UNIVERSITY COLLEGE OF ENGINEERING-NAGERCOIL

ANNA UNIVERSITY CHENNAI-600025

INTERNSHIP REPORT
SUBMITTED BY
DHANUSH M
REG No:962821114014
ME 3511-Summer Internship (Two Weeks)
In partial fulfillment of the requirements for the award of the Degree
of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

July/November-2023
 STUDENT PROFILE

Submitted by : DHANUSH M

Semester : FIFTH

Department : Mechanical Engineering

Course Title : ME3511-Summer Internship

Industrial : Tamil Nadu State Transport

Department Corporation Ltd Tirunelveli
Ranithotamworkshop,Nagercoil.
Duration :23.06.2023 To 10.07.2023
(15 days)
 FACTORY PROFILE

Name Tamil Nadu State Transport

Corporation Ltd (Tirunelveli),
Ranithotamworkshop,
Nagercoil Region.

Status Tamil Nadu State Government.

Location Ranithottam, Nesamony nagar,

Nagercoil-629001.

Head office Tamil Nadu State Transport

Corporation Ltd. TIRUNELVELI.
ACKNOWLEDGEMNET
All praise, glory and honour be to the Lard Almighty,
source of all knowledge for his gracious presence and guidance
that enabled us to work with effort and complete the summer
internship in time.
It is indeed a great pleasure to express our sincere thanks
to [Link] ,M.E., Ph.D., Dean of UCEN for his sincere
guidance and encouragement in all aspects of the summer
internship.
We also convey our heartful thanks to
[Link],[Link]., Ph.D., Head of the Department,
Mechanical Engineering and our summer internship faculty
Co-ordinator for his encouragement and support to complete
our summer internship.
We wish to convey our sincere thanks to all the
teaching and non-teaching staffs of Mechanical Engineering
Department. Our heartfelt gratitude and thanks to our parents
and friends for their perceptual support.
 Table of Content

[Link] TITLES

1. INTRODUCTION OF THE INDUSTRY

2. DAILY PROGRESS AND DUTY IN

INTERNSHIP

3. SWOT ANALYSIS

4. LEARNING OUTCOMES

5. CONCLUSION
INTRODUCTION OF THE INDUSTRY

Tamil Nadu State Transport Corporation Ltd. – (TNSTC) is a

government owned public transport bus operator in Tamil
Nadu.
It operates Intercity bus services to cities within Tamil Nadu,
and from Tamil Nadu to its neighbouring states. It also operates
town busses from major cities and towns of Tamil Nadu to its
neighbourhoods, with the exception of Chennai, where the
public bus service is operated by MTC, a subsidiary of TNSTC. It
is the second largest road transport corporation in India, and it
is one of the largest road transport corporations in the world.

Ranithottam Workshop It is an important workshop in

Kanyakumari district which is a check point for buses and
stopping point for all buses Three types of bus are repaired
here like
 Town Bus
 Deluxe Bus
 AC Bus
The three most important sections under the workshop here
are
 Recondition Unit
 Tyre reconditioning
 Cage Building
This Ranithottam Workshop is a workshop under Nagercoil
Zone Tirunelveli corporation Limited.
where the work is done 24 hours a day with 3 shifts.
DAILY PROGRESS IN INTERNSHIP

Day 1 Basic training

Day 2 Air cleaner section, Tie rod section

Day 3 Engine section

Day 4 propeller shaft section, Gearbox section

Day 5 Electrical section ,Air compressor section

Day 6 Radiator section, seating section

Day 7 clutch section, store Section

Day 8. Front axle section

Day 9 Rear axle section

Day 10 Maintenance machinary section, welding section

Day 11 Brake chamber section

Day 12 cage building section

Day 13 Fuel injection pump section

Day 14 painting section

Day 15 Tyre reconditioning section

Day 1: Basic training
Learning about various section in the industry
Organization chart

The division workshop where I trained is the division where the

damaged buses are repaired and the valis are made functional
[Link] workshop has 3 very important divisions.
1. Reconditioning section
2. Tyre Refurbishment Section
3. Cage building section
[Link] section
Here they repair damaged or malfunctioning parts and make them
work smoothly again.
2. Tyre Refurbishment Section
The tyre retreading segment is a segment that processes old tires and
reuses them.
[Link] building section
A cage building section refers to a specific area within a facility where
specialized bus cages are constructed. A bus cage is an enclosure or
compartment designed to securely hold buses or other large vehicles.
These cages are typically made from steel or other sturdy materials and
are used for various purposes such as storage, maintenance, repairs, or
security.

Three types of buses such as Town Bus, AC Bus, Deluxe bus are being
repaired in this workshop.
The air cleaner is an essential component of the vehicle's engine
system, responsible for filtering out dust, pollutants, and other
contaminants from the air before it enters the engine.
Day2: Air cleaner section, Thyroid section
Air cleaner section:
Purpose:
Use:
The attached air filters capture pollutants, ensuring that clean air is
released into the atmosphere. The air purifiers in these buses utilize
high-efficiency particulate absorbing filters and activated carbon filters
to reduce levels of polluting gases and suspended particles by
approximately 90%.
Tie rod section:
Purpose:
Tie rods and tie rod end ball joints are what connect the steering rack
gearbox to the steering knuckles so the turning input from the driver
makes its way to the wheels. Tie rods thread onto the steering rack to
also allow for steering alignment adjustments to be made.
Use
Serving as the pivot point between the steering rack, steering arm and
steering wheel, tie rods not only help move your wheels when you
steer but they make turning possible.
DAY 3: Engine section

This section is the heart of the reconditioning unit. Here engines, which
has some major problems will be reconditioned and used again. For dis
mantling an engine the time allotted is 8hrs for assembling an engine the
allotted time is 24hrs, the main problem raised on engine section is
wearing of piston. Only experienced mechanics will be allowed to work
in engine section. Once the engine is serviced it is allowed to run on a
servise desk where the problems are verified.

A 4-stroke diesel engine is a type of internal combustion engine that

operates on the Diesel cycle. It is commonly used in heavy-duty
vehicles, such as trucks, buses, and construction equipment, as well as
in many stationary power applications.
The 4-stroke diesel engine follows a cycle consisting of four strokes:
intake, compression, combustion, and exhaust. Here is a brief
explanation of each stroke:

 [Link] Stroke: In this stroke, the piston moves downward,

allowing the intake valve to open. As the piston moves downward,
it creates a vacuum that draws in air into the cylinder. The air is
then mixed with fuel injected into the cylinder.
 [Link] Stroke: After the intake stroke, the piston moves
upward, compressing the air-fuel mixture inside the cylinder. The
compression causes an increase in pressure and temperature,
making the mixture highly combustible.
 [Link] Stroke: At the top of the compression stroke, when
the piston is near the end of its upward movement, the fuel is
 ignited by a spark plug. This ignition causes a rapid combustion,
with the expanding gases pushing the piston down with significant
force.
 [Link] Stroke: As the piston reaches the bottom of the
combustion stroke, the exhaust valve opens, allowing the
combustion gases to escape from the cylinder. The piston then
moves back up, pushing out the remaining exhaust gases.

The 4-stroke diesel engine differs from a 4-stroke gasoline engine

primarily in the fuel injection and ignition process. In a diesel engine,
fuel is injected into the cylinder under high pressure using a fuel
injector, while a spark plug is used in gasoline engines to ignite the air-
fuel mixture.
Overall, the 4-stroke diesel engine is known for its efficient fuel
consumption, high torque output, and durability, making it a popular
choice for heavy-duty applications.
Engine system’s :
 Air system
 Breaking system
 Lubrication system
 Electrical system
 Fuel system
Parts of engine
 Engine block
 Cylinder
 Piston
 Connecting rod
  Crankshaft
 Flywheel
Three types of engine used in this workshop
 BS2 R/C ENGINE
 BS3 R/C ENGINE
 BS4 R/C ENGINE (common rail)
The workshop BS2&BS3 engine repair system only carried out not then
worked BS4 . So for BS4 engine mechanism is not available in this
workshop .
DAY4: propeller shaft section, Gearbox section.
Propeller shaft section:
The drive shaft also called propeller shaft. Propeller shaft is a
component of the drive train in a vehicle, with the purpose of delivering
torque from the transmission to the differential, which then transmits
this torque to the wheels in order to move the bus.

In a bus, the propeller shaft serves the same purpose as in other

vehicles, which is to transmit torque from the engine to the wheels
Bus propeller shafts are usually made of high-strength steel to handle
the increased torque and load requirements. They may also have
additional support and reinforcement to ensure durability and minimize
vibrations.

The propeller shaft in a bus is connected to the transmission or gearbox

at one end and the differential or axle assembly at the other end. It
transfers power from the engine to the wheels, allowing the bus to
move forward or backward.

Regular maintenance and inspection of the bus propeller shaft are

crucial to ensure its proper functioning and to prevent issues such as
excessive wear, misalignment, or failure. This can include checking for
any signs of damage, lubricating the universal joints, and ensuring
proper alignment and balance.
Gearbox section :

The gearbox in a bus, also known as the transmission, is responsible for

controlling the power and torque from the engine and transmitting it to
the wheels at different speeds. It allows the driver to change gears to
match the desired speed and driving conditions.

In a bus, the gearbox is typically a manual transmission, although some

buses may have automatic transmissions. Manual transmissions require
the driver to manually shift gears using a gear lever, while automatic
transmissions shift gears automatically based on the vehicle’s speed
and load.
The gearbox in a bus is designed to handle the high torque and load
requirements of the vehicle. It consists of various gears, shafts, and
synchronizers that work together to transmit power efficiently and
smoothly. The driver can select different gears, such as first, second,
third, etc., depending on the speed and load conditions.

Regular maintenance and inspection of the bus gearbox are important

to ensure its proper functioning and longevity. This can include
checking the fluid levels, inspecting for any leaks or damage, and
replacing worn-out components. Proper gear shifting techniques and
avoiding excessive load or strain on the transmission can also help
prolong its lifespan.
DAY5:Electrical section ,Air compressor section
Electrical section:

The electrical section of a bus refers to the components and systems

that are responsible for generating, distributing, and controlling
electrical power throughout the vehicle. Here are some key aspects of
the bus electrical section:

Power Generation: The bus electrical system typically includes an

alternator or generator that converts mechanical energy from the
engine into electrical energy. This electrical power is used to run
various electrical systems and devices on the bus.
Wiring and Cables: The electrical section consists of a network of wires
and cables that connect various electrical components and systems
throughout the bus. These wiring systems carry electrical power from
the source to the destination, allowing for the operation of lights, audio
systems, air conditioning, and other electrical devices.
Fuse Box: The bus electrical system incorporates a fuse box or a set of
fuses and relays. These components protect the system from electrical
faults and overloads by interrupting the electrical circuit whenever
there is a surge in current or a short circuit.
Switches and Controls: The bus electrical section includes various
switches and controls that are used to operate different electrical
systems, such as lighting, HVAC (Heating, Ventilation, and Air
Conditioning), and multimedia systems. These switches and controls
allow the driver or passengers to turn on or off specific electrical
functions as needed.
Dashboard Instruments: The instrument panel or dashboard contains
various gauges, displays, and indicators that provide information about
the status and performance of the bus's electrical and mechanical
systems. These instruments include the speedometer, fuel gauge,
engine temperature indicator, battery voltage, and warning lights for
system malfunctions or faults.
Safety Systems: The bus electrical section encompasses safety systems
such as lighting, signaling, and horn systems. These systems ensure
visibility and communication on the road, allowing the bus to operate
safely, signal intentions, and warn other drivers or pedestrians.

Proper maintenance and inspection of the bus electrical section are

essential to ensure the reliable operation of electrical systems.
Checking for loose connections, damaged wiring, or faulty components
can help prevent electrical failures and ensure the safety and efficiency
of the bus.

Starter:
The bus starter, also known as the starting motor, is an essential
component of the bus’s electrical system and engine starting process.
Its main function is to provide the initial mechanical rotation to the
engine’s crankshaft, enabling the combustion process to begin.
Function: The primary function of the bus starter is to convert electrical
energy from the battery into mechanical energy, which is then used to
crank the engine’s flywheel. This mechanical rotation initiates the
engine’s combustion cycle and allows it to start running.
Electric Motor: The bus starter consists of an electric motor, usually
powered by a 12V or 24V DC electrical system. The motor receives
electrical power from the battery and is activated by the ignition
switch.
Construction: The starter motor is typically constructed with a heavy-
duty, rugged design to withstand the high torque and demanding
starting conditions of a bus engine. It is composed of various
components, including a motor housing, solenoid, armature,
commutator, brushes, and a pinion gear.
Solenoid: The starter solenoid is an integral part of the starter motor. It
serves to engage the pinion gear with the engine’s flywheel when the
ignition switch is turned on. The solenoid also acts as a relay to initiate
the flow of electrical current to the starter motor.
Pinion Gear: The pinion gear is a small gear on the end of the starter
motor shaft. When the solenoid engages, it pushes the pinion gear
forward to mesh with the engine’s flywheel. This connection allows the
rotation of the starter motor to transfer to the engine, cranking it and
initiating the combustion process.
Safety Features: Bus starters often include safety features to prevent
damage to the starter motor or engine. These features may include
overload protection, built-in thermal protection, and a magnetic switch
to prevent engaging the starter while the engine is running.
Maintenance: Regular maintenance and inspection of the starter motor
are essential to ensure its proper functioning. This includes checking
the electrical connections, ensuring the solenoid is engaging properly,
and inspecting the brushes and commutator for wear.
Alternator:
The bus alternator, also referred to as the charging alternator, is a vital
component of the bus's electrical system. Its primary function is to
generate electrical power and recharge the battery while the engine is
running. Here are some key details and functions of a bus alternator:
Function: The main function of the bus alternator is to convert
mechanical energy from the engine into electrical energy. It does this
by using the rotational motion of the engine's crankshaft to spin a set
of magnets inside its stator. This generates an alternating current (AC),
which is then converted into direct current (DC) by a rectifier.
Power Generation and Battery Charging: The alternator is responsible
for generating electrical power to run the various electrical systems and
accessories of the bus, including lights, air conditioning, audio systems,
and other onboard equipment. It also replenishes the charge in the
battery, keeping it in optimal condition.
Voltage Regulation: The bus alternator employs a voltage regulator to
maintain a stable output voltage. This regulator ensures that the
electrical system operates at the correct voltage to prevent damage to
components and ensure efficient charging of the battery.
Construction: The bus alternator consists of several key components,
including the rotor, stator, rectifier, diodes, voltage regulator, and
pulley. The rotor is the rotating part, connected to the engine's
crankshaft via a belt or pulley. The stator surrounds the rotor and
contains the windings that generate the electrical current. The rectifier
converts the AC current into DC, and the diodes ensure that the current
flows in one direction.
Output Capacity: The output capacity of the bus alternator can vary
depending on the electrical load requirements of the bus. It is typically
designed to provide sufficient power to run all necessary electrical
systems and accessories, while also charging the battery.
Maintenance: Regular maintenance of the bus alternator is essential to
ensure its proper functioning. This includes checking the belt tension,
inspecting the electrical connections for corrosion or damage, and
ensuring the voltage regulator is functioning correctly.
Upgraded Alternators: In certain cases, buses may be fitted with
upgraded alternators to handle higher electrical loads, such as those
associated with additional lighting, multimedia systems, or other
power-consuming equipment.
Battery ssection

Battery: The electrical section includes a battery that serves as a

storage unit for electrical energy generated by the alternator. The
battery provides power to start the engine, and it also supplies power
during startup and when the engine is not running.
Aircompresser section:
The air compressor section of a bus refers to the components and
systems that are responsible for generating compressed air used in
various systems and components on the bus. Here are some key aspects
of the bus air compressor section:

Air Compressor: The air compressor is the main component of the air
compressor section. It is typically driven by the engine and is responsible
for compressing air from the atmosphere and delivering it to the bus’s
air system. The air compressor is usually a reciprocating or rotary type
compressor.
Air Storage Tanks: The compressed air generated by the air compressor
is stored in air storage tanks. These tanks help to maintain a constant
supply of compressed air to various systems and components on the bus.
The size and number of air storage tanks may vary depending on the
bus’s requirements.
Pressure Regulator: The air compressor section may include a pressure
regulator, which is used to regulate the pressure of the compressed air
delivered by the air compressor. It ensures that the pressure is
maintained within the specified range for optimal operation of the air-
powered systems.
Air Dryer: To remove moisture from the compressed air and prevent
damage to the air system, an air dryer is often included in the air
compressor section. The air dryer helps to remove water vapor and
moisture from the compressed air before it is supplied to the bus’s air-
powered systems.
Air Brake System: One of the primary uses of the compressed air from
the air compressor section is in the bus’s air brake system. Compressed
air is utilized to activate the air brakes, providing the necessary force to
stop the bus effectively.
Suspension System: Compressed air from the air compressor section is
often employed in the bus’s air suspension system. It helps to maintain
proper suspension levels and provides a comfortable ride by adjusting
the air pressure in the suspension components.
Pneumatic Systems: Compressed air may also be utilized in various other
pneumatic systems and components on the bus, such as air-operated
doors, air-powered accessories, and air suspension leveling systems.
Proper maintenance and inspection of the bus air compressor section are
essential to ensure reliable operation and optimal performance. Regular
checks for air leaks, proper lubrication, and the condition of air filters are
necessary to maintain the efficiency of the air compressor and other
components in the air system. Additionally, monitoring the pressure and
quality of compressed air helps to prevent malfunctions and ensure the
safe operation of the bus’s pneumatic systems.
DAY 6: Radiator section, seating section
Radiator section
A radiator is the key component of the engine’s cooling system. Its
main role is to disperse a mix of antifreeze and water throughout its
fins, which releases some of the engine’s heat while taking in cool air
before continuing to pass the rest of the engine.
 BS2 radiator -Metal coolant tank
 BS3radiator – plastic coolant tank
 BS4 radiator – plastic coolant tank
One Radiator 5liter capacity.

Seating section:
The seating section of a bus refers to the arrangement and components
related to the seats provided for passengers. Here are some key aspects
of the bus seating section:
Seats: The main component of the seating section is the seats
themselves. Bus seats are designed to provide comfort and safety to
passengers during their journey. They are typically equipped with
cushioning, backrests, and armrests, and are often covered with durable
upholstery material for easy maintenance.
DAY 7 : Clutch section, Store section

Clutch section:
The clutch plate section of a bus refers to the and systems that make up
the clutch assembly, which is responsible for transmitting power from
the engine to the bus’s transmission. Here are some key aspects of the
bus clutch plate section:

Clutch Plate: The clutch plate, also known as a friction disc or clutch disc,
is a key component in the clutch assembly. It is a flat, circular metal plate
with friction material bonded to its surface. The clutch plate is positioned
between the flywheel (connected to the engine) and the pressure plate
(connected to the transmission).
Friction Material: The friction material on the clutch plate provides the
necessary grip and friction against the pressure plate and flywheel to
engage and disengage the clutch. It is typically made of a high-friction
material such as organic, ceramic, or metallic composite.
Pressure Plate: The pressure plate is another critical component of the
clutch assembly. It is a circular metal plate that exerts pressure on the
clutch plate, compressing it against the flywheel. The pressure plate is
connected to the clutch mechanism and is responsible for controlling the
engagement and disengagement of the clutch.
Clutch Cover: The clutch cover, also called the clutch housing or clutch
casing, encloses the clutch assembly and provides protection and
support to the clutch components. It is typically made of a durable metal
material and is bolted or secured to the engine or transmission housing.
Clutch Release Mechanism: The clutch release mechanism includes
components such as the clutch release bearing, release fork, and
hydraulic or mechanical linkage. These components allow the driver to
engage and disengage the clutch by actuating the clutch pedal.
Clutch Alignment Tool: When replacing or installing a new clutch plate, a
clutch alignment tool is often used. This tool ensures proper alignment
of the clutch plate with the flywheel and pressure plate during
installation, preventing damage and ensuring smooth operation.
Clutch Replacement and Maintenance: The clutch plate section requires
periodic maintenance and eventual replacement due to wear and tear.
Regular inspections and maintenance can help identify early signs of
clutch plate wear, such as slipping, noise, or difficulty in engaging gears.
When necessary, clutch plate replacement involves removing the
transmission, separating the clutch assembly, and installing a new clutch
plate.

Store Section:
The store section is a designated area within a bus workshop or
maintenance facility where various spare parts and supplies for buses are
stored and managed. This section plays a critical role in ensuring that the
workshop has the necessary inventory to carry out repairs and
maintenance on buses efficiently.
The store section typically includeincludees the following components
and activities:
Parts Storage: The section will have appropriate storage systems, such as
shelves, racks, or bins, to store different types of bus parts. These parts
can include engine components, electrical and electronic parts, braking
system parts, suspension parts, and more. They may be organized based
on type, size, or category for easy access and inventory management.
Inventory Management: A dedicated staff member or team is
responsible for managing the inventory in the store section. This includes
monitoring stock levels, ordering new parts when needed, and keeping
track of the movement of parts in and out of the store.
Receiving and Inspection: When new parts arrive, they are received and
inspected to ensure their quality and accuracy. This involves checking for
any damage, shortages, or discrepancies between the received items
and the purchase orders or invoices.
Record-Keeping: Accurate records are maintained for all parts, including
details such as the part number, description, quantity on hand, supplier
information, and cost. This information allows for effective inventory
management, reordering, and tracking of costs.
Issuing Parts: When a bus needs a specific part for repair or maintenance,
the store section is responsible for issuing the requested part to the
workshop staff or technicians. This is usually done based on a requisition
or work order system to ensure proper documentation and
accountability.
Stock Rotation: To prevent parts from becoming obsolete or
deteriorating, the store section implements stock rotation practices. This
involves ensuring that older or lesser-used parts are used before newer
ones, minimizing waste and maintaining inventory freshness.
Safety and Security: The store section ensures that all parts are stored in
a safe and secure manner, with measures in place to prevent theft,
damage, or unauthorized access. This can include physical security
measures, such as locked storage areas and surveillance systems.
Waste Disposal: The store section may have designated procedures for
the proper disposal of waste materials, such as used or damaged parts,
oils, fluids, or packaging materials. This ensures compliance with
environmental regulations and promotes responsible waste
management practices.

Overall, the bus workshop store section plays a vital role in supporting
the smooth operation and efficiency of bus maintenance and repairs. It
ensures that the workshop has a well-organized and stocked inventory
of parts, enabling technicians to quickly access and install the necessary
components to keep buses in optimal condition.
DAY8: Front axle section

In a bus, the front axle section is similar to that of a regular vehicle but
with some differences due to the larger size and weight of the bus.
The front axle of a bus typically consists of the following components:
Differential: The differential distributes power to the front wheels while
allowing them to rotate at different speeds during turns.
Axle shafts: The axle shafts transmit power from the differential to the
front wheels, enabling them to rotate and propel the bus.
Spindles: Spindles connect the axle shafts to the hub assemblies and
provide support for the wheels.
Hubs and bearings: Similar to regular vehicles, hubs and bearings allow
for smooth rotation of the wheels.
Suspension system: Buses often have heavy-duty suspension systems to
support the weight of the vehicle and provide a comfortable ride. This
may include components such as leaf springs, coil springs, or air
suspension.
Steering system: The front axle section also includes the steering system,
which allows the driver to control the direction of the bus. This may
consist of components such as steering knuckles, tie rods, and steering
arms.
Overall, the front axle section in a bus is designed to handle the greater
weight and loads that come with larger vehicles. It is engineered to
provide stability, control, and durability for the safe operation of the bus
on various road conditions.
Parts :
 Main axle
 Right side sub axle
 Left side sub axle
 Thrust bearing
 King pin
Caster angle (viewed from the side) is the angle between the vertical
steering axis and the vertical plane of the wheel.
Camber angle (viewed from the front) is defined as the angle between
the centre line of the wheel and the vertical line.
DAY 9 :Rear axle section

The rear axle section of a bus is an important component of its drivetrain

system. It is responsible for transmitting power from the engine to the
rear wheels, allowing the bus to move forward.
The rear axle section of a bus generally consists of the following
components:
Differential:
The differential is a gear mechanism that distributes power to the rear
wheels while allowing them to rotate at different speeds, particularly
during turns. It ensures that torque is evenly distributed to both rear
wheels.
Axle shafts: Axle shafts transmit power from the differential to the rear
wheels, allowing them to rotate and propel the bus forward.
Hubs and bearings: Hubs and bearings enable smooth rotation of the
rear wheels. They provide support and reduce friction as the wheels turn.
Suspension system: Buses typically have robust suspension systems for
the rear axle to support the weight of the vehicle and provide a
comfortable ride. This may include components such as leaf springs, air
bags, or coil springs.
Brake system: The rear axle section also includes the braking system,
which allows the driver to slow down or stop the bus. This may include
components such as brake drums, shoes, and hydraulic or air brake lines.
The rear axle section of a bus is designed to handle the weight and load
carrying capacity of the vehicle. It is engineered to provide stability,
control, and durability to ensure safe and efficient operation of the bus.
DAY 10: Maintenance Machinary section, welding section
drilling machine:

This machine is used to drill holes in various parts and components of the
bus. It has a rotating arm that can move in different directions, allowing
for drilling in different angles and positions.
Boring machine:
This machine is used for enlarging or smoothing out existing holes in the
bus components. It can be used to create precise holes for various
purposes, such as fitting bearings or bushings.
Grinding machine:

This machine is used for grinding or polishing metal surfaces of the bus
components. It uses an abrasive wheel or belt to remove material and
create a smooth and finished surface. It can be used for removing sharp
edges, smoothing out welds, or improving the surface finish.
Punching machine:
This machine is used to create holes or indents in the bus
components by applying a strong force. It is commonly used for creating
holes for bolts or other fasteners, or for creating indents for locating
different parts.
Lathe machine:

This machine is used for shaping and machining metal components of

the bus. It can be used for turning, facing, or threading operations. It uses
a rotating workpiece and cutting tools to remove material and create the
desired shape.

Welding section
Welding is a fabrication process whereby two or more parts are fused
together by means of heat, pressure or both forming a join as the parts
cool. Welding is usually used on metals and thermoplastics but can also
be used on wood. The completed welded joint may be referred to as a
weldment.
Types:
 Gas welding
 Arc welding
DAY11: Brake chamber section

The bus brake chamber section is an essential component of the bus’s

air brake system. It is responsible for converting the compressed air
into mechanical force to engage the brakes and slow down or stop the
bus.
The brake chamber section typically consists of one or more brake
chambers, push rods, clevises, and other connecting hardware. The
brake chambers are the main components that convert air pressure into
mechanical force. They contain a diaphragm and a return spring. When
the air pressure is applied, the diaphragm expands, pushing the push rod
outward and engaging the brakes.
The push rod Is connected to the brake chamber and transmits the force
from the diaphragm to the brakes. It is usually made of a sturdy metal
material to withstand the force generated during braking.
Clevises are used to connect the push rod to the brake shoes or brake
pads. They provide a pivot point and allow for proper alignment and
movement of the brake components. Clevis pins and cotter pins are used
to secure the clevises and ensure a proper connection.
Overall, the brake chamber section plays a vital role in the safe operation
of the bus’s braking system. It effectively converts the air pressure into
mechanical force, ensuring reliable and efficient braking performance.
Front brake chamber

Rear brake chamber

DAY 12: Cage building section

The cage is typically installed in a designated area of the bus, such as a

storage compartment or luggage area, to secure items or prevent them
from moving during transit.
DAY 13:Fuel injection pump

A bus fuel injection pump is a vital component of a diesel engine. It is

responsible for delivering fuel to the engine cylinders at the correct
timing and pressure. Here are some key aspects of a bus fuel injection

Function: The fuel injection pump is designed to deliver fuel to the

engine cylinders in precise amounts and at the right timing. It is driven
by the engine's camshaft or timing chain and is responsible for
pressurizing the fuel and sending it to the injectors.
Fuel Pressure: The fuel injection pump ensures that the fuel is delivered
at the correct pressure. This is important for efficient combustion and
engine performance. The pressure rating of the pump depends on the
specific engine requirements.
Timing Control: The fuel injection pump controls the timing of fuel
delivery to each cylinder. It ensures that the fuel enters the cylinder at
the right moment, synchronized with the engine's rotation. This timing is
crucial for optimal combustion and power generation.
Injection System: The fuel injection pump is part of a larger fuel injection
system that includes injectors, fuel lines, and other related components.
The pump works in tandem with the injectors to deliver fuel to the
engine cylinders.
Electronic or Mechanical: Depending on the bus's age and engine type,
the fuel injection pump can be either electronic or mechanical. Electronic
fuel injection pumps have electronic controls that regulate the fuel
delivery, while mechanical pumps rely on mechanical mechanisms such
as springs and plungers.
Maintenance and Repair: Proper maintenance and regular inspection are
essential for the fuel injection pump's longevity and performance. This
includes periodic cleaning, filter replacement, and adjustment of fuel
delivery timing. In case of any issues, repairs or replacements may be
necessary.
Fuel Efficiency: A well-functioning fuel injection pump optimizes fuel
consumption and contributes to the bus's overall fuel efficiency. Regular
maintenance and checks can ensure that the pump operates at its best
efficiency, minimizing fuel wastage.
Diesel Particulate Filters (DPF): Some modern buses use diesel
particulate filters to reduce exhaust emissions. These filters can affect
the fuel injection pump's operation by increasing back pressure.
Therefore, it is important to ensure that the fuel injection pump is
compatible with the DPF system and properly maintained for optimal
performance.

The fuel injection pump is a critical component of a bus's diesel engine.

It ensures the precise delivery of fuel to the engine cylinders, controls
timing, and contributes to the bus's overall performance and fuel
efficiency. Regular maintenance and proper operation are necessary to
keep the fuel injection pump in good working condition.
Pump speed -1400rpm
Pump testing machine cost= ₹2,10000

Pump types:
 Inline pump
 Distributed pump
Operation:
 Suction
 Compression
 Power
 Exhaust
Pump section parts:
1. tappet roller assembly
2. plunger spring
3. upper plate
4. flat quadrant
5. controls sleeve
6. delivery holder
7. delivery valve
8. element
9. fly weight assembly
10. Control rod
11. Fuel feed pump
12. Governer cover.
DAY 14: painting section

The painting section is a dedicated area in a bus repair or maintenance

facility where buses are painted or repainted. This section typically
includes specialized equipment and tools for painting large vehicles like
buses.
Stickering section:
The stickering section may be responsible for the maintenance and
replacement of stickers as needed. This includes removing old or
damaged stickers and replacing them with ones .Stickers on the bus to
see vehicle numbers and root numbers And reflective stickers are used
to make buses visible in the distance at night.
DAY 15: Tyre reconditioning section

Common processes involved in tyree refurbishment:

Inspection: Each tyre is thoroughly inspected to assess its condition. This
includes checking for tread wear, sidewall damage, punctures, and other
issues that may affect the tire’s performance and safety.
Cleaning: The tyre is cleaned to remove dirt, debris, and any foreign
objects that may have been stuck in the tread.
Repair: Any visible damage or punctures on the tire’s surface are
repaired. This can involve patching holes, filling in sidewall damage, or
plugging punctures to restore the tire’s integrity.
Buffing: The old tread layer is removed from the tire’s casing using a
buffing machine. This process smoothens the surface and prepares it for
retreading.
Retreading: A new layer of tread compound is applied to the buffed
surface of the tire. This is done using specialized equipment, such as a
retreading machine, which applies pressure and heat to properly bond
the new tread to the old casing.
Curing: The retreaded tire is placed into a curing chamber, where it
undergoes a curing process. Heat and pressure are applied to ensure that
the new tread compound bonds securely to the tire’s casing. This process
also helps to enhance the tire’s structural integrity.
Finishing: Once the curing process is complete, any excess tread is
trimmed to achieve the desired tread pattern. The tire is also inspected
for any imperfections and corrected if necessary.
Quality Control: Each refurbished tire undergoes rigorous quality control
checks to verify its structural integrity, dimensional accuracy, and overall
performance. This ensures that the tire meets or exceeds industry
standards for safety and reliability.
Balancing: The refurbished tire is balanced to ensure even weight
distribution. This is done by adding weights to the wheel assembly to
eliminate any imbalance, reducing vibrations during operation.
Packaging and Storage: After refurbishment, the tires are properly
packaged and stored until they are ready for installation on buses. This
helps to prevent any damage or deterioration while awaiting use.
Adherence to small and large chambers
1. Is GUM affixed to the studs of the tire covering before loading the
tire into the big chamber? Is the AIR part fixed and patched? Look
like this and then hit PROTECTIVE – CLOTH and put ENVELOP
2. Is there a TUBE leak before loading the tires into the chamber? Is
there an ENVELOP league? As should be checked by giving AIR (20-
PSI) in the TUBE and loading in the chamber
3. Chamber AIR should be upto 60PS I- after loading tires
4. TUBE AIR – 90- PSI – 5. CHAMBER – 125°C – TEMPERATURE – HEAT
1.45 HOURS CURING TIME IS GIVEN AFTER 125° -C
5. ENVELOP LEAK AFTER INSTALLATION OF TIRES IN CHAMBER? If
there is an AIR leak, it should be removed and fixed immediately
7.E.B- POWER CUT but immediately switch on the generator and start
the chamber.
8. After the CURING TIME (1.45) in the chamber the tires should be
removed from the chamber immediately.
SWOT ANALYSIS:
Strengths:
Wide range of spare parts available: The bus workshop store section has
a diverse inventory of spare parts, ensuring that a variety of bus repair
and maintenance needs can be met promptly.
Efficient inventory management: The dedicated staff in the store section
ensures that inventory levels are monitored, and reordering is done in a
timely manner. This helps prevent stockouts and delays in repairs.
Proper storage and organization: The section maintains a well-organized
storage system for parts, making it easier for staff to locate and retrieve
the required components quickly.
Accurate record-keeping: The store section maintains detailed records of
parts, suppliers, and costs, enabling better tracking of inventory and cost
control.
Compliance with safety and security protocols: The section implements
measures to ensure the safety and security of stored parts, reducing the
risk of theft or damage.

Weaknesses:
Limited storage capacity: If the store section has a limited storage space,
it may face challenges in managing a large inventory or stocking bulky
parts. This can lead to difficulties in locating and organizing parts
efficiently.
Potential for obsolescence: If certain parts are not used frequently, there
is a risk of them becoming outdated or obsolete. This can result in waste
and increased costs.
Dependence on external suppliers: The store section relies on external
suppliers for new parts, which can lead to delays if there are supplier
issues or disruptions in the supply chain.
Lack of necessary facilities:
Roads inside also damaged. All the places spread in iron nut and bolt
[Link] 4 engine maintenance machine is not available.

Opportunities:
Collaboration with suppliers: The store section can explore partnerships
or collaborations with reliable suppliers to ensure a steady and timely
supply of parts. This can help reduce lead times and improve efficiency.
Adoption of technology: The use of inventory management software or
systems can enhance the accuracy and efficiency of inventory
management processes, reducing the risk of stockouts and improving
overall operations.

Threats:
Price fluctuations: Fluctuations in the cost of parts or changes in supplier
prices can pose challenges for the store section in managing costs and
budgeting effectively.
Counterfeit parts: The emergence of counterfeit parts in the market
poses a threat to the store section's ability to source genuine parts. This
can affect the quality and reliability of repairs and maintenance.

It is important for the bus workshop store section to leverage its

strengths, address its weaknesses, capitalize on opportunities, and
mitigate threats to ensure efficient operations and customer
satisfaction.
LEARNING OUTCOME:
Participating in an internship in the mechanical department of a
transport corporation in Tamil Nadu can provide you with valuable
learning outcomes that are specific to the field of mechanical
engineering within the transportation industry. Here are some potential
learning outcomes you might .
gain from such an internship:
1. Vehicle Maintenance and Repair: Develop practical skills in diagnosing,
repairing, and maintaining various types of vehicles used in the transport
corporation, such as buses, trucks, and other fleet vehicles.
2. Mechanical Systems Understanding: Gain a deep understanding of the
mechanical systems within vehicles, including engines, transmissions,
brakes, suspension, and steering systems.
3. Troubleshooting Abilities: Enhance your ability to identify and
troubleshoot mechanical issues, using diagnostic tools and techniques to
address problems effectively.
4. Hands-on Experience: Acquire hands-on experience working with
tools, equipment, and machinery used in vehicle maintenance and
repair, honing your practical mechanical skills.
5. Safety Practices: Learn about safety protocols and best practices in a
mechanical workshop environment, ensuring that maintenance and
repair tasks are conducted in a safe and compliant manner.
6. Preventive Maintenance: Understand the importance of preventive
maintenance schedule and practices, which contribute to prolonging the
lifespan of vehicles and reducing breakdowns.
7. Parts Management: Gain insights into inventory management and
procurement of spare parts, including sourcing, ordering, and tracking
parts for repairs.
8. Documentation and Reporting: Develop skills in documenting
maintenance and repair activities, maintaining accurate records, and
generating reports for management and regulatory purposes.
9. Collaboration and Teamwork: Work collaboratively with fellow
mechanics and technicians, learning to communicate effectively and
contribute to a cohesive team environment.
10. Environmental Considerations: Gain awareness of environmental
regulations and sustainability practices related to vehicle maintenance,
including proper disposal of hazardous materials and adherence to
emissions standards.
11. Quality Assurance: Understand the importance of quality control and
quality assurance in mechanical work, ensuring that repairs and
maintenance meet the highest standards.
12. Operational Efficiency: Learn how mechanical operations impact the
overall efficiency and reliability of the transport corporation's fleet,
contributing to smooth operations and customer satisfaction.
13. Leadership Exposure: Observe how senior mechanics and supervisors
lead and manage the mechanical department, providing insights into
potential career growth and leadership roles.
14. Problem-Solving Skills: Develop strong problem-solving skills as you
address complex mechanical issues, finding creative and effective
solutions to ensure vehicle performance and safety.
15. Professional Ethics: Gain an understanding of ethical considerations
within the mechanical department, including integrity, transparency,
and adhering to professional standards.
16. Career Exploration: Use the internship as an opportunity to explore
various roles within the mechanical department of a transport
corporation, helping you make informed decisions about your future
career path.
CONCLUSION:
Internship in the mechanical department of a transport corporation in Tamil
Nadu offers a rich and multifaceted learning experience within the dynamic
field of mechanical engineering and transportation. Throughout this
internship, you will have the opportunity to acquire valuable skills, insights,
and knowledge that are crucial for a successful career in the transport
industry. The hands-on nature of the internship will empower you to develop
practical expertise in vehicle maintenance, repair, and mechanical systems,
while also fostering your ability to collaborate effectively in a team
environment.
As you delve into diagnosing and troubleshooting mechanical issues, you'll
strengthen your problem-solving skills and learn to apply innovative solutions
to real-world challenges. The emphasis on safety practices and adherence to
environmental regulations will instill in you a sense of responsibility and
ethical consideration that is essential in any professional setting.
Furthermore, your exposure to preventive maintenance practices, inventory
management, and documentation will equip you with a comprehensive
understanding of the operational intricacies within a mechanical department.
This exposure extends to leadership insights, allowing you to witness how
experienced professionals manage and lead teams, providing a glimpse into
potential future roles.
By actively engaging with your mentors, peers, and projects, you'll not only
build a robust skill set but also cultivate a network of industry contacts. This
network can serve as a valuable resource as you mark on your career journey
within the transportation sector or beyond.
As you reflect on your internship experience, consider how the knowledge
and skills you've acquired align with your long-term goals. Whether you
decide to pursue a path within mechanical engineering, transportation
management, or a related field, the lessons learned during this internship will
undoubtedly contribute to your growth and success. As you move forward,
remember that this internship is just the beginning of a journey marked by
continuous learning, adaptability, and the pursuit of excellence in the ever-
evolving landscape of mechanical engineering and transportation.