REPORT. Saeed
REPORT. Saeed
COMPLETED AT
IN
MECHANICAL ENGINEERING
BY
MOHAMMAD ABUSAEED
ACKNOWLEDGEMENT
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
MOHAMMAD ABUSAEED
TABLE OF CONTENTS
1. INTRODUCTION
1.1 Mission
1.2 Vision
1.3 Core Values
1.4 SANY Motto
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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2. PRODUCT OF SANY
2.1 Excavator
2.1.1Types of Excavator
2.2 Hoisting Solution
2.3 Concrete Solution
2.4 Wind Solution
CHAPTER NO. 1
1. Introduction
SANY Heavy Industry India Pvt Ltd (SANY India) is a wholly owned subsidiary of SANY
Heavy Industry Co Ltd (SANY Heavy Industry), China.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
SANY India was established in December 2002. In the year of 2007, SANY Group
signed a memorandum with the Government of Maharashtra to build a new plant which
would cater to the increasing demand of construction machinery needs in the India market.
This was the first big investment by any Chinese MNC in Maharashtra and also the first
overseas investment of SANY Group. Complying with the culture of Sany Group, Sany India
insists the mission of "quality changes the world" and holds the vision of "building first-class
enterprise, fostering first-class talent, making first-class contribution".
With the inauguration of the plant in 2012, SANY India operates in four Business
Units viz: Excavator, Heavy Equipment Machinery, Concrete Machinery and Renewable
Energy.
Through these business units, SANY India offers products like excavators, truck
mounted cranes, crawler cranes, transit mixers, batching plant, piling rigs, motor graders,
reach stackers, rubber tyre gantry cranes(RTG cranes), rail mounted gantry cranes(RMG
cranes), wind turbine generators and many more.
The state of art manufacturing facility in Chakan of Pune employs over 300 people. It
also hosts a global training center where trainees are trained by simulators. SANY India, with
its head office in No. E-4, Chakan Industrial Area, Phase-3, Kuruli, Taluka- Khed, Pune,
Maharashtra, is supported by 7 regional offices located at Ahmadabad, Bangalore, Chennai,
Hyderabad, Kolkata, Mumbai and New Delhi. SANY now has 28 dealers with close to 100
touch points which cater to India, Sri Lanka, Bangladesh and Nepal. Today SANY India
manufacturing plant in Chakan, acts as a hub not only catering to the equipment needs of
India but also to the neighboring countries as African continent, Middle East and South Asia.
The story of Sany India began with importing 4 motor graders dating back to 2002. It
was the first time when Sany entered Indian market. Building further on the entry in India,
SANY India was established, with setting up branch offices in 6 central cities, with a promise
to serve customers in every state. In 2007, the investment of SANY in India laid the
foundation stone for Sany India, with intention to build and create a production base of
construction equipment machinery in Pune. This was not only the first overseas investment of
SANY group but also the first case that Chinese company setting up manufacturing facilities
overseas in the construction machinery industry. The year of 2007 is not only a historic year
for SANY India but also marked the beginning of a new chapter in QUALITY for
construction equipment industry in India.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
The SANY Pune Industrial Park was inaugurated in 2009. Marked by the opening of
Pune Industry Park, SANY rolled out its blueprint encapsulating localization, investment,
design, manufacturing, people and customers. Within a short span of 2 years of operations,
Sany India has already ranked No.2 in concrete machinery market. And in 2014, the localized
excavators SY220C-9 went offline in Pune Industry Park, which marked the beginning of
SANY India’s localized strategy. Besides, SANY India also achieved the first terminal sales
of general-purpose chassis crane SPC250 and top-level design for many crane models.
1.1 MISSION
1.2 VISION
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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Good conduct is prior to business work, striving for Excellency and efficiency, innovation,
passion.
CHAPTER NO.2
2.PRODUCTS OF SANY
1.Excavator.
2.Hoisting solution.
3.Concrete solution.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
4.Wind solution.
2.1 Excavator
2.1.1TYPES OF Excavator
1. Mini Excavator.
SANY mini excavators is suited for land excavation for housing projects. With small body,
the engines of SANY mini excavator deliver top performance and tremendous power, with
increased fuel efficiency and low emissions. Multiple working modes, intelligent control
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INTERNSHIP REPORT SANY INDIA
systems and a variety of attachments and parts make SANY mini diggers capable enough to
be used in versatile operation in all kinds of work environments.
2. Small Excavator.
3. Medium Excavator.
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4. Large Excavator.
SANY large excavators with good price are specially designed for heavy-duty mine
operations. With high durability and humanized design, the big excavator is built to deliver
maximum performance and ease of operation. Our advanced safety and technology features
ensure you get increased productivity without compromising on safety and efficiency.
SANY hydraulic cranes are mainly used for various material handling and erection
jobs in steel yard, oil sector, civil construction and wind energy sector for support operations.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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1.Truck Cranes
SANY truck crane features by high stability, advanced design, multiple functions and ease of
operation. With ultra-long and super strong boom system, SANY truck cranes have super
lifting capacity. The adjustable hydraulic system and intelligent electric control system make
the truck cranes in high efficiency and low fuel consumptions.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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SANY rough terrain crane is well-received in the market with its high flexibility and multiple
functions. Rough terrain cranes can be used to lift heavy-duty loads in various construction
sites and narrow space. Designed by hi-tech software and combined with mechanics of
materials ,SANY rough terrain crane possesses perfect mobility and controllability.
3. Crawler Cranes
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
SANY crawler cranes posses many honors, like the "NO.1 lifting equipment in Asia" and the
"NO.1 lifting equipment in the world". With four-wheel walking device and widened track
gauge, SANY crawler crane has excellent stability and integrity. The strengthened
components and reliable engine with advanced control system make the crawler
crane capable enough to be used in tough environment.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
SANY concrete machinery has a versatile product line, such as concrete transit mixer and
batching plant. SANY India concrete solution can meet the demands of consistent mix quality
and extreme working conditions. With advanced technology and reliable components, SANY
India concrete equipment can be used for various applications.
1.Transit Mixer
2. Batching Plant
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
SANY batching plant features by high quality, high efficiency, ease of operation and high
profit. For the concrete mixing plant, SANY provides full set of solutions to customers
include installing, training, operation guidance, maintenance and financing. If you purchase
SANY concrete mixing plant, the professionals and technicians with plenty of experience are
always at your service.
iii. Conditions: Producing various kinds of concrete including quaking concrete and hard
concrete, suitable for large or medium scale building works, road and bridge works
and precast concrete plants.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
SANY wind energy machines become more and more important with the demand for wind
power increasing. SANY India provides full set of wind solution to meet customer’s needs.
SANY India wind turbine generator features high power generation and high reliability, low
construction cost and low maintenance cost.
CHAPTER NO. 3
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INTERNSHIP REPORT SANY INDIA
R&D is an important means for achieving future growth and maintaining a relevant product
in the market. There is a misconception that R&D is the domain of high tech technology
firms or the big pharmaceutical companies. In fact, most established consumer goods
companies dedicate a significant part of their resources towards developing new versions of
products or improving existing designs. However, where most other firms may only spend
less than 5 percent of their revenue on research, industries such as pharmaceutical, software
or high technology products need to spend significantly given the nature of their products.
Investment in R&D can be extensive and a long term commitment. Often, the required
knowledge already exists and can be acquired for a price. Before committing to investment in
R&D, a company needs to analyze whether it makes more sense to produce their own
knowledge base or acquire existing work. The influence of the following factors can help
make this decision.
Timing
Setting up a R&D wing only makes sense if the market growth rate is slow or relatively
moderate. In a fast paced environment, competitors may rush ahead before research has been
completed, making the entire process useless.
Risk
Because of its nature, R&D is not always a guaranteed success commercially. In this regard,
it may be desirable to acquire the required research to convert it into necessary marketable
products. There is significantly less risk in acquisition as there may be an opportunity to test
the technology out before formally purchasing anything.
Cost
Considering the long term potential success of a product, acquiring technology is less risky
but more costly than generating own research. This is because license fees or royalties may
need to be paid and there may even be an arrangement that requires payments tied to sales
figures and may continue for as long as the license period. There is also the danger of
geographical limitations or other restrictive caveats. In addition, if the technology changes
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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mid license, all the investment will become a sunk cost. Setting up R&D has its own costs
associated with it. There needs to be massive initial investment that leads to negative cash
flow for a long time. But it does protect the company from the rest of the limitations of
acquiring research. All these aspects need to be carefully assessed and a pros vs. cons
assessment needs to be conducted before the make or buy decision is finalized.
The initial pool of ideas is vast and may be generic. The team will then sift through these and
locate ideas with potential or those that do not have insurmountable limitations. At this point
the team may look into existing products and assess how original a new idea is and how well
it can be developed.
Develop Ideas
Once an idea has been thoroughly researched, it may be combined with a market survey to
assess market readiness. Ideas with true potential are once again narrowed down and the
process of turning research into a marketable commodity begins.
Researchers may work closely with product developers to understand and agree on how an
idea may be turned into a practical product. As the process iterates, the prototype complexity
may start to increase and issues such as mass production and sales tactics may begin to enter
the process.
As the product takes shape, the process that began with R&D divides into relevant areas
necessary to bring the research product to the market. Regulatory aspects are assessed and
work begins to meet all the criteria for approvals and launch. The marketing function begins
developing strategies and preparing their materials while sales, pricing and distribution are
also planned for.
Launch
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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The product that started as a research question will now be ready for its biggest test, the
introduction to the market. The evaluation of the product continues at this stage and beyond,
eventually leading to possible re-designs if needed.
At any point in this process the idea may be abandoned. Its feasibility may be questioned or
the research may not reveal what the business hoped for. It is therefore important to analyze
each idea critically at every stage and not become emotionally invested in anything.
GATE 2: Prototype modeling, Testing and inspection, Report making and sign off.
GATE 3. Pilot production, vision of issue, Action plan and then R&D out.
MASS PRODUCTION
A concrete plant, also known as a batch plant or batching plant or a concrete batching plant,
is equipment that combines various ingredients to form concrete. Some of these inputs
include water, air, admixtures, sand, aggregate (rocks, gravel, etc.), fly ash, silica fume, slag,
and cement.
When the plant starts working, conveyor belt will convey the materials of the hopper until the
conveyor belt stops. Then under the control of the control instrument, it will batch the
materials in turn. When finishing, the control instrument will start the conveyor belt to
convey batching materials to next link.
PLD Concrete Batch Plant is composed of feeding system, weighing system and electric
control system.
1. Feeding system: feeding system is composed of storage hopper and feeding device. The
feeding system of Concrete Batch Plant is to feed materials into weighing hopper under the
control of electric control system.
2. Weighing system: it is the main part of Concrete Batch Plant, and consists of weighing
hopper, suspension devices, sensors weighing system and batching controller.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
3. The electric control system of concrete batching plant is regards as the core of the whole
equipment. Only a small problem can result to the machine stop running and delay the
construction period.
1. MIXER:
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
The SANY mixer with two horizontal shafts is independently developed for the high
efficiency concrete mixing equipment. This mixer is capable to produce the high quality
concrete in the shortest time. The mixing takes only 25 seconds. With the internationally
prevalent planetary gear reducer drive, the mixer presents better mixing ability, even and fast
mixing and extraordinarily high productivity. The mixer concentrates four patent
technologies, namely the malfunction diagnosis device for shaft end seal, the detection and
warning device for motor temperature, the detection and warning device for lubricating oil
temperature inside reducer and the safety device for overhaul door. Developed on the basis of
the research achievements regarding hydrodynamics and tribology, the mixing arm and the
mixing blade bear excellent mixing quality and efficiency. After a 12-second mixing, the
homogeneity of concrete reaches 85%, and it will rise to 95% in another 12- second mixing.
Special reducer of world-famous brand is adopted and featured by high reliability, long
service life, large transfer torque and outstanding power performance.
The world-renowned electric centralized instant control lubrication pump ensures the shaft
end seals filled with grease; meanwhile, 4 shaft end seals are equipped with a manual oil
filling point. The digital control processing center assures the coaxiality of the two bearing
holes of mixing tank, so that the shaft end seals are dependable. The equipment is in the
nature of low noise and low energy consumption. Made of the anti wear high chromium cast
iron and processed through the special heat treatment, the liner plate and mixing blade have
the extra long life to withstand over 60,000 tank ·times of mixing. Multiple protections on
shaft end seals efficaciously prevent leakage of concrete. The pneumatic door bears obvious
advantages, such as compact in structure, quicker than hydraulic door, free of leakage and
pollution, and centralized and convenient for maintenance. Besides, the manual discharge
door is set against unexpected electricity cutoff.
2. FEEDING SYSTEM
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
The various types of aggregate feeding systems for batching plants of different design and
manufacturers:
AGGREGATE BELT CONVEYOR : The cleaner scraper plate is made of high anti-wear
polymer material, with desirable cleaning effect and long service life. The suspension carrier
roller with automatic aligning function and the counterweighted take-up with constant tension
force are adopted, making easy adjustment for belt conveyer. The frame is designed into
standard segments, easy for installation, manufacture and conveying. The belt conveyer is
sealed with hood so as to abate pollution to environment; And the overhaul aisle and safety
armrest are equipped to facile it at etheroutine maintenance. The adjusting striker plate at
tail of the inclined belt availably regulates the fall point of aggregate and prevents deviated
running of belt Pre-designed and bolted structures enable faster erections and dismantling of
the systems. Choice of different inclinations and belt widths offers various models suitable
from 30 m3 to 160 m3 capacity batching plants.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
3. WEIGHING SYSTEM
1.
a) STRAIN GAUGE: Strain gauge load cells are the most common in industry. These
load cells are particularly stiff, have very good resonance values, and tend to have
long life cycles in application. Strain gauge load cells work on the principle that
the strain gauge (a planar resistor) deforms when the material of the load cells
deforms appropriately. Deformation of the strain gauge changes its electrical
resistance, by an amount that is proportional to the strain. The change in resistance of
the strain gauge provides an electrical value change that is calibrated to the load
placed on the load cell.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
c) HYDRAULIC LOAD CELL: The hydraulic load cell uses a conventional piston and
cylinder arrangement with the piston placed in a thin elastic diaphragm. The piston
doesn't actually come in contact with the load cell. Mechanical stops are placed to
prevent over strain of the diaphragm when the loads exceed certain limit. The load
cell is completely filled with oil. When the load is applied on the piston, the
movement of the piston and the diaphragm results in an increase of oil pressure. This
pressure is then transmitted to a hydraulic pressure gauge via a high pressure hose.
The gauge's Bourdon tube senses the pressure and registers it on the dial. Because this
sensor has no electrical components, it is ideal for use in hazardous areas. Typical
hydraulic load cell applications include tank, bin, and hopper weighing. By example,
a hydraulic load cell is immune to transient voltages (lightning) so these type of load
cells might be a more effective device in outdoor environments. This technology is
more expensive than other types of load cells. It is a more costly technology and thus
cannot effectively compete on a cost of purchase basis.
d) PNEUMATIC LOAD CELL: The Load cell is designed to automatically regulate the
balancing pressure. Air pressure is applied to one end of the diaphragm and it escapes
through the nozzle placed at the bottom of the load cell. A pressure gauge is attached with
the load cell to measure the pressure inside the cell. The deflection of the diaphragm
affects the airflow through the nozzle as well as the pressure inside the chamber.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
2. SHACKLE PIN :
The HCSS load shackle range from PT weighing systems is a superb range for suspension
weighing and for measuring tension is cables and anchorages. The SLSP is fitted to a Hi-
Load shackle with sleeve and anti-rotation plate. Available in weighing capacities 6.5t, 12t,
25t and 55t, all with industry standard shackles and high safe load the HCSS comes complete
with mating connector, requiring only the addition of cable and a display.
Fully sealed IP67 stainless steel load cell
a) Galvanized high-load shackle
b) Ideal for cranes, barges, sea anchors, load testing
c) Fully assembled, ready to install
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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management system can be formed by the lab software, finance software and other relevant
softwares. The on-site real-time fault diagnosis system enables unprofessional users to easily solve
problems that they encounter in the course of production. Additionally, the remote fault diagnosis
system can be, added in light of customers’ requirements. Precise measuring performance and high
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
reliability. The target value of sand and water can be adjusted on-line according to production
requirements. Also, it can automatically convert production value in light of the water ratio in
aggregate. The discharging order and discharging interval of aggregate can be altered randomly.
Long-distance office management and bill printing can be achieved via network. (non-standard
configuration). It is able to print all kinds of delivery notes. As the delivery notes software bears the
block-by-block function, users can adjust the software by themselves to meet different needs.
Console at Work Automatic control over the whole process from inputting, batching, to discharging,
mixing and outputting; Real-time tracking and displaying the set value, weighing value, weighing
error, and the batching data; The double display screens show the monitoring system and
management system simultaneously. With the 3D animation simulating the manufacture process, the
activities of each material door and the production progress are clear at a glance. It has the functions
to suspend the batching, feeding and outputting process. When the process fails, it will automatically
suspend it and send a message for handling the problem. The selection of job specification has
filtering function, which can display just the used job specification. The formats and items of
delivery notes can be custom-made. It can start the same production task by one key.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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We have received sbp30 dispatch list. We have added Pictorial Aid column in dispatch list.
Before After
Before After
1.Parts identification is difficult for workers. It becomes easier to identify parts.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
3.Images column was not added in dispatch list. Pictorial ad column added in dispatch list.
In Our project we have done some work study before new dispatch packing list. We have
done analysis about have much time workers required for finding parts. After calculating that,
we have started taking photos of parts.
By using work study data we have prepared new dispatch packing list. After circulating
sbp30 list to production department, it is observed that workers time has been reduced for
finding parts.
4.2.2.Future scope
2. This reduces workers time. We can utilize that time to other ways.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
After circulating SBP30 packaging list we have observe that it is working or not. After
observing for 2-3 days and interacting with workers we found that it is time reducing and
helpful for workers.
We have taken some feedback from workers for some modification in dispatch list.
4.2.4. Modifications
After getting feedback from workers following are some modifications to be done-
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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4.2.5.Calculations of SBP30-
1) The total load on the structure is calculated as:
For analysis of single aggregate bin, we have to calculate loading conditions for a single bin,
so:
4) Radius of gyration:
R = √((BH3-bh3)/12/BH-bh)
5) Reactions at columns, Rc :
Each column is supporting 2 beams at a time, so it will be loaded with the half of the load
that is transferred from short and long beam.
Rc = UDL*(Length of a long beam + Length of a short beam)/2
= UDL*(Ll+Ls)/2
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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Mb = UDL*(Ls)2/8
7) Bending stress:
So, the bending moment will produce bending stresses on the beam
σb = Mb*y/I
8) Shear force:
The beam will experience a shear force acting on the cross section,
Fs = UDL*Ls
9) Shear stress:
The shear stress acting on the beam due to uniformly distributed load is
τ = (3*Shear force on beam)/(2*Cross section)
= (3* Fs) / (2*A)
14) The yield strength (Syt) and tensile strength (Sut) values are obtained from the Indian
standard material charts.
15) The factor of safety (Fs) is considered according to the industry requirements.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
Before After
1.Parts identification is difficult for workers. It becomes easier to identify parts.
3.Images column was not added in dispatch list. Pictorial ad column added in dispatch list.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
INTERNSHIP REPORT SANY INDIA
5.
0 References-
1.Design of machine elements,V.B.Bhandari,3rd edition(page 46-141)
2.strenth of materials by R.K.Bansal,4th edition page no.(1-6, 194,
195, 235-238, 256-262, 526-530)
3. SANY parts manual for- SBP 30
SBP60
SBP90
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.
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DEPARTMENT OF RESEARCH AND DEVELOPMENT, SANY, INDIA.