Four Weeks Industrial Training at

SPEEDCRAFTS LTD, PatnaSubmitted in Partial Fulfillment for award of Degree of

Bachelor Of technology in Mechanical Engineering

Department Of Mechanical Engineering, Maharishi Markandeshwar University, Sadopur,

Session 2013-14

Submitted By:

PARAG PRIYANKRoll No. 75114037

B.Tech (M.E, 4Th SEM)Batch:- 2011-2015

ABOUT THE COMPANYThe foundation stone of SPEEDCRAFTS Ltd now an ISO 9001 company (manufacturer of Road Building Component) was laid down in the year 1971 at Patna, by Mr R.K.Agarwala now handled by Mr. S. K. Agarwala in the capital of Bihar being the first one in the state with commitment to deliver quality and excellence, the company has ranked top on the industrial map of India. From a modest beginning, the Company is having manufacturing unit spread over 25 acres of land, with approximately 20,000 sq. metres. (200,000 sq.ft) of covered area, in-house machine shops, fabrication shop, press shop, mechanical, hydraulic and electrical assembly facilities and paint shop as well as handling and packing facilities and quality control division. Company’s plant shares its one of boundaries with JAI PRAKASH INTERNATIONAL AIRPORT, PATNA as it is in the very close vicinity of one end of the runway. Their production is always of high quality which provides it acceptable and acclaimed by Indian Railways, Defence, State Government Road Departments, Contractors and Various Construction Industries because the products are raised on Stringent International and Indian Standards. Now company has opened another unit in HARIDWAR for detailed manufacturing and governing.

PRODUCTS AT A GLANCE

Asphalt Batch Mix Plant Asphalt Drum Mix Plant

Asphalt Plant (American Specs) Mobile Asphalt Plant

Wet Mix Macadam Plant Concrete Batching Plant

INTERNATIONAL TIE-UPS1. As emerging on the globe the Company decided to work for the Railway Track

Maintenance Equipment and for the same it has collaborated with HARSCO RAIL (North America) to produce some of the quality and excellence and service and sparing too. This is the company’s first tie-up in field of railway track maintenance and working for Indian Railways.

2. Secondly, the Company has tied up with M/s BERNARDI IMPIANTI, Italy, World Leaders in Asphalt Mixing Technology for manufacture of Batch type Asphalt Plants in India. These plants are available from 80 to 260 tph capacity. It produces some of the following products under collaboration in the Haridwar plant

3. The company has recently entered an amicable tie-up with Dmix S.R.L. to start the production of Self Loading Concrete Mixers in the modern manufacturing facilities in Haridwar. This again enables company to stretch its arm over the market where there are customers for self-loading concrete mixer anywhere in the world.

Containerised Concrete plant Mobile Concrete Plant

Bitumen Pressure Distributor Pothole Repairing Machine

Diesel Road Roller Paver Finisher

Mobile Hot Mix Plant Concrete Conveyor

Road Sweeper Chip Spreader

Products Raised Within Tie-Ups

In collaboration with DMIX SRL :-

DS 1000 DS 2500

DS 4000

OHE tower Wagon Railway Utility Vehicle

Over Head motorcar Over Head Track Maintenance Car

And other components like Rail threader, Gang Bus, Flash Butt welding machine, Ballast Hooper Car, Inspection Car and other.

In Collaboration with RAIL HARSCO:-

In Collaboration With Bernardi Impianti:-

Asphalt plants

Other products raised under this collaboration are Dryer Drum, Burner, Batching Tower, Bag House Filter, Control Unit.

Market InvolvementThe company has totally stretched its arm over the globe . Not only in India but in the other countries too the company has managed to grasp the center and keen of the customers . As the products are robustly there is no alternative in terms of performance, design and quality so it is a bane for the company. In over 60 countries of Europe, Asia, USA, Africa and some parts of NewZealand the company is exporting almost all its components. With annual turnover of Rs. 250 Crore the company is commemorating on the map. Some of its Indian Customer of this company are follows:-

1) L&T2) Nagarjuna Constructions3) Bihar State Road Development Authority4) Ministry of Defence, India5) KMK Construction, Indore6) Gammon Construction7) Jaypee Construction8) Geet Constructions, Faridabad9) And many other construction companies and contractors

International ClienteleAs mentioned earlier that company is international exporting on each corner of globe following are some of the major international customers:-

1) M/s Kays Consultancy & Marketing Service, Bhutan 2) Quasi Engineering Works, Bhutan 3) Annapurna Construction Company, Nepal4) Panjore Construction, Bhutan 5) Rirab Construction, Bhutan6) Passwing Construction, Bhutan7) M/s Innovetech Pti (Ltd), Singapore8) M/s Mr. S & S Sons Constructions, Tanzania 9) M/s Sarzameen Aftab Construction Company, Afghanistan10) Acciona Construction ltd, Spain11) Obrascón Huarte Lain, Spain12) Julius Berger Construction, Nigeria13) Rocad Constructions, Nigeria14) And many other anonymous companies

Management Chart

SRI S.K. AGARWALAChairman-cum-Managing Director

SRI R.K. AGARWALA

Executive Director

SRI S. AGARWALADirector International

Export

SRI S. KHADERIADirector Work

SRI R. AGARWALADirector Imports

SRI GOPAL AGARWALADirector Finance

SRI H.K. SHARMADirector Operations

(Haridwar Unit)

SRI S AGARWALADirector International

Export

Mr. M.J. JAFERIDGM, Marketing

Mr. A. KUMARManager Export

Mr. SAMEER KUMARAsst. Manager Export

Mr. ASHUTOSH JEETAsst. Manager

SRI V.P. NAYAKAsst. Manager

Mr. ANUBHAVSenior Executive

Marketing

Miss. SMRITI SINGHExecutive Marketing

Mr. MUKESHMarketing Head

Miss APARNAMarketing Executive

SRI GOPAL AGARWALADirector Finance

Mr. LALIT MOURGM Finance

Mr. KAJORI DASManager Finance

SRI NAND JHASenior Accountant

Mr. ABINDYO GHOSHAccount Officer

SRI SHYAM KHADERIADirector Work

MR. MANOJ DGM, Work

SRI RAKESH SINHASenior Manager Production

Mr. ABHAY KUMARManager Production

Mr. CHANDAN

JHAHEAD HR

ROAD ROLLERQ. WHAT IS A ROAD ROLLER?

A road roller (sometimes called a roller-compactor, or just roller) is a compactor type engineering vehicle used to compact soil, gravel, concrete, or asphalt in the construction of roads and foundations, similar rollers are used also at landfills or in agriculture. Today there are simply taking Static Roller, Pneumatic Roller, Vibratory Roller and others.

Static Road Roller

HISTORY OF ROAD ROLLER:- The first road rollers were Horse Driven Rollers aroun 18th century

Since the effectiveness depends upon the power of Road Roller, In 19th Century Steam Road-Roller were Introduced.

Horse Driven Rollers

Steam Road Rollers

Q. What is the use of Road Roller ?

Road rollers use the weight of the vehicle to compress the surface being rolled (static) or use mechanical advantage (vibrating).These rollers feature two rows (front and back) of mild steel heavy rolls that overlap, and the flexibility of the rolls provides a kneading action that seals the surface and with some vertical movement of the wheels, enables the roller to operate effectively on uneven ground.

Q. How is Road Roller manufactured ?

The Company handles every part of the manufacturing of Diesel Road Roller in such a way that each and every component to be fitted or assembled anyhow must cope the roller to pass any kind of stringent condition in future if it faces any time in its lifetime.The construction of Road Rollers is not easy although the company has employed many a new techniques so that they are able to manufacture 25-30 road rollers and almost 360 per year.

Plant Layout Road Roller

Chasis Fabrication Shop

(Line 1) (Line 3)

(Line 2)

Mild Steel From store to Fabrication Shop

CHASIS FABRICATION CENTRE Wheel Fabrication Centre Front Roll Yoke Shop

Gas Cutting Shop Floor

Wheel Rolling machines and Lathe Machines for grooving

Fabrication & Final Drive ring on rear roll and internal bushing of both rolls

Assembly Line

Pressure Balancing weight installed

Gear Box Fabrication shop

Production Process Chart – Road Roller

(Line 4)

1. Mild Steel Fabrication

In the Mild Steel fabrication center the sheet arrives after being cut from PLASMA ARC CUTTING MACHINE and then taken to Chasis Fabrication Shop And Front Roll Yoke Shop and Awning Shop.

Plasma Arc Cutting Machine

2. Chasis Fabrication:-

The manufacturing and fabrication of the chasis takes place under the Chasis Fabrication Shop.In the chasis manufacturing Mild Steel sheets are used. The chasis of a road roller is basically very un-identical that of used in automobiles normally. The chasis is big as compared and is made by joining of five different parts by welding and drilling on the end corners of plates to fix it with help of bolts

Chasis of Road Roller

3. EngineThe engine or prime mover is basically exported from SIMPSON INDIA Ltd. The engine is of 4 cylinder inline diesel engine. It delivers a power of 41.5 bhp @ 1500 rpm. The engine provides the much power required to operate whole system. The flywheel of the engine is really huge.

4. Front Roll Yoke And CarriageFront roll (wheel) Yoke is made by using MILD STEEL and is fabricated whole in the Front Roll Fabrication Shop adjacent to Chasis Fabrication Shop under same roof.The yoke is pivoted in the head of roller to withstand sudden jerks and loads. The carriage is bolted tightly on both sides of yoke to provide a good support for movement of front roll.On both the ends there is a big center hole so that the carriage is easily fixed into this with joints and clamps.Carriage is another component which is provided with yoke which basically governs holds the Front Roll with help of axle and bush pipe on both sides.

5. Transmission(a) Gearbox:-The gear box is totally made and fabricated out of MILD STEEL. Bevel gears, large and heavy spur gears and pinions which are made of some special alloy are housed in the gearbox. The gearbox contains 17 bearings and all are dependent on each other, if one gets tamed then it will affect the operation of others and the transmission will be deprived.The whole of operation takes place under GEARBOX FABRICATION SHOP.The gear box is having the bevel gears which messes with helical gears of driving shaft or main shaft.There are total of 10 gear wheels comprising haringborne (double helical), spur and bevel gears. There are in total 12 holes on the gearbox, 5 on both sides and 1 on front face and rear face. The diameter of holes on front and rear side is 260 mm and 150mm respectively. While on the side faces there are two holes of equal diameter that is 110mm and other three are of 230mm, 160mm, 175mm. The dimensions of gear box is 800x380x450mm.The fabrication of gearbox is done on lathe machine. The basic fabrication process done here is boring which is carried out to achieve greater accuracy of the diameter of a hole. The cutting tool used here was the carbide tip P01.

Gear Box Fabrication

After all the fabriction operation is employed to make the gearbox ready, it is taken to gearbox test centre where it is tested for three hours so that it is confirmed that it is ready to perform in any stringent condition. The testing happens in GEARBOX TESTING SHOP just in rear side of Gear box fabrication shop.

(b) Clutch:-The Clutch is really a matter of wonder here. The clutch is heavy automotive and double action type. The clutch consist of two clutch plates one for forward motion & another for reverse motion but is controlled with single lever separately provided for both kind of motions.

Clutch For Roller

The clutch box is casted and then machined. The diameter of clutch plate is 330mm. After the fabrication of clutch it is assembled to the gear box under the GEARBOX & CLUTCH ASSEMBLY.

6.GEARBOX & CLUTCH ASSEMBLY:-

Here the assembling of clutch and gearbox is done. The gear box arrives after successfully passing the test in Gear Box Testing Shop. The assembly is done and precisely checked and after this the whole transmission setup is taken to the roller assembly to be fitted with engine stored already in the roller.Gearbox is first engaged to clutch by help of shafts coming out from gearbox. Now the clutch is coupled to flywheel of engine. Hence the clutch rests in between the transmission system and whole of this system is in single line.

7. PROCESS OF TRANSMISSION:-When the engine is started and the gear is employed by the help of lever present in upper cabin, and the motion is selected by another lever which governs the motion and clutch (let it be forward or reverse motion and clutch) present in left side of driver seat then it happens that the desired direction of motion is achieved by clutch lever and the speed is taken by gear lever the accurate gear starts meshing with the main or driver gear on main shaft.This tends to give motion to the driven shaft. Now there are two Final Drive Pinion coming out of the gear box which are connected to driven shafts. The Left Hand Final Drive pinion is connected to Clutch & driven shafts by help of Bevel Gears in gearbox and it has the power of accelerator and all while, the Right Hand Final Drive Pinion is free and just rotates on power of LHFDP.The wheels are fitted here in such a way that the rear axle goes under center hole and teeth of Final drive pinion meshes with the Drive ring present in both rear rolls.

Final Drive Point & Rear Axle

Total arrangement of engine-clutch-gear

8. WHEELS (ROLLS):-

The wheels or rolls are made from heavy Mild Steel. The sheet is of depth 36mm. It is rolled on rolling machine to get a circular shape. This all happens in Wheel Fabrication Section.

Mild Steel Sheet Being RolledGrooving Process of Rear Roll on Lathe

(a)Rear Roll:-This roll is much more engineered as compared to front roll. It contains Final Drive Ring which meshes with final drive pinion and provides motion and center bush in which the rear axle is fixed. The diameter of rear roll is 1370mm and width of 535 mm. The unballasted weight is 302 kg and ballasted weight is 406 kg for 10 tonThe rear roll has one more fabrication process as compared to front roll. In this the grooving is done so that the final drive ring having 72 teeth is attached by use of bolts and side welding. The diameter of this ring is 536mm and is 100mm thick

Final roll after total fabrication

(b) Front Roll:-It is fabricated and machined in such a way that it is hold good on Front Roll Yoke and Carriage. All the processes are same like rear roll except grooving which is not done in this roll. The diameter of this roll is 1030mm and width is 470 mm. The unballasted weight of front roll is 200 kg and ballasted weight is 280 kg for 10 ton.

Front roll on Lathe, bush is being developed

9 Heads:-The heads are again made of Mild Steel. They are very amazingly designed. It has two wholes one for the steering and another for pivoting the yoke (front roll).

10. Brakes:-The brakes are fully self-wrapping and contracting type.The brake is fixed over the final drive ring in rear roll and covers the circumference of drive ring. The brake shoes are riveted to the brake ring. When brake lever is acted upon then brakes contracts and meshes with outer ring of final drive ring on rear roll and hence the vehicle is stopped. Basically the brakes are provided for locking of wheels and for parking of the road roller.But the rollers are not fully dependent on these brakes. The clutch lever is also employed during this operation.

11. Steering:-Easily operated mechanical steering comprising of worm shaft and gear. It is designed to give jerk free movement to front rolls. The steering wheel is casted and its shaft comes out from the roller head.The worm used here is single start.

12. Pressure Balancing Device:-Two weights are provided on the base of chasis with sliding floor. These are governed by the arm coming out from the body near the rear roll. It provides variation of pressure on rolls and also helps the Road roller to roll on inclined and sloppy surface. The weights are of 500 kg and 250 kg.

13. Scrappers:-Adjustable and reversible scrapers are fitted to cover the entire width of all rolls.They are again made up of mild steels and used to take out mud and other negative things that sticks to the rolls like concrete and muds.

Front roll scrappers Rear roll Scrappers

14.Ballast:-Arrangement for ballasting the roller with either sand or water is provided in all the rolls. Opening this on all the four wheels can make easy loading of ballasting of water and sand. It is done to increase the weight so that pressure can be incresed.

Ballast arrangement on rear roll

15. Other Parts:- Road roller have some more parts like Awning, fuel tank, water tank and water sprinklers. TECHNI CAL SPECIFI CATION

Model DRR/ 10 (4 speed) & DRR-3/ 10 (3 speed)

Unballasted Weight 8,000 Kg. Water Ballasted Weight 9,000 Kg. Sand Ballasted Weight 10,000 Kg. Engine S-4(I)/RB-33 41.5/37.5 BHP. at 1500 RPM. Overall Length 4880 mm. Rolling Width 1810 mm. Overall Height 2860 mm. Dia. of Rear Rolls 1370 mm. Width of Rear Rolls 535 mm. Dia. of Front Rolls 1030 mm. Width of Front Rolls 940 mm.

Line Pressure Minimum Maximum

Front Rolls Rear Rolls 27.6 Kg./cm. 47.5Kg./cm. 41.1 Kg./cm. 61.7Kg./cm.

Overlap of Rolls 100 mm. Wheel Base 2800 mm. Turning Radius 3935 mm.

No. of Speeds Model DRR/10 Model DRR-3/10

4 forward and 4 reverse 3 forward and 3 reverse

Speed Model DRR/10 Model DRR-3/10

1.95 to 9.00 Km./hr. 1.74 to 7.47 Km./hr.

Gradient 1 in 5. Fuel Tank Capacity 150 ltrs. (including spare tank) Water Tank Capacity 225 ltrs. (including spare tank) Permissible Variation ± 5%

16. Paint Shop:-After the roller is ready in assembly shop it is taken to the paint shop where it is painted manually in such a way that there is none kind of imperfection. First the primer is coated on the surface with help of spray jet and then after some hours the paint is coated on the surface of road roller with the help of another spray jet.

Roller being painted in Paint shop

17. Road Roller:-When all above task completes for one then it is taken to the test center, where all of its dynamism and other operations are checked in condition which is really very hostile and asks the product give its 100%. The test drivers are very experienced and do not compromise if there is a slight complaint with performance.

The test ride completes under 45 minutes of drive in stringent conditions.

18. Quality Control Division:-All products manufactured are thoroughly inspected and tested for quality and reliability. The inhouse testing laboratory well equipped with advance and sensitive testing equipment controlled by experienced Engineers, faithfully uncompromising on the subject of quality. If any fault is found, then the component is sent back to that particular section to rework. The checks begin with the incoming material and components and ends only when the finished product is tested and taken over to store.

One of the laboratory of Quality Control Division

19. Lubrication Chart:-It is a kind of chart which is pasted on the body of road roller after test driving and passing out all the checks from Quality Control Division and after the servicing.The chart provides all the necessary information for lubricating like where the oil has to be given where the grease has to be given and what time interval.With the help of this chart the owner or the operator can easily keep lubricating the roller and hence as a result it will provide with the desired eminent performance.

Lubrication Chart

Machine Shop

Number Of Lathe MachinesRadial Drilling Machine

Rolling Machine Plasma Arc Cutting Machine

Bending Machine Shearing Machine

LESSON LEARNTThe most important lesson what I have learnt here is that how to keep in cohesion with each other and work for the best output in the time when your competitors are just not following but trying to pull you down. The discipline and the keen and magnanimous “love with the work” and cohesion and team spirit have been a lesson that inspired me more in my whole training period.Well apart from this the lesson what has been in-housed in me was from the section in what I was training. The manufacture of Road Roller is totally captured in me. The journey from tiny mild steel to huge and hunk Road Roller has been totally understood. Each and every operations have been considered very carefully. The machining operation like boring, grooving and gas cutting and welding processes has been learnt. The process of wheel rolling fabrication, chasis fabrication, gearbox fabrication, clutch-gear assembling and the assembling of the total of road roller has been carefully learnt.Thus, I can say that I have in-housed all those things which is required to make a huge Road roller using tiny mild steel sheets.

THANK YOU

ALL For

Paying the

Gracious

Attention!!!