INTERNSHIP REPORT 2019

ATLAS HONDA (MOTERCYCLE)

ABDUL REHMAN

BSMT 01171034

5th Semester

THE UNIVERSITY OF LAHORE

DEPARTMENT OF TECHNOLOGY (MECHNICAL)

 Dedicated

To

My Beloved Father

Abdul Ghafoor

&

Mother

Mrs. Abdul Ghafoor

 PREFACE

Internship is one of the keys for understanding more deeply the concepts learned from
formal education by going through practical practices adapting industries. And this
rationale brought us to Atlas Honda.

During our internship we have learned a lot about production of bikes and also learned
about robotic arm and design an arm to increase production. Every topic from crust to
core was explained to us and this report is an over view of what I learned. Information
in this report is gathered from different sources like instruction manual. Project
proposals. Online websites and notes provided by instructors.

This document gives reader insight of design techniques for robotic arm, which is
hydraulically powered. It also define a unique way of design a robotic arm by using
simple mechanisms. Interactive visuals provide an ease to reader for understanding
design of arm and don’t let reader to get bored as traditional text does.

I have tried my best to eliminate all mistakes and misrepresentation of facts but since
its natural for humans to make mistakes, so I ask your pardon for any such mistakes.
 ABSTRACT

Industrial training is one of the requirements for the award of the Degree in Bachelor
of Science in Mechanical Engineering and Technology of The University of
Lahore. As such, students are required to write and submit reports at the end of their
training.

This report is the record of the work I personally did during my industrial training at
Atlas Honda from July to August.2019 as per company policy.

It contains several topics which altogether explain the objectives of industrial training,
entail background information about Atlas Honda, various activities carried out at the
Manufacturing Plant, and I worked on a project of Hydraulic Robotic Arm which is
going to be used on hydraulic press.

This report also covers the description of departments and describe production line
tasks of Atlas Honda. Furthermore this report covers, Description of tools and
techniques learned, Schedule of internship, Skills learned during intern ship, Role and
responsibilities of internes, suggestions and recommendation, in last but not least
Conclusion.
 TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................ 11
1.1. Atlas Group .............................................................................................................. 11
1.2. Atlas group Timeline ............................................................................................... 12
1.3. Atlas Honda Limited ................................................................................................ 12
1.4. Karachi Plant ............................................................................................................ 13
1.5. Sheikhupura Plant .................................................................................................... 13
1.6. Exports ..................................................................................................................... 13
1.7. Regional Office ........................................................................................................ 14
1.8. Vision and Mission .................................................................................................. 14
1.8.1. Vision ............................................................................................................... 14
1.8.2. Mission............................................................................................................. 14
1.9. Strategic Goals ......................................................................................................... 14
1.9.1. Customers ........................................................................................................ 14
1.9.2. Quality.............................................................................................................. 14
1.9.3. Local Manufacturing ........................................................................................ 14
1.9.4. Technology ...................................................................................................... 15
1.9.5. Shareholders..................................................................................................... 15
1.9.6. Employees ........................................................................................................ 15
1.9.7. Corporate Citizens ........................................................................................... 15
2. ORGNIZATIONAL CHART .................................................................................................. 16
3. A BRIEF DESCRIPTION OF DEPARTMENTS........................................................................ 17
3.1. The departments are explained briefly below: ......................................................... 18
3.0.1. Human Resources/ CA/ Admin: ...................................................................... 18
3.0.2. Admin and IR:.................................................................................................. 18
3.0.3. Corporate Affairs: ............................................................................................ 18
3.0.4. Finance: ............................................................................................................ 18
3.0.5. Logistics ........................................................................................................... 18
3.0.6. Vendor Procurement: ....................................................................................... 19
3.0.7. Maintenance: .................................................................................................... 19
3.0.8. PPC: ................................................................................................................. 19
3.0.9. Information Technology (IT): .......................................................................... 19
3.0.10. Stores: .............................................................................................................. 19
3.0.11. Quality Assurance: ........................................................................................... 20
3.0.12. Casting Plant: ................................................................................................... 20
 3.0.13. Engine Plant: .................................................................................................... 21
3.0.14. Manufacturing Plant......................................................................................... 22
3.0.15. Assembly Plant: ............................................................................................... 23
4. PROJECT AREA OF TRAINING ........................................................................................... 24
4.0. Complete Project Report on Design of Hydraulic Robotic Arm ............................. 24
4.1. Introduction ............................................................................................................. 24
4.1.1. Introduction about Mechanism ........................................................................ 24
4.1.2. Application....................................................................................................... 25
4.1.3. Parts ................................................................................................................. 25
4.1.4. Hydraulic actuation .......................................................................................... 25
4.1.5. Principle of a Hydraulic Robotic Arm ............................................................... 25
4.2. Classification of Robotic Arm ................................................................................... 26
4.2.1. Introduction ..................................................................................................... 26
4.2.2. Exposition ......................................................................................................... 26
4.2.3. Classification of robots..................................................................................... 29
4.2.4. Robots according to lack of restriction rate..................................................... 30
4.2.5. Cartesian robot ................................................................................................ 30
4.2.6. Cylindrical robot ............................................................................................... 31
4.2.7. Spherical robot ................................................................................................. 31
4.2.8. Advantages and Disadvantages of robotic arms.............................................. 32
4.2.9. Robots as their controlling methods................................................................ 33
4.2.10. According to the power source that is used by robot movements ................. 33
4.2.11. Robots according to their sharpness degree ................................................... 34
4.2.12. Classification made by two letters coding ....................................................... 34
4.2.13. Imitation ........................................................................................................... 36
4.3. Conceptual Design & Methodology ......................................................................... 36
4.3.1. Concept ............................................................................................................ 36
4.3.2. Conceptual Design ........................................................................................... 37
4.3.3. Methodology .................................................................................................... 37
4.4. Design of Robotic Arm ............................................................................................. 37
4.4.1. Important parts description ............................................................................. 38
4.4.2. Part Solid Drawing Steps .................................................................................. 42
4.4.3. 2D Drawings ..................................................................................................... 49
4.4.4. Load Calculation Formulas ............................................................................... 54
5. SCHEDULE OF INTERNSHIP PROGRAM ............................................................................ 55
5.0. Daily Tasks ................................................................................................................ 55
6. DESCRIPTION OF EQUIPMENT/ TOOLS AND TECHNIQUES .............................................. 56
6.1. Aluminum Alloy/High pressure Die Casting Machine .............................................. 56
6.1.1. What is high pressure die casting (HPDC)? ...................................................... 56
6.1.2. Advantages of the high pressure die casting process ...................................... 57
6.1.3. Application ....................................................................................................... 57
6.2. Low Pressure Die Casting Machine .......................................................................... 57
6.2.1. What is low pressure die casting (LPDC)? ........................................................ 58
6.2.2. Advantages of the low pressure die casting process ....................................... 58
6.2.3. Application ....................................................................................................... 58
6.3. Gravity die casting machine ..................................................................................... 59
6.3.1. What is gravity die casting (GDC)? ................................................................... 59
6.3.2. Advantages of the tilting gravity die casting process ...................................... 60
6.3.3. Application ....................................................................................................... 60
6.4. Spot Welding Machine ............................................................................................. 60
6.4.1. What is spot welding? ...................................................................................... 61
6.4.2. Advantages of spot welding ............................................................................. 61
6.4.3. Used for ............................................................................................................ 61
6.5. Seam Welding Machine ........................................................................................... 61
6.5.1. What is seam welding? .................................................................................... 62
6.5.2. Advantages of seam welding ........................................................................... 62
6.5.3. Used for ............................................................................................................ 62
6.6. TIG Welding Machine............................................................................................... 64
6.6.1. What is TIG welding? ....................................................................................... 64
6.6.2. Advantages of TIG welding .............................................................................. 64
6.6.3. Used for ............................................................................................................ 65
6.7. Conveyor Belt ........................................................................................................... 65
6.7.1. What is conveyor belt? .................................................................................... 65
6.7.2. Advantages of conveyor................................................................................... 65
6.7.3. Used for ............................................................................................................ 66
6.8. CNC Machines .......................................................................................................... 66
6.8.1. CNC Machine: How Does It Work? .................................................................. 67
6.8.2. Advantages of CNC machines .......................................................................... 67
6.8.3. Applications of CNC machines ......................................................................... 67
6.8.4. Used for ............................................................................................................ 68
7. SKILLS AND TECHNIQUES LEARNED DURING INTERNSHIP............................................... 69
8. ROLE / RESPONSIBILITIES OF THE INTERN ....................................................................... 70
9. USE FULL POINTS FOR NEW INTERNS .............................................................................. 72
9.1. Definition and Benefits of an Internship .................................................................. 72
9.1.1. Definition ......................................................................................................... 72
9.1.2. Benefits of an Internship.................................................................................. 72
9.1.2.1. Career Exploration ....................................................................................... 73
9.1.2.2. Leadership and Skill Development............................................................... 73
9.1.2.3. Networking and Establishing Mentors and References ............................... 73
9.1.2.4. Resume Enhancements................................................................................ 73
10. SUGGESTIONS/ RECOMMENDATIONS ............................................................................. 74
10.1. To the Organization ............................................................................................. 74
10.2. To the university, ................................................................................................. 74
11. CONCLUSION.................................................................................................................... 76
1. INTRODUCTION

Atlas Honda Limited is a public listed company which was incorporated on October
16, 1962. It is a joint collaboration between Honda Motor Company Limited Japan, the
largest and most reputed motorcycle brand in the world, and Atlas Group, one of
Pakistan’s most renowned business conglomerates. The Company is principally
engaged in progressive manufacturing and marketing of motorcycles and spare parts.

Atlas Honda Limited is the largest motorcycle manufacturer in Pakistan with the
strongest brand value and highest customer loyalty. The Company is considered a
pioneer of motorcycle industry in the country and has been leading two wheeler market
successfully for over 50 years.

The Company currently has a production capacity of over 1.35 million units per annum
and continues to maintain its status as market leader both in terms of volume and
quality. It also exports its motorcycles and spare parts to Bangladesh and Afghanistan.

With highest quality products, state of the art manufacturing facilities, largest
dealership network & impeccable after sales service, Atlas Honda Limited is today
considered a benchmark for two wheeler manufacturing. It has been proudly and
successfully fulfilling its role as the flag bearer of motorcycle industry in Pakistan.

As one of the largest tax payers in the private sector and being one of the best employers
in the country, Atlas Honda Limited stands as a beacon of light for the corporate, social
and intellectual sectors of Pakistan.

Further information about the Company is as follows:

1.1. Atlas Group

The Atlas group is known for dealing in a lot of sectors such as engineering, trading,
and financial services. The Atlas group was founded in 1962 with the foundation of
its first company known as Shirazi investments (Private) Limited. Now a day it has
become as group of fifteen companies, of which six are the public limited companies.
The Atlas group is the one who has promoted not only the sense of corporate
governance but also introduced a lot of modern technologies.

Following companies are working under the name of Atlas group in Pakistan.

1.2. Atlas group Timeline

 1962 Shirazi investments

 1963 Atlas Honda
 1966 Atlas battery
 1973 Shirazi trading
 1980 Atlas insurance
 1981 Atlas engineering
 1992 Honda Atlas cars
 1997 Honda Atlas Power Product
 2002 Atlas Asset Management
 2007 Atlas Power
 2007 Atlas World Wide
 2008 Atlas Venture
 2011 Atlas Autos
 2012 Atlas Hi-tech
 2012 Atlas Metals

1.3. Atlas Honda Limited

Atlas Honda Limited is currently operating under a joint venture between the Atlas
Group and the Honda motors. The company was firstly created by the acquisition of
Panjdarya motors by the Atlas Autos Limited. Atlas Honda Limited was also operating
In the Bangladesh before the Pak indo war 1971. After the separation Atlas Honda
Limited stopped its operations in Bangladesh. Currently Atlas Honda Limited is the
market leader in the Pakistan motor bike industry due to his quality and customers
relationship management. Atlas Honda Limited is known for undertaking the
capabilities of local production to higher economical levels. Currently Atlas Honda
Limited has two main factories located in Sheikhupura and Karachi, to produce high
quality bikes in Pakistan Atlas Honda Limited has a well-established research and
development department, which is keep on expanding. Atlas has succeeded to complete
twelve Joint Venture, Technical Assistance Treaties between local dealers and foreign
producers for the transmission of technology. Apart from that Atlas has directly
completed Nine Joint Venture, Technical Assistance Treaties other than Honda. Atlas
Honda Limited is determined to revolutionize companies operation by research and
theory. The style of management, classifications and procedures are altered according
to the current market trends. Atlas Honda Limited always tries and prefer to make
decisions by allowing all types of employee’s to take part in the decision making
process. Many involvement programs such as AlaMayar, (launched in 1985), are
encouraged to let positive assertiveness and teamwork. The company launches training
and development programs to motivate employees to build themselves and incorporate
their motivation towards the Atlas Honda Limited. Atlas Honda limited is playing the
leading role in the distribution system in the Pakistani motor bike industry. It has more
than 1600 deals all around the country to fulfill the demand of bikes in the market.

1.4. Karachi Plant

The first plant of atlas Honda limited is located in the capital of Sindh, Karachi. It is
located at the F-36, Estate Avenue Karachi. The plant is spread over an area around five
Acres. In the start the production was just only seven bikes per day but according to
current statistics it is producing around 300 bikes of only CD 70 version per day.

1.5. Sheikhupura Plant

The second and the main plant of Atlas Honda Limited is located in the city of Punjab
known as Sheikhupura. This plant was founded in 1981 and currently it is spread over
around twenty seven Acres. It is currently producing more than 2000 bikes per day and
all models such as CD 70, CD Dream, Pridor, CG 125 and CB 125 F, CB 250 F.

1.6. Exports

Atlas Honda Limited is also exporting its bikes in the Bangladesh, Sri-lanka and
Afghanistan bike market.
1.7. Regional Office

Atlas Honda Limited currently has four regional offices in Pakistan.

 Lahore
 Rawalpindi
 Multan
 Rahim Yar-khan

1.8. Vision and Mission

1.8.1. Vision
To be a Market leader in the motorcycle industry, emerging as a global competitive
center of production and exports.

1.8.2. Mission
A dynamic growth oriented company through market leadership, excellence in quality
and service and maximizing export, ensuring attractive returns to equity holders,
rewarding associates according to their ability and performance, fostering a network of
engineers and researchers ensuing unique contribution to the development of the
industry, customer satisfaction and protection of the environment by producing
emission friendly green products as a good corporate citizen fulfilling its social
responsibilities in all respects.

1.9. Strategic Goals

1.9.1. Customers
Our customers are the reason and the source of our business. It is our joint aim with
our dealers to ensure that our customers enjoy the highest level of satisfaction from
use of Honda Motorcycles.

1.9.2. Quality

Ensure that our products and services meet the set standards of excellence.

1.9.3. Local Manufacturing

Be the industry leader in indigenization of motorcycles parts.
1.9.4. Technology
Develop and maintain distinct business advantages through continuous induction of
improved hard and soft technologies.

1.9.5. Shareholders
Ensure health and viability of business and thus safeguarding shareholders interest by
maximizing profit.

1.9.6. Employees
To enhance and continuously up-date each member’s capabilities and education and
to provide an environment which encourages practical expression of the individuals
potential in goal directed team efforts and compensate them attractively according to
their abilities and performance.

1.9.7. Corporate Citizens

Comply with all government laws and regulation, to maintain high standard of ethics
in all operations and to act as a responsible members of the community.
2. ORGNIZATIONAL CHART
3. A BRIEF DESCRIPTION OF DEPARTMENTS

On the day of our first visit to Atlas Honda Limited, the Human Resources department
made sure that not a single moment of our visit of Atlas Honda goes to waste. They
took us to different departments of the plant or asked the managers of some plants to
give some of their precious time to us so that we can have an idea that how the
departments are working together in huge setup like Atlas Honda. The orientation was
divided into seven days in which we visited different departments or were briefed by
the managers of some departments. The schedule of the visits was provided to us. The
departments we visited are listed below:
3.1. The departments are explained briefly below:

3.0.1. Human Resources/ CA/ Admin:

HR department is responsible for the recruitment of new staff and appraisal and training
of the existing staff. The HR department is working separately for Karachi and
Sheikhupura but the policy is being made in Islamabad. The administration is
responsible for managing the major functions of the organization that include from
Security to transport and dining facility of the staff. The HR of Atlas has made various
worker friendly rules that are facilitating their employers. These rules even include the
issuance of a motorcycle to grade 13 and above on easy installments. Atlas is also
running many social and welfare organizations that include a hospital and school as
well.

3.0.2. Admin and IR:

Admin department of Atlas is responsible for making several policies regarding the
growth of the organization and security as well. The motive of Atlas is to provide
customers with quality products and give a reasonable profit to the shareholder as well.
IR and Admin jointly are responsible for successful and smooth running of the
organization.

3.0.3. Corporate Affairs:

Corporate affairs department is the major backbone of any organization. In Atlas
Honda, the corporate affairs department is responsible for interlinking all the other
departments with one and other. The department plays an important role in the
promotion of concurrent engineering.

3.0.4. Finance:
The finance department is responsible for carrying all the work related to accounts and
money. Finance department gives the salaries to the employers and manages the money
received from the dealers after selling them the bikes and money given to the vendors.

3.0.5. Logistics
Logistics is the management of the flow of resources between the point of origin and
the point of consumption in order to meet some requirements, for example, of customers
or corporations.
3.0.6. Vendor Procurement:
The vendor procurement department makes arrangements of the vendors. It allows the
vendors to makes bids by offering them the quotation. The vendor with the lowest bid
wins.

3.0.7. Maintenance:
The maintenance department performs all the maintenance works whether it is about
maintaining the machines or maintaining the plant. The production of the electricity in
the gas and diesel plant also comes under the maintenance department.

3.0.8. PPC:
PPC involves all the production plan according to market demand. The production plan
for the entire month is given to the shops at the start of that month. PPC involves the
analysis of the market which determines how much the production of the bikes should
be as per demand. PPC follows these steps to achieve its goals.

3.0.9. Information Technology (IT):

The IT department is responsible for maintaining all the computer data of the company.
It is performing a lot of works from managing the computers, installing the software
and managing the LAN in the plant and its head offices. The IT department has the
official license of Microsoft Office 2004 and Windows XP.

3.0.10. Stores:
The store is the department which is situated in front of the security gate of the Atlas
Honda plant. Store is one of the most important department for manufacturing, HPDC
& LPDC, casting and vendors. All the products that are made in a department are stored
in the store before being passed to the other department. For example all the castings
are moved to the store before being machined in the Hi-tech plant.
3.0.11. Quality Assurance:
The quality assurance department is playing an important role in providing the
customers high quality motor bikes. Honda has maintained this tradition for quite a long
time now and that is the reason why they are the major shareholders of the motorbike
industry in Pakistan.

3.0.12. Casting Plant:

In casting plant many of the parts are manufactured which are then used as parts in the
motorcycle. The parts that are casted include the crankcase, crank cover, crank shaft
and cylinder head. The casing plant is divided into three shops and perform following
tasks i.e.
3.0.13. Engine Plant:
The engine plant (also called as the Hi-tech) is one of the biggest department and is still
being expanded due to high production rate. The engine plant collects all the parts of
the engine in the raw form which are then machined to form the finished products. The
products are checked for high accuracies and the parts which are up to the mark are sent
to the assembly plant. Engine plant further divided into five shops which performs
following tasks i.e.
3.0.14. Manufacturing Plant:

The manufacturing plant includes the paint shop and the shop that makes the body of
the bike. The sheets are brought here and are punched and stamped to form the body of
the bike. The parts include the side covers of the bike. The sheets are then painted in
the paint shop to give the unique look to the bike and stickered to make it more
beautiful. Manufacturing plant also divided into two shops which perform following
tasks i.e.
3.0.15. Assembly Plant:
Assembly plant is the final department from which the bike passes. All the parts of the
motorbike are collected in the assembly plant and are assembled properly. The bike is
checked before it is sent to the store and to the dealer. This has been divided into
following shops as shown:

Assembly Plant

Frame welding Engine Frame

ED Paint Shop
Shop Assembly Shop assembly shop

Spot Welding Degreasing Engine Frame

Tig Welding Rinsing Cranck Case Engine

Mig Welding Phosphating Gears Fule Tank

Rinsing
Mud Guard
with RO

ED painting Other Parts

Baking

Finished parts
4. PROJECT AREA OF TRAINING

4.0. Complete Project Report on Design of Hydraulic Robotic Arm

4.1. Introduction
Hydraulic Robotic Arm is a system which coupled by machines and hydraulic. It is
widely applicable in all kinds of large engineering equipment’s. Such as arm frame of
crane. The arm system of the redundant freedom, strong, nonlinear, coupled with rigid
and flexible characters. In hydraulic robotic arm the dynamic differential equation is
built with the driving force of the hydraulic cylinder as the main force.

By using the PD controlled theory without de coupling and rank decreasing only with
feedback from control of the arm and position pose and movement the relationship
between the hydraulic system and the end positions & pose is studied. The simultaneous
result prove the movement equation built by this way can clearly describe each dynamic
character of the mechanical arms.

A hydraulic drive system is a drive or transmission system that uses pressurized

hydraulic fluid to power hydraulic machinery. The term hydrostatic refers to the transfer
of energy from flow and pressure, not from the kinetic energy of the flow.

A hydraulic drive system consists of three parts: The generator (e.g. a hydraulic pump),
driven by an electric motor, a combustion engine; valves, filters, piping etc. (to guide
and control the system); and the actuator (e.g. a hydraulic motor or hydraulic cylinder)
to drive the machinery.

4.1.1. Introduction about Mechanism

A robotic arm which is hydraulically operated and controlled filled with some fluid. It
is consists of various parts connected to each other in a pre-designed manner which are
guided in a constrained way to obtain required output.
4.1.2. Application
These arms are used in assembly lines of mega factories to assemble various parts of a
product and also to paint vehicles. They are also used in earth movers to pick up heavy
weight and keep them where required. Same principle is being used in JCB’s,
automobile lifters, etc.

4.1.3. Parts
In the mechanism, each part has been provided with certain degree of freedom to move
in a constrained way to guide other parts and also to pick up small weight items and to
place them wherever required. The complete mechanism consists of a vertical link. Its
one end is connected or better to say hinged, another horizontal link which is free to
reciprocate about a certain point in an up-down way of motion. To this link is connected
a sliding/ railing mechanism.

4.1.4. Hydraulic actuation

All the movements above are controlled hydraulically by hydraulic jacks attached to
each one.
The hydraulic supply acts like the arm’s heart and muscles. It provides the energy for
pushing, pulling, and lifting.

Mechanism of hydraulic jack

4.1.5. Principle of a Hydraulic Robotic Arm
Pascal's law is the basis of hydraulic drive systems. As the pressure in the system is the
same, the force that the fluid gives to the surroundings is therefore equal to pressure ×
area. In such a way, a small piston feels a small force and a large piston feels a large
force. The same principle applies for a hydraulic pump with a small swept volume that
asks for a small torque, combined with a hydraulic motor with a large swept volume
that gives a large torque. In such a way a transmission with a certain ratio can be built.
Most hydraulic drive systems make use of hydraulic cylinders. Here the same principle
is used a small torque can be transmitted into a large force. By throttling the fluid
between the generator part and the motor part, or by using hydraulic pumps and/or
motors with adjustable swept volume, the ratio of the transmission can be changed
easily. In case throttling is used, the efficiency of the transmission is limited. In case
adjustable pumps and motors are used, the efficiency, however, is very large. In fact,
up to around 1980, a hydraulic drive system had hardly any competition from other
adjustable drive systems.
Nowadays, electric drive systems using electric servo-motors can be controlled in an
excellent way and can easily compete with rotating hydraulic drive systems. Hydraulic
cylinders are, in fact, without competition for linear forces. For these cylinders,
hydraulic systems will remain of interest and if such a system is available, it is easy and
logical to use this system for the rotating drives of the cooling systems, also. An
important advantage of a hydraulic drive is its high power density: the mass of a
hydraulic drive is several times smaller than the mass of an electric drive of the same
power.

4.2. Classification of Robotic Arm

4.2.1. Introduction
In that work, it has been explained the classifications of the robotic arms which have
used hard, dangerous and high level sensitive works, according to unrestraint levels,
power supply which is used by the joint accelerators, control methods, sharpness grades
and codification with double letters. According to those classifications, it has been
explained the specifications of the robotic arms, usage fields, working spaces,
advantages and handicaps against each other.

4.2.2. Exposition
Robot has a meaning of slave or working in Czech and Slovak languages. Robotic
means the science of robot and it’s named firstly by Issac ASIMOV.
Robots are very functional manipulators which are projected for moving some
materials, hand tools or special equipment’s by giving then a series of preplanned
duties. Need of industrial robotand their use is increasing by computer supported
conception and parallely computer supported production.

Most important feature that separates the robot from the other machines is; robots can
be programmed several times and they have control system that provides to do more
complex processes nearby mechanic systems. In a word, robot is an industrial
manipulator controlled by computer. Robot science is a branch of instruction that
contains several engineering as electric and electronic engineer, mechanical engineer,
computer engineer and math engineer. In examples; mechanical engineering is curious
about robots dynamical and statically constitution, computer engineering is interested
in software part of robots and electric engineering is concerned with perceptional
concept of robots.

All the robots have a working space as to their organs and joints. That working space
is the open place where robot’s extremity functionary can move freely. By the help of
robot manipulator’s joint changes extremity functionary’s position according to main
shaft and find of inclination is forward kinematics; bye the position and inclination
knowledge of extremity functionary, found of joint changes of robot manipulator is
reverse kinematics. Kinematics is interested in act of objects. Robot’s strength sped and
acceleration analysis can be made by robot kinematics.

A robot is composed of prismatic (sliding) or revolving kind of joints which can move
freely by themselves and organs which combine the joints each other, revolving joint,
(Fig. 1.) allows revolving between two organs. Prismatic joint, (Fig. 2.) allows linear
movement joint angle is re-movement that consists of revolving in revolving joint.

Joints slip is re-movement that consists of linear movement between organs in prismatic
joint.

Joint angle is the joint changeability in revolving joints, joint slip is the joint
changeability in prismatic joints.
 Fig. (1) Revolving joint Fig (2) Prismatic joint

Manipulators are accepted as open-tipped kinematics chain of bounded rigid things.

While one tip of the chain is bound to main environment, the other tip is bound to tip
functionary. Consequently, action of manipulator is ever all of movements of each
organs according to the others. Expressions which constitute this kinematics chain
consist of homogeny transformation matrix that includes the location and inclination of
robot for determining the manipulator movement, it is necessary to determine the
inclination and location of rigid thing in space.

Inclination of rigid thing in Cartesian space, transformation matrix and the location of
rigid thing are founded by locating vector. Six lack of restriction degree is enough for
reaching at any point in three dimension space. Redundancy becomes at robots whose
lack of restriction degree is more than six. Redundance can be defined as the place
which is hatched by two different joints at the sometime.

Fig. Robot and working space

Basic frame {B} inactive part of robot, in other words, first hoop of kinematics chain.

Station frame {S} the frame where robot makes all actions.

Wrist frame {W} it is the last organ of manipulator and the last ring of the chain.

Tool frame {T} a suitable component is placed according to action that we want the
robot to do.

Goal frame {G} the frame which is onto thing where the robot is going to operate.

4.2.3. Classification of robots

Robots are principally classified in two groups as serial and parallel robots. Serial
robots are formed from a row of joints and organs which combine these joints each
other. (Fig.) Serial robots have an extensive working space and a few amounts of
mechanical parts. Parallel robots come together more parallel organs between main
frame and last functionary. (Fig.) When these two robots are compared with their rate
of carriable mass to mechanic constitution mass jobs and parallel robots are used for
big mass jobs.

Fig. Serial robot Fig. Parallel robot

Robots can be classified in five different classes according to their lack of restriction
rate, source of power used for revolving joints, control methods, sharpness degree and
two letter code.

4.2.4. Robots according to lack of restriction rate

Robots which are used industry are generally these six lack restriction rate robots.
While classifying the robots according their lack of restriction rate, it’s looked for the
functions of first three organs.

For example;
If first there organs have a prismatic joint, this robot is Cartesian robot. (Prismatic
Prismatic Prismatic – PPP)

If the first organ has a revolving joint but the second and third have prismatic joint, this
robot cylindrical robot. (Revolute Prismatic Prismatic – RPP)

If the first two organs have revolving, third organ has a prismatic joint and all joints are
parallel to each other; this kind of robot is Scara robot. (Revolute Revolute Prismatic –
RRP)

If the first two organs have revolving joint and the third organ has a prismatic joint this
robot is spherical robot. Also if first three organs have revolving joint, this robot is
revolving robot.

4.2.5. Cartesian robot

The robot which is projected as being prismatic joint of first three joints is Cartesian
manipulator. That kind of robot has the least kinematics order. Although their
mechanical constitution is well-made (strong) their activity skills in working space are
quite Lowe Cartesian kind of manipulators are mostly used for carrying the things from
somewhere to somewhere that have a high capacity and weight.
 Fig. Cartesian robot and working area
4.2.6. Cylindrical robot
A kind of manipulator which is constituted from joints that first joint is revolving, the
second and third joints are prismatic kinds. Although their mechanical constitution is
well-made, theirwrist location line changes according to horizontal action. So as
Cartesian robots, they are used for carrying the things that have high capacity and
weight. Hydraulic cylinder is usually used as movement at prismatic joint.

Fig. Cylindrical robot and working area

4.2.7. Spherical robot
In spherical manipulator, first two joints are formed by revolving joints and the third
joint is formed by prismatic joint. Although their mechanical constitution is not well-
done than Cartesian robot, their activity skills in working space are rather high.

Fig. 8 Spherical robot and working area

Revolving robot
Manipulator whose first three joints have revolving joints is revolving manipulator.
These robots have the highest activity skills in working space. It is the most skillful
manipulator. In Project of the manipulator human arm was referenced.

Fig. Revolving robot and working area

4.2.8. Advantages and Disadvantages of robotic arms

Robot Advantages Disadvantages

Cartesian The kinematic equation is simple. Size of working space is smaller than
Mechanical constitutions are well made. robot’s size.
In each point of working space, there Robot can’t reach its own body.
huge sized activity skill are same. It is difficult to protect prismatic joints
It is easy to add new things because they from dust in environment.
have simple kinematic constraint.

Cylindrical Because main frame is revolving, speed They have small working space as
of tip functionary is high. compare to spherical robots.
Their kinematic equations are simple. Huge sized activity skills change
They have an extensive working space as according to arm length.
to Cartesian robots.
Spherical They have an extensive working space. Due to their complex kinematic equation,
their control is difficult.
Huge sized activity skills are different at
each point.
Revolving They have very extensive working space. Huge sized activity skills are different at
It is easy to move all revolving joint. They each point.
are very plaint and fast. Due to their complex kinematic equation,
their control is difficult.
4.2.9. Robots as their controlling methods
Robots are classified in two groups as their controlling.

4.2.9.1. Robots controlled from a point

There isn’t a determined working area for these kinds of robots. Lack of restriction
degree is smaller than six and they usually used for carrying a thing from somewhere
to somewhere. Robot is used by an operator.

4.2.9.2. Continual trajectory controlled robots

These kinds of robots are controlled as following a pre-determined trajectory. Robot is
programmed by operator before start using. During the run of robot, operator doesn’t
interfere it this kind of robots periodically repeats the programmed action.

4.2.10. According to the power source that is used by robot movements

Because the robots ought to do job which is given, it is important to stir up the joints in
an appropriate order. Joint activity in these robots is achieved by electric motors,
pneumatic cylinder and hydraulic cylinders.

4.2.10.1. Stirring up with electric motor

Special envisagement electric motors are used for stirring up the joints of this kind of
robots. Because of the circular action of engine shaft, it’s usually used for activity of
revolving joints. So, Dc servo type motors whose revolving angle can be decreased
under 1°, are used for his arm. Dc servo type motors that they have redactor provide
high torque with low voltage. It is easy to control.

4.2.10.2. Stirring up with hydraulic cylinder

This kind of robots joints are stirred with hydraulic cylinder. It is usually used to
activate the prismatic joints because of the constitution of cylinder. They are used at
hard Works in industry that they provide a high torque with low energy.

Because their performance is not linear, their control is more difficult than electric
engines.
4.2.10.3. Stirring up with pneumatic cylinder
These kinds of robots are alike to hydraulic cylindrical robots, but their control is
difficult. Because, air is used in pneumatic cylinder and air presume is not enough to
provide the flux of cylinder but their constitution is simple. As hydraulic cylinder
robots, these kinds of robots are used for activity of joints.

4.2.11. Robots according to their sharpness degree

It is separated into three groups as straightness, replacement, and resolution.

4.2.11.1. Resolution
It is known that robots are controlled by control system. It is the arability of changing
for the signals that is sent to control system.

For example; a robot whose joints are placed by servo motor has a high. While a robot
whose joints are placed by hydraulic cylinder has a low.

4.2.11.2. Straightness (Accuracy)

There is a software which was prepared for the control for robots by their control
systems. We can control the robot by programmer it with this software of the program
of tip functionary
.
4.2.11.3. Replacement (Interconvertibility)
Replacement is a special feature of robot that robots tip functionary comes to the same
point after doing the jobs.

4.2.12. Classification made by two letters coding

Huang and Milenkovic have improved a code formed from two letters for describe the
robot types. According to that, first letter explains the property of first joint and the
revolving comparing the second one. The second letter explains the third joint and the
relation between second and third joints.

Used letters and symbols

 S: slipping, slide (Fig. A)
C: upright turning at slipping axis (Fig. B)
N: upright turning at turning axis (Fig. C)
R: upright turning to slipping axis or parallel to turning axis (Fig. D)

Fig. Symbols used at two-letter coding

Huang and Milenkovic have used sixteen unit of two-letter combination for robot
organs. All these compositions are useful and they aren’t different. A useful organ must
have an extensive sized activity skill in three dimension space; difference is that each
organ is different from the other categories.

Fig. Symbolic figures which identifies the robots at two-letter

Huang and Milenkovic haven’t found useful the codes; CN, NC, RS and SR. RS and
SR robots are usually used in industry although they don’t find useful and different.
The reason that these two robots don’t find useful and different is because they rake the
same area with CS robot.
4.2.13. Imitation
Imitation or simulation is an animation of physical activity by the help of programs
which are necessary at computer atmosphere before acting a physical activity. Robot
programs are tested with imitation programs before testing on true robots. There are
advantages of testing the programs. If robot programs are loaded to robot before testing
by the help of imitation, robot can damage itself or environment. For this reason, testing
robot programs (after software) provides time and Money. A good robot imitation
program could modelise the position of organs, inclinations and environment.

4.2.13.1. Classification of robot imitation programs

It is separated in two class as online or offline.

Online programming
Online programming is realized when the robot is at production position. It is used to
reach the tip functionary of robot at determined point.

Offline programming
Programming is done before producing the robot in offline programming and robot is
produced after programming. This type of robots are wed at repeating process. If we
want to do other action with the robot, first we delete the old program and it is
programmed again.

4.3. Conceptual Design & Methodology

4.3.1. Concept
The basic concept used behind the operation is PASCAL’s LAW. This law states that
when a pressure is applied at one point of a fluid contained in a constrained volume,
then the pressure due to that force is equally transmitted to all the points of the fluid,
which are acted upon by the same pressure. Using the same principle, we applied
pressure to fluid in piston cylinder which is transmitted to other end of tube which is
connected to a cylinder. This motion of the piston is used to move the links or parts of
the mechanism which are attached to respective end of piston.
4.3.2. Conceptual Design
1.) The sliding mechanism used in the design, maintain its simplicity but at the
same time increases its efficiency, ability, area of coverage.
2.) Linear bearing and two hydraulic jack’s mechanism used to provide linear
motion. It works smoothly without any jerks or shocks and giving more smooth
work.
3.) A motor with timing belt used to get rotational motion. We use timing belt
because it has low percentage of slip and it also gives maximum output.
4.) Hydraulic oil having least compressibility and high efficiency is used as a fluid
in cylinders of jack.
4.3.3. Methodology
All the dimensions of the parts including their weights, their required job, are decided
effectively to obtain overall dimensions of the mechanism and allow required degree of
freedom and to obtain required motion and do the required task.

4.4. Design of Robotic Arm

Material used:

Mild steel

Parts: Quantity

Square tube 1, 5 ft, long, 8 in, wide, 5 mm thick

Plate’s 6 pieces

Ball bearing 3 pieces two have load capacity of 2KN

and one
Which can bear rotational motion of
magnate

Shaft 1 piece
Hydraulic cylinder 2 pieces

Motors 2 pieces

Pulley (for timing belt) 2 pieces

Belt (timing belt) 1 piece

Linear bearings 4 pieces

Slides 2 pieces

Magnate 1 piece
4.4.1. Important parts description

4.4.1.1. Square tube

The square tube use as basic component in cylindrical robotic arm and it is available in
prescribe dimensions.

Mild Steel Square Tube

4.4.1.2. Ball bearings
A ball bearing is a type of rolling-element bearing that uses balls to maintain the
separation between the bearing races.

The purpose of a ball bearing is to reduce rotational friction and support radial and axial
loads. It achieves this by using at least three races to contain the balls and transmit the
loads through the balls. In most applications, one race is stationary and the other is
attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races
rotates it causes the balls to rotate as well. Because the balls are rolling they have a
much lower coefficient of friction than if two flat surfaces were sliding against each
other.

Ball Bearing
4.4.1.3. Shaft
Shaft is a mechanical component for transmitting torque and rotation, usually used to
connect other components of a drive train that cannot be connected directly because
of distance or the need to allow for relative movement between them.

Shaft
4.4.1.4. Hydraulic Cylinder
A hydraulic cylinder (also called a linear hydraulic motor) is a mechanical actuator that
is used to give a unidirectional force through a unidirectional stroke. It has many
applications, notably in construction equipment (engineering vehicles), manufacturing
machinery, and civil engineering
 Hydraulic Cylinder
4.4.1.5. Motor
An electric motor is an electrical machine that converts electrical energy into
mechanical energy. Most electric motors operate through the interaction between the
motor's magnetic field and electric current in a wire winding to generate force in the
form of rotation of a shaft. Electric motors can be powered by direct current (DC)
sources, such as from batteries, motor vehicles or rectifiers, or by alternating current
(AC) sources, such as a power grid, inverters or electrical generators. An electric
generator is mechanically identical to an electric motor, but operates in the reverse
direction, converting mechanical energy into electrical energy.

Motor
4.4.1.6. Linear Bearing & Slides
A linear-motion bearing or linear slide is a bearing designed to provide free motion in
one direction. There are many different types of linear motion bearings. Motorized
linear slides such as machine slides, XY tables, roller tables and some dovetail slides
are bearings moved by drive mechanisms. Slides use for sliding purposes.
 Linear Bearing with Slides
4.4.1.7. Timing Belt Pulley
Pulleys are applied in a number of ways such as using forces, lifting loads and
transmitting the power.
 In nautical cases, the assembly of axle, wheel and supporting shell is termed as
a block.
 The drive component of a pulley system may in terms of cable, belt, rope or
chain that flows over the pulley inside the groove.

Timing Pulley and Timing Belt

4.4.1.8. Magnet
An electromagnet is a type of magnet in which the magnetic field is produced by an
electric current. Electromagnets usually consist of wire wound into a coil. A current
through the wire creates a magnetic field which is concentrated in the hole, denoting
the center of the coil.
 Magnet
4.4.2. Part Solid Drawing Steps

Step 1

Step 2
Step 3

Step 4

Step 5

Step 6
Step 7

Step 8

Step 9
Step 10

Step 11

Step 12
Step 13

Step 14

Step 15
Step 16

Step 17
Step 18

Step 19
4.4.3. 2D Drawings

Front
Top
Right side
Left side
Default Orientation
4.4.4. Load Calculation Formulas
We can calculate load through this formula.

𝑊 = 𝑚𝑔

𝑚 = 𝜌𝑉

𝜌 = 7850𝑘𝑔/𝑚3(For mild steel)

𝑉 = 𝑙 × 𝑤 × ℎ (For solid square block)

A = BH-bh

M = ALρ

By using these formulas we can calculate load and it allows us to select suitable bearing.
We can select bearings through by reading the catalog of manufacturers, as shown in
figure
5. SCHEDULE OF INTERNSHIP PROGRAM

Schedule of Internship program of Atlas Honda

Plant Start End
Manufacturing Plant 12/07/2019 09/08/2019

5.0. Daily Tasks

Date Day Tasks
12/07/2019 Friday Departments Visit
13/07/2019 Saturday Plant Off
14/07/2019 Sunday Plant Off
15/07/2019 Monday Introduction to Manufacturing Plant
16/07/2019 Tuesday Meeting with AM, Project Distribution, Robotic Arm
17/07/2019 Wednesday Visit to Project site, Taking Dimensions
18/07/2019 Thursday Draw Rough Drawing of Robotic Arm
19/07/2019 Friday Plant off
20/07/2019 Saturday Plant off
21/07/2019 Sunday Plant off
22/07/2019 Monday Meeting with AM Consulting Design Rough Drawing
23/07/2019 Tuesday Made Some Changes in Rough Design
24/07/2019 Wednesday Drawing Final Design on Creo 5.0
25/07/2019 Thursday Working on Final Design
26/07/2019 Friday Working on Final Design
27/07/2019 Saturday Plant off
28/07/2019 Sunday Plant off
29/07/2019 Monday Meeting with AM, Consulting Final Design
30/07/2019 Tuesday Finishing Final Design
31/01/2019 Wednesday Draw 2D Drawings
01/08/2019 Thursday Draw 2D Drawings
02/08/2019 Friday Draw 2D Drawings
03/08/2019 Saturday Draw 2D Drawings
04/08/2019 Sunday Plant off
05/08/2019 Monday Meeting with AM, Consulting 2D Drawings
06/08/2019 Tuesday Write Report on Project
07/08/2019 Wednesday Write Report on Project
08/08/2019 Thursday Write Report on Project
09/08/2019 Friday Submitted the Final Project Report to AM, and HR.
6. DESCRIPTION OF EQUIPMENT/ TOOLS AND
TECHNIQUES
6.1. Aluminum Alloy/High pressure Die Casting Machine

Aluminum Alloy Die Casting Machine

6.1.1. What is high pressure die casting (HPDC)?

In a high pressure die casting process, molten metal or metal alloy is injected at high
speed and high pressure into the mould.

High pressure die casting

Horizontal high pressure die casting machines ensure the die closes completely. These
are rated by how much closing force they can apply. That can range from 550 to 5600
tonnes.

Depending on the metal being used, the injection unit that fills the mould can either be
hot chamber or cold chamber.

In hot chamber die casting, the metal is held within the die casting machine itself, then
drawn into the chamber and forced into the mould by the injection piston. These parts
of the machine are in constant contact with the molten metal.
In cold chamber process the metal is first melted in a separate furnace and transferred
to a holding furnace, then poured into a shot sleeve and injected into the mould.

6.1.2. Advantages of the high pressure die casting process

High pressure die casting technology can produce very large light alloy parts, in high
volumes and great speeds.

These machines deliver light alloy parts with high precision, superior surface finish,
excellent uniformity and optimum mechanical properties.

The high pressure die casting process can also produce components with thin walls and
"co-cast” parts with different types of inserts, such as screws and liners that then
become an integral part of the product itself.

6.1.3. Application
Cold chamber high pressure die casting technology is ideal for production of a diverse
range of aluminium and magnesium automotive castings such as engine blocks,
gearbox casings, oil sumps, engine mounts and structural parts like cross-car beams.

It is widely used in other sectors to manufacture components in applications that range

from the simplest – a lighting component – to the most demanding, such as aerospace
engine parts.

6.2. Low Pressure Die Casting Machine

Low pressure Die Casting Machine

6.2.1. What is low pressure die casting (LPDC)?
In low pressure die casting, the die is filled with metal from a pressurized furnace, with
pressures typically around 0.7 bar.

The holding furnace is positioned in the lower part of the vertical die casting machine,
with the molten metal injected upwards directly into the bottom of the mould.

The pressure holds the metal in the die until it solidifies.

6.2.2. Advantages of the low pressure die casting process

One of the main advantages of this process is the precise control of die cavity filling.

Molten metal flows quickly and smoothly through the feeding conduits, reducing oxide
formation and preventing porosity.

6.2.3. Application
This process was created for the production of axially symmetrical parts such as car
wheels.

However, by employing sand cores within the die, it is also well suited to producing
parts with hollow sections and complex geometries.
6.3. Gravity die casting machine

Gravity die casting machine

6.3.1. What is gravity die casting (GDC)?

Gravity die casting was one of the very earliest processes to be invented for metal and
light alloy die casting. In this process which can be fully automated, the molten metal
is poured directly from a ladle into a semi-permanent or permanent die.

The goal is to fill the die with minimum turbulence through one or more channels to
reduce oxidation and foaming. This minimizes porosity and inclusions, giving
optimum metal characteristics in the final casting.

Gravity die casting equipment can have a vertical or horizontal mould opening, or
tilting technology with 0/90 ° or 0/120 ° tilting provides an alternative. With tilting
die-casting, the metal flow at the die inlet is controlled by the tilting angle and speed
of the die.
6.3.2. Advantages of the tilting gravity die casting process
One of the advantages of tilting gravity die casting is that it can produce dense, high
quality castings with excellent mechanical attributes like strength and stiffness. That
makes it very suitable for demanding automotive applications like brake system and
suspension components.

Gravity die casting technology’s main advantages include:

 suitability for high-volume, automated production

 minimum investment required for small and medium volume production
 produces parts with excellent mechanical properties that are also suitable for
heat treatment

As sand cores can be placed within the mould, gravity die casting can also produce
parts with complex shapes.

6.3.3. Application
Gravity die casting technology is ideal for diverse complex aluminium casting
production of automotive parts such as: turbos, brake calipers, knuckles, engine
cylinder heads, engine blocks and pistons. It suits many other industries too, from
lighting components to kitchen tools.

6.4. Spot Welding Machine

Spot welding machine

6.4.1. What is spot welding?
The process uses two shaped copper alloy electrodes to concentrate welding current
into a small "spot" and to simultaneously clamp the sheets together. Forcing a large
current through the spot will melt the metal and form the weld.

6.4.2. Advantages of spot welding

 In this type of welding the base metal does not undergo to large heat affected
area.
 This type of welding is an easy process.
 Spot welding has a high production rate.
 Spot welding can be applied to different metals to join.
 Spot welding is a low-cost process.
 There is a possible to weld multiple metals at a time.
 It can be operated through automatic and manual type.
 Thin metals can be welded more efficiently.
 It does not require more skilled persons at operation.
6.4.3. Used for
 For holding left and right panel of fuel tank
 For welding emblem placing
 For holding left and right panel of frame body
 For Front fender rivet wielding

6.5. Seam Welding Machine

Seam welding machine

6.5.1. What is seam welding?
Seam welding is a welding technique in which the two similar or dissimilar metals are
connected by supplying an electric current and in this process a nugget formation takes
place. Mostly, these nuggets are formed in the form of butt or the overlapping welding
components.

6.5.2. Advantages of seam welding

 This welding is a quicker process than spot welding.
 It is a continuous welding technique suitable for gas & liquid tight containers.
 Energy is utilized efficiently in this technique.
 It doesn’t need the use of filler material.
 No pollutions like fumes of gases because filler material is not utilized.
 This technique can produce liquid tight & gas-tight joints.
 Since the joint is forged due to heat & pressure, a durable weld is formed in
seam welding.
 This welding is easy to operate.
6.5.3. Used for
 It is used in the assembly of fuel tanks.

MIG Welding Machine + Robot

MIG welding machine MIG welding robot

What is MIG welding?
MIG welding is an arc welding process in which a continuous solid wire electrode is
fed through a welding gun and into the weld pool, joining the two base materials
together. A shielding gas is also sent through the welding gun and protects the weld
pool from contamination. In fact, MIG stands for metal inert gas. A 75 percent argon/25
percent carbon dioxide blend (also called 75/25 or C25) works as the best all-purpose
shielding gas for mild steel. It produces the least amount of spatter, best bead
appearance and won't promote burn-through on thinner metals. Copper plated mild steel
wire used as filler material.

Advantages of MIG welding

 High quality welds can be produced much faster

 Since a flux is not used, there is no chance for the entrapment of slag in the weld
metal resulting in high quality welds

 The gas shield protects the arc so that there is very little loss of alloying
elements. Only minor weld spatter is produced

 MIG welding is versatile and can be used with a wide variety of metals and
alloys

 The MIG process can be operated several ways, including semi and fully
automatic

Used for
 Fuel tank right and left panel welding.

 Frame body left and right panel welding.

6.6. TIG Welding Machine

TIG welding machine

6.6.1. What is TIG welding?
TIG (tungsten inert gas) welding, also known as gas tungsten arc welding (GTAW), is
an arc welding process that uses a non-consumable tungsten electrode to produce the
weld. TIG welding utilizes a constant current welding power supply to generate an
electric arc between the tungsten electrode and the workpiece, using the resultant heat
to create the weld.

The weld area is generally protected from atmospheric contamination by use of an inert
shielding or cover gas (argon or helium).

6.6.2. Advantages of TIG welding

 Capable of producing very neat, high quality welds

 Excellent visibility of weld puddle

 Virtually no smoke or spatter

 Effective on very thin material and parts of varying thickness

 Good at producing gas-tight joints

 Relatively easy to switch between welding different materials and most TIG
machines can be used for stick welding just by swapping the torch and flipping
a switch. Most material use the same shielding gas (pure argon) and wire feed
is manual so you just pick up a different filler rod.
  Works well on virtually all metals (including aluminium and magnesium with
AC capable machines).

 allows a high degree of control over heat input

 Travel rate and current can be changed on the fly which is very useful for
complex welds

 Capable of autogenous welds (no filler)

6.6.3. Used for

 Frame body complex parts welding
 Fuel tank ripple welding

6.7. Conveyor Belt

Conveyor Belt
6.7.1. What is conveyor belt?
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to
belt conveyor). A belt conveyor system is one of many types of conveyor systems. A
belt conveyor system consists of two or more pulleys (sometimes referred to as
drums), with an endless loop of carrying medium—the conveyor belt—that rotates
about them. One or both of the pulleys are powered, moving the belt and the material
on the belt forward.
6.7.2. Advantages of conveyor
 It is one of the cheapest ways to move material long distances.
 There is virtually no degradation of your product caused by conveying.
 The conveyor can have changes in elevation.
 The material can be visible on the belt while being conveyed.
 Belts can be loaded virtually any place along the belt.
  The belt can have “trippers” to unload the belt almost any place.
 Belt conveyors can have metal separators designed in.
6.7.3. Used for
 Move assembled parts forward

6.8. CNC Machines

CNC lathe CNC milling

CNC Shaper CNC Honing

CNC Broaching
6.8.1. CNC Machine: How Does It Work?
As discussed in the last part, a typical lathe comprises of a bed, headstock, tailstock,
chuck, tool turret, carriage and a spindle for feeding purposes. The following steps
define how this particular machine works:

1. First Step: After checking the machine for the working faults, a cylindrical
workpiece is attached to the chuck. Its position can differ as per requirement.
2. Second Step: Now set the spindle on the desired speed, thus rotating the chuck
and the workpiece. Major attention needs to be paid on the spindle speed as
any discrepancy can cause cutting errors. Check if the workpiece is turning
properly.
3. Third Step: Now locate the cutting tool at the desired feed by moving the tool
turret and carriage. Pay special attention to feeding speed.
4. Fourth Step: Remove all the excess metal by moving the carriage to get the
finished product.

6.8.2. Advantages of CNC machines

 Machining is accurate
 Time taken to perform a job is very less
 Safe to operate
 Number of operators required to operate a machine are reduced
 No possibility of human error
 Reliable
 Even very complex designs can also be made
 Low maintenance required
 They are versatile
 Uniformity in designs
 They could run for all 24 hours a day

6.8.3. Applications of CNC machines

 Metal removal industries
 Material fabrication industries
  For non-conventional machining industries where the machining task is
difficult to perform manually
6.8.4. Used for
 Crank case facing
 Boring
 Threading
 Shaping
 Gear teeth cutting
 Face milling
7. SKILLS AND TECHNIQUES LEARNED DURING
INTERNSHIP

An internship assists with career development by providing real work experiences that
provide students with opportunities to explore their interests and develop professional
skills and competencies. During internships, we are provided with opportunities to
apply what we learned in classes to actual practice. It is expected that we will also be
challenged to examine how our attitudes, beliefs, and values influence the process.
It was valuable time here in ATLAS HONDA PRIVATE LIMITED and we learn
unlimited here are a few point I have summarized.

 We learnt about the leadership & Team work to do an effective work.

 We learnt about tactics to maintain discipline & How to deal with workers.
 We learnt How to control quality problems, defects in material, Laboratory
Testing of Hardness of a material and How to meet the demands of customers.
 We also learnt about Designing.
 Further, important software like AutoCAD, Creo5.0, Solid Works.
 We have learnt how to make a powerful team to achieve target and to solve their
problem.
 We have learnt about all machining process and heat treatment process.
 We have learnt about CNC machining process in CNC cell
 Learn how to face Problems in industrial sector.
 We observe the heat treatment section more closely and that help us understand
heat treatment process.
 Motor-cycle manufacturing process was complete elaborated to us and we
collected knowledge.
 We observe modern machine like Spark erosion and CMM machines along with
advance machining center and small hole drilling machines smart welding
robotic arm etc.
8. ROLE / RESPONSIBILITIES OF THE INTERN

The overall responsibility of the student is to devote himself/herself to the learning of

helpful interaction with service users.

1. To obtain at least an 80% grade on written and oral assignments in the

internship.
2. To negotiate the internship contract with the Field Instructor and the Field
Director.
3. To follow agency policies with regard to time schedules, regulations, and
matters of dress.
4. To prepare agendas for discussions with the Field Director and Field Instructor.
5. To leave word with the agency secretary and or supervisor as to where s/he is
and when s/he will return.
6. To report absences and reasons for absences immediately to the Field Instructor.
7. To participate in her/his midterm and final evaluations with the Field Instructor.
8. To participate in an evaluation of the Social Work Department.
9. To write a short assessment of the internship placement at the end of her/his
internship.
10. To carry out an evaluation of the Field Instructor.
11. To complete assignments for the internship seminar.
12. To participate in an end of term discussion and complete the Skills and Services
Feedback form.
13. To evaluate the Field Director / Course Evaluation.
14. To provide evidence of having completed the 480 hours including attendance at
a minimum of one workshop or conference, a minimum of two agency visits.
15. Answer phone inquiries, direct calls, and provide basic company information;
oversee mail deliveries, packages, and couriers
16. Perform clerical duties, take memos, maintain files, and organize documents;
photocopy, fax, etc. as needed
17. Assist in preparing information and research materials; create and maintain
PowerPoint presentations
18. Take notes and memos during meetings; type documents, drafts, and reports;
sort and manage files
19. Run general industry related errands
20. Manage databases and input information, data, and records
21. Research and gather documentation on company position in the industry
22. Set up, break down, organize, and maintain conference rooms, training rooms,
and meeting rooms; update company calendars
23. Attend company functions and networking events
24. Shadow multiple office positions and train in a variety of tasks
25. Update and post supervised social media and website content; respond to web
correspondence, social media posts, and emails
9. USE FULL POINTS FOR NEW INTERNS
9.1. Definition and Benefits of an Internship
9.1.1. Definition

An internship is:

 A structured work experience related to a student's major and/or career goal

 An experience that should enhance a student's academic, career, and personal
development
 Supervised by a professional in the field
 An experience that can be one academic term (summer, spring, fall) or multiple
academic terms in length
 Paid or unpaid, part-time or full-time
 An experience that is mutually agreed upon by the student, supervisor and/or
faculty member
 Meets registration requirements for 0 credit hour or academic internship course
 Depending on the field the experience might also be called a practicum or co-
op

9.1.2. Benefits of an Internship

One of the recurring themes in any entry level job search is lack of experience. "Where
do I get experience if no one is willing to hire me?" The answer is simple: Get an
internship!

Students planning to enter the permanent workforce should complement their academic
preparation with a range of other experiences, such as study abroad, community service,
undergraduate research experiences, participation in sports and other student
organizations, membership in pre-professional organizations, and internships.

An internship offers you the chance to learn by doing in a setting where you are
supervised by a work-place professional and have the opportunity to achieve your own
learning goals, without the responsibilities of being a permanent employee.
An internship also offers you the opportunity to work with someone who can become
a mentor for you - not only in the internship but throughout your career.

9.1.2.1. Career Exploration

 Learn about a career field from the inside and decide if this is the right career
field for you
 Work alongside a professional in your chosen career area
 Observe the workplace and see if it matches expectations

9.1.2.2. Leadership and Skill Development

 Learn new skills and add to your knowledge base while gaining confidence in
your abilities
 Opportunity to practice communication and teamwork skills
 Gain industry knowledge first hand from an organization and professionals
 Provide evidence that you have initiative, are reliable, and have a sense of
responsibility
 Apply some of the ideas learned in school and provide a bridge between school
and the professional world
 Achieve a sense of accomplishment by contributing to an organization

9.1.2.3. Networking and Establishing Mentors and References

 Meet new people and practice networking skills while establishing a network of
professional contacts, mentors, and references.
 Open to door to advice on the next steps to take on your career path.

9.1.2.4. Resume Enhancements

 Gain valuable experience and accomplishments to add to your resume and/or
enhance your application to graduate school.
 Create an advantage over other job or graduate school applicants.
 Potential for a full-time job offer at the end of the internship based on your
performance.
10. SUGGESTIONS/ RECOMMENDATIONS

10.1. To the Organization

 Facilitation; The management of HR should buy more facilities such as
computers, vehicles so as to enable smooth running of the company’s activities
and respond to the dynamic competition environment. This technological
advancement will enable the organization to change from manual to
computerized methods of processing documents and proper record keeping.
And also provide place for interns. Provide proper schedule for all four
departments.
 More opportunities to students to do intern in their organization; The intern
would also recommend the Organization to continue giving internship
placements to as many students as they can because some miss this experience
which is also important requirement of the University due to the fact that they
failed to get placements.
 Allowances, the organization should give allowances to interns most especially
transport allowances to cater for transport cost most students stay far from the
internship places hence increasing my expenses. Therefore the intern
recommends the Organization to put that in to action in order to motivate interns
and boost their productivity levels in performing their tasks during the field
attachment.
 Serious supervision to the workers and students, the organization should
increase and ensure more supervision over the employees in order to work
effectively and also eliminate workers who relax, work lazily and perform
actively after seeing their supervisors.
 Job enlargement: The management of Amnesty Commission should also carry
out job enlargement and enrichment such that it mitigate the conflict amongst
employees for roles and tasks .This will ensure good industrial relations
between the supervisors and subordinates at the organization.

10.2. To the university,

 Constant supervision of students, the intern recommends the university to carry
out constant supervision and monitoring of students during the internship
training so as to encourage them to perform the duties fully and also accurately.
 This will also put a close link between the academic supervisors and the field
supervisors so as to foster appropriate assessment of what the interns are doing
in the field.

 Secure Internship placements for students. The University should help students
to secure internship positions according to their respective programs undertaken
at the University through giving students recommendations in order to ease their
training periods and also avoid the ache gotten by students in search of
internship placements

 Should continue with internship program, this is because it helps to prepare the
students for their careers in future and also enable the students to practice the
theoretical knowledge obtained during class be exercised practically. It also
helps to develop students understanding of work ethics, employment demands,
responsibilities and opportunities.
11. CONCLUSION

The internship program helped me to gain important knowledge on auto-mobile

industry, their culture, work environment and all about auto-mobile development.
Participating in weekly team meeting with AM, Project manager and other team
members and discussing on the threats of the projects helped me attain the faith to
develop a never give up attitude. At the same time it helped me learning the structure
of auto-mobiles and mechanisms used in auto-mobile industry and inspired me to be
striver, responsible and confident. The internship program has increased my team work
capabilities as well respect to the team mate’s ideas and suggestions. Team discussions
like brain storming sessions helped me identify and solve numerous problem issues
which would have been impossible to otherwise. I would like to convey my thanks IIT,
DU for providing me an opportunity gain idea of the competitive environment in the
professional field. It has certainly lifted my software development skills in terms of
design and coding. I now look forward to facing the upcoming challenges of the world.