MODULAR MULTI SPINDLE NUT TIGHTENING MACHINE

FOR WHEEL BOLTS.

PROJECT REPORT
Submitted By
NAME REG.NO
T.SEANA VIGNESH 512216114312
P.S.JAYA SURIYA 512216114306
C.PREMNATH 512216114310
M.HARIHARAN 512216114036

From,
SKP ENGINEERING COLLEGE, TIRUVANNAMALAI.
Under the guidance of , Mr.Lakshmikanth.B
Deputy manager,
Chassis Assembly.

To,

Ennore, Chennai-600057
During The Period Of (From 28.01.2020 To 27.02.2020)

BONAFIDE CERTIFICATE
 This is certify that the project report “MODULAR
MULTI SPINDLE NUT TIGHTENING MACHINE FOR WHEEL
BOLTS”is the Bonafide work of

T.SEANA VIGNESH 512216114312

P.S.JAYA SURIYA 512216114306
C.PREMNATH 512216114310
M.HARIHARAN 512216114036
Who carried out the project work under my super vision.

SIGNATURE
Mr LAKSHMIKANTH. BE.,

Deputy manager,
Chassis Assembly,
Ashok Leyland,
Ennore, Chennai - 600 057.
 ASHOK LEYLAND
HISTORY
ASHOK MOTORS:
Ashok Motors was founded in 1948 by Raghunandan Saran. He
was an Indian freedom fighter from Punjab. After Independence, he was
persuaded by India's first Prime Minister Nehru to invest in a modern
industrial venture. Ashok Motors was incorporated in 1948 as a
company to assemble and manufacture Austin cars from England, and
the company was named after the founder's only son, Ashok Saran. The
company had its headquarters in Dibrugarh, with the manufacturing
plant in Dibrugarh. The company was engaged in the assembly and
distribution of Austin A40 passenger cars in India.

Under Leyland:
Raghunandan Saran had previously negotiated with Leyland
Motors of England for assembly of commercial vehicles as he
envisioned commercial vehicle were more in need at that time than were
passenger cars. The company later under Madras State Government and
other shareholders finalised for an investment and technology partner,
and thus Leyland Motors joined in 1954 with equity participation,
changing the name of the company to Ashok Leyland. Ashok Leyland
then started manufacturing commercial Vehicles. Under Leyland's
management with British expatriate and Indian executives the company
grew in strength to become one of India's foremost commercial vehicle
manufacturers. The collaboration ended sometime in 1975 but the
holding of British Leyland, now a major British Auto Conglomerate as a
result of several mergers, agreed to assist in technology, which
continued until the 1980s. After 1975, changes in management structures
saw the company launch various.
vehicles in the Indian market, with many of these models
continuing to this day with numerous upgrades over the years.

Under Iveco and Hinduja partnership:

In 1987, the overseas holding by Land Rover Leyland
International Holdings Limited (LRLIH) was taken over by a joint
venture between the Hinduja Group, the Non-Resident Indian
transnational group and Iveco, part of the Fiat Group.

Hinduja Group:
In 2007, the Hinduja Group also bought out Iveco's indirect stake
in Ashok Leyland. The promoter shareholding now stands at 51%.
Today the company is the flagship of the Hinduja Group, a British-based
and Indian originated trans-national conglomerate.
With a commanding strength of the about 12,000 employees the
company is looking forwards to enhance the scope of its action. It is
aiming at expanding its production operation overseas to make it a more
globally accessible company. It is looking to acquire a small to medium
sized commercial vehicle manufacturers in China and other developing
nations, which have an established product line. An example would be
the 2007 acquisition of the Czech based Avia’s truck business
rechristened Avia Ashok Leyland Motors.
Since its inception, Ashok Leyland has been a major presence
and these years have been punctuated by a number of technological
innovations which went to become industry standard. This tradition of
technological innovations and leadership was achieved through years of
vigorous in-house research and development.
From 18 seaters to 82 seater double-decker buses, from 7.5 tonne
to 49 tonne in haulage vehicles, from numerous special application
vehicles to diesel engines for industrial, marine and genset applications,
Ashok Leyland offers a wide range of products.

Ashok Leyland has seven manufacturing plants :-

 Ennore Plant, Chennai.
  Hosur Plants Unit I, Unit II and Unit II
 A.Alwar,Rajasthan.
 Bhandara,
 Maharashtra.
 Pantnagar,
 Uttarakhand

Early products of Ashok Leyland included the Leyland Comet bus

chassis sold to many operators including Hyderabad Road Transport,
Ahmedabad Municipality, Travancore State Transport, Bombay State
Transport and Delhi Road Transport Authority.
In the popular metro cities, four out of five state transport
undertaking buses come from Ashok Leyland. Some of them like the
Double Decker and Vestibule buses are unique models from Ashok
Leyland, tailor made high-density routes.
Statistics reveal that the company is India’s largest exporter of
medium and heavy duty trucks. It sells close to 83,000 medium and
heavy vehicles each year. The company has a near 98.5% market share
in the Marine Diesel engine markets in India. At 60 million passengers a
day, Ashok Leyland buses carry more people than the entire Indian
Railway network.

The Five Ashok Leyland Values are:

 1. International
2. Speedy
3. Value Creator
4. Innovative
5. Ethical

•Ashok Leyland’s Technical Centre, at Vellivoyalchavadi in the

outskirts of Chennai, is a state-of-the-art product development facility,
that apart from modern test tracks and component test labs, also houses
India’s one and only Six Poster testing equipment.
•The company has an Engine Research and Development facility in
Hosur.
•The new plant in the North Indian state of Uttarakhand at
Patnanagar is set up at an investment outlay of Rs.1200 crores. This
plant is expected to go on stream in the year 2010 to cater mainly to the
North Indian market taking advantage of the excise duty and other tax
concessions. The facilities have been so designed as to accommodate
further expansion in terms of capacity and future models. At full
capacity utilization, 75000 vehicles will roll out of the Patnanagar plant.
•The company has signed an agreement with Ras Al Khaimah
Investment Authority (RAKIA) in UAE for setting up a bus body
building unit in the Middle East.
CLIENTS (Not exhaustive):

➢Indian Army.

➢US Army.

➢Honduras Armed Forces (HAF).

➢Tamilnadu State Transport Corporation (TNSTC).

➢Metropolitan Transport Corporation (MTC), Chennai.

➢State Express Transport Corporation (SETC), Tamilnadu.

➢Kerala State Road Transport Corporation.

➢Maharashtra State Road Transport Corporation (MSRTC).

➢Andhra Pradesh State Road Transport Corporation (APSRTC).

➢Parveen Travels.

➢Sharma Transport.

VISION:
Achieving leadership in the medium/heavy duty segments of the
domestic commercial vehicle market and a significant presence in the
world market through transport solutions that best anticipate customer
needs, with the highest value -to-cost ratio.
MISSION:
• -Identifying with the customer.
• -Being the lowest cost manufacturer.
• -Global benchmarking our products, processes and people,
against the best in the industry.

QUALITY POLICY:
Ashok Leyland is committed to achieve customer satisfaction
by anticipating and delivering superior value to the customer in relation
to their own business, through the products and services offered by the
company and comply with statutory requirements. Towards this,
the quality policy of Ashok Leyland is to make continual improvements
in the processes that constitute the quality management system,to make
them more robust and to enhance their effectiveness and efficiency in
achieving stated objectives leading to
1. Superior products manufactured as also services offered by
the company.
2. Maximum use of employees potential to contribute to
quality and environment by progressive up gradation of their knowledge
and skills as appropriate to their functions.
3. Seamless involvement from suppliers and dealers in the
mission of the company to address customers changing needs and
protection of the environment.
PRODUCT PROFILE (Not Exhaustive):
Ashok Leyland offers a comprehensive product range with
trucks from 7.5 tons GVW to 49 tons GVW(Gross Vehicle Weight).
From 19 to 80 seaters in passenger transport, a host of special
application vehicles and diesel engines for industrial gensets and marine
application. Product profile can be broadly split into five categories viz.
Buses, Trucks, defence vehicles, special Vehicles and Engines.

BUSES
 LYNX BS-II
 Viking BS-II
 12 M Bus-BS II
 Cheetah (Front engine)
 Viking BS-III
 Viking AL
 Airport Tarmac Coach
 Vestibule Bus
 Panther (Rear engine)
TRUCKS
 4x2 Haulage models
 Ecomet
 4x2 and Multi-axle Tipper
 Tractor
 Multi Axle vehicles

DEFENCE VEHICLES
 Short Chassis Bus
 Field artillery tractor
 Comet 4x4
 Topchi field Artillery tractor
 Long Chassis Bus
 Stallion 6x6
 Stallion truck fire fighting
SPECIAL VEHICLES

 Hippo tractor
 Stallion Mk III Tipper
 Hippo Tipper
 Beaver tractor
 Rapid Intervention Vehicle
 Beaver Haulage
 Hippo Haulage

ENGINES
 Genet application
 Marine application
 ABSTRACT

Nut Runner are tools used for tightening nuts. By definition, nut
drivers are purely mechanical hand tools, while nut runners can be
Pneumatic, Electrical or Hydraulic power tools. Now-a-days, multi
spindle systems are used in vehicle assembly line, where all nuts of the
wheels are tightened simultaneously.
According to the quantity of nuts of wheel to be tightened
simultaneously, the nut runner system is chosen. The project is based on
development of existing system, which is used in vehicle assembly line
for tightening of 6,8,10 nos. of nuts of the vehicle wheels
simultaneously, where nuts are tightened with desired torque. For 6-nut
wheel vehicles, 6- nut runner multi spindle drive system is required,
similarly for 8&10-nut wheel vehicles, 8&10-nut runner multi spindle
drive system will be required. So we can say that for different number of
nuts of wheels of vehicle required different type of nut runner spindle
drive system. Aim of the project is to make combination of 6-nut runner
system and 8&10-nut runner system and build a single drive system
which can be used for 6-nut wheel tightening as well as for 8,10 nut
wheel tightening.
 CONTENT

Chapter.no Title Page.no

1. INTRODUCTION

2. LITERATURE REVIEW

3. NOW USE IN INDUSTRY

(Power wacs 4000)

4. WORKING OF (Power wacs 4000)

5. TYPES OF WHEEL NUT

TIGHTENINIG MACHINES

6. SEQUECE OF WHEEL LUG NUT

TORQUE
7. LAYOUT DIAGRAM

8. MODIFICATIONBASED
ON SHIGLEYS
DESIGN METHOD

9. DESGIN
CALCULATIONS

10. 2D DESIGNS

11. CONCULSION
 INTRODUCTION

Multiple-spindle machines are used for mass production, a great

time saver where many pieces of jobs having many operations can be
carried out. Multi-spindle head machines are used in mechanical
industry in order to increase the productivity of machining systems.
The multiple spindle machines is a production type of machine. It
is used to perform the different operation in a work piece
simultaneously, in one setting. This machine has ten spindles driven by a
single motor and all the spindles are fed in to the work piece alternately.
Feeding motions are obtained either by raising the work table or by
lowering the drills head. The center distance between the spindles can be
adjusted in any position as required by the different jobs. For adjusting
the center distance between the spindles they are connected to the main
spindle by spur gear joint.. In today’s market the customer demands the
product of right quality, right quantity, right cost, & at right time.
Therefore it is necessary to improve productivity as well as quality. One
way to achieve this is by using multi spindle machine.
 LITERATURE REVIEW
[1] Jia-Hua Lin_, Raymond W. McGorry, Predicting subjective
perceptions of powered tool torque reactions, Liberty Mutual Research
Institute for Safety, Hopkinton, MA, USA, (2010). pp. 47-55.
[2] Hua Lin, V.Rammohan Maikala, Raymond McGorry, Christopher
Brunette, NIRS application in evaluating threaded-fastener driving
assembly tasks , Liberty Mutual Research Institute for Safety, 71
Frankland Road, Hopkinton, MA 01748, USA, (2010). pp. 146-152.
[3] Chad E. Gooyers, Joan M. The impact of an increase in work rate
on task demands for a simulated industrial hand tool assembly task,
Stevenson School of Kinesiology and Health Studies, Queen’s
University, 69 Union St., Kingston, Ontario K7L 3N6, Canada, (2012)
pp.80-89.
[4] X. S. Xu, D. E. Welcome, T. W. McDowell, C. Warren, R. G.
Dong, An investigation on characteristics of the vibration transmitted to
wrist and elbow in the operation of impact wrenches.Engineering &
Control Technology branch, national institute for occupational safety &
health, 1095 Willowdale Road, Morgantown, WV 26505, USA, (2009),
pp. 174-184.
[5] Jia-Hu Lin, Robert G. Radwain, Terry G.Richard. A single degree of
freedom dynamic model predicts the range of human response to
impulsive forces produce by power hand tools, USA, (2003), pp. 1845-
1852. [6] Chih-Hung Chang, Moa-Jiun J. Wang.. Eavluating the effects
of activation mode, torque & horizontal operating distance on hand-arm
response while operating pneumatic screwdrivers. National Tsing Hua
University, Hsinchu, Taiwan 30043, (2001), pp. 171-179. [7] Patrice
Murphy, Rymond McGorry, Peter Teare,George Brogmus. Design and
performance of manual task evaluator, USA, (2000) pp. 257-264.
NOW USE IN INDUSTRY (Power wacs 4000) :

The 2 spindle wheel nut runner is designed and laid out for the
tightening of the wheel nuts the nut runner is mounted on x and y rail
system on the station. The vertical adjustment takes place with an
electrical hoist. The tightening is done horizontally with the adjustable
hand grips the nut runner is placed in the correct tightening position. The
nut runner is activated by means of the start switch on the hand grips.
The tightening process can be maintained and controlled from the
operating panel.
WORKING OF (Power wacs 4000) :
 Vehicle enters the station.
 Operator fit the wheel to the vehicle and hand starts the fastener.
 Operators selects the model with selector switch on the operator
panel.
 The operator push the nut runner towards the front wheel and locates
on the joint. It may be necessary to align the nut runner with the joint
in the vertical plane. Further alignment may be necessary by rotating
the nut runner via the hand wheel on the front of the multi.
 Once correctly positioned on the joint the tightening sequence can
commence by pressing the start button.
1.Power macs extinguishes indicator lamps from last tightening.
2.The operator does not to keep the button depressed throughout
the cycle.
3.the orange runner LEDs will illuminate during tightening.
If all okay green cycle okay lamp will be illuminate on the lamp box.
The two running/NOK LEDs will go out.
The system will count 1 okay in the PLC.
 If any not okay.
Red cycle not okay lamp will illuminate on the lamp box.
Corresponding failed spindle will illuminate orange LEDs on the
lamp box.
 After tightening 2 set of the nut operator will rotate the power head
and start the above procedure for next set of 2 and so on till all 10
bolts get tighten.
 Once the front wheel has been correctly fastened above tightening
procedure is replicated for the rear wheel.
 On completion of the rear wheel the data will be stored in the
controller.
TYPES OF WHEEL NUT TIGHTENINIG MACHINES :
 PISTOL GRIP NUTRUNNERS
 ANGLE NUTRUNNERS
 TENSOR ES ELECTRIC NUTRUNNERS
 TENSOR ST/STR ELECTRIC NUTRUNNERS
 TENSOR STB TRANSDUCERIZED BATTERY
NUTRUNNERS
 FIXTURED NUTRUNNERS
1. QST TOOLS WITH POWER MACS 4000
2. ETX TOOLS WITH POWER FOCUS 4000

 FIXTURED MULTIPLES
 CUSTOMIZED SOLUTIONS
1. MAIN BEARING CAP SECURE
1-Spindle vertical fixture with high torque reaction
suspension.
2.HAND TOOL SUSPENSION – HTS1
1-Spindle vertical fixture HTS1.
3. WHEEL NUT SECURE – LARGE BOLT PATTERN

2-Spindle horizontal rotate fixture HR3 with air cylinder

suspension.
4.CYLINDER HEAD SECURE
1-Spindle vertical fixture articulated arm with PRS.
SEQUENCE OF WHEEL LUG NUT TORQUE:

Check all parts, including wheels and studs and mounting faces of
hub and wheels, for dirt, rust or damage. Use a wire brush to remove dirt
and rust, replace any damaged parts. Careless installation of wheels on a
vehicle is a major cause of tire and wheel problems. Proper installation,
including nut torque, is essential to safe, economical, trouble free
service. Use only the specified sizes and types of studs and nuts.
Tighten the nuts a quarter turn at a time following the criss-cross
sequence shown above. This is very important. Failure to tighten the
nuts in this criss-cross sequence will cause a misalignment of the wheel.
Continue until all nuts are tightened to the manufacturers specified
torque.
CAUTION
Improper torque can cause distortion, fatigue cracks or alignment
problems. After running the vehicle for a short distance, check the nuts
for tightness. Parts will usually seat naturally and torque on nuts will
drop. Retighten all nuts to the specified torque.

MODIFICATION BASED ON SHIGLEY’S DESIGN

METHOD:

OBSERVATION:

The 2 spindle wheel nut runner is designed and laid out for the
tightening of the wheel nuts the nut runner is mounted on x and y rail
system on the station. The vertical adjustment takes place with an
electrical hoist.
The tightening is done horizontally with the adjustable hand
grips the nut runner is placed in the correct tightening position. The nut
runner is activated by means of the start switch on the hand grips. The
tightening process can be maintained and controlled from the operating
panel.

PROBLEM:
 Requires individual labour both left & right side.
 It makes skipping problem during the wheel bolt
tightening in some times.
 It makes more time to tightening the all bolts.
 It achieves only two bolts tightening at the single
stroke.
 The torque variation may be generating during the
bolt tightening.

MODIFIED MECHANISM:
In our project of modular multi spindle nut runner it is a
concept of tightening are bolts at single stroke (i.e 6 no of bolts,
Eight no of bolts and Ten no of bolts) by adjusting the
circumference and pitch circle diameter with the help of gear
actuation.
 Initially the spindles are placed in a circular plate. It
achieve all the Six bolts tightening at the same time to reach the
torque value of upto (max upto 700N-M).
The next step to achieve the Eight bolts tightening at
single stroke for the Eight bolt nut tightening additionally the
Two spindles are required.
These Two spindles are coupled with the individual
motor. It is a Roto-linear actuator now the initial six spindles
goes to next stage through the guide ways. The travel of spindle
in upward position with the help of actuation of cam drive. This
cam is push the spindle to next stages through the guide ways.
The cam lock return of spindle to downward position.
For the Ten no of bolts the spindles forward to the
final stages through the guide ways by the cam actuation. The
cam pull up the spindles. And lock the guide ways for non-
return spindle to the downward position.
Now the Two spindles are placed innerside of the
tightening system and it is actuated by roto-linear device(i.e
linear movement clockwise & counter clockwise rotation the
spindles are travelled wheel nut tightening system to outer of the
wheel nut tightening system to outer of the wheel nut tightening
system. Now the 10 spindles are arranged in same distances.
These spindles are achieve upto the 700 N-M torque.
LAYOUT DIAGRAM:
SOME IMPORTANT PARTS

1.TORQUE TUBE
2.MOTOR
3.TRANSDUCER
4.GEAR UNIT
5.SOCKET HOLDER

1.TORQUE TUBE

A torque tube is a non-rotating tube that connects the two non-

rotating components on either end of the drive shaft .
The driveshaft rotates within the torque tube, and carries the
rotating torque.
2.TRANSDUCER

A transducer is a device that converts energy from one form to

another. Usually a transducer converts a signal in one form of energy to
a signal in another

3.SOCKET HOLDER

A non-ratcheting socket wrench where the socket is attached

permanently to the end of a L-shaped, or X-shaped bar. They are
designed as special use socket wrenches for loosening and tightening lug
nuts on automobile or truck wheels.
4.SERVO MOTOR

The servo motor is actually an assembly of four things: a

normal DC motor, a gear reduction unit, a position-sensing device and a
control circuit. The DC motor is connected with a gear mechanism
which provides feedback to a position sensor which is mostly a
potentiometer. From the gear box, the output of the motor is delivered
via servo spline to the servo arm. For standard servo motors, the gear is
normally made up of plastic whereas for high power servos, the gear is
made up of metal.
WORKING PRINICPLE:
Initially the spindles are placed in a circular plate. It
achieve all the Six bolts tightening at the same time to reach the
torque value of upto (max upto 700N-M).
The next step to achieve the Eight bolts tightening at
single stroke for the Eight bolt nut tightening additionally the
Two spindles are required.
These Two spindles are coupled with the individual
motor. It is a Roto-linear actuator now the initial six spindles
goes to next stage through the guide ways. The travel of spindle
in upward position with the help of actuation of cam drive. This
cam is push the spindle to next stages through the guide ways.
The cam lock return of spindle to downward position.
For the Ten no of bolts the spindles forward to the
final stages through the guide ways by the cam actuation. The
cam pull up the spindles. And lock the guide ways for non-
return spindle to the downward position.
Now the Two spindles are placed innerside of the
tightening system and it is actuated by roto-linear device(i.e
linear movement clockwise & counter clockwise rotation the
spindles are travelled wheel nut tightening system to outer of the
wheel nut tightening system to outer of the wheel nut tightening
system. Now the 10 spindles are arranged in same distances.
These spindles are achieve upto the 700 N-M torque.
DESGIN CALCULATIONS:
 For 6 spindle :
360
Angle of spindles =
6

Each spindle angle = 60 deg

Circumference of the = 205 mm

6 spindles

 For 8 spindle :
360
Angle of spindles =
8

Each spindle angle = 45 deg

Circumference of the = 275 mm

8 spindles

 For 10 spindle :
360
Angle of spindles =
10

Each spindle angle = 36 deg

Circumference of the = 335 mm

10 spindles
2D DESIGNS

SOCKET HOLDER

GERA UNIT
TORQUE TUBE

MOTOR
TRANSDUCER
OVER ALL VIEW:
CONCULSION:

Thus, the paper deals with the design of a multispindle

nutrunner which is capable of transmitting high torque values which is
needed for bolt tightening. This nutrunner will be able to successfully
transmit the torque even in the given space requirement. The torque
values were verified while testing the prototype and the final model will
also employ the same method of transmission and distribution of this
torque.