BRACT’s Vishwakarma Institute of Technology, Pune

END SEM REVIEW

Course: Internship module
Company Name : Schindler India Pvt. Ltd.

Name: Tanay Ravindra Kudale

GR No.: 12020089
Faculty Mentor: Prof. Dr. S.P Chippa
Internship Guide Name: Mr. Abhishek More

Mechanical Engineering Department

SCHINDLER INDIA
PVT. LTD.
• Started in 1874 in Switzerland

• Our Products: Elevators, Escalators,

Moving walks

• “Leadership through Customer Service”

• Project location:- Schindler INW

 TYPES OF
ESCALATOR

ESCALATORS Commercial Public Transport

9300- 9700-
11/15/20/35 0S/1S/2S/3S/0X/1X

Projects:-
Projects:- 1. Pune Metro
1. Mall of Ranchi 2. Bangalore Metro
2. Phoenix mall 3. NCRTC
3. Dumdum pass 4. Nagpur metro
 Major Components and
assemblies used in the Escalator

• Truss/Frame
• Track Block
• Drive
• Drive shafts
• Electrical system
• Steps
• Step Chain
• Comb Plate
• Tracks
• Balustrade
• Handrail
• Safety System
• Skirting
 Kolkata Metro
Testing (KMRL) Supplementary
Factory Acceptance Tasks
Testing
 OBJECTIVES

• To conduct Factory Acceptance Test of Escalator for Kolkata

Kolkata Metro metro project to provide quality assurance along with

Factory customer satisfaction.

• To study all the drawings, welding standards used in escalator.
Acceptance • To study various ISO and EN115 standards for preparing the

testing (FAT) prototype test plan.

• Validated each and every part during assembling
• To assure best quality product to the customer

PROJECT DURATION

• 1-09-2022 to 25-11-2022.
METHODOLOGY
Date of customer FAT

Planning and assemblying escalator

Prepared documents as per government

tendor

Finalized the prototype test plan via group

meetings

Approved it with higher authority

Gathered all the quality instruments

required for testing.

Final Testing
 LITERATURE

Safety rules for the construction and installation of escalators and passenger conveyors,
BS EN 115:1995, The standard for escalators and moving walks, EN 115-1:2017 defines
safety requirements for escalators and moving walks. It also covers all escalator major dangers
and hazards as well as misusages and situations related to the above-mentioned. The objective
is to protect people/objects against risks of accidents during installation, operation,
maintenance & inspection work. 
 DAY 1 Motor Test
Roller
Inspection
Step Chain
Inspection
Drive Chain
Inspection

Glass SS
DAY 2 Balustrade
Inspection
Balustrade
Inspection
Handrail
Inspection
Step
Inspection

Truss Escalator Full

DAY 3 deflection
test
24 Hours
Running Test
Noise level
test
Braking Test Assembly
Inspection

TIMELINE DAY 4 SIGN OFF

FOR
TESTING
 INSPECTION DAY 1

• MOTOR • ROLLER • STEP CHAIN • DRIVE CHAIN

• Comply with • Material:- • Break force:- • Breaking
EN115 std. Elastomer with >=155kN. strength:-
• Motor plate metal die cast • Dimensional >=284kN
hub. check
• Rated rotate
• Dia:- 100mm
speed:-1496
r/min
• Test
certificate
 INSPECTION DAY 2

• Glass/SS • Handrail • STEP

inspection • Synthetic • Break force:-
• Comply with material >=155kN.
EN115 std. • Hardness >70 • Dimensional
• Test certificate A check
• Dimensional • Dimensional
check
check
INSPECTION DAY 3

Truss Deflection Test

Fig 1. Dial indicator

• Truss deflection is an important criterion to demonstrate truss

stability
• Truss deflection shall be recorded under full load conditions
• As per EN115, passenger load shall be assumed as 5000N/m2 and
an additional load of outer cladding panel as 300N/m2
• Total dead weight :- 5300 N/m2
Fig 2. Load test
• Instrument:- Dial Indicator.
 CALCULATION

• Passenger Load ： 5000N/ m2: (As per EN 115)

• Outer Cladding load: 300N/ m2: (As per Contract conditions)
• Loading area ： z1*L; (‘z1’ is the nominal width of step & ‘L’ is
the total Horizontal span)
i.e. 19.755 m (span) x 1m (step width) = 19.755 m2
• Total weight to be loaded: 5300 x 19.755 = 104701.5 N (10672.93
Kg)
• Total weight to be loaded on Steps: 180 kg / step x 41 visible steps
= 7380 Kg Fig 3. Deflection test schematic

• Remaining weight to be loaded on top & bottom floor plate:

10673 – 7380 = 3293 Kg
• Result:- Deflection of 4.93mm was observed.
 24 HOURS RUNNING
TEST

Purpose of the inspection

• It checks whether escalator prototype comply
with contract requirement.
• Carry out a 24 hours continuous running test,
12 hours in each direction, without stopping
except to change direction.
• Record temperature of main parts after
running 12 hours for each direction.
• Create report

Fig 4. Running test animation

 Direction: Upper Direction: Down

REPORT FORMAT Item Start

Value
End Value
after running
12 hours
Start
Value
End Value
after running
12 hours
Remark

Date/Time 　 　 　 　 　
Voltage (V) 　 　 　 　 　
Current (A) 　 　 　 　 　
Ambient temperature
(℃ ) 　 　 　 　 　
TEMP of Motor surface
(℃ ) 　 　 　 　 　

TEMP of Gearbox surface

(℃ ) 　 　 　 　 　
TEMP of Controller (℃) 　 　 　 　 　
TEMP of Inverter (℃) 　 　 　 　 　

TEMP of service Brake (℃) 　 　 　 　 　

TEMP of Safety brake (℃) 　 　 　 　 　

TEMP of Left handrail
surface (℃ ) 　 　 　 　 　
TEMP of Right handrail
surface (℃ ) 　 　 　 　 　

Table 1. inspection report for running test

*Dimensional readings and outputs are not shared due to confidentiality
 NOISE LEVEL TEST
RESUL
Purpose of the inspection No. TESTS Value required
T
Downward direction
• It checks whether escalator prototype comply with 1 Noise level at the ≤70 dB(A)  
Escalator top position
contract requirement and EN115 Downward direction ≤70 dB(A)
2 Noise level at the  
• As per EN 115-1:2017(E) Clause:- Escalator Middle position
Downward direction ≤70 dB(A)
3 Noise level at the  
A declaration that the emission sound pressure Escalator bottom position
upward direction ≤70 dB(A)
level measured under free field conditions at a 4 Noise level at the  
Escalator top position
distance of 1.00 m from the surface of the upward direction ≤70 dB(A)
5 Noise level at the  
machinery and at a height of 1.60 m from the Escalator Middle position
upward direction ≤70 dB(A)
floor plate is expected not to exceed 70 dB(A). 6 Noise level at the  
Escalator bottom position
7 Ambient Noise    
• Instrument:- Noise meter
Table 2. inspection report for Noise level test
*Dimensional readings and outputs are not shared due to confidentiality
 BRAKING DISTANCE TEST

Purpose of the inspection

• It checks whether escalator comply with contract
requirement and EN115.

• The brake shall automatically bring the escalator to a Table 3. Stopping distance with speed

halt whenever the power is interrupted. Sr.

No
Load
%
Direction
of travel
Current
(A)
Voltage
(V)
Speed
(m/s)
Slip
distance
Escalator
Speed
(m)
1 No Up          
• Maximum stopping distances for the various conditions Load Down          
2 25% Down          

as per EN-115 are as follows. 3

4
50%
75%
Down
Down
 
 
 
 
 
 
 
 
 
 
5 Full Down          
Load
• The reading were taken under No load, 25%, 50%, 75%
Table 4. Report for braking test
and full test load
*Dimensional readings and outputs are not shared due to confidentiality
ESCALATOR FULL
ASSEMBLY TEST (FAT)
• It checks whether escalator prototype is compliant with
contract and EN115.

• Carry out a full escalator assembly inspection

• Escalator Assembly test: The Contractor shall develop

his own inspection checklist for the manufacturing
process and for the checking of the assembled escalator.

• Instruments:-Vernier caliper, measuring tape, feeler

gauge, etc.
CONCLUSION

• Alignment with Schindler quality team & customer representative along

with third party inspector for validation of actual output of testing in front
of all member.

• Signing off project document to get prototype approval & further

production go ahead.
SUPPLEMENTARY
TASK
 Quality Assurance Calibration of
plan instruments

5S Audit of whole Dashboard using In-house calibration

plant Power BI of Gantry rail
 QUALITY ASSURANCE PLAN

Development of Quality Assurance plan

• A quality assurance plan is a document that
highlights the standards a given manufactured
product should adhere to.
• Customer service

• Process Transparency

• To ensure quality of product

• Quality Assurance Plan.

Fig 5. Quality Assurance
IN-HOUSE
CALIBRATION OF
INSTRUMENTS

• As a cost saving initiative, it was suggested by quality

team to practice in-house calibration of instruments.
• Total 150 gauges were inspected using the master
instrument like Vernier caliper, micrometer.
• Tackle uncertainties by ensuring proper calibration.

• Cost saving of about Rs. 15000 was made.

• Result: Most of the instruments were found ok, and

the inspection report was verified by the quality head.
5S AUDIT
• Conducted 5S audit activity for consecutive 3
months.

• Identified all the major and minor improvement

Fig 6. 5S
zones.
5S SEP ESCALATOR PLANT
• Major contribution in collecting the reports and
analyzing the obtained report and then presenting it
to the reporting manager.

• Awards were given for the best performing zones

leaders.
CALIBRATION OF GANTRY RAIL

• Gantry rail checking and rectification

of rails in factory premises
• On Sunday, we had third party
inspection company in our plant
• The API laser tracker had a range of
80m and accuracy of 0.7micrometer.
Fig 7. Portable Coordinate measuring machine • Had a vendor visit at KVPL for trial
of Bosch laser tracker.
 DASHBOARD
USING POWER BI

• All the defect data was cleaned and

transformed into a standard format.

• Prepared a dynamic dashboard using

analysis tools like pivot & Power BI.

• Presentation of summarized data and

readings was delivered during the Fig 8. Dashboard using Power BI

biweekly meetings with China.