Project on sdl 01

PROJECT ON
STUDY OF MANUFACTURING PROCESS FOR MAJOR
COMPONENT OF SDL AND PREPARATION OF PROCESS
SHEETS FOR FABRICATION, MACHINING AND
ASSSEMBLY
SUBMITTED BY:
HIMANSHU KUMAR
ABIT CUTTACK
REG.NO. 1301206185

CERTIFICATE
This is to certify that Mr. HIMANSHU KUMAR have successfully completed the
Project on “STUDY OF MANUFACTURING PROCESS FOR MAJOR
COMPONENT OF SDL AND PREPARATION OF PROCESS SHEETS FOR
FABRICATION, MACHINING AND ASSEMBLY” in TRF Ltd. JAMSHEDPUR.
He has undergone training at “Works Dept.” from 01 JUNE 2015 to 26 JUNE 2015.
AT
TRF LTD., JAMSHEDPUR
JHARKHAND
Under the guidance of:
Mr. SANTOSH KUMAR
(DIVISIONAL MANAGER)

INDEX
 ACKNOWLEDGEMENT
 INTRODUCTION ABOUT TRF
 EXECUTIVE SUMMARY
 VISION, MISSION, VALUES & BUSINESS PRINCIPLE
 TATA GROUP CUSTOMER PROMISS
 ABOUT PRODUCT OF TRF
 PULLEY
 IDLER
 FEEDER
 SIDE DISCHARGE LOADER
 SCREEN
 WAGON TRIPPER
 DIFFERENT WORK PRODUCTION DEPARTMENT
 PLANNING & PROCESSING PLANNING
 PREPARATION
 FEBRICATION & WELDING
 GENERAL MACHINE SHOP
 GENERAL ASSEMBLY
 PULLY SECTION
 IDLER MACHINE SHOP

ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of any task
would be incomplete without the mention of the people who have made it
possible, and whose constant guidance and encouragement served as a boon
and made any effort with success.
My heart full thanks to Mr. S.K.Misra (principle of ABIT CUTTACK) for
allowing me to pursue my B.tech in mechanical summer training at TRF.
His words of wisdom and patience were much more than a blessing.
And also my special thanks to Mr. JAYANT KUMAR SINHA
(MANAGER, TRAINING & DEVELOPMENT) TRF, for allowing me to
undertake the project study in their organization.
I would like to express my sincere gratitude to Mr.Santosh Kumar
(DIVISIONAL MANAGER), who helped me by providing useful data and
information relevant to complete my work at TRF.
I would like to thanks Mr. D.K.PAUL for his co-operation and guidelines.
I also would like to thanks all those who have helped me directly or
indirectly in completion of this project and last but not the least I thank all
the employees of TATA ROBINS FRASER (TRF) JAMSHEDPUR, for
their kind co-operation.
DATE:
HIMANSHU KUMAR

TRF LIMITED – A SHORT PROFILE
TRF Limited, established in 1962, is part of the Tata Group of Companies
which consists of more than various enterprises operating in seven business
sectors, in over various countries.
Over the last five decades, TRF has emerged as a pioneer in solutions for
material handling equipment and processing systems required in the
infrastructure development, In quest of rapid growth, TRF has also diversified
into automotive applications business. It envisages to grow five times in five
years and become a Rs 2500 crore Company by 2013 by enhancing focus on
material handling business and auto applications business.
The TRF Works at Jamshedpur spreads over nearly 22 acres and this includes
six covered manufacturing bays on nearly 21,250 square meters. TRF’s skilled
manpower meets the expectation of its customers by continuously adapting new
technology, upgrading skills and serving its customers on time. They also use
several process improvement tools and techniques like TOC-CCPM, quality
circles, cross functional teams, to attain the highest level of productivity.
The Bulk Material Handling Equipment Division specializes in the design
and manufacture of a wide range of material handling equipment used in the
infrastructure industries, such a wagon tipplers, stacker reclaimers, ship
loaders and unloaders, traveling wagon loaders. The Port and Yard
Equipment Division focuses on the design, supply, and stockyards including
level luffing cranes, ship loaders and unloaders, container cranes, stacker-
reclaimers and special purpose cranes for power and metallurgical plants.

EXECUTIVE SUMMARY
TRF Limited, established in 1962, is part of the Tata Group of Companies which
consists of more than various enterprises operating in seven business sectors, in over
various countries. The Tata group, founded in the last quarter of the 19th
century, at a
time when India had just embarked on the road to independence, committed to aligning
its business opportunities with nation building activities.
Over the last five decades, TRF has emerged as a pioneer in solutions for material
handling equipment and processing systems required in the infrastructure development,
In quest of rapid growth, TRF has also diversified into automotive applications
business. It envisages to grow five times in five years and become a Rs 2500 crore
Company by 2013 by enhancing focus on material handling business and auto
applications business.

GROUP COMPANIES
The company’s subsidiary, York transport equipment (Asia) pvt
limited, Singapore is engaged in the business of trailer under gear,
which includes axles, suspension and other components, with market
presence in 27 countries. York transport equipment(Asia) pvt ltd has
manufacturing facilities in Singapore, Australia, China and India.
TRF has also set up adithya automotive applications limited, an
automotive applications unit for a fixed body truck application in
India. The provide end-to-end solution through fabrication and
machining for tipplers, load bodies, etc. TRF acquired the Dutch
Lanka trailer (DLT) manufactures limited, Sri Lanka. DLT is a world
class trailer manufacturing facilities in Sri Lanka, omen and India. It
exports trailers to as many as 30 companies.
BUSINESS UNITS
The company has three business unit which cater to the material
handling requirement of costumers in the core infrastructure
development industries such as power and steel plants, cement, ports,
fertilizers and mining. TRF’s material handling products and systems
are known in the market, in India and overseas for their reliability,
productivity, longevity. The company been constantly upgrading and
developing new products and systems with the help of internationally
reputed enterprises having cutting edge technical expertise.

The company’s operations are segregated into four division
Bulk material handling equipment handling equipment division
specializes in the design and manufacture of a wide range of material
handling equipment used in the infrastructure industries, such as
wagon tipplers, stacker reclaimers, ship loaders and unloaders,
traveling wagon loaders, etc.
Bulk material handling systems division offers a complete package
of material handling and allied systems and services on a turnkey
basis.
Port and yard equipment division focuses on the design, supply,
erection and the commissioning of material handling equipment for
ports and stockyards including level luffing cranes, ship loaders and
unloaders, container cranes, stacker-reclaimers and special purpose
cranes for power and metallurgical plants.
Design and engineering
TRF with the help of application engineering customizes its products
to specific application, ensuring customer satisfaction. Stressing on
the constant need to improve performance and create a sense of
reliability. TRF’s specially work towards integrating their expertise
and tend specification with customer demand. Adding further values
to the system are regular feedback and suggestion CAD networks,
interfaced with business information system, further facilities the
operation of key process.

Vision, Mission, Values, & Business Principles
Vision:

MISSION
To be an international leader in material handling equipment,
processes and systems.
VALUES
Trust
Respect
Fellowship
Excellence
Responsibility
BUSINESS PRINCIPLES
Sense of urgency
Continuous improvement
Consistency and detail
Slide 3
Tata Group Customer Promise
Customer Centricity is intrinsic to our culture.
We promise to:
• Develop deep understanding of the unique needs of our Customers
• Deliver pioneering products and services of outstanding quality and value
• Delight our Customers with great experiences at every touch point
This is how we will always demonstrate responsible leadership with trust.

WORK PRODUCTION DEPARTMENT
Work production department of TRF is divided into various sections:
 Planning & process planning
 Preparation
 Fabrication & welding
 Fabrication
 General machine shop
 Bay 4th
machine shop
 Bay 5th
assembly
 Pulley section
 Idler machine shop

Side Discharge Loaders
Side Discharge Loaders:
The M412 crawler mounted side discharge loader is a low profile high
output machine. The latest development in the fields of hydraulics and
fabrication and underground work are considered while designing the
loaders and they are developed to offer maximum benefit to the
mining industry. Flameproof electrical make them suitable for
operation in gassy mines.

MAJOR COMPONENT OF SIDE DISCHRGE LOADER:
 BUCKET
 BOOM
 GEAR
 ELECTRIC MOTOR
 MOTOR MOUNTING FRAME
 BOOM MOUNTING BRACKET
 AUXILIARY TANK
 HYDRAULIC FITTING & PIPES
 HYDRO MOTOR
 CENTRAL SECTION
 COOLER
 CHAIN
 ROOLER
 IDEALER
 RETURN IDEALER
 SPROKET HUB
 SOVES CYLINDER
 LIFT CYLINDER
 FLAPE OPENING CYLINDER
 TRIPPLE GEAR PUMP
 CHAIN CONVEYER
 STAFFA HYDRAULIC MOTOR
 INLINE FILTER

SPECIAL FEATURES:
Outstanding power/weight ratio; Low heat generation; Low center of
gravity; Low specific base pressure; Fail safe parking brake; Track
aligning guards; powerful flood lights; emergency stops; dead man
switch; heavy duty construction; Protection of sprocket from ingress
of dust..
The manufacturer reserves the right to change the specifications
and/or design, of this machine at anytimewithout notice.
The other variants of Side Discharge Loaders available are:
 Extra Low Height - 1.0 cum bucket capacity.
 Standard Height with CRD arrangement - 1.0 cum bucket
capacity.
All the above machines are approved by DGMS, India for use in
underground coal mines.

Side Discharge loader with roof drilling machine

TECHNICAL SPECIFICATION:
Bucket capacity (standard): 1.0m3/1.5m3
Traveling speed (max.): 2.6kmph
Total weight: 8500kgs/9000kgs
Ground pressure: 0.9kg/cm2
Tractive force: 5200kgs
Breakout force: 3000kgs
Electrical components: flame proof for
Underground gassy mines
Negotiable gradient for
Driving and loading: 1:4 cross gradient 1:6
System pressure: 125bar
Traction motor: Radial piston fixed
Displacement type
Payload (max.): 2.0MT
Drive power (max.): 55KW
Hydraulic medium: HFB68

TECHNICAL SPECIFICATION FOR STANDARD HEIGHT
SDL MODEL: M412 FOR USE IN COAL MINES:
SCOPE:
The specification covers design, manufacture, supply, erection and
commissioning requirement of loaders for use in coal faces for the
purpose of loading coal. The machine shall be designed to work in
underground coal faces to scoop and load runs of mine coal into
transport equipment.
The machine offered is indigenously developed by us complying with
the requirements and standards contained in NIT specification. The
machine has been proved in service in coal mines of CIL or its
subsidiary companies and has the approval of Directorate General of
Mines Safety, Dhanbad.
SERVICE CONDITION:
The machine is designed for use in drivage of gallery heading or in
depillaring section in underground gassy coal mines and shall load the
coal/shale/hard sand stone etc. The machine shall be able to work
satisfactorily & give guaranteed performance under heavy dust laden
atmosphere with ambient temperature of up to 45 Deg. C (max.) with
a relative humidity of
98 %(max.) Present.
The machine shall work in gallery dimensions of height
approximately 2.2Mtrs. & above and of width approximately 4.2Mtrs.
The machine shall be able to take sharp turns without repeated
maneuvering.
The machine shall be able to work on load in mucky floor with
gradient of 1 in 4 at places, and with up to 250mm of water at some
faces and in cross gradient of 1 in 6. The machine will be equipped
with triple grouser shoe for adequate gripping on the floor to prevent
slipping down the gradient or in the muddy faces. Additional
advantages of the Triple Grouser Shoe are as follows.

Strength of Triple Grouser Shoe is 3 times more than Single Grouser
Shoe.
Triple Grouser Shoe provides better floor gripping.
Climbing of machine at higher gradient will not pose problem.
GENERAL DESCRIPTION OF THE MACHINE:
The machine shall be compact, low profile, narrow wheel based
crawler mounted and electro hydraulically powered with smooth
control system & excellent maneuverability and stability with
sufficient ground clearance. The machine shall be designed to ensure
low center of gravity, heavy duty construction, and capable of being
easily & quickly maintained & inspected. The machine shall be
designed to ensure that fittings and dismantling for the purpose of
maintenance of boom, lift & shovel cylinders & buckets or other sub-
assemblies shall be easy & quick at the working face.
The machine shall be electro-hydraulically powered so as to ensure
smooth operation & control. All electrical shall be FLP with approval
from DGMS, Dhanbad for use in Indian gassy coal mines & ISI
marked. The electrical shall be suitable for voltage 525 V +/-10%, 3
phase, 50 Hz +/- 5%. The operating levers & controls shall be
conveniently located for the machine operator. The operator shall be
able to see properly all-round the machine so that travelling and
loading safety will be ensured. All the operations shall be done
through hydraulic transmission arrangements and shall be designed
for maximum rated load capacity of the machine.
The fluid used for operation of the hydraulics shall be non-toxic and
non- inflammable, FRHF, Type : HFB-68 of either Fuchs or
Lubrichem conforming to IS:10532(Pt.2) -1983 duly approved by
DGMS. Hydraulic hoses and hose assemblies shall be in accordance
with DGMS (Tech) circular no. 1 of 1996 DT. 31.01.96 and shall be
approved by DGMS for use in underground coal mines.

Suction Strainer has not been provided in Hydraulic System Design of
the offered machine as its incorporation shall lead to premature failure
of Hydraulic Traction Motor and Pump due to cavitation. However,
Pressure Line Filters of 10 microns have been provided in the system
for oil filtration in the hydraulic circuit. Further, Filling Strainer of
100 microns has been provided in the Auxiliary Tank to prevent
ingress of dust and other foreign particles. Apart from above, baffle
plates and magnetic plug have also been provided in the Auxiliary
Tank to prevent ingress of dust and foreign particles in the hydraulic
system.
Power take-off point shall be provided with the machine for other
small hydraulic equipment.
The Electric motor & other sensitive components shall be suitably
located / protected from floor water the level of which is up to
250mm.
There will be independent drives for the crawlers of the machine so
that the machine can take quick and sharp turns.
The bucket will be so designed as to ensure that 1.0 CUM of mineral
can be scooped and transported with minimum spillage. The bucket
will be designed to suit the rugged duty conditions and for ease of
replacement in underground.
The machine shall be equipped with a dual discharge bi-directional
chain conveyor side discharge bucket capable of loading coal into
Coal Tubs / Chain Conveyor.
The capacity of the hydraulic tank shall be sufficiently large so that
the hydraulic system will not get abnormally heated during the
operation of the machine and will not cause any discomfort to the
operator.

MAIN FEATURES OF SDL:
TRACKS:
The machine shall be fitted with wide track shoes and extra-large
tracks for ensuring stability and low ground pressure to enable the
machine to negotiate gradients up to 1 in 4 and cross gradients 1 in 6.
The machine shall be fitted with triple grouser track pads and track
shall be suitable for working in severe underground conditions.
The track shall be hydraulically powered through suitable hydraulic
motors and reduction gear boxes. Each right and left tracks shall be
independently powered.
Fail safe brake shall be provided for the tracks so that the machine
shall stand even in the inclined position in the gradient of 1 in 4.
Turning of the machine shall be done through independent drives for
tracks, by blocking or reverse rotation of crawlers.
The speed of the machine shall be smoothly controlled by hydraulic
control valve. Zero to maximum speed shall be obtained by operation
of control levers with less effort, preferably pilot control. The speed
of the machine shall be same in both the directions of the travel.
LOADING BOOM & BUCKET:
The machine shall be equipped with loading boom and 1.0 CUM
bucket for collection of coal from the face, carry and unload on to a
coal tub / chain or belt conveyor. The height of the boom shall be
suitable to unload coal into tubs up to a height of 1.5 M.
The side discharge chain bucket shall be bi-directional, suitable to
unload coal from either sides of the machine. The chain shall be
double out board, fitted with suitable flights, hydraulically powered
with suitable hydraulic motor.
The attachment and detachment of the bucket for changing the
direction of unloading shall be quick and easy. It shall be carried out
easily at the coal face.

The break-out force of the machine shall not be less than 4500Kgs for
enabling the machine to fill the bucket in one stroke.
The boom shall be fitted with suitable hydraulic cylinders for lifting
and rolling back.
All the operation of the loading boom and bucket shall be through
hydraulic control valves.
HYDRAULIC SYSTEM:
The machine shall be fitted with heavy duty Triple Gear Pump for
feeding hydraulic fluid independently to each track and services.
Pressure Line Filters with by-pass and clogging indicator shall be
provided in the hydraulic circuit to maintain clean fluid.
The capacity of the oil tank shall be sufficiently large to keep the fluid
at low operating temperatures and for better hydro-dynamics of fluid.
And shall not cause discomfort to the operator.
The tank shall be robust and there shall be sealing arrangement
between matching parts.
The tank shall be provided with oil level indicator, low fluid cut-off
switch and high temperature cut-off switch set at 65 Deg.C.
The hydraulic system shall be incorporated with radiator / cooler of
adequate capacity and fan cooled.
The design of oil tank and cooling system shall ensure that the
temperature of hydraulic system does not exceed 65 Deg.C under full
load, continuous working conditions and the system shall be suitable
to operate the machine in hot and humid underground mining
conditions, where ventilation requirement shall adhere to Coal Mines
Regulation 1957 with latest amendments.

All hydraulic hose assemblies and fittings of the machine shall have
DGMS approval.
Self-sealing hydraulic fluid filling arrangement shall be provided to
prevent ingress of dirt with hand pump and filter.
Hydraulic Fluid Pressure Meter shall be provided for online condition
monitoring of the machine.
The machine shall be designed to operate on DGMS approved Fire
Resistant Hydraulic Fluid (FRHF), HFB-68. All Hydraulic
components and system shall be compatible to HFB-68 FRHF.
ELECTRICALS:
The electro-hydraulically powered machine shall be fitted with
adequately rated FLP motor, suitable for 525 +/- 10% V, 3 Ph., 50 Hz.
The motor shall be provided with FLP Plug & Socket assembly
approved by DGMS.
All on-board FLP electrical shall be approved by DGMS for use in
underground gassy coal mines of India.
The machine shall be provided with halogen / metal halide lights both
in the front and rear side of the machine to ensure good visibility.
Entire lighting arrangement shall be suitable to work on 24 V and all
fittings shall be FLP type, DGMS approved and ISI marked.
All power cables shall have indirect entry.
BUCKET:
The machine shall be equipped with a dual discharge bi-directional
chain conveyor bucket capable of loading in Coal Tubs / Chain
Conveyor.
The bucket will be so designed as to ensure that 1.5 CUM of mineral
can be scooped and transported with minimum spillage. The bucket
will be designed to suit the rugged duty conditions and for ease of
replacement in underground.

There will be independent drives for the crawlers of the machine so
that the machine can take quick and sharp turns.
The Electric motor & other sensitive components shall be suitably
located / protected from floor water the level of which is up to
250mm.
Power take off point shall be provided with the machine for other
small hydraulic equipment.
SAFETY FEATURES OF THE MACHINE:
Starting arrangement through pilot circuit / switch shall be provided
with the machine keeping the Gate End Box at far end.
Low fluid level cut-off and High fluid temp. Cut-off switches shall be
provided with the machine. Adjustable temperature cut-off switch
between65-70 degree C shall be provided. The design of the
equipment and cooling system shall ensure that the temperature of the
fluid does not exceed the present limiting temperature, which shall be
generally maintained at 65 Degree C as per IS:14480 and IS:10532
(PII). The machine shall be designed to ensure that temp. of hydraulic
fluid does not exceed 65 Deg. C under service condition mentioned
and there will not be overheating of the system.
The machine shall be provided with suitable lights both at front and
rear ends to ensure good visibility. Entire lighting arrangement shall
be suitable for 12V / 24V electric supply and all the electrical fittings
used shall be FLP type, ISI marked and approved by DGMS,
Dhanbad. The bulb shall be replaceable type.
The machine shall have provision for lock & key to
Prevent unauthorized operation.
Suitable operator’s canopy shall be provided.
The machine will be provided with temp. Gauge as an add-on feature.

GENERAL TECHNICAL SPECIFICATION FOR FLAME
PROOF MOTOR FOR SDL:
1. The motor shall be flameproof, Gr.I Gasses, conforming to the
requirement of IS: 2148, 325, 3682 and other relevant Indian
Standards.
2. The motor shall be DGMS approved and ISI marked.
3. The system voltage shall be 525 Volts with fluctuation +/- 10%,
50 Hz +/- 5%, 3 phase.
4. Ear thing system : Restricted Neutral
5. The motor shall be suitably rated for the working conditions in
underground Coal Mines, ambient temperature 45 Deg.C(Max.)
and 98% RH.
6. The class of insulation for the motor shall be F.
7. The motor shall be provided with suitable plug and socket
arrangement for the attachment of trailing cable, type FT-7
conforming to IS 14494/98 of 25 sq.mm size.

TECHNICAL DATA SHEET OF SIDE DISCHARGE LOADER,
MODEL: M412:
1. Name of the Firm : TRF Limited, Jamshedpur.
2. Name of collaborator & address : Developed in-house.
3. Model / Type No. : M 412
4. Main Motor : 55 KW
5. Overall length : 5000 mm.(approx.)
6. Overall Width : 1750 mm (approx.)
7. Height (over canopy) : 1800 to 2200 mm (adjustable)
8. Track Pad Width : 330 mm
9. Ground pressure
Triple Grouser Pad : 0.9 Kg./Sq.Cm. (approx.).
10. Weight with Bucket etc. : 8800 Kg. (approx.)
11. Max. tramming Speed : 2.6 KMPH
12. Hydraulic pump
a) Type : Fixed Displacement Triple Gear Pump
b) Make of Pump : Parker
c) Capacity : 100+100+70 LPM
d) Pressure of pump : Traction – 125 Kg./sq.cm
Service – 90 Kg./Sq.cm
13. A. Hyd. Motor (Traction) :
a) Type : Radial Piston, 5 cylinder
b) Make : Kawasaki (Staffa)
c) Capacity : 442 cc / revolution
B. Hyd. Motor (Oil Cooler)
a) Type : Geared Motor
b) Make : Parker
C. Hyd. Motor (Chain conv.)
a) Type : Gerotar
b) Make : Danfoss
14. Type of oil / fluid used : Fire Resistant Hyd. Fluid, HFB-68
15. Type of oil cooler & heat : Forced Air Cooled /16 KW/hr.
dissipating capacity
16. Capacity of Tank
Main Tank : 250 Ltr.
Auxiliary Tank : 135 Ltr.
17. Discharge Mechanism : Bi-directional dual discharge bucket
i.e., by opening the side flap of bucket
by actuating flap opening cylinder in
& then rotating the chain conv. drive
hydraulic motor in desired direction of
discharge

18. % by value of imported component : 16%
19. Light front / rear : Provided
20. Audio Visual Alarm : Provided
21. Safety Features:
a) Safe filling arrangement : Provided.
b) High oil temperature cut off : Provided.
c) Low oil level cut off : Provided
d) Canopy : Provided.
e) Hose fail safety : Provided.
f) Provision for power take off : Provided at 90 Kg/Sq.Cm & 70 LPM
22. Gradients on which vehicle will : Above 1 in 3
Slide/ roll down by itself
TECHNICAL AND DIMENSIONAL PARAMETERS:
Overall length of the machine : 5000 mm (approx.)
(Bucket in roll back position)
Width of machine including bucket : 1750 mm (approx.)
Height over canopy : 1800 mm to 2200 mm (adjustable)
Ground clearance : 200 mm (approx.)
Bucket capacity : 1.0 CUM
Track pad width : 330 mm
Ground pressure : 0.9 Kg/Sq.Cm
Speed : 2.6 Km/hr (approx.)
Discharge Height of Bucket Conveyor : 2700 mm (approx.)
Gradient to be negotiated : 1 in 4 / 1 in 8 cross gradient
Minimum turning radius : The machine shall negotiate sharp
Right angle turning without repeated
maneuvering

CONCLUSION:
I am the trainee of B.TECH in Mechanical Engineering from ABIT
CUTTACK. I have completed my project in TRF LTD.
JAMSHEDPUR, JHARKHAND.
I heartily thank the organization for providing me this great
opportunity and convey the best regards.

BIBLIOGRAPHY:
1. TRF MANNUAL
2. WWW.TRF.CO.IN
3. SIDE DISCHARGE LOADER MANUAL

DECLARATION:
We hereby declare that our project training report is submitted to TRF
Ltd. Jamshedpur in partial fulfillment of the requirement for the
purpose of project training done by us during the period June 01, 2015
to June 26, 2015 under the valuable guidance of Mr. SANTOSH
KUMAR.
We have tried our level best to prepare a creditable and acceptable
report on the subject’
HIMANSHU KUMAR
B.TECH IN MECHANICAL ENGINEERING
ABIT CUTTACK

Project on sdl 01

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