Universal joint

Universal joints are used for connecting two shafts inclined at angles to one another. For transmitting the rotary motion from the engine to the road wheels throughout the variations in position of the rear axle with respect to the gear box and chassis, universal joints are most suitable. It shows the principle of universal joint.

Detonation

It is caused by the fuel with a low octane rating and is the tendency for the fuel to autoignite in an engine combustion chamber.
The resulting knock or ping is the sound of the pistons slamming against the cylinder walls. Severe detonation can break pistons and destroy engines.
This early ignition of fuel creates a shock wave throughout the cylinder as the burning and expanding fuel air mixture collides with the piston that is still traveling towards T.D.C. (top dead center) .

Hydraulic lifting (valve)

All the engines have hydraulic valve lifters in one form or another. The most common types of engine that has them is your vehicle engine. They created to get rid of the need for combustion engines to have mechanical clearance in the engine valve train.
The reason that clearance is required is to keep the valve from being held open and destroyed as the valve train goes through its process of thermal expansion. In in effect, hydraulic valve lifters keep the valve healthy and protected from an engine normal thermal expansion process.

Differential

Differential  : When the vehicle travels around a corner, the distance traveled by the outer wheel is greater than that traveled by the inner wheel. If the wheels are mounted on dead axles so that they turn independently of each other, (the front wheels of the vehicle an ordinary vehicle) they turn at different speeds to compensate for the difference in travel. But the the wheels are positively driven by the engine to device is necessary to permit them to revolve at different speeds without interfering with the propulsion of the vehicle. To accomplish this purpose, a system of the differential gears is provided to allow the outer wheel to revolve at a higher speed than the inner wheel while turning corner. In this way, the inner wheel skidding of the which involves the sliding friction. being harmful for the life of the tyres is overcome

Construction and working :

Figure shows the construction and working of the differential mechanism.
It Consists of The Following components:
(i) Crown wheel or ring gear
(ii) Drive pinion or crown pinion.
(iii) Cage
(iv) Sun gears
(v) Planet or star pinions.
The drive pinion meshes with the crown wheel. The crown wheel is free to rotate on the rear axle half shafts whereas the sun gears are splined on the ends of each half shaft. The cage is rigidly attached to the crown wheel. The cage consists of the pin on which two planet pinions are mounted. The planet pinions are free to rotate on the pin but are meshed with the sun gears.

When the vehicle is traveling straight in the head position, the power flow from the drive pinion is shown in the Figure a. The drive pinion gives the power to the crown wheel whereas the crown wheel, cage, the pin and the planet pinions rotate the one unit. The planet pinions revolves on the pin but the axes their transmit the power to the sun gears. The sun gears and the half shafts are splined together and revolve due to the rotary motion of the planet gears to the whole .

Cone clutch

It shows the cone clutch. It consists of two cones, internal and external cone. Friction material of a wire and asbestos are used for fitting on internal cone. The cones are held together in position by a large and strong coil spring. The torque is transmitted from the engine to the flywheel and internal cone to the splined shaft when the clutch is engaged. The foot operated clutch pedal is employed to pull out the internal cone and overcome the spring pressure during disengagement of the drive. Cone clutch was used for larger and earlier type vehicles but now it has become obsolete due to certain disadvantages.

Press and Weld Operations for Front Fender (Scooter)

  

The Honda Two Wheeler press shop consists of 4 Hydraulic Presses capable of producing 350 Ton force each. A bank is fed into the first press which is draws it into the form. The next press is fitted with a shearing die which cuts the excess parts (flashes) and pressed part is finished. 

The finished part is visually inspected and buffing is done to ensure that no defect/dent reaches the weld area. The presses work in pair of two. One for drawing and second for shearing.

Then these parts are sent to the weld section where they are clamped in a jigand a robotic arm welds the two parts together. An operator then checks the weld done by the robot in order to ensure that there is no welding miss or spatter. These defects are rectified by manual welding or by buffing. The second part of the fender is welded using spot welding. The weld is then inspected again. Finally the brake wire harness is welded. Also the L stay and R stay are welded (Stay are the clips) which are used to hold the fender along with the fork assembly. A fiber tool is used to remove any seam from the external surface.The welded part is then sent for paint. Where it is painted and sent for Fork Assembly in AF-1

FRAME ASSEMBLY PROBLEMS:

1. Swing arm pressing.
2. Handle switch fitment.
3. Reducing line stoppage.
4. Race cone pressing.