BMTC Report

ENGINE TRANSMISSION AND BODY DESIGN
WORKSHOP LAYOUT
Fig.1 Layout
Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 1

CHAPTER 1
ABOUT THE COMPENY
1.1 History of BMTC

The BMTC is one of the three Subsidiaries of Karnataka State Road Transport
Corporation, in the context of the city's expansion in the year 1997, Bangalore Transport
Service(BTS) was formed. Later Bangalore Transport Service(BTS) became Bangalore
Metropolitan Transport Corporation. and the colour scheme of BTS was also changed
from red to a blue and white combination. For this day BMTC still remains a division of
KSRTC. The profits earned by BMTC are used to cover the losses from the NWKRTC
and NEKRTC divisions of KSRTC.
Introduced on 4 February 2010, Bus Day is an event calling all the citizens of
Bangalore to use public transport. The idea behind Bus Day is to observe the change
switch can brought in the city in trying to respect environment, traffic situation, health of
individual’s perception. The 4th of every month is observed as a "Bus Day"
1.1 Types of services

The following are the special services apart from ordinary services run by BMTC:
Suvarna: Similar fare to ordinary buses serving important feeder routes, painted in red or
green/white scheme.
BIG 10: Suvarna class buses with special green and bottle green livery plying on 12
major corridors towards the central commercial district. These buses are numbered with a
G prefix.
BIG Circle: Suvarna class buses with special white coloured BIG Circle livery. These
buses ply on inner and outer ring roads. Buses are numbered with a C prefix or a K
prefix.
Atal Sarige: Low fare buses painted with Indian tri-colour livery.
Vajra: Air conditioned Volvo buses painted in blue livery (earlier red) running on
important routes serving the IT companies and major residential areas.
Vayu Vajra: Blue coloured (Earlier green/red) Volvo buses operated in 12 routes
connecting to Kempegowda International Airport. Free Wi-Fi access is provided to the
commuters in these buses.

Marcopolo AC and Corona AC: Air conditioned buses with lower fare than Vajra
services plying on select routes. (Marcopolo AC is now out of service & Corona AC has
the same fare as Volvo)
Metro Feeder: Special buses running on 18 routes as feeder network to the Metro
stations.
Hop On Hop Off: This service was introduced for sightseeing in Bangalore. It covers a
route connecting about twenty landmarks of great historic, religious and scientific
significance. (no service now)
BMTC has also introduced Mercedes Benz buses on a trial basis. BMTC has also
introduced buses powered by solar energy on trial basis in Bangalore.
The BMTC announced that it would acquire 150 electric buses by September 2017. The
project will be funded by the Union Government's Faster Adoption and Manufacturing of
Electric Vehicles scheme of National Electric Mobility Mission Plan 2020.
Major bus stations: BMTC has 34 bus stations across the city and the 3 major bus
stations are located at:
1. Majestic
2. K. R. Market
3. Shivajinagar
BMTC has 10 Travel and Transit Management centers (TTMCs) located at

Shantinagar, Banashankari, Jayanagar4th block, Koramangala, Kengeri, Yeswanthpur,
Vijayanagar, Domlur, ITPL and Mysore Road Satellite Bus Station.
1.2 BMTC’s Idea

Intelligent Transport System: To benefit the commuters and promote the usage of
public transportation, the BMTC launched its Intelligent Transport System (ITS) on 25
May 2016.Under this project, BMTC buses were equipped with GPS in a phased manner
which would transmit the location of the bus to the ITS control room. A mobile app was
launched on the android platform which was made available in two languages, English

and Kannada. The app provides information about bus routes and bus stops. Real time
location of buses on a particular route can also be tracked, which requires the users to
switch on the GPS on their device. By early 2017, BMTC would be prepaid smartcards
for commuting, which would eliminate the need to pay the exact amount ofchange.
Smart card: BMTC unveiled a smart card for its bus services for the first time in June
2016. The company introduced smart cards on trial-basis on BMTC Bus No. 335
operating between Majestic and Kadugodi bus stations in March 2017.Apart from serving
as an identification document, the smart cards can be used to purchase bus tickets and
also swiped at point-of-sale (POS) enabled merchant establishments. The card costs Rs 5
and can be recharged for up to Rs 10,000. Recharges higher than Rs 10,000 require the
customer to provide identification. According to Axis Bank, the BMTC's partner in the
project, the smart card is India's "first open loop EMV contactless smart card". The cards
"open-loop" structure

CHAPTER 2
ENGINE
Engine is a machine designed to convert one form of energy into mechanical

energy. Combustion engines are heat engines driven by the heat of a combustion process.
The internal combustion engine is an engine in which the combustion of a fuel occurs
with an oxidizer in a combustion chamber. In an internal combustion engine, the
expansion of the high temperature and high pressure gases, which are produced by the
combustion, directly applies fore to components of the engine, such as the pistons and
moving it over a distance, generates mechanical work.
2.1 Cylinder Block
The cylinder block is the main body of the engine between the cylinder head and
oil pan. The cylinder block and crank case are made of a cast ferrous alloy or semi steel
which gives great resistance to wear than older type of a cast ferrous iron. Some engines
use cylinder block cast aluminium with steel cylinder linings. The upper part of the
cylinder block contains the cylinders and water jackets. The lower part forms the crank
case which serves as a support and cover for the crank shaft cam shaft which are
supported by suitable bearings.
Figure 2.1.1a & 2.1.1b Cylinder Block

2.2 Cylinder Bore

The bore or cylinder bore is a part of a piston engine. The bore also represents the
size of the diameter of the cylinder in which a piston travels. The value of a cylinder’s
bore, and stroke, is used to establish the displacement of an engine.
Figure 2.2.1 Cylinder Bore
2.3 Camshaft
A camshaft on an internal combustion heat engine is a device that controls both
the input of fuel and the expulsion of exhaust fumes. It consists of several radial cams,
each displacing intake or exhaust valves. This camshaft is connected to the crankshaft
via belt, chain or gears. This ensures consistent timing of the valves in relation to the
motion of the pistons.
Major problems with camshafts.
• The wear in cams profile causes the cam followers improper working.
• The improper working of cam followers causes the distortion in the working of the
rocker arm and valve springs, these problems create the imbalanced opening in the valve
heads.
Solutions.
• Workers in the this department deals with the problem in the camshaft by using cam
grinders and gives the actual finishing of the cam profiles.
• While reconditioning period the camshaft is cleaned and lubricated by the oil.

2.4 Crank Shaft
The crank shaft made of forged steel is located in the crank case directly below
the cylinders. Forged steel is steel that has been heated until red hot and then hammered
or pressed into the proper shape. The bearing surfaces of the shaft are accurately ground
to size and the entire shaft is delicately accurately balanced. The crank shaft is supported
in the crank casing by bearings known as main bearing. The purpose of the crank shaft is
to change the reciprocatory action of the piston in the cylinder to the rotary motion of the
flywheel. This conversion of the motion is accomplished by the use of offset cranks
called throws. The throw has a bearing surface known as crank pin to which the
connecting rod is attached.
Major problems seen in the Crankshaft.
• A crankshaft is subjected to enormous stresses, potentially equivalent of several tonnes

of force due to which the friction, noise and vibrations are observed in the crankcase.
• Engine loses up to 75% of its generated energy in the form of friction.
Solution.
• To avoid friction, the crankshaft is subjected to the proper sequencing of balancing of

rotating masses.
Figure 2.4.1 Crank Shaft

2.5 Piston
A cylindrical metal component which reciprocates in the cylinder under gas

pressure. It is connected to the piston rod or to the connecting rod. The piston of an
engine is the first part to begin movement and to transmit power to the crankshaft as a
result of the pressure and energy generated by the combustion of the fuel. The piston is
closed at one end and open on the other end to permit direct attachment of the
connecting rod and its free action.
Piston has three rings namely,
• Compression ring: It prevents compression leak between cylinder and piston.

• Oil ring: It helps in lubrication between piston and cylinder.
• Oil strap: It prevents oil from moving into the combustion chamber.
Major problems occurring in pistons:
• Overheating due to combustion defaults.
• Clearance restriction in upper sliding surface area.
• Wear and tear of compression ring and oil rings
• Insufficient compression.
Solutions
• Workers replaces the damaged pistons and also replaces the piston rings and oil rings.
• They thoroughly clean the carbon particles present on the surface of the piston and they
check whether the sufficient combustion is occurring or not.
Figure 2.5.1a & 2.5.1b Piston

2.6 Connecting Rod

A connecting rod is a rigid member which connects a piston to a crank or crankshaft
in a reciprocating engine. Together with the crank, it forms a simple mechanism that
converts reciprocating motion into rotating motion.
Major problems with connecting rod
Connecting rod twists due to constant pounding of the explosive pressures developed in
the combustion area.
Solutions.
Workers replaces the old connecting rod with new one and prevents the happening of
twisting moments under tons of load.
Figure 2.6.1a & 2.6.1b Connecting Rod

2.6 Damper Pulley (Harmonic Damper)
A harmonic damper is a device fitted to the free (accessory drive) end of the
crankshaft of an internal combustion engine to counter torsional and resonance
vibrations from the crankshaft. The harmonic balancer often serves as a pulley for the
accessory drive belts turning the alternator, water pump and other crankshaft driven
devices.
Major problems occurring in the damper pulley.
2.6.1 The rubber layer in the harmonic balancer dries or wears out which causes the
entire harmonic balancer to completely fail by separating.
2.6.2 Engine belts will usually come off and vehicle will be left without engine
accessories due to wear out rubber layer
2.6.3 Harmonic damper can no longer absorb the harmonic vibrations when it gets
too old due to which the engine will shake excessively and therefore dangerous to the
engine at high speed.
Solution.
2.6.4 It is seen that the rubber layer in the harmonic balancer is oftenly replaced after
a certain period of time.
2.6.5 If the engine is found to be excessively shaking, then the damper pulley will be
replaced by the new one.
Figure 2.7.1 Damper Pulley

CHAPTER 3
TRANSMISSION
3.1 Clutch
Clutches are useful in devices that have two rotating shafts. In these devices, one
of the shafts is typically driven by a motor or pulley, and the other shaft drives another
device. The clutch connects the two shafts so that they can either be locked together and
spin at the same speed, or be decoupled and spin at different speeds. The clutch allows
us to smoothly engage a spinning engine to a non-spinning transmission by controlling
the slippage between them. A clutch works because of friction between a clutch plate
and a flywheel.
Major problems seen in the clutch system.
• Clutch plate wear.

• Improper shifting of gear.
• Sound is occurred while shifting of gear.
• Jerk is produced in transmission system due to wear in the clutch plate.
Solutions.
• If any of parts like clutch cover, spring, clutch plate is weared out then they
replaced by the new one while reconditioning.
Figure 3.1.1 Clutch

3.2 Gear Box
Figure 3.2.1a & 3.2.1b Gear Box
The transmission allows the gear ratio between the engine and the drive wheels to
change as the speeds up and slows down.
• To understand the basic idea behind a standard transmission, the diagram below shows a
very simple two-speed transmission in neutral:
Figure 3.2.1c Schematic Diagram of Gear
• Let's look at each of the parts in this diagram to understand how they fit together:
• The green shaft comes from the engine through the clutch. The green shaft and green
gear are connected as a single unit. (The clutch is a device that lets you connect and
disconnect the engine and the transmission. When you push in the clutch pedal, the
engine and the transmission are disconnected so the engine can run even if the car is
standing still. When we release the clutch pedal, the engine and the green shaft are

directly connected to one another. The green shaft and gear turn at the same rpm as the
engine.)
• The red shaft and gears are called the lay shaft. These are also connected as a single
piece, so all of the gears on the lay shaft and the lay shaft itself spin as one unit. The
green shaft and the red shaft are directly connected through their meshed gears so that if
the green shaft is spinning, so is the red shaft. In this way, the lay shaft receives its
power directly from the engine whenever the clutch is engaged.
• The yellow shaft is a splined shaft that connects directly to the drive shaft through the
differential to the drive wheels of the car. If the wheels are spinning, the yellow shaft is
spinning.
• The blue gears ride on bearings, so they spin on the yellow shaft. If the engine is off but
the car is coasting, the yellow shaft can turn inside the blue gears while the blue gears
and the lay shaft are motionless.
• The purpose of the collar is to connect one of the two blue gears to the yellow drive
shaft. The collar is connected, through the splines, directly to the yellow shaft and spins
with the yellow shaft.
• However, the collar can slide left or right along the yellow shaft to engage either of the
blue gears. Teeth on the collar called dogteeth, fit into holes on the sides of the blue
gears to engagethem.
Now, let's see what happens when shift into first gear.
Figure 3.2.1d Gear Shifting Process

• In this picture, the green shaft from the engine turns the layshaft, which turns the blue
gear on the right. This gear transmits its energy through the collar to drive the yellow
drive shaft. Meanwhile, the blue gear on the left is turning, but it is freewheeling on its
bearing so it has no effect on the yellow shaft

• When the collar is between the two gears, the transmission is in neutral. Both of the blue
gears freewheel on the yellow shaft at the different rates controlled by their ratios to the
layshaft.
• When we make a mistake while shifting and hear a horrible grinding sound, you are not
hearing the sound of gear teeth mis-meshing. As we can see in these diagrams, all gear
teeth are all fully meshed at all times. The grinding is the sound of the dogteeth trying
unsuccessfully to engage the holes in the side of a blue gear.
• The transmission shown here does not have "synchros", so if we are using this
transmission you would have to double-clutch it. In double-clutching, we first push the
clutch pedal in once to disengage the engine from the transmission. This takes the
pressure off the dog teeth so we can move the collar into neutral. Then you release the
clutch pedal and rev the engine to the "right speed." The right speed is the rpm value at
which the engine should be running in the next gear. The idea is to get the blue gear of
the next gear and the collar rotating at the same speed so that the dog teeth can engage.
Then we push the clutch pedal in again and lock the collar into the new gear. At every
gear change we have to press and release the clutch twice, hence the name "double-
clutching."
• We can also see how a small linear motion in the gear shift knob allows you to change
gears. The gear shift knob moves a rod connected to the fork. The fork slides the collar
on the yellow shaft to engage one of two gears.
• Reverse gear is handled by a small idler gear (purple). At all times, the blue reverse gear
in this diagram is turning in a direction opposite to all of the other blue gears. Therefore,
it would be impossible to throw the transmission into reverse while the car is moving
forward -- the dog teeth would never engage. However, they will make a lot ofnoise.
Figure 3.2.1e Idler Gear

Three major problems occurring in the gear boxes are.
• Dark oil or low oil level is seen due to the overheating.

• Smoke coming from shafts is seen because of the overheating issues.
• Oil leakage is found in the gear box which in turn reduces the oil level in the gear box
and thus reduces the smooth functioning of the gears.
• The seal cracks present in the gear box allows the dust and water inside the gear box
which reduces the life span of the gearbox.
• The sound in the gear box indicates that there will no sync the various parts the gear
system.
Solutions.
• It is seen that proper lubrication is done to avoid the noises and proper shifting of gears.
• The seal cracks are further being air tighten so that the oil leakage isprevented.
3.3 Propeller Shaft
Fig 3.3.1.a Propeller Shaft

Fig.3.1b Propeller Shaft
A propeller shaft(propeller shaft), or Cardan shaft is a mechanical component for

transmitting torque and rotation, usually used to connect other components of a drive
train that cannot be connected directly because of distance or the need to allow for
relative movement between them.
To allow for variations in the alignment and distance between the driving and
drive components, drive shafts frequently incorporate one or more universal joints, jaw
couplings or rag joints, and sometimes a splined joint or prismatic joint.
Joints in the propeller shaft.
• Slip joint
• Universal joint
Major problems seen in the propeller.
• The distortion in propeller shaft creates vibration and shaking in the vehicle.
• Vibrations are also caused by the lack of lubrication on the U-joint.
• A low squeaking noise is observed. Upon accelerating the squeaking noise becomes
louder and the noise becomes low upon deceleration this is the sign of worn U-joint.
Solution
• Proper lubricating at the U joint reduces the vibrations.

• The bolts tightened up at the Universal joints should reconditioned oftenly.

3.4 Differential
Fig.3.4.1 Differential
Fig.3.4.2Complete structure of differential assembly
When an Automobile negotiates a turn, the distance travelled by outside wheels

is greater than that travelled by inside wheels in the same time. If the wheels are
mounted on dead axles, so that the turn independent to each other (like front wheels of
an ordinary passenger vehicle), the wheels will turn at different speeds to com pen ate
for the difference in travel. But if the engine drives the wheels, some device is necessary
which will allow the wheels to revolve at different speeds. To do this a device called
differential is provided in the rear axle. This will increase tile end of outside wheels and
reduce the speed of inside wheels, when the vehicle travels around a corner, in the
meantime keep the speed of all the wheels same when the vehicle is going straight head.
This avoids skidding when the vehicle is taking turn.

Operation of differential
• It consists of a drive pinion or bevel pinion, attached to the shaft which is coupled to the
propeller shaft. A crown wheel or ring gear which is bolted to the differential cage is in
mesh with the bevel pinion. The cage carries a cross pin or spider (cross pin is used
when two pinion gears are employed and spider is used when four pinion gears are used)
to support two differential pinion gears which are in mesh with the two differential side
gears (sun gears) which are splined to the axle half shafts. The ring gear (crown - wheel)
is free to rotate on the half shaft.
• When the propeller shaft turns the bevel pinion, the pinion will turn the crown wheel.
The crown wheel in turn will revolve the differential cage and cross pin. The axle side
gears will still not turn. By adding two differential pinion gears (The cross pin will pass
through these gears) that mesh with the side gears, the revolving cage will turn the axle
side gears with it.
When the vehicle is going straight ahead, the crown wheel turns the cage. The
differential pinion gears and axle side gears are moving around with the cage and pinion
gears do not

CHAPTER 4
FUEL INJECTION PUMP (FIP)
4.1 Fuel Injection Pump
Fig.4.1 Fuel injection pump
An Injection Pump is the device that pumps fuel into the cylinders of a diesel
engine. Traditionally, the injection pump is driven indirectly from the crankshaft by
gears, chains or a toothed belt (often the timing belt) that also drives the camshaft. It
rotates at half crankshaft speed in a conventional four-stroke engine. Its timing is such
that the fuel is injected only very slightly before top dead center of that cylinder's
compression stroke. It is also common for the pump belt on gasoline engines to be driven
directly from the camshaft. In some systems injection pressures can be as high as 200
MPa (30,000PSI).
NOTE- MAJORITY OF FIP’S ARE MANUFACTURED BY BOSCH IND PVT LTD

4.2 Injector
Fig.6 Fuel injector
The fuel injector is used

✓ To atomize the fuel to the required degree of fineness.
✓ To distribute the fuel for proper mixing of fuel and air.
✓ To prevent fuel injection on cylinder walls and top of the piston.
✓ The fuel injection must start and stop instantaneously.
Parts
1. Constant and adjustmentsim
2. Retaining spring
3. Distance piece-holds nozzle
4. Spindle
5. Nozzle
6. Valve fitting
Reconditioning procedure
Checking of injector includes the following steps

✓ checking spray pattern
✓ checking dribbling
✓ leakage check
✓ pressure check

4.3 Air Compressor
Fig.7 Air compressor
Air compressor is fitted onto an engine and it helps in compressing air to high
pressure for use in braking systems and all the pneumatic controls of the vehicle.
Parts of an air compressor (reciprocating type)

• compartments – inlet and outlet
• Cylinder
• Piston with rings
• crankshaft
• Read and read plates-inlet (has 4 holes)
• Outlet (has 2holes)
Note- Major Parts for air compressor in BMTC are manufactured by TVS and WABCO.

4.4 Turbo Charger
Fig.17 Turbo charger

Turbochargers are a type of superchargers. It effectively 'charges' the incoming
air, which is the definition of supercharging. The turbo differs from a supercharger in
that it derives its power from a different source than previously described designs. The
previous designs received power from the driveshaft of the engine. Turbochargers derive
their power from exhaust gasses.
Uses
• Boosts the air supply to the engine and increases thermal efficiency.
• Reduces pollution by decreasing the exhaust.
• 80% of the waste gas energy is recovered to drive the turbine which in turn runs the
compressor.
• Size of the engine is reduced.

CHAPTER 5
BUS BODY DESIGN
5.1 Chassis Structure Section

The starting point of the coach building starts from the structure section. The
structure gives the primary shape and rigidity to the bus. Here the newly arrived engines
come for primary structure development. The whole outer body structure is divided into
three major parts namely top, bottom and sides. The bottom (floor) section is welded
onto the chassis of the bus. The top and side sections are separately developed as per
specifications and are welded onto their respective places.
The following images shows the horizontal bars welded to the chassis.
Figure 5.1.1aNewlyarrivedChassisFigure 5.1.1b Beams Welded to Chassis

The floor consists of 12 horizontal bars which takes the overall load capacity of
the bus. After that they are inter connected with cross bars.
The left and right sides of the bus are separately done as shown in the figure. These are
made using rectangular steel bars. The specifications are shown next to it.
Figure 5.1.1cProduction layout of the left right portion Figure 5.1.1d Part being produced
Figure 1Part beingProduced

The roof top portion of the bus is prepared side by side. For this a separate jig is
used as shown I the figure. It uses steel bars of “hat section” which are bent using
hydraulic bending machine.
Figure 5.1.1e Layout of the roof section Figure 5.1.1f Part Being Produced
At last all these parts are welded on to the chasse is to form the full structure. The
figure shows the final arrangement at the structure section. All the parts are welded
together using carbon-di-oxide welding. Since CO2 welding is more rigid, stronger than
normal electrode welding, CO2 welding is employed. This sectional so accommodates the
cabins for battery box, toolbox, foot board and currier carriage box. When all the
processesare finished the bus is then passed to the panelling section.
5.2 Panelling Section
All the Panelling process is done using different types of metal sheet. The
flooring is done using embossed sheets for fine gripping. This sheet is about 3.05mm
thick and covers all the floor space.
The remaining all the portions of the outer and inner sections are covered using
normal 1.22mm thick aluminium sheet. The gap between outer and inner sections of
body is filled with foam sheets which give dimensional stability during production mean
while also acts as an insulator of temperature between layers of sheet.

Figure 5.2.1 Arriving of bus toPanelling Section

The following figure shows the newly arrived bus which passed structure section
and entered panelling section. Here the electrical wiring is partly done for all electrical
components like lights, stop lights and tail lamps. All the sheet metals are held in place
using pop rivets. The metal sheets are cut, bent and formed to required shapes using
appropriate machines.
5.2 Functions of Chassis
1. To carry load of the passengers or goods carried in the body.

2. To support the load of the body, engine, gear box etc.,
3. To withstand the forces caused due to the sudden braking or acceleration
4. To withstand the stresses caused due to the bad road condition.
5. To withstand centrifugal force while cornering

POWER TRANSMISSION
• ENGINEBG+230CUMMINS BS4;WATER COOLED,TURBOCHARGER

INTERCOOLED CNG ENGINE;INBUILT HYDRODYNAMICRETARDER
• EMISSIONS NORMS: BSIV
• ENGINE CYLINDERS:9
• MAX POWER:231BHP@2800
• MAXTORQUE:678NM@1600RPM
• TRANSMISSION:MANUAL
• FUELTANK(LTRS):80
• TURNINGRADIUS(mm):20200
• MAXSPEED(KM/HR):72
DESIGN & BUILD
• BODY OPTIONS: FULLYBUILT

• CHASSIS TYPE: CHASSIS WITHOUT FACECOWL
• FRONT TYRE :11R22.5PR
• REAR TYRE :8.25R16-16PR
• WHEELBASE(mm):6300
• OVERALLLENGTH(mm):12000
• OVERALLWIDTH(mm):2600
• OVERALLHEIGHT(mm):3350
• FRONTOVERHANG(mm):2490
• REAROVERHANG(mm):3150
• NOS OFSEATS:35+D
• STEERING: HYDRAULIC POWER STEERING
• FRONT &REAR BRAKES: AIR BRAKES
• FRONT SUSPENSION: PNEUMATICSUSPENSION
• REAR SUSPENSION: HYDRAULIC DOUBLE ACTING TELESCOPICTYPE
• SHOCK ABSORBER AT FRONT & REAR

BMTC AT A GLANCE
EVERYDAYTRAFFIC REVENUES 5.06 CRORES
NUMBERSOFVEHICLES 6783
NUMBERSOFSCHEDULES 6143
DAILYSERVICESKMS 11.58LACS
NUMBERS OFBUSTRIPS 71673
DAILY PASSENGERSCARRIEDAROUND 4.96 MILLION DEPOTS 45
BUSSTATIONS 53
STAFFEMPLOYED 34076
BUSSTAFFRATIO 5:8

Learning Objectives
• The core objectives that have been learnt thought the internship was a complete
cognition process that are as listed as follows
• To get a brief idea regarding the engine transmission system, various kinds of clutches
gears used their working and performance.
• To understand the basis of bus body design that includes the design of chassis ,frames
the seating arrangement etc.
• Knowing the materials used to manufacture various parts of the vehicle alloys ,elements
etc that are used thereby by resulting in the long life of the bus
• Analysis of springs and the suspension systems so as to ensure the passengers comforts
• Basic understanding of the manufacturing methods used to manufacture the different
parts of the bus.
• To get an overall idea about the work atmosphere present in a manufacturing firm and
thus resulting in the individual development .

Our Opinions to Improve The Plant

• Train all machine operators on proper machine operation and safety procedures.
• Inspect machinery before each use ensuring that safeguarding systems are in place and
• working properly.
• Follow all machine operating and maintenance instructions.
• Use appropriate personal protective equipment such as safety glasses or goggles
• respiratory protection and hearing protection.
• Exercise good housekeeping. Clean all tools after each use and store them properly.
• Keep work area clean and well unit.
• Ensure hazardous energy is isolated and controlled if access to hazardous part is

needed.

Conclusion
• what is company or organization and how it works
• working atmosphere in the company
• how a company tries to achieve a goal or success by setting various rules,

standards and techniques
• various technologies, system and machines employed by the company and
how they run
• how the company is benefitting itself and also the society
• different kinds of people putting efforts to take the company to new

heights
• how the company train the newly employed people and encourage them
References
1. www.mybmtc.com
2. www.wikipedia.org
3. “Automobile Engineering” Textbook by Author “ R.B.Gupta”.
4. “Strenght of Materials” by author “R S Khurmi”.



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ENGINE TRANSMISSION AND BODY DESIGN

Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 1

1.1 History of BMTC

1.1 Types of services

Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 2

BMTC has 10 Travel and Transit Management centers (TTMCs) located at

1.2 BMTC’s Idea

Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 3

Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 4

Engine is a machine designed to convert one form of energy into mechanical

2.1 Cylinder Block

Figure 2.1.1a & 2.1.1b Cylinder Block

Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 5

2.2 Cylinder Bore

Figure 2.2.1 Cylinder Bore

Major problems with camshafts.

Dept. of Mechanical Engg, BIT Bangalore, 2018-19 . Page 6

2.4 Crank Shaft

Major problems seen in the Crankshaft.

• A crankshaft is subjected to enormous stresses, potentially equivalent of several tonnes

• To avoid friction, the crankshaft is subjected to the proper sequencing of balancing of

Figure 2.4.1 Crank Shaft

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A cylindrical metal component which reciprocates in the cylinder under gas

Piston has three rings namely,

• Compression ring: It prevents compression leak between cylinder and piston.

Figure 2.5.1a & 2.5.1b Piston

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2.6 Connecting Rod

Major problems with connecting rod

Figure 2.6.1a & 2.6.1b Connecting Rod

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2.6 Damper Pulley (Harmonic Damper)

Major problems occurring in the damper pulley.

Figure 2.7.1 Damper Pulley

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Major problems seen in the clutch system.

• Clutch plate wear.

Figure 3.1.1 Clutch

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3.2 Gear Box

Figure 3.2.1a & 3.2.1b Gear Box

Figure 3.2.1c Schematic Diagram of Gear

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Figure 3.2.1d Gear Shifting Process

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Figure 3.2.1e Idler Gear

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Three major problems occurring in the gear boxes are.

• Dark oil or low oil level is seen due to the overheating.

3.3 Propeller Shaft

Fig 3.3.1.a Propeller Shaft

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Fig.3.1b Propeller Shaft

A propeller shaft(propeller shaft), or Cardan shaft is a mechanical component for

Joints in the propeller shaft.

Major problems seen in the propeller.

• Proper lubricating at the U joint reduces the vibrations.

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Fig.3.4.2Complete structure of differential assembly

When an Automobile negotiates a turn, the distance travelled by outside wheels

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