Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Scribd Logo
Upload

Welcome to Scribd!

  • 405 views

    PPT

    Uploaded by

    Jacob Smith
    JCB manufactures construction vehicles like backhoes and excavators. This document analyzes leakages in JCB's hydraulic systems. It describes the assembly line and major components. To study leakages, the document proposes inspecting machines at a specific "inspection zone" along the line. Major leakage points are identified, like joints on hydraulic rams. The causes of leakages are improper torquing, manufacturing defects, human errors, and contamination. Solutions proposed include dye tests, replacing pipes to reduce elbows, and inspecting more at the proposed zone to catch issues earlier.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    PPT

    Uploaded by

    Jacob Smith
    405 views22 pages
    JCB manufactures construction vehicles like backhoes and excavators. This document analyzes leakages in JCB's hydraulic systems. It describes the assembly line and major components. To study leakages, the document proposes inspecting machines at a specific "inspection zone" along the line. Major leakage points are identified, like joints on hydraulic rams. The causes of leakages are improper torquing, manufacturing defects, human errors, and contamination. Solutions proposed include dye tests, replacing pipes to reduce elbows, and inspecting more at the proposed zone to catch issues earlier.

    Original Description:

    leak free analysis

    Original Title

    ppt

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    JCB manufactures construction vehicles like backhoes and excavators. This document analyzes leakages in JCB's hydraulic systems. It describes the assembly line and major components. To study leakages, the document proposes inspecting machines at a specific "inspection zone" along the line. Major leakage points are identified, like joints on hydraulic rams. The causes of leakages are improper torquing, manufacturing defects, human errors, and contamination. Solutions proposed include dye tests, replacing pipes to reduce elbows, and inspecting more at the proposed zone to catch issues earlier.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    405 views22 pages

    PPT

    Uploaded by

    Jacob Smith
    JCB manufactures construction vehicles like backhoes and excavators. This document analyzes leakages in JCB's hydraulic systems. It describes the assembly line and major components. To study leakages, the document proposes inspecting machines at a specific "inspection zone" along the line. Major leakage points are identified, like joints on hydraulic rams. The causes of leakages are improper torquing, manufacturing defects, human errors, and contamination. Solutions proposed include dye tests, replacing pipes to reduce elbows, and inspecting more at the proposed zone to catch issues earlier.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 22

    Leak Free Analysis of JCB

    Backhoe Loaders

    Introduction to company
    1.

    2.

    3.

    JCB is named after its founder Joseph Cyrill


    Bamford,producing yellow&black engineering
    vehicles,diggers,excavators.
    Company was founded on october ,1945 in
    Stanffordshire,England and first product was
    farm trailer from war surplus material.
    It has two plants in India one in Haryana & other
    in Pune.

    Products manufactured by
    JCB

    Different units at JCB plant


    Different units at JCB(Haryana) are -:
    1. Assembly unit .
    2. Weld &fabrication unit.
    3. Paint shop unit.
    4. Transmission unit.
    5. Central materials unit.
    6. Purchase unit.
    7. Marketing&Finance.

    Assembly Line Layout


    MAIN FRAME

    BOOM & DIPPER


    FITMENT

    INNER LEG
    FITMENT

    TYRE MOUNTING

    FRONT
    AXLE
    FITMENT

    BRAKE
    BLEADING

    STONE
    GUARD
    FITMENT

    CAB FITMENT

    LIFT RAM &


    LOADER ARM
    FITMENT

    LVB & EVB


    CONNECTION

    FRONT END

    FUEL TANK &


    HYDRAULIC
    TANK
    FITMENT

    COOLING
    SYSTEM

    KPC FITMENT

    ELECTRICAL
    CONNECTIONS

    SKID & MAIN


    FRAME
    DROPPING

    Boom-Dipper Assembly
    1.

    2.

    Boom Sub-Assembly -:Boom is fittted


    hydraulic ram which provide movement when it
    is attached with machine.This is responsible for
    loader bucket movement.
    Dipper Sub-Assembly-:It is also same as
    boom assembly the only differnce is that this
    assembly is responsible for excavators
    movement.

    Engine Sub - Assembly


    Engine sub assembly mainly consist of 4 parts-:
    1. Engine-:A kirloskar 76HP,gross power 56 kw at
    2200 rpm engine is installed in backhoes.
    2. Torque Converter-:Takes the place of
    mechanical clutch&able to multiply torque when
    difference between input &output is substantial.
    3. Fly Wheel-:A rotating disc that stores kinetic
    energy.
    4. Gear box-:4 speed fully syncromesh gear box
    with electrically reversing shuttle.

    Specification of products
    manufactured by JCB(HRY)
    JCB 3DX Backhoe loader-:4 cylinder,76HP,4speed synchromesh,3300psi hydraulics ,front
    wheel steering.
    2. JCB 3DX Super Backhoe loader-:4
    cylinder,90HP,4-speed synchromesh with
    reversing shuttle,3300p hydraulics, front wheel
    drive.
    3. JCB 4DX Backhoe loader-:4 cylinder,96HP,4speed synchromesh with reversing
    shuttle,3300psi hyadraulics ,front wheel.
    1.

    Valve Blocks
    1.

    2.

    Excavator valve block-:EVB mounting plates


    provides base on which valve block is fitted
    then adaptors which provide inlet and outlet for
    hydraulic oil.EVB is used for controlling
    excavator bucket.
    Loader valve block-:Responsible for
    movement control of loader bucket.

    Other Sub -Assemblies


    Radiator assembly-:cooling unit, hydraulic
    cooler for cooling of hydraulic oil, seal are
    components of radiator.
    2. King post carriage-:it provides supporting
    mech. to boom dipper . It is a combination of
    slew ram , boom lock, bushes, feed pipe &
    seals.
    3. Cab Assembly -:it is operating room of the
    entire machine.
    1.

    Leakage Analysis
    1.

    2.

    3.

    The aim of our project is to determine the cause


    of hydraulic leakages that has been occuring in
    JCB machines .
    As there are so many joints and hose pipes
    present in machine so 100% efficient is not
    possible.
    This leads to loss in efficiency, wastage of time
    &extra expenditure.

    Mechanism involved in the


    hydraulic movements

    Actuation of various arms are controlled by fluids


    that are made to flow by piston mechanism for
    the movement of arm/pistons.

    Losses due to leakages


    The basic losses due to leakage are-:
    1. Clean up.
    2. Make up fluid.
    3. Disposal of waste oil.
    4. Contamination ingress.
    5. Decrease in machine efficiency.
    6. Increase in expenditure to machine.

    Major joints of leakage


    1

    Front axle ram

    14

    hydraulic cooler/radiator plug

    LVB to feed pipe

    15

    Return feed pipe to hydraulic cooler

    EVB to boom ram

    16

    Oil tank to hydraulic cooler

    EVB to dipper ram

    17

    Hose to lift ram

    EVB to bucket ram

    18

    Fuel tank to fuel pump

    EVB to slew ram

    19

    Hose to loader bucket ram

    EVB to leg hose

    20

    Orbitral unit to front axle ram

    EVB to return feed pipe

    21

    Orbitral unit hose to LVB

    Header piston joints

    22

    Orbitral unit to hose hydraulic pump

    10

    Hydraulic pump to LVB

    23

    EVB hose to legs

    11

    Feed pipe to tank

    24

    EVB hose to boom ram

    12

    LVB to return feed pipe

    25

    EVB hose to dipper ram

    13

    Oil tank to hydraulic pump

    26

    EVB hose to bucket ram

    27

    Radiator hose

    Some of important joints

    Front axle ram

    Gear pump to
    hydraulic cooler

    EVB to boom,
    dipper &bucket
    rams

    Hydraulic tank to
    pump

    Hose to lift ram

    EVB hose to
    boom ram

    Methodology of Analysis
    Studied all the
    hydraulic joints

    Complete
    inspection of
    joints

    All leakage
    duly
    noticed

    Reduced the
    no. of
    machines
    inspected for 2
    days

    Left all the


    machines

    Compared the
    hot bay test
    report

    Inspection zone
    1.

    2.

    3.

    It is quite inevitable a proper inspection


    technique as most of the leakages occur due
    to operators negligence.
    Method to significantly reduce the number of
    leakage point during assembly line is
    introduction of inspection zone.
    This inspection zone includes the point where
    the cab is placed to where the loader arm is set
    on the framework.

    Features of inspection zone


    The introduction of inspection zone has following
    features-:
    1. As most of the hydraulic joints ,that are prone to
    leakages ,are open in this region,it provides

    Easy Inspection Vicinity.


    2.

    Maximum number of machines can be


    inspected. Only four minutes is required on
    one machine by two operators.

    Advantages of inspection
    zone
    Advantages are -:
    1. A lot of time is wasted in the Hot bay & PDI
    zone to rectify the leakages.
    2. Hydraulic oil losses can be minimized ,saving a
    lot of money.
    3. Expenditure related to clean up of leakages
    ,disposal and contamination can be easily
    prevented.

    Major causes of leakage


    Major causes of leakages are-:
    1.
    2.
    3.
    4.

    Leakage due to improper torquing.


    Leakage due to manufacturing defects.
    Leakage due to defect because of man-power.
    Leakage because of contamination of oil.

    Other ways to tackle


    leakages
    The methods are-:
    1. Hydraulic dye test.
    2. Hot bay test.
    3. Replacement of metal pipe.
    4. Reduction of elbows and T-pieces.

    THANK
    YOU

    &

    HAVE A
    NICE DAY

    You might also like