FACULTY COLLEGE OF ENGINEERING DEPARTMENT OF MECHANICAL AND AUTOMOBILE ENGINEERING. In association with RECTANGLE AUTOMOTIVE TECHNOLOGIES PRESENTS

Transcription

1 FACULTY COLLEGE OF ENGINEERING DEPARTMENT OF MECHANICAL AND AUTOMOBILE ENGINEERING In association with RECTANGLE AUTOMOTIVE TECHNOLOGIES PRESENTS 30-DAY INHOUSE RALLY CAR BUILDING INTERNSHIP 10 th April to 9 th May 17 BRIEF REPORT RESOURCE PERSON DETAILS SI NO NAME OF THE GUEST DESIGNATION 1 SURAJ S D FOUNDER & CEO, RECTANGLE AUTOMOTIVE 2 RAMCHANDRA B KULKARNI CONSULTANT, RECTANGLE AUTOMOTIVE 3 VIJAY THARD CONSULTANT, RECTANGLE AUTOMOTIVE 4 JOYTHIVANNAN SENIOR ENGINEER, KGTTI 5 AVINASH IDEAL MOTORSPORTS 6 RAJATH KATTIMANI TORQUE AUTOMOTIVE SOLUTIONS 7 VIDYASAGAR INTERN, RECTANGLE AUTOMOTIVE 8 SUHAS R INTERN, RECTANGLE AUTOMOTIVE 9 ANISH BIWAS INTERN, RECTANGLE AUTOMOTIVE

2 Week 1 Interns have undergone theoretical and practical training on IC engines, sensors, actuators, engine cooling, lubrication, exhaust systems and turbo-charging. Activities are performed to make sure every individual intern have the assessment sheet for each module. And interns are guided one on one from trainer. Such, every individual point out the sensors position, function, failure cause & trouble shooting. Mr.Vijay Thard and Suraj S D have engaged the training for the contents. First 3 days of the training have brought up the confidence in interns to physically know all the physical components of above mentioned topics.

3 Interns have formed into team of 5 and involved in measuring the dimensions of the vehicle such as wheel base, turning radius, front & rear overhang, departure & arrival angles. Significance of all the physical parameters have been taught by trainers. Vehicle dimension activity sheet. Tyres Followed by training modules on automotive tyres. Module consist of understanding the tyre terminology, specifications, types, applications, tyre failure and cause analysis for the failure. Team of 2 interns have given with the activity sheet and set of tyres after the theory sessions to perform the detail understanding of all parameters.

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5 Car dis-assembly Activity involves interns to dis-assemble the exterior components of the car such as bumper, front grill, fenders, rear bumper & wheel cover.

6 Under-body systems Dis-assembly of Engine guard, exhaust systems and lighting system

7 Week 2 Welding training Expert from Karnataka German Technical Training Institute has engaged the training for welding module. Module consist of practical and theory sessions on MIG and ARC welding.

8 Tube Notching theory pipes. Activity to perform tube notching for 90 0, 60 0 & 45 0 and further to perform welding to join notched

9 Tube Notching practical s Preparing the workpiece for tube notching, each intern practiced the notching activity for different angles. Tube welding is practiced for the same workpiece.

10 Suspension dis-assembly Dis-assembly of antiroll-bar, torsion bar and suspension dis-assembly practice. And session on suspension has been delivered by Vidyasagar. Suspensions components, variants and different set-up for suspension on racing and rallying.

11 Training on Brakes and Suspension

12 Roll-cage design Roll-cage serves the primary function to provide the safety for the driver & co-driver. FIA defines the regulations for roll-cage design, students have taught on how to take dimensions for roll-cage design and interns have created the 1:1 scale drawings.

13 Week 3 Interns have involved in dis-assembling the engine from the car and strengthen the chassis to mount the roll-cage in tandem team of students have built the 1:1 prototype of the roll-cage. Chassis strengthening Engine Dis-assembly preprations

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15 Engine dis-assembly from car Dis-assembling engine have been the wonderful experience for interns.

16 ECU Tuning Rajath, Torque motors, explained interns about ECU tunings and re-mapping in order to enhance the vehicle performance in the rally. During the course students have practiced the tuning and trainer have provided the ECU maps of Skoda Octavia. Rajath explained about the hardware and software necessary to do tuning. Demo of the map extraction done on NISSAN Micra.

17 Week 4 During week 4 interns have involved in mounting the roll-cage, assembling the interior and exterior parts, assembling the engine back to car. To overview the rally and building the car, idel racing from bangaluru has brought the rally build Esteem, students had the opportunity to discuss with the team on tuning done on the vehicle and ECU maps, suspension modifications and adjustments. Team have let the opportunity for few students to sit on the co-driver seat to experience few rally driving modes. Roll-cage installation Tube bending is done using CNC bending process, team of students visited facility at peenya with 1:1 scale prototypes. During the bending, settings for bending, bend angles, die radius and requirement of the bending were taught.

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19 Interns have finished the mounting of roll-cage, assembling the engine, exterior and interior parts and suspension. Built up rally car has been driven for functionality.