PROJECT REPORT

SUBMITTED BY:
Jaideep Singh
B.tech.
M.D.University
Department of mechanical Engineering
TABLE OF CONTENTS
 Acknowledgement
 About CBI
 Product of CBI
 Drum Brake Assembly
5 s
 ACKNOWLEDGEMENT

Practical training is an integral part in an Engineering course. In

connection to the project subject, I personally feel that it was a great
experience and challenge for me, the entire scenario was new but
incorporated a great learning curve. CBI is the leading Multinational
Company & Top in the automotive component manufacturing segment.
At the onset, I profusely thank CBI MANESAR, for providing a platform
to me here for this academic exercise. CBI ambition is to enhance the
quality of life with solutions that are both innovative and beneficial. I
took my task as a challenge and remained dedicated to the work.
I would like to bid a very grateful thanks to the Plan Head Mr. Rajat
Tandon and Manufacturing Head Mr. Sanjay Tomar, who played a vital
role in providing me this golden opportunity, of pursuing industrial
training from such an esteemed organization. I also thank him for
explaining various concepts of quality assurance and taking a keen
interest in my project.
I express my heartiest thanks to Mr. Vinod Kumar & Mr. Amit Tondak
for their immense support and aid in clearing my concepts about Drum
Brake, Hose line and Rotor line. Even the associates showed their deep
interest while explaining the job which they were performing on their
respective platforms. I would like to thanks Mr. Jaspreet Singh, Mr.
Rahul Yadav and Mr. P.K Panda for taking out time from his schedule to
explain the various practical aspects of Brake and hose line and
constantly inquiring me about what I have learnt.
 ABOUT CBI

Chassis Brakes International history started in the 30s, when Vincent

Bendix had acquired the rights to French engineer Henri Perrot’s
patents for drum brakes. Bendix Corporation was then created in USA
and launched manufacturing of 4 independent wheels braking system.

In 1983 Bendix was acquired by the Allied Corporation later named

Allied Signal Inc.

In 1996, Robert Bosch Gmbh acquired the brake business of Allied

Signal Inc. This particular milestone turned the company into a systems
supplier of complete braking and brake control systems for vehicles.
In June 2012, Chassis Brakes International is born from the sale of
Bosch Foundation Brakes activity to KPS Capital Partners. Chassis
Brakes International is one of the world’s three largest manufacturers
of automotive foundation brakes and foundation brake components.
Chassis Brakes International is one of the worldwide market leaders for
foundation brake components, systems and services. The company
develops and produces innovative brake systems for the global
automotive industry. Our competitive and high-quality range of
products offers solutions for all market requirements.
 PRODUCTS OF CBI

1:- Drum Brakes

Features
 High reliability and NVH robustness
 Integrated parking brake function with high efficiency
 No roll-away by design
Low pad wear and automatic re-adjustment, with temperature
compensation
2:- Rotors & Drums

Chassis Brakes International has its own rotors and drums production
and machining in China and Australia and machining facilities in Brazil
and India
We currently manufacture two different types of rotors:
 Solid disc
 Ventilated disc
DRUM BRAKE

The Drum Brakes helps in slowing the

vehicle. It transforms a part of kinetic
energy of the vehicle by friction into
potential energy which is dissipated
to the environment. The energy so
dissipated represents BRAKING.
It can be found in the current vehicle
on the rear wheels. In most of the
cases Drum Brakes assure the parking
of the vehicle on the hillside without
any movement.
Generally speaking, any braking system should be near the receiving
component, this is to avoid shocks in transmission element during
braking.
Parts of Drum Brakes:
Wheel Cylinder Auto Adjusting Body Hand Brake Lever

Strut, C & D Spring Back Plate Brake Shoe

  Wheel cylinder
 Auto Adjuster
 C Spring
 D Spring
 Strut Spring
 Hand Brake Lever
 Back plate
 Pivot Pin
 Push Nut
 Shoe Set Pin
 Shoe Set Cup
 Grommet etc.

 Functions of parts of Drum Brakes:

1. Wheel Cylinder

i) The wheel cylinder consists of a number of components.

ii) One w/c is used for each wheel.
iii) Two pistons operate the shoes, one at each end of the w/c.
 iv) When hydraulic pressure from the master cylinder acts upon
the piston cup, the piston is pushed towards the shoes,
forcing them against the drum.
v) When the brakes are not being applied, the piston is returned
to its original position by the force of the brakes shoe return
springs.

2. Auto Adjuster

The role of the automatic adjuster is to assure the same course of

the pedal movement by maintaining the constant clearance
between the shoe and the drum. This system can be either
incorporated into the wheel cylinder (heavy goods vehicles) or
outside the wheel cylinder (light vehicles). The adjustment is
generally made during the functioning of the main brake
(hydraulics).
 Types of Auto Adjuster:
There are two types of A/A body available-
I. Automatic adjuster with teeth(ONE SHOT)
II. Automatic adjuster incremental (RAI or RA US).

3. Brake shoe & Liner:

Trailing Shoe
Leading Shoe

i) The Brake shoe allows to maintain the position of the lining

and to transmit the effort of the braking in the Braking Plate.
ii) It is held on to the Back Plate with the Hold down Assembly
consisting of Pin, Retainer and spring.
 iii) Liner is a layer of particular friction material of suitable
thickness which is always in the contact of brake shoe of the
wheels of the vehicles.
iv) Liner is attached to the rim with the help of raisin gum under a
very high temperature of oven & at very high pressure.
v) Liner is basically made up from a special coarse material which
produces an appreciable amount of friction for braking action.

4. Back Plate:

The role of the back plate is to position the shoes and wheel
cylinder with regard to the vehicle and to pass on the braking
effort of shoes in the vehicle. This piece interfaces the new vehicle
for every project.
Construction and testing of Drum Brakes (Model YP8 New)
A.AUTO ADJUSTER RIVETING:

I. It is made up of two parts namely, the A/A body & Leaf spring
(cut and without cut leaf spring).
II. Leaf spring is fixed with the help of two rivets on the A/A body
by the pressing machine.

B.AUTO ADJUSTER SUB ASSEMBLY:

 Following parts on the A/A body, which are as follow:-
i. Auto adjusting nut
ii. Auto adjusting bolt
iii. Auto adjusting spring
iv. Pawl
v. Rocker.

C.SHOE SUB ASSEMBLY:

Following parts are assembled which is as follows:

 Shoe, HBL, D spring, C spring, shunts spring, A/A assembly.

i. Now, a control lever is tightly riveted in TR shoe through two

rivets through riveting machine.
ii. Now, we take another single shoe called LD shoe.
iii. In two upper slots; the slot which is at lower level will be
attached with the auto adjuster & on both sides of adjuster,
 there is a shunt spring on one side and A/A spring in opposite
side.
iv. In upper slot, D spring is fixed & in lower slot C spring is fixed.

D. WHEEL CYLINDER LEAK TESTING & BP PRESSING:

Note:- Apply the torque

i. Wheel cylinder is placed over the fixture for leak testing by a

pressure setting machine having a working pressure of 5.20 bar.
ii. If there is no leakage, the wheel cylinder will opt for “OK” & if
there is leakage it will be rejected as “NO GO”.
iii. Take back plate on which spline bolt are tightly pressed on its
hole by machine having a working pressure 5.30 bar.

 Torque Wrench:-
A torque wrench is a tool used to precisely apply a
specific torque to a fastener such as a nut or bolt. It is usually in
the form of a socket wrench with special internal
 Wheel Cylinder Leakage Testing
a) Leakage limit- 147 Pa or 15 mm of
water colm.
b) Detection Time – 5 sec.
c) Balancing Time – 5 sec.
d) Charging Time – 5 sec.
Wait for ok/ Not ok signal, machine
punch the dot mark on ok piece.

mechanisms. It was invented by Conrad Bahr in 1918 while

working for the New York City Water Department. It was
designed to prevent overtightening bolts on water main and
steam pipe repairs underground. A torque wrench is used where
the tightness of screws and bolts is crucial. It allows the operator
to measure the torque applied to the fastener so it can be
matched to the specifications for a particular application. This
permits proper tension and loading of all parts. A torque wrench
measures torque as a proxy for bolt tension. The technique
suffers from inaccuracy due to inconsistent or uncalibrated
friction between the fastener and its mating hole. Measuring
bolt tension (bolt stretch) is more accurate but often torque is
the only practical means of measurement. In Brake assembly,
this torque wrench plays an important role. In W/C Leakage
Testing process first we have to check the tightness of the
bleeder screw with the help of torque wrench. Without applying
torque the machine further not perform the test.
Drum Brake Wheel Cylinder Torque Specification

Model Torque Specification as Per Drawing

Alto - CD 0.7 to 1.0 Kgm

Omni 0.7 to 1.0 Kgm

Model - B 0.7 to 1.0 Kgm

O2 0.7 to 1.0 Kgm

CDX 0.7 to 1.0 Kgm

Model - P 0.7 to 1.0 Kgm

Model - k 6.5 + - 1.5 Nm

YP-8 6.5 + - 1.5 Nm

YR-9 0.7 to 1.0 Kgm

E.BACK PLATE & WHEEL CYLINDER MOUNTING:

i. Now, Wheel cylinder is fitted over hole in back plate, then wheel
cylinder is tightly screwed by means of M6 bolts & B6 washers.

ii. Now, Grommet is fastened on the hole of the back plate.

iii. Now, stick the sticker to identify the back plate (RR for right & LL
for left).
F. SHOE SUB ASSEMBLY MOUNTING ON BACK PLATE:

i. Now, put the back plate & wheel cylinder assembly on the
fixture on which SHOE SET PINS are placed on two opposite
sides of the assembly.
ii. Now, the shoe sub assembly is fixed on the back plate & wheel
cylinder assembly in such a way that the two ends of the wheel
cylinder which sealed by boot are compressed tightly and other
ends of shoe sub assembly is set in the anchor plate in back
plate.
iii. Now, shoe set springs is fixed on the shoe set pins on which
shoe set cups are attached firmly in such a way that back plate
& shoe assembly is tightly screwed.

G. SHOE DIAMETER SETTING & FINAL INSPECTION:

Note: Torque is used first.

 i. Here, the above assembly is placed on the fixture of a machine
for checking the shoe diameter. Before checking the shoe
diameter the assembly is placed over drum gauge to check the
center.
ii. Placed the bleeder cup after inspection its goes for the trolley.

COMMON DEFECT HISTORY IN DRUM BRAKE:

 Tube seat miss-W/c,
 Thread damage-W/c,
 Bleeder screw wrong-W/c,
 Bleeder screw loss-W/c,
 Spline bolt damage-Bp,
 W/c mounting bolt: - M6 bolt, other over size,
 Parking cable fitment problem-BP,
 Wire guide pipe lose- BP,
 Presence of the burr on back plate,
 W/c mounting washer missing- M6 washer,
 Batch code marking not clear-Bp,
 Dust cover problem in Bp,
 Boot cut- W/c,
 Anchor plate band-Bp,
 Shoe set pin miss and shoe come out from shoe set pin,
 Control lever not returning to its original position-A/A body,
 Any part miss from the brakes,
 Wrong part found in the brake assembly like RH part in LH
assembly,
 Shoe liner damage,
 Shoe fitment out etc.
 5S
What is 5S?

5S is the name of a workplace organization method the uses

a list of
five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke.Tra
nsliterated or translated into English, they all start with the letter
"S". The list describes how to organize a work space for efficiency
and effectiveness by identifying and storing the items used,
maintaining the area and items, and sustaining the new order.
The decision-making process usually comes from a dialogue about
standardization, which builds understanding among employees of
how they should do the work.

5S was developed in Japan and was identified as one of the

techniques that enabled Just in Time manufacturing.
Two major frameworks for understanding and applying 5S to
business environments have arisen, one proposed by Osada, the
other by Hirano. Hirano provided a structure for improvement
programs with a series of identifiable steps, each building on its
predecessor. As noted by John Bicheno, Toyota's adoption of the
Hirano approach was '4S', with Seiton and Seiso combined.
 Seiri (Sort):-

 Remove unnecessary items and dispose of them properly.

 Make work easier by eliminating obstacles.
 Reduce chance of being disturbed with unnecessary items.
 Prevent accumulation of unnecessary items.
 Evaluate necessary items with regard to cost or other factors.
 Remove all parts not in use.
 Segregate unwanted material from the workplace.
 Need fully skilled supervisor for checking on regular basis.
  Don`t put unnecessary items at the workplace & define a red-
tagged area to keep those unnecessary items.

 Seiton (Systematic Arrangement):-

 Can also be translated as "set in order", "straighten" or

"streamline".
 Arrange all necessary items so they can be easily selected for use.
 Prevent loss and waste of time.
 Make it easy to find and pick up necessary items.
 Ensure first-come-first-served basis.
 Make workflow smooth and easy.
 All above work should be on regular base.

 Seiso (Shine):-
 Can also be translated as "sweep", "sanitize", "shine", or "scrub".
 Clean your workplace completely.
 Use cleaning as inspection.
 Prevent machinery and equipment deterioration.
 Keep workplace safe and easy to work.
 Keep work place clean.

 Seiketsu(Standardize):-
 Standardize the best practices in the work area.
 Maintain high standards of housekeeping and workplace
organization at all times.
 Maintain orderliness. Maintain everything in order and
according to its standard.
 Everything in its right place. (Chilled totes in chilled area, Dry
totes in dry area.)
  Every process has a standard.

 Shitsuke(Sustain):-
 To keep in working order.
 Also translates as "do without being told" (though this doesn't
begin with S).
 Perform regular audits.
 Training and Discipline.
 Training is goal oriented process. Its result feedback is necessary
monthly.
 KAIZEN
Kai in Japanese means change and Zen means good. The literary
meaning of kaizen is change for good.
Kaizen is the Japanese philosophy of continues improvement by all the
employees in an organization so that they perform their task a little
better each day. It is a never ending journey centered on the centered
on the concept of starting new each day with the principle that the
existing methods/process can always be improved.

KAIZEN EXAMPLE:
 Space saving,
 Operation improvement,
 Energy saving,
 Material flow improvement,
 Weight reduction,
 Quality improvement,
 Protection of surrounding,
 Safety and accident prevention.
 POKA YOKE

 Poka yoke means Mistake – Proofing

 Mistake proofing recognizes that every human will make
mistakes and tries to set up systems that minimize or
eliminate those mistakes.
 When a poka – yoke is designed in a way that it helps the
operator to recognize the defect before it is about to occurs,
it is called a prevention or prediction type poka- yoke.
 When a poke – yoke helps the operator to know immediately
on the occurrence of the defect then it is after the defect is
produced. The merit of this type of poka – yoke is based on
the stage at which the defect is detected. In simple language
“Earlier the better”.

COMMON MISTAKE PROOFING DEVICES:

 Guide pins
 Blinking lights and alarms
 Limit switches
 Proximity switches
 Counters
 Checklists etc.