Implementation of Lean in Four-Wheel Drive Front Axle Sub Assy line

This project deals with the Optimizing the process and eliminating the waste in Four Wheel Drive front axle sub assembly line. Four wheel drive sub assembly line consist of 20 different sub-assemblies are available. In which Axle housing sub assy takes more time to complete i.e. around 20.8 min which is more than TAKT time. In this most fatigue operation is Bush pressing which is done by manual hammering. Due to the manual hammering process TAKT time increases and improper bush assy into the axle housing which leads to failure in the front axle function which results in warranty claims thus increasing the external cost to the company. As the existing process is manual, the accuracy of the pressing operation is not to the standards, while pressing the bush, there is no assurance of full placement of the bush in the axle, also the fatigue is more, and there may be chances of lack of skill in the work. The interference tonnage is found to be 3 to 4 tonnes and so the intensifier unit for the appropriate pressure is to be designed initially 100% inspection is done after bush pressing to check correct position of bush assy, internal diameter of the bush using gauges, Further through PFMEA critical process are identified for failure .

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Multi-objective optimisation for battery electric vehicle powertrain topologies

Proceedings of the Institution of Mechanical Engineers Part D Journal of Automobile Engineering ◽

10.1177/0954407016671275 ◽

2016 ◽

Vol 231 (8) ◽

pp. 1046-1065 ◽

Cited By ~ 1

Author(s):

Pongpun Othaganont ◽

Francis Assadian ◽

Daniel J Auger

Keyword(s):

Energy Consumption ◽

Electric Vehicles ◽

Gear Ratio ◽

Front Axle ◽

Passenger Cars ◽

Multi Objective ◽

Component Sizing ◽

Trade Offs ◽

Wheel Drive ◽

Four Wheel Drive

Electric vehicles are becoming more popular in the market. To be competitive, manufacturers need to produce vehicles with a low energy consumption, a good range and an acceptable driving performance. These are dependent on the choice of components and the topology in which they are used. In a conventional gasoline vehicle, the powertrain topology is constrained to a few well-understood layouts; these typically consist of a single engine driving one axle or both axles through a multi-ratio gearbox. With electric vehicles, there is more flexibility, and the design space is relatively unexplored. In this paper, we evaluate several different topologies as follows: a traditional topology using a single electric motor driving a single axle with a fixed gear ratio; a topology using separate motors for the front axle and the rear axle, each with its own fixed gear ratio; a topology using in-wheel motors on a single axle; a four-wheel-drive topology using in-wheel motors on both axes. Multi-objective optimisation techniques are used to find the optimal component sizing for a given requirement set and to investigate the trade-offs between the energy consumption, the powertrain cost and the acceleration performance. The paper concludes with a discussion of the relative merits of the different topologies and their applicability to real-world passenger cars.

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