TRANING REPORT

AT
SUBROS LIMITED.
(Sector 8, IMT Manesar,
Gurugram, Haryana-122051)

SUBMITTED BY:- UNDER THE GUIDANCE OF:-

DHEERAJ KUMAR PANDIT Mr. PRITAM SIR
Branch-ECE (Assistant Manager)
Roll no. – 221901403

DEPARTMENT OF
ELECTRONIC AND COMMUNICATION ENGG.
Ch. Ranbir Singh State Institute of Engineering and Technology
Jhajjar, Haryana

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 DECLARATION

I hereby Certified that the work which is being presented in the report titled
“SUMMER INTERNSHIP” by “DHEERAJ KUMAR PANDIT” in partial
fulfilment of requirements for the award of degree B.Tech. Submitted in the
department of Electronics and Communication Engineering at Ch. Ranbir Singh
State Institute of Engineering and Technology, is an authentic record of my
own carried out during a period from 17-06-2024 to 16-07-2024 under the
supervision of Mr. PRITIM SIR and Mr. KESHAV SIR.

DHEERAJ KUMAR PANDIT

Branch - ECE
Roll no.- 221901403
College- Ch. Ranbir Singh State Institute of Engineering and Technology,
Jhajjar, Haryana

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 ACKNOWLEDGEMENT

First I would like to thanks Mr. Pawan Sir, HR head, of Subros Ltd, Manesar
for giving me opportunity to do an internship within the organization.
I also would like to thanks Mr. Pritam sir, Assistant manager, of Subros Ltd,
Manesar to guide to do an internship within the organisation.
I also would like to thanks Mr. Keshav sir of Subros Ltd to guide to do an
internship within the organisation.
I also would like to thank all the people that work along with me in Subros
Ltd, imt manesar, Gurgaon, with there patience and openness they created an
enjoyable working environment.

It is indeed with great sense of pleasure and immense sense of gratitude that I
acknowledge the help of these individuals.

I am highly indebted to Director Dr Ravin Ahuja, for facilities provided to

accomplish this internship.

I would like to thank my head of department Prof. Sachin Dahiya for his
constructive criticism throughout my internship.

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 INTRODUCTION
About SUBROS LIMITED :-

Subros Limited,
founded in 1985 as a
joint venture public
limited company with
36.79% ownership by the
Indian promoters and
20% ownership by Denso
Corporation, Japan &
11.96% ownership by
Suzuki Motor
Corporation, Japan, is
the leading manufacturer of thermal products for automotive applications in
India, in technical collaboration with Denso.

The company has grown from a capacity of 15,000 AC units in 1985

comprising of largely an assembly operation, into the largest and only
integrated manufacturing unit in India for auto air conditioning systems.
Subros manufactures compressors, condensers, heat exchangers and all
connecting elements required to complete AC loop and caters to all
segments viz. passenger vehicles, buses, trucks, refrigeration transport, off-
roaders, residential air conditioners & railways.

Subros has manufacturing plants at Noida , Manesar, Pune, Chennai ,

Nalagarh and Karsanpura with an annual capacity of 1.5 Million AC Kits per
annum beside a well equipped R&D Center and Tool Room at Noida.

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 Table Of Content

S. no TOPIC Page No.

1. Cover Page …………………1
2. Declaration …………………2
3. Acknowledgement ....………………3
4. Introduction ….……………...4
5. Overview of Automotive A.C System …………………6
6. Literature Review …………………7
7. Basic Principles of Air- Conditioning ..………………..7
8. HVAC System ….………………8
9. Working of Car AC .………………...9
10. HVAC line process ………………...10
11. 7 QC tools ...……………….14
12. Cycle time study ………………..16
13. Ladder logic ………………..18
14. Working of ladder logic ……………….19
15. Conclusion ………………20

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 OVERVIEW OF AUTOMOTIVE A.C SYSTEM

Automotive air conditioning systems operate under variable loads in order to provide
passengers’ comfort under wide outside temperature conditions. Under medium operating
conditions, temperature stratification in the air stream at the exit of the evaporator is
observed, which might lead to passengers’ discomfort. The cause of this problem is uneven
feeding of the evaporator’s parallel channels with the refrigerant liquid phase from the two
phase mixture stream in the header. Channels with a lower inlet liquid flow rate are dried-
out and the hotter outside air stream could not be effectively cooled only by the remaining
refrigerant vapour flow.

HISTORY
The history of automotive air conditioning started in 1933 in New York, when the luxury
car manufacturer offered installing an air conditioning unit with a heater. At that time the
automobile has to be shipped to their workshop and was shipped back to local vendors after
installation. Later in 1953, Chrysler Imperial was the first production car to offer a modern
automotive air conditioning system as an option with single switch operation.
By the 20th century, the demand for AC units in cars increased rapidly and now all the
manufacturers provide AC units as standard facilities. Initially, its purpose was purely
luxury,
but now people use it as a safeguard against heat, dust, cold and smoke.
 The 1940 Packard was the first car to offer factory-installed air-conditioning.
 By 1969, more than half of all new cars sold were equipped with A/C.
 Some brands affixed window decals to promote their air-conditioned automobiles.
 In a 1971 front-page story, the New York Times implicated air-conditioning in the
death of the convertible, postulating that: "In the age of air-conditioning, real air
has lost its value."
 After the freon used in A/C units was blamed for depleting the ozone layer
automakers were required to switch from R12 to the less harmful R134a refrigerant by
1996.
 Volkswagen calls its manual air-conditioning system "Climatic;" automatic A/C is
"Climatronic."
 Today, more than 99 percent of all new cars are air-conditioned.
 Accent and Elantra; Jeep Wrangler; Kia Forte and Rio; Mazda 3; Mitsubishi
 Testing by Consumer Reports found that using a car's air-conditioner resulted in a
more than 3-mpg loss at highway speeds. Driving with the windows open had no
measurable effect on fuel economy.

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 LITERATURE REVIEW

This paper studies the dynamics of temperature and humidity of atmosphere in a car
compartment by the concept of enthalpy in analysing the heat exchange involved. With heat
change decomposed into sensible heat and latent heat, we are able to derive dynamics of
temperature and humidity of the car compartment after taking into account of the difference
of apparatus sensible heat factor and room sensible heat factor. These two formulas are used
in conjunction with two control strategies on flow rates of supply air to simulate the
intended controlled car compartment at constant enthalpy and of constant temperature. The
contribution of this work is to provide a framework for automobile air-conditioning analysis
and simulation.

Automobile air conditioning systems cool the occupants of a vehicle in hot weather.
Automotive air conditioning is the process by which the air is cooled and cleaned, the
humidity lowered and the air circulated. The quantity and quality of the air is also controlled.
Under ideal conditions the air-conditioning system can be expected to accomplish all these
tasks at the same time.

The air-conditioning system in modern vehicles is designed to lower the temperature to

therefore assess the system’s performance. The manifold and hand valves allow the system to
be purged of refrigerant, evacuated of air and moisture, and recharged with new refrigerant.
Most modern gauge sets use two gauges, but some air- conditioning systems that use a
pressure control regulator for the evaporator may require a second low-pressure gauge.

BASIC PRINCIPLES OF AIR-CONDITIONING

The basic principle behind the operation of an HVAC unit is conduction and convection.
Heat is transferred from a low-temperature region to a high-temperature region in the
vehicle, due to the pressure difference. This process of heat transfer is called Refrigeration.

Air conditioners use a fluid, called refrigerant, that absorbs heat when in a liquid state and
in the process becomes a gas (evaporate). The fluids boil at different temperatures depending
on the pressure that it is under. To increase or decrease the boiling point of a substance, we
must alter the pressure on the substance. Increasing the pressure increases the boiling point.
To decrease the boiling point, decrease the pressure. This extremely simple principle is the
basis of all air conditioning and refrigeration systems, from home refrigerators and window
A/C units to the largest industrial applications.

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 HVAC System

The acronym HVAC stands for Heating, Ventilation and Air conditioning. The automobile
HVAC system can be thought of as a climate control system having three subsystems:

H Heating
V Ventilation
AC Air conditioning

 Heating
The purpose of the heating system is to add heat in the winters. Heating the passenger
compartment is a comparatively easy task, since there is such an abundant supply of
waste heat produced in the engine. This waste heat is expelled into the exhaust system
and absorbed into the engine parts and oil. The heat that is absorbed by the engine
parts must be removed, or the engine would fail in minutes. This is the job of the
engine cooling system. We can tap into this heat source to provide heat to the
passenger compartment.

 Ventilation
The purpose of ventilation air is to keep the car interior fresh, replace stale air, prevent
carbon monoxide from the exhaust, and create positive cabin pressure. The air ducts
allow outside air into the interior via cabin filter to clean the air by trapping dust and
pollen particles before they enter the passenger compartment.

 The automobile compartment is heated due to several factors such as:

a. Higher temperature of outside air
b. Solar radiation
c. Engine/exhaust heat

 The amount of heat absorbed is dependent upon:

a. Automobile insulation
b. Position of sun and intensity of solar radiation
c. Variation of light and shadow
d. Vehicle colour
e. Tinted glass
f. Vehicle speed
g. Wind direction and velocity

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 WORKING OF CAR AC
The working of an automobile AC system is also almost the same as the normal AC but
little difference is there-
1. The evaporator which is another heat exchanger used in AC takes heat from the
passenger’s cabin which in turn converts the liquid refrigerant flowing through the
evaporator
into vapours which in turn provide cooling with the help of the blower fan.
2. This vapor having high-temperature low pressure is then sent to the compressor which
in turn increases the pressure over the vapours and converts the vapor refrigerant into a
liquid
refrigerant. Now the refrigerant is in high pressure and high-temperature liquid state.
3. This high-pressure high-temperature liquid refrigerant is then sent to the condenser
which lowers the temperature of this refrigerant by forced convection provided by the
radiator fan or by separated fan used. Now the refrigerant is having a low temperature
but the pressure of the liquid is almost the same.
4. This high pressure and the low-temperature refrigerant is then sent to expansion valve
which in turn releases the pressure from the refrigerant and convert it into its original
state.
5. This refrigerant is then again sent to the evaporator for the further cycle.

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 HVAC LINE PROCESS
MODEL NAME – YCA, YJC

 FAN PRESSING
Motor Fan Loading and Pressing Machines play a pivotal role in optimizing
manufacturing processes, especially when it comes to assembling components like
fans onto motors. These machines automate what used to be manual tasks,
streamlining work lows and enhancing ef iciency.
These specialized machines are designed to automate the process of loading and
pressing fan components onto motors in various industrial applications.

 FAN BALANCING
Fan balancing in an HVAC system is crucial for ensuring ef icient operation and
comfort. Here are the key points:
Fan balancing helps to distribute air evenly throughout the system, reducing noise
and vibration, and preventing wear and tear on the fan and motor.

 CASE OPENING /LOCK CLAMP ASSY

 THERMISTOR ASSY
The thermistor is a type of temperature sensor that measures the ambient
temperature and sends this information to the HVAC control system. This helps in
maintaining the desired temperature by adjusting the cooling or heating output
accordingly.
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 Importance:
 A properly functioning thermistor ensures ef icient operation of the HVAC
system. If the thermistor fails, it can lead to issues like improper cooling or
heating, as the system won’t be able to accurately regulate the temperature.

 HEATER CORE CAULKING

 HTR & EVAP. CORE ASS.
In HVAC systems, HTR stands for Heater Core, and EVAP stands for Evaporator
Core. Both components are essential for the heating and cooling functions of the
system:
Heater Core (HTR):
Function: The heater core is responsible for heating the air that is blown into the
cabin. It works by transferring heat from the engine’s coolant to the air passing
through it.
Evaporator Core (EVAP):
Function: The evaporator core cools the air by absorbing heat from the air passing
through it. The refrigerant inside the evaporator absorbs this heat and evaporates,
cooling the air.

Evaporator Core

 ROTOR DOOR ASSY

 ROTOR DOOR & UPPER CASE ASSY
 SIX SXREW TIGHT

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 LEVER ASSY
In an HVAC system, the lever assembly (LEVER ASSY) is typically associated with
controlling air low through the ducts.
The lever assembly is used to adjust dampers within the ductwork. These dampers
control the low of air to different parts of the building, allowing for balanced and
ef icient distribution of heated or cooled air.

Importance:
 Proper adjustment of these levers ensures that all areas receive the
appropriate amount of air, improving comfort and system ef iciency.

 BLOWER MOTOR ASSY AND RESISTOR

 EXPANSION VALUE ASS
In HVAC systems, the expansion valve plays a crucial role in regulating the low of
refrigerant. It reduces the pressure and temperature of the refrigerant as it moves
from the condenser to the evaporator, allowing it to turn into a cool, low-pressure
liquid. This process is essential for ef icient heat transfer and cooling.

 FOOD DUCT
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 ROTORY DOOR & LEVER ASSY
 FR DUCT ASS.
 DLT& ALT
Air Leakage Test in HVAC
Air leakage tests are essential for ensuring the ef iciency and performance of HVAC
systems.
Purpose:
 To identify and measure the amount of air escaping from the ductwork.
 To ensure that the HVAC system is operating ef iciently and not wasting
energy.

Differential Leakage Test in HVAC

Differential leakage tests are used to detect and measure leaks in HVAC systems by
comparing pressure differences.
Purpose:
 To accurately measure small leaks that might not be detected by other
methods.
 To ensure the integrity of the HVAC system.

 VIBRATION
Vibration testing is a crucial part of the HVAC manufacturing process to ensure the
reliability and longevity of the equipment.
Purpose:
 To identify and mitigate potential issues caused by vibrations in HVAC
systems.
 To ensure that the equipment operates smoothly and quietly, reducing wear
and tear on components.

 TEST BENCH
 ROBO INSPECTION
Robo inspection in HVAC AC manufacturing involves using advanced robotic
systems to inspect and ensure the quality and ef iciency of HVAC units.
Purpose:
 To enhance the accuracy and ef iciency of inspections.
 To identify defects or issues that might not be visible to the human eye.

 FINAL INSPECTION

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 7 QC TOOLS
The 7 QC Tools, also known as the “Seven Basic Quality Tools”, are essential
for process improvement and quality management. These tools help analyse
and solve work-related problems effectively. Let's explore them brie ly:

 Check Sheet: Used for collecting, recording, and analysing data. It

provides a basis for further action in problem-solving processes.

 Fishbone Diagram (Cause-and-Effect or Ishikawa Diagram): Helps

identify potential causes contributing to a problem or effect. Factors like
Man, Machine, Method, Material, Measurement, and Environment are
considered during brainstorming sessions.

 Histogram: A bar graph representing frequency distributions of data. It's

widely used in Six Sigma problem-solving processes. It tells you how
often each different value in a set of data shows up.

 Pareto Chart: Prioritizes signi icant problems by narrowing down the

problem area. It follows the 80-20 rule, where 80% of problems are
caused by 20% of major factors (Vital Few). It’s like a bar chart with a
data-driven twist.

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 Control Chart: Monitors process performance over time, detecting
variations and ensuring stability. Historical control limits are the
Sherlock Holmes here.

 Scatter Diagram: Helps identify relationships between two variables,

showing patterns or correlations.

 Strati ication Diagram (or Process Flowchart): Organizes data into

categories for better analysis. It’s like separating data gathered from
various sources so patterns emerge. Some lists swap this for a lowchart
or run chart.

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 CLOCK TIME STUDY
Car AC systems involve intricate components like compressors, condensers, evaporators,
and fans. Ensuring their efficient assembly is crucial for optimal performance.

In car AC manufacturing:
 Cycle Time (C.T.): Think of it as the time it takes to assemble one unit (e.g., a car AC
system).
 Study: Analysing this time—how long each step takes, where bottlenecks occur, and
how to optimize it.

PARTS MANUFATURED IN 1 SHIFT :-

 Total Working Minutes in 1 shift = 510 Minutes

 Tea Break and Lunch Break time = 50 Minutes
 Total Manufacturing Time = (510-50) Minutes
= 460 Minutes = 27,600 Seconds
 Time Taken for Manufacturing One Part = 40 Seconds
 NO. of Parts Manufactured in 1 shit = 27,600/40
= 690 Parts

CT STUDY OF HVAC LINE

PROCESS NAME AVERAGE TIME TAKEN
(in sec)
 Fan pressing 34.45
 Fan balancing 24.71
 Case opening/lock clamp assy. 17.85
 Thermistor ass. 27.16
 Htr core caulking 24.29
 Htr & evapourator core ass. 35.69
 Rotor door ass. 26.48
 Rotor door and upper cae ass. 14.26
 Six screw tight 19.70
 Lever ass. 22.89
 Blower motor ass. And resistor 20.35

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 Expansion valve ass. 27.37
 Food duct 12.56
 Rotory door & lever ass. 17.71
 FR duct assembly 28.06
 DLT &ALT 39.09
 Vibration 23.75
 Holder ilter ass. & thread checking 29.03
 Test bench 22.71
 Robo inspection 34.58
 Final jauging 19.93
 Final inspection 30.19

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 LADDER LOGIC
Ladder logic is basically a program that is represented by a graphical diagram,
which is based on a circuit diagram of relay logic. This program contains two
vertical lines called ‘rails’ and horizontal lines called ‘rungs’ which makes it
look like a perfect ladder. The graphical representation of the ladder logic
program is called as Ladder Logic diagram (LLD).

Ladder Logic Components :-

 Rail and Rung:-
Vertical lines are called rails and the horizontal lines are called rungs.
 Concept of NO/NC switch:-
NO (Normally Open) and NC (Normally Closed) are used to represent the state
of current low or contact in electronics circuit, which is also used is PLC ladder
logic programming. These terms de ine whether the switch is open or closed.
 Normally Open:-
 In ladder logic diagrams, a normally open contact is shown as an open gap
and becomes a solid line when activated.
 Normally Closed:-
 In ladder logic diagrams, it’s represented as a solid line, becoming an open
gap when activated.

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  Output/Coil:-
Output devices are such as motor, valve, indicator, lights etc. but in
LLD it is represented by vertical line with a label representing the output
device.

Working of Ladder Logic:-

 Firstly two rails are taken, and then a rungs. The rails will work here as
a supply of source or current supply.
 The left rail is connected to the input switch and the right rail in
connected to the output coil. and the switch and coils are connected
through a wire.
 Then add input switch, it can be NO or NC depending on the logic to
be created. Switches should be placed at the left side rail. The
number of switch and placement of it can vary depending on the logic
is creating.
 For creating this logic, we create truth table, and according to that, put
the switch, if input is ‘0’ , generally NO switch is used, but NC switch
can also be used, but in that case we have to make it opened, or false.
For ‘1’ input, NC switches are used, but same like previous NO switch
can also be used.
 An output coil should be connected to the right side rails.

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 CONCLUSION

In this project, we have tried to consolidate the idea of the Automotive Air
conditioning from its conceptualization to its current status and future
implications. The Automotive Air conditioning outweighs the current modes
of conditioning in several ways, making it a ground-breaking application. It
has a clear edge over present conditioning, travel and automobiles as it causes
very less pollution.
It is thus safe to say that if the Air Conditioning in automobiles are
bene icial, it will lead to a decline in the previous superior mode of
conditioning. And similar to the concept of general air conditioning system.
Not only is the Automotive Air conditioning much cheaper but also
overcomes most of the disadvantages of general air conditioners. Initially, the
fuel prices might prevent a wide clientele, but over time, these issues can be
ixed and the Air conditioning System is our next big step in the automobile
industry.

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