um165m
um205m
um125m
Machine

Station nine :- Middle, front and back door welding and grinding station
- Tools :-

1 Vise- grip 11R -
2 Vise- grip 6R 01
um165m
um205m
um125m
Machine

Station ten :- Capsule assembly station
- Tools :-

1 Vise- grip 11R -
2 Vise- grip 6R -
3 Hammer - 02
4 Pin - 10
5
Machine

Station eleven:- Capsule welding and grinding station Tools :-

1 Vise- grip 11R 01
2 Vise- grip 6R -
um165m
um205m
um125m
Machine

Station twelve :- Capsule final inspection and checking station
- Tools :-
1 Vise- grip 11R -
2 Vise- grip 6R -
3 C-clamp Strong hand -
um165m
um205m
um125m
Machine

Jig and template for each station
Station one: - Accessory production station
No Part no Description Materia Qty

l
1 GA0019090 Mid Right Door Window Nut AL 1
17 Plate Template 5052
2 GA0019090 Mid Right Door Window AL 1
18 Frame Template 5052
3 GA0019090 Door Handle Flange ST 52 1
45 Template
4 GA0019010 Mid Door Frame Jig Weld 1
65
5 GA0019010 Mid Door Frame Jig Weld AL 1
65 5052
6 GA0019007 Front Right Wheel Housing 1
53 Jig Weld
7 GA0019007 Front Left Wheel Housing 1
51 Jig Weld
8 GA0019090 Stool Bosses Template AL 1
68 5052
1. Station two :- Accessory production station
No Part no Description Material Qty

1 GA0019090 Back Door Window Nut AL 5052 1
23 Plate Template
2 A00190902 Back Door Window Frame AL 5052 1
4 Template
3 GA0019090 Motor Cover Drain1 AL 5052 1
59 Template
4 GA0019090 Rear Seats Template AL 5052 1
05
5 GA0019009 Door Overlap Jig Weld 8
20
6 GA0019090 Front Window Anti- ST 52 1
88 Vandalism Net Template
7 GA0019009 Mid Door Window Jig 1
50 Weld
8 GA0019000 RHS Profile 60x60x2.9- Steel,Mil 4
19 1998 d
9 GA0019090 Main Ceiling Bracket AL 5052 1
40 Template
2. Station three:- Accessory production station
No Part no Description Material Qty

1 GA0019009 Side Wall Window Jig 1
30 Weld
2 GA0019005 Cell Jig Weld 1
40
3 GA0019005 Ceiling Internal Jig Assy 3
90
4 GA0019090 Headlight Anti-vandal ST 52 2
97 Template
5 GA0019000 RHS Profile 40x40x2.9- Steel,Mil 6
53 1500 d
6 GA0019090 Front Ceiling Template AL 5052 1
32
7 GA0019090 Front Ceiling Sun Shield AL 5052 1
41 Template
3. Station four :- Left and right side wall welding and grinding station
No Part no Description Materia qty
l
1 Side Wall Channel Bracket 1
Template
2 Side Wall Handle Template 1
3 Left well jegs 1
4 Side Wall Front Template 1
5 GA0019007 Table 4000x2000 1
30
4. Station five :- Back wall welding and grinding station
No Part no Description Materia qty

l
1 GA0019090 Back Wall Int1 Template AL 1
27 5052
28 5052
29 5052
30 5052
5 Back wall jig 1
5. Station six: - Main calling welding and grinding station
No Part no Description Material qty

1 GA0019090 Main Ceiling Template AL 5052 1
33
2 GA0019005 Cell Jig Weld 1
40
3 GA0019005 Ceiling Internal Jig Assy 3
90
4 GA0019004 Ceiling Jig Left Plate Weld 1
10
5 GA0019004 Ceiling Jig Right Plate Weld 1
20
6 GA0019010 Ceiling Jig Support Weld 2
30
7 GA0019005 Ceiling internal jig weld Steel,Mi 3
95 ld
8 GA0019000 RHS Profile 60x60x2.9-1998 Steel,Mi 4
19 ld
9 GA0019090 Turret Hatch Protection AL 5052 1
39 Template
10 GA0019090 Turret Hatch Top Template AL 5052 1
34
19 ld
12 GA0019090 Turret Cover Template AL 5052 1
81
`13 RHS Profile 80x80x5-2100 ST 52 44
6. Station seven :- Dog house or firing house welding and grinding

station

1 GA0019007 Front Jig Weld 1
85
2 GA0019010 Front Window Jig Weld 1
20
3 GA0019000 10mm Spacer ST 37 16
56
4 GA0019000 6mm Space ST 37 8
57
19 ld
6 GA0019008 Front Bumper Jig Weld 1
30
7 GA0019007 Front jig weld 2
85
7. Station eight :- Window frame welding and grinding station

1 GA0019006 Bumper Grill Jig Weld 1
15
8. Station nine :- Middle, front and back door welding and grinding
station

1 GA0019090 Door Handle Flange ST 52 1
45 Template
20
20
4 GA0019090 Mid Door Ext1 Template AL 5052 1
46
5 GA0019090 Mid Door Ext2 Template AL 5052 1
47
6 GA0019010 Mid Door Frame Jig Weld 1
65
9. Station ten :- Capsule assembly station

1 GA0019090 Motor Cover Piston1 AL 5052 1
55 Template
2 GA0019008 Motor Cover Jig Weld 1
10
10. Station eleven:- Capsule welding and grinding station

1 GA0019090 Mid Right Door Window AL 5052 1
18 Frame Template
2 GA0019006 Rotation Jig 1
30
3 GA0019006 Cell Rotation Back Jig Assy 1
60
4 GA0019006 Cell Rotation Front Jig Assy 1
80
5 GA0019007 Rear Cell Rotation Adaptor1 1
60 Weld
6 GA0019007 Rear Cell Rotation Adaptor2 1
70 Weld
7 GA0019000 Sub Assy Jig Wedge ST 52 8
43
 Man power and professions for each station

Station one: - Accessory production station
Profession: - 1. ----------------------------------- 02
2. ------------------------------------01
Station two: - Accessory production station
Profession: - 1. Welder ----------------------------------- 02
2. Grinder------------------------------------01
Station three: - Accessory production station
2. Grinder------------------------------------01
Station four: - Left and right side wall welding and grinding station

2. Grinder------------------------------------02
Station five: - Rear wall welding and grinding station

2. Grinder------------------------------------01
Station six: - Main calling welding and grinding sta
2. Grinder------------------------------------02
Station seven:- Dog house or firing house welding and grinding station
2. Grinder------------------------------------01
Station eight: - Window frame welding and grinding station

2. Grinder------------------------------------01
Station nine:- Middle, front and back door welding and grinding station
2. Grinder------------------------------------02
Station ten:- Capsule assembly station
2. Grinder------------------------------------02
Station eleven Capsule welding and grinding station
2. Grinder------------------------------------02
Station twelve:- Capsule final inspection and checking station
2. Grinder------------------------------------01
 To used safety equipments are: - 1. Goggle
2. Eye glass
3. Glove
4. Safety shoe
5. Eye shield
Zilla assembling station

1. Diss assembling area
2. Chassis shorting area
3. Chassis shorting area
4. Capsul (cell) preparation before assembling
5. Chassis assembly
6. Capsul assembly
7. Electrical assembly
8. Fitting and finishing
Station 01:- disassembly area
 Tools, equipment and machine for each station
Socket wrench ----------------------1 set
Combination wrench---------------1 set
Ring wrench -------------------------- 1 set
Screw driver: - 1. Flat
2. Philips head
Long nose paler
Diagonal cutter
Electrical knife
Regular paler
Special tools
Remover
Hammer:- 1 plastic
2 metal
Lever
Machine
No Machine name Model Quantit Remark

y
1 Drill machine Makita 01
3 Over head Crain 2-5 tons 01
Pneumatic rammer 01
A.C machine 01
Jig and template:- model 64006101----------------------01
Station 02:- Chassis shorting area

- Cutter paler
- Hammer
- Tries squire
- Level gauge
- Meter
- Open wrench Ø 41
- Special pen
Machine
N Machine name Model Quantity Remark

o
4 Welding machine EN 60974-1 01
Jig and fixture

GA0019008 Chassis jig assembly 01
35
C-clamp Strong hand um165m 08
Vis- gripe R12 04
Station 03:- Chassis shorting area

- Cutter paler
- Hammer
- Trie squire
- Level gauge
- Mater
- Open wrench Ø 41
- Special pen
Machine

o
Welding machine EN 60974-1 01
Jig and fixture

GA0019008 Chassis jig assembly 01
35
C-clamp Strong hand um165m 08
Vis- gripe R12 04
Station 04:- Capsul (cell) preparation before assembling

Combination wrench--------------- 1 set
Special tools ------------Ø 10
Rachet wrench
Socket wrench ----------- Ø 10,22,27,30,32
Open wrench-------------- Ø10,13,15,17
Flat screw driver
Long nose
Knife
Cutter paler
Ruler
Machine

1 Pneumatic rammer 01
2 Grinder machine Makita 01
9554HN
Station 05:- Chassis assembly

Combination wrench---------------------- 1set
Socket wrench------------------------------1set
Open wrench-------------------Ø13,18,21
Ring wrench-------------------- Ø10,13,16,18,21,30,32
Lever
Hammer
Paler
Machine

2 Grinder machine Makita9554HN 01
5 Jack (hydraulic ,manual ) 01
Jig and fixture
Station 06:- Capsul assembly

Socket wrench---------------1set
Ring wrench------------------1set
Open wrench------------------1set
Combination wrench--------Ø24
Lever
Hammer
Knife
Meter
Machine
1 GA001900835 Stand (life spring) 01
2 C-clamp Strong hand um205m 08
3 Vis- gripe R6 04

o
Station 07:- electrical assembly

Small socket wrench ---------------1set
Big socket wrench------------------1set
Combination wrench---------------1set
Screw driver ------------------------1flat
2 Philips head
Long nose
Diagonal cutter
Electrical knife
Regular paler Special tools
Machine

6 A.C machine 01
Station 04:- Materials for capsul (cell) preparation before assembly
1. A.c condenser -----------01

a. A,c evaporator-------------01
2. Aluminum electrode-------03
3. Dain age pipe----------------02
4. T-type distributer pipe---------01
5. Aluminum weld nut --------------01
6. Clamp------------------------------02
7. Compressor distributer pipe--------01
8. M8xm16 nut-----------01
9. M6xm16 nut ----------16
10. How pressure filter-----------01
11. Nitrogen
12. Oxygen
13. Astelin
14. Hoses
15. O-ring
16. Electrical belt
Station 05:- Materials for chassis assembly station
1. Front bottom support weld

2. Front steering shock absorber
3. Front limit belt belt top left plat
4. Front suspension spring
5. Muffler and beam connection
6. Front shock absorber
7. Rear shock absorber
8. Fuel tanker assemble
9. Gear box protection supporter
10. ,, ,, ,, rear ,, weld
11. Shock absorber
12. Chassis contact rubber
13. Fuel tanker protection supporter
14. Fuels assembly
15. Chassis cell connection plate
16. Chassis connection spacer
17. Fuel line
18. Propeller shaft
19. 4. Wheel selector
20. Capsul line
21. Radiator protection plate
22. Wiper motor
23. Front bumper
24. Front door
25. Slam lath adapter
26. ,, ,, ,, space
27. Front door
28. 16x20 bolt
29. Flat washer
30. Front weld support spring
31. Chassis cover supporter plate
32. ,, ,, ,, rubber
33. M16 nut
34. Motor frame supporter weld
35. DIN 6921 m10x30 bolt
36. ,, 6927 m10 nut
37. .. 6921 m12x13 bolt
38. ,, 6927 m12 nut
39. Motor cover rod
Station 06:- Electrical assembly station
M4x16 cross recessed pan mechanism screw ---------------24

M8x16 hexagon flange bolt ------------------------13
M6x16 hexagon flange bolt ------------------------33
M6x12 hexagon bolt -------------------------35
M10 hexagon flange nut-------------------2
M6x16 crossed recessed pan head screw ------------2
M4x10 regular bolt ----------------------2
M4x12 cross pan head mechanism screw with nut & washer -------10
M5x10 hexagon flange bolt ----------4
M8x10 regular bolt ---------------16
M6x12regular bolt nut washer -----------------28
Special insert screw ------------------------8
Man power requirement for zilla welding station
No Work area Description work Number of need Remrk

profession
1 Accessory Welder 02
production station Grinder 01
4 Left and right side Welder 03
wall welding and Grinder 02
grinding station
5 Rear wall welding Welder 02
and grinding station Grinder 01
6 Main calling welding Welder 03
and grinding station Grinder 02
7 Dog house or firing Welder 02
house welding and Grinder 01
grinding station
8 Window frame Welder 02
welding and grinding Grinder 01
station
9 Middle, front and Welder 02
back door welding Grinder 02
and grinding station
10 Capsule assembly Welder 02
station Grinder 02
11 Capsule welding and Welder 03
grinding station Grinder 02
12 Capsule final Welder 01
inspection and Grinder 01
checking station
2.4 WORK PIECE OR WORK TASKS WE HAVE BEEN

EXCUTING
We have been executing in bus production on AC and gas tank assembly of buses but when we
arrive to the company they were finishing production and waiting to sale the production
before staring new because they are assembled more than 100 buses then we cannot get the
opportunity to execute the tasks we were assigned.
2.5 PROCEDURES WE HAVE BEEN USING WHILE
PERFORMING OUR WORKS TASKS
First listening company Engineer orientation Engineer SAUD for all factories then visit the entire
seven factories they are
1 bus production factory
2 light vehicle production factory
3 heavy duty truck production factory
4 tank production factory
5 vehicle system production factory
6 body and frame production factory
7 maintenance of heavy duty truck production factory
After seeing all factories we choose to work our project from two factories they are light vehicle
and tank production factory .Then we select tank production factory. Finally we start our
project on zilla car
2.7 CHALLENGES FACING WHILE PERFOMING OUR WORK

TASKS
Initially, factory has their own safety clothes, this safety clothes are given only for factory
workers
Pocket money given from Jimma University is not enough and the company did not gave us any
money
The third and fourth month payment from Jimma University not sent for us in time
The place we are placed that is bus production factory there is no work is done because all
material is not full they wait for material coming from Djibouti.
In this company there is no internet connection

The company far from town around 3or 4 kilometers
2.8 Measures taken to overcome these challenges

In order to overcome challenges mentioned above Firstly we ask different heads in the factory
for safety clothes and also from workers but we cannot get it so we bought from shop from our
food money.
Secondly the pocket money given from Jimma University not enough so we receive money from
our family.
Thirdly, the third and fourth month payments are sent for after three weeks so we borrow and
also ask our family and receive money from our family.
Fourthly ,in bus production no continuous work we are changes the production factory Since
internet connection is useful for some information for our project and other we use internet
cafe and other café Since the company far from town we go on time to wait the service bus for
going and coming.
CHAPTER 3
Overall benefit gained from internship
3.1 In terms of improving practical skills
Before we go to Bishoftu automotive industry we have not goods in practical skills because
there is no assembling laboratory for automotive. In terms of practical skill we have knowledge
for assembling of automotive in light vehicle production factory and we observe how Bi-cup are
assembled based on -
loading of chassis
-how fuel tanker assembled
-how fuel transport pipe to engine and fuel returning pipe from engine assembled
-How differential assembled
-how shaft assembled
-how wheel assembled
-how engine gear box, transfer case assembled
-how body assembled
-how electric system assembled and so on
3.2 In terms of up grading our theoretical knowledge

We were gain from internship theoretical knowledge was base for practical knowledge. For
these reason previous theoretical knowledge helps for developing our internship practical skill
and practical knowledge play great role in developing practical skill. This for practical skill we
are sure that unless theoretical knowledge practical skill was valueless.
3.3 In terms of improving inter personal communication

skills
We gain good communication skill from internship because company has diversified person,
from different nation and nationalities, religion, cultures, customs, language and so on.
We communicate with workers, students, factory supervisor and company administration

bodies with their leadership structure, working skills by tolerance all the above difference. In
this way we develop inter personal communication skill with workers and administration.
3.4 In terms of improving over team playing skills

In team of our internship we are improve team playing skill because team playing is very
important for working together , help to each other , sharing of knowledge , simplify the work
,speed up the work and so on.
3.5 In terms of improving leadership skills

In order to improve our leadership skill we follow first our partnership leadership feature, and
then company supervisor leadership structure order and company administration structure. It
was Very important for improving our leadership skill.
In general, we gain from internship how each leadership follows their own step.
3.6 In terms of understanding about work ethics related

issues
We gain from internship, how workers flow work ethics in order to improve productivity and
quality of product. Also we understand some ethics of company for workers, responsibility of
workers, accountability of workers, for accounting and respecting of the principles of company.
We gain the above mentioned principles from company in the time of internship. These
improve our future production and quality of work.
3.7 In terms of entrepreneurship skills

In terms of entrepreneurship skill we gain from internship
-how to work together with partners
-think positive attitude for partnership or friend when work together
-Develop self -confidence with broad mildness and so on
CHAPTER 4 PROJECTS
4.1 PROBLEM IDENTIFIED AND SOLUTION PROPOSED
In bishoftu automotive industry we have seen different problems in different area of
manufacturing sectors. This sectors includes, light vehicle production factory in which we have
seen that ,in section one of the factory chassis were reversed by fork lift , this take some time
and it need great man power. To solve this problem we propose an idea that use machine that
work manually and electronically.
The other sectors were we have seen problem was tank production factory one of the job done
in tank production factory iszilla assembly. Zilla manufacturing process include disassembling
the chassis of special ford automobile and the chassis is shorten by 27cm in special cutting tools
after it has been put on six supports which are screwed to the chassis to pull it up and down.
These screws are adjusted to know the accuracy of the chassis to be cut out. And we found it
that this adjustment process have problem in taking time and it is also very tidy.
The other problem we have seen in the zilla manufacturing process were, performance test of
the zillaautomobileZilla automobile have different sensors and the full f unction of this sensors
cannot be known unless it is driven and tasted for one thousand kilometers.But the company
does not have any mechanism for performing this performance test. So we give this problem
primary attention and try to solve this problem by taking an idea in which we take machine that
work like house running machine without traveling thousand kilometers outside.
4.2 PROJECT SELECTED FOR PRIORITIZED PROBLEM

IDENTIFIED
In working our design project we select machine that used to test the performance of zilla
automobile. The working principle of the machine, the machine has rotating conveyer belt
whose driving shaft is connected to gear box in it one end. And the gearbox is connected to the
motor output shaft. In performing the test the automobile is set on the belt and as the car
driven forward the belt rotate in opposite direction to that of the automobilewheel. The speed
of rotation of the belt must be at least equal to that of rotation of the wheel. In order to
perform the test at different speed of the automobile we use torque sensors which are
connected to differential axel of the wheel .This sensors are also connected to the motor to
Vary the output speed by using input speed come from differential axel of the wheel
4.3 DESIGN
Main components or parts
Design description
To design Zilla military car performance test machine, there are different parts that should be
designed properly. These are conveyer belt that used to run the car on it both wheel and
conveyer belt rotate in opposite direction gives as tangential velocity of both.
Construction and calculation of conveyer belt and the drive drum shaft
For the wheel from the speed of car find rpm to maintain the speed of conveyer belt
Given parameters: - speedmax of car =200km/h(55.5m/s)
- Length of car = 5658mm (5.658m)
- Width of car = 2350mm (2.350m)
- Total weight of the car= weight of car +weight of the person
= 6850kg+70kg
= 6920 kg
Then to find the speed of wheel: - diameter of wheel =0.854m
- Wheel circumference=πD
=3.14x0.854m
= 2.683m
- Revolution per second (RPS) = revolution per minute (RPM)

60
Speed of car (m/s) =RPS x wheel circumference
RPS = 55.5m/s =20.68 RPS
2.68m
RPM=RPS x 60 from RPS =RPM/60
= 20.68 x60
= 1241.14 RPM of wheel
Then its angular speed (ω) = 2πN
60
=2x3.14x1241.14
60
= 129.98rad/s
The angular velocity of wheel determines the tangential velocity of the car wheel and conveyer
belt.
Radius of wheel (Rw) =0.427m
Tangential velocity (Vt)=ωRw
= 129.98 x 0.427
= 55.05m/s(the tangential velocity is the same for both wheel and convery belt)
Assume the drive drum shaft diameter(Ddd) =200mm(0.2m)
Vt=55.05m/s
Mass of drive drum shaft - Mw= x Vdrive drum

= 611kg/m3 x 0.022 x 2.5=120kg
From the above Vtw=Vtc=ωcxrdd
Then ωc=Vtc/rdd =55.05m/s
0.1
= 550.5rad/s(angular speed of conveyer belt)
The speed of conveyer belt - will be

ωc = 2πNc
60
RPMC=ωcX60 =55.05X60=33030= 5256.20rpm
2π 2(3.142) 6.284
The length of conveyer belt- design from the given parameters of length of car and width
of car then the length of the conveyer belt (LC ) = 2Lcar+ circumference of drive drum shaft + 2m
= 2(5.658) + 0.6284 +2
= 13.944m
͌ 13 m
Center distance
To determine center distance in mm when belt length and pulleys are known
Capprox = K+ √ K2 – 32D2
16
=50.744 + √ 50.7442 - 32 x 0.22Where, K = 4LC -6.28D
16 = 4 x 13 – 6.28 x 0.2
=6.342mm = 50.744mm
Temperature effect on conveyer belt for pp material
Δl=change in length in mm + =elongation
- =contraction
Δb = change in width in mm
lo=belt length at initial temperature in m=13m
bo= belt width at initial temperature in m= 2.5m
t2= operating temperature = 40 co
t1=initial temperature =20 co
a=coefficient of thermal expansion for pp material = 0.15
thenΔl = lo(t2-t1)a
= 13(40-20)0.15
= 39mm
Δb=bo(t2-t1)a
=2.5 (40-20)0.15
= 7.5mm
To Determine the mass of conveyer belt assume:-

- the thickness of the belt = 10mm(0.01m)
- the length of belt =13m
- the width of belt =2.5m
from the above =m/v m=v
= 0.01x13x2.5x ( ) where,( ) =640 kg/m3
= 208kg
Determine the effective pull force (Fu)

Coefficient of friction µTbetween pp belt material and wear stripe of dry steel =0.31
Total load (weight of car + a person) =6920 kg
Mass of the entire belt mb=208kg
Then Fu = µTxg(m+mb)
=0.31 x 9.81(6920+208)
= 21707.37N
Force determining belt selectionFb=Fu X C1/C2Operational factor C1= +0.2

=21707.37x0.2Temperature factor C2=1.0
0.1
=43414.74 N
Shaft load FW = Fu X C1 + mw X g where Fu=21707.37, C1=0.2, mw=120kg,g=9.81

FW = (21707.37 X 0.2) + (120 X 9.81)
FW = 5518.674 N
Power required at the drive drum

PA =Fu X V (kw)
1000 X 60
But speed (V) means tangential velocity of the conveyer belt so Vt = 55.05m/s
Then change m/s to m/min Vt =55.05 m X 60s =3303 m/min
S 1min
PA =21707.37 X 3303
1000 X 60
PA = 1194.99 kw
Bearing center distance (I) =Lb + Clearance

= 2.5 + 0.1
=2.6m
Deflections on drive drum for square shaftYm = 0.156 x FW X I3
E X d4
= 0.156 X 5518.674 (2.6)3
2.1 X 105 X 0.2
= 0.36
Roller support - in long conveyer and with heavy load support roller are often used
instead of slider beds to reduce the effective pull with the center distance greater than
2000mm support rollers should also be installed on the return side this prevents excessive belt
sag from the belt’s own weight support roller pitch for unit goods
- the distance between the support rollers are determined according to the length of
the edge of unit goods you want to convey
LO = support roller pitch on upper side (mm)
Lu = support roller pitch on return side(mm)

YB = maximum conveyer belt sag (mm) = 0.01
F = belt pull in the place concerned in N
mo + mB = weight of good conveyed belt in kg/m = 6850kg + 208kg = 7058kg
Kf % = relaxed tension(elongation) value in accordance with ISO 21181 in N/mm width = 12
bo = belt width in mm = 2500mm
Ɛ % =elongation at fitting =
F =Ɛ %.Kf %.bo
= 0.1 x 12 x 2.5
= 3N
LO =√YB.800.F LO max≤ 2bo
mo + m B
= √ 0.01 x 800 x3
7058
= 0.058mm
Recommendation
Lu = 2-3 LO max
= 0.116mm
MOTOR POWER The motor output power (shaft) is given by
PM = PA/η Where, η = Overall efficiency by taking the power losses of gear-box and couplings
into account = 0.94
Therefore, PM = 1194.99/0.94 = 1271.26kW
MOTOR SELECTION At present, all the motors are of 1500 rpm. By referring the catalogue,
the selected motor is of 37 kW/1500 rpm (Nominal power). The shaft diameter of the motor is
60mm.
GEAR BOX SELECTION: For gear box selection, we need to calculate the reduction ratio.
Reduction ratio= output rpm/input rpm Asthe motor is of 1500 rpm, Input
rpm = 1500 rpm
Reduction ratio = 5256rpm/1500rpm
=3.5
We get the torque from the
Following formula
πNT
PA =2
60
T =60 xPA
2 πN
T =60 x 1194.99
2 x 3.14 x 5256.20
T = 2.17Nm
[N=5256.2 rpm at output]
STRUCTURAL DESIGN TORQE SENSER
The element is subjected to shear and normal stress. Here the considerable stress in the design of
torque measuring instrument is the shear stress. The normal stress is used when measuring thrust
on the shaft or the combined effect of torque and thrust together.
The shear stress due to torque is given by:
xy=TRs/Js Js=1/2P[Rs-Ri]
T=torque
Rs= surface radius of the shaft
Ri= inner radius of the shaft ( for hollow shafts), Ri=0 for solid shaft
Js=polar moment of inertia
A Mohr’s circle is constructed for stress transformation of the element described by another x’-y’
coordinate system.Torque is measured by measuring the shear stress experienced by the shaft
that is being driven. If the shaft is subject to torsion the principal stresses and the shear stress are
identical as shown by Fig. (b)
fig.(a) fig. (b)
The normal stresses due to the torque produced along the x’-y’ coordinate equal to the shear
produced in magnitude, is given as:
x’= TRs/Js y’= -TRs/Js
The strain along the x’-y’ are governed by the equations:
x’= (x’y'
y’y’x’
The properties E & depends on the material of the shaft.
GAUGE LAYOUT DESIGN

Four strain gauges are installed on the shaft surface at position along 45 degree (+and-)
oblique to the shaft axis. The four strain gauge are arranged in Wheatstone bridge to measure the
strain and compensate for thermal effects and bending moment.
A strain gauge is essentially a resistance element. In general, the resistance of a strain

gauge varies when it is subjected to a strain.
fig.(a) fig.(b)
Two factors are considered for selecting the gauges:
1) the gauge factor and
2) the gauge size.
The smaller the gauge size, the more exactly the strain of the target point is measured.
A gauge factor (F) :is defined as the resistance variation of the gauge (R/R) per unit
strain (), and it is given by:
Fg= (Rg/Rg) /(Rg/ Rg) /L/L)
Where: L=length of specimen subjected to strain
For a given F, the unknown strain can be determined by measuring (R/R). the
quantity is usually measured by connecting the strain gauge into wheatston bridge circuit.
fig. (a) fig. (b)
The output voltage is initially zero, when: R1*R3=R2*R4 considering a full wheatston
bridge circuit ,i.e: all the four gauge resistances are active (all gauge resistances change due to
the strain of the shaft caused by the torque.
Torque - Full Torsion Bridge configuration

Where:
max = maximumtwist
strain
T=torque applied
E= modulus of elasticity
R=radius of the shaft
= poisson ratio
Fig.: applied torque and strain relation
EO/Ei = F
(maxF*
We have the two general equations for full torsion bridge configuration
max = 2R3] * (1+)  Eqn. (1)
EO/Ei = F (maxF*Eqn. (2)

Where: F= the gauge factor
EO= the wheatston bridge output voltage
Ei=the wheatston bridge excitation voltage
The output from the Wheatstone bridge can be expressed as:
EO/Ei = R1/(R1+R2) – R4/(R3+R4) - - - - - - - Eqn.(3)
Note that changes of resistance in adjacent gages (R1 and R4, for example) have the same (or
numerically additive) effect on bridge output when the changes are of opposite sign. When the
changes in adjacent arms are of the same sign, they have opposite (or numerically subtractive)
effects. Conversely, the effects of resistance changes in opposite arms (R1andR3, for example)
are reversed: changes in resistance with like signs in opposite arms have the same effects on the
output and changes with unlike signs in opposite arms have opposite effects.
The bridge is balanced and produces no output when:
R1/(R1+R2) = R4/(R3+R4) OR R2/(R1+R2) = R3/(R3+R4)
i.e: R1R3=R2R4
or R2/R1=R3/R4
A change in resistance of one or more of the gages will unbalance the bridge so that an
output signal is produced. Eqn.(3) can be used to determine the output of any unbalanced bridge
simply by adding the resistance change of each affected resistor to the initial value of that
resistor.
EO/Ei = [(R1+R1)/ (R1+R1+R2+R2)] – [(R4+R4)/(R3+R3+R4+R4)]

The result should yield: EO/Ei = F * 
OR
EO/Ei = (Re/Re+1) * [R/R1-R2/R2+R3/R3-R4/R4]
The result should yield: EO/Ei = F * 
Where: Re = ratio of resistance ratio in the wheatston bridge (R2/R1 or R3/R4)
If we assume R1=R2=R3= R4=R,then
EO/Ei = [R+R/(2R+R1+R2)]– [R+R/(2R+R3+R4)]
The relationship between the torque and the measured strain can be obtained by
combining these equations and substituting in eqn.(1)
max = 2R3] * (1+)  Eqn. (1)

From eqn. (1)
2R3] * (1+)
R3 /2(1+) but, J=R4/2 J is the polar moment of inertia

Therefore
J/2(1+)R since:  EO /Ei F

The relationship between the torque and the wheatston bridge output is given by:
J/2F(1+)REi ]EO
For a considerable zero-offset the relation equation will be modified to:
J/2F(1+)REi ]EO
EO=EOEO(initial)
SIGNAL CONDITIONING AND READING DISPLAY

In order to fit the requirement of data acquisition system used, an amplifier is arranged to
magnify the signals. the magnification factor of the operational amplifier determined by the
ratio of the resistances of the wheatston bridge
i.e: R2/R1 = R3/R4
A signal digitizer is used to convert the voltage to digital signal for on-line monitoring of the
torque using computers (personal computer). the torque is proportional to the out put voltages,
and ready to be read after calibration.
Signal digitalized-we use potentiometer to regulate the input voltage for the motor
Vehicle performance testing machine 3D drawing

RECOMMENDATION
The main objectives of this company are to increase productivity and quality of work. Due to
that company should be follow clear government policy. Company should be train skilled man
power and should be considered their salary with their work, unless it leads weakness of worker
motivation.
The company must have good maintenance because of good maintenance save company from
unwanted wastage of income. So company should follow good maintenance Technic with the
help of electrical sensor for checking of automotive to the next work level.
CONCLUSION
Generally conclusion about Bishoftu automotive and locomotive industry.We conclude that for
this industry based on work flow from simple work level to complex work level. This does not
mean no power needs difference, but here is technical work difference.
Based on the above idea companies have enough man power, but there is no enough skilled
man power. This industry have good administrative structure, because company themselves
follow governmental strategies of development policy. Due to that company have many
factories. There is more or less maintenance is there in this company, but no full maintenance
in this company.
Theseadministrative levels to high administration level. From my observation company technical
workers have no work motivation, because there is no balance salary with their work. There is
no electrical sensor to check in automotive to finish assembling in the company. Companies
have the problem of supply spare parts with scheduled time and so on
REFERENCES
[1] Book of Machine design Prof .R .B .Gupta
[2] Book of machine design P.C. SHARMA
[3] Book of machine design D.K.AGGARWAL
[4] Physical property measurement system (ppm)
[5] Pressure gage and switches pdf
[6] Measurment of force of acceleration torque and power pdf
[7] Strain measurement application pdf[8] 206 - fms - prolink -constructing and calculating
conveyors-en.pdf
[9] 305 - fms - recommendation – machine – design –en .pdf
[10] WEG- dc-motors -50019095-brochure –english.pdf
[11] Different module in bishoftu automotive industry library

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JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

Executive summary …………………………………………………………………... II

List of figures ………………………………………………………………………… IV

List of tables …………………………………………………………………………. V

Chapter 1 BACK GROUND

1.1 HISTORY OF BISHOFTU AUTOMOTIVE INDUSTRY……………………………………….

1.2 BASIC CUSTOMER OF ORGANIZATION ………………………………………………………….

1.3 ORGANIZATIONAL STRUCTURE AND WORK FLOW…………………………………………..

Chapter 2 OVERALL INTERNSHIP EXPERIENCE

2.2SECTION OF COMPANY WE HAVE BEEN WORKING……………………………………………

2.3 WORK FLOW IN THIS SECTION…………………………………………………………………………..

2.4 WORK PIECE OR WORK TASKS WE HAVE BEEN EXCUTING……………………………………..

2.6 HOW GOOD WE HAVE BEEN IN PERFORMING OUR WORK TASK……………………………

2.7 CHALLENGES FACING WHILE PERFORMING OUR WORK TASK………………………………..

2.8 MEASURES TAKEN TO OVERCOME THESE CHALLENGES…………………………………………

Chapter 3OVERALL BENEFITS GAINED FROM INTERNSHIP

3.2 IN TERMS OF UPGRADING OUR THIOROTICAL KNOWLEDGE…………………………………..

3.3 IN TERMS OF IMPROVING INTERPERSONAL COMMUNICATION SKILLS…………………

3.4 IN TERMS OF IMPROVING OUR TEAM PLAY SKILL…………………………………………………

3.5 IN TERMS OF IMPROVING OUR LEADERSHIP SKILLS……………………………………………….

3.6 IN TERMS OF UNDERSTANDING ABOUT WORK ETHICS…………………………………………..

3.7 IN TERMS OF ENTREPRENEURSHIP SKILLS……………………………………………………………..

1.1.3 CORE ACTIVITY

 Military Automotive and engineering vehicles overhaul and maintenance service

1.3Organizational structure and work flow

1.3.1 Design and development

1.3.2 Power train

Fig. no 1 engine head Fig. no 2 engine block

1.3.3Vehicle production factory

1.3.4 Vehicle system production factory

1.3.5 Construction machinery production factory

1.3.6 Body and frame production factory.

1.3.7 Tank production factory

1. Job flow of the industry

Operational Logistics Purchasing

Market research repulsion for purchase

Factories Head of Market Logistics Purchase

2.2 SECTION OF COMPANY WE HAVE BEEN WORKING

-Light production factory

-Tank production factory

2.3 WORK FLOW IN THE SECTION

There are four lines in bus production factory. They are

 trim production line

Trim production line

Station 1 AC and fuel tanker assembly

Important measures should be taken during the operation includes

Station 2Play wood assembly

JOB DESCREPTION OF STATION 2

Station 3 Decorative assembly

 Side market lamp

Station 4Mirror assembly

Station 5 Floor mat assemblyatthis station material used is

STATION 6 Dash board assemblies

 Power supply switch

Station 7 Passenger seat assembly

At this station materials used are

 Electrical control box

JOB DESCREPTION OF STATION 7