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JBM is a multi unit, multi product group with extensive and
diversified interests in engineering and precision tooling, dies,
chemicals, textiles and facilities spread over different parts of
the country. The JBM engineering group deals in a broad
range of sheet metal assemblies, die casting components and
forging for the domestic and the export market. JAY BHARAT
MARUTI LIMITED, set up in 1987, is the largest joint venture of
MARUTI UDYOG LIMITED, in collaboration with SUZUKI
MOTOR CORPORATIONOF JAPAN. It was started by Mr
Surender Kumar Arya of Bombay.
WELD SHOP
•
WELDING ROBOTS
•
WELDING LINES FOR VARIOUS MODELS
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•
STATIONARY SPOT WELDING
•
PORTABLE SPOT WELDING
•
MIG/TIG WELDING MACHINES
•
SPECIAL PURPOSE WELDING MACHINES
Public Limited
Maruti Udyog Limited
- 29. 2 8 %
Company with
S.K. Arya & Associates
- 29. 28 %
shareholding
Public
- 41. 44%
Total Plants
Plant I – March, 1989
Plant II – April, 1996
Plant III – Sept, 2006
1987
88-89
95-96
96-97
97-98
98-99
99-00
00-01
01-02
02-03
04-05
05-06
06-07
06-07
07-08
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Company Incorporated
Commercial Production
Plant-2 commissioned
Exhaust System M-800 & Omni
Fenders
Baan IV Software System
Exhaust system ‘Alto’ & ‘Wagon-R’
M-800 Car Under Bodies
Versa line
Fuel Neck Filler & Electroplating
Axle line & “CED” Painting
Swift line
Plant-3 Commissioning
‘Zen Estilo’ line commissioned
‘SX-4’ line commissioned
Maruti Suzuki India Ltd
03-04 Excellence in Cost Reduction through VA / VE
03-04 Superior Performance through KAIZEN
03-04 Outstanding Overall Performance
03-04 Superior Performance in Cost Reduction through Yield
Improvement
04-05 Vendor Performance Award for Alto cost reduction
04-05 Vendor Performance Award for Overall Commendation
04-05 Vendor Performance Award for Yield Improvement
04-05 Tier II Vendors Up-gradation Certificate
CII–EXIM Bank
03-04 Strong Commitment to Excel
04-05 Strong Commitment to Excel
05-06 Significant Achievements in Business Excellence
06-07 Significant Achievements in Business Excellence
Japan
Europe
Thyssen Krupp
India
Maruti Udyog
Bellsonica
Daiwa Excel
Hamamatsu Pipe
Futaba Co.
JFE
Metal One
Yorozu
Thailand
Thai Summit
Union Autoparts
Geographic tie ups for world class technology
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The exhaust system collects, quiets, and cleans the exhaust gases
from the engine.
The system carries the gases to the rear of the car and discharges
them into the air.
The components of the engine that allow air-flow outside the engine
are:-
1. Camshafts
2. Exhaust Valve and exhaust ports
3. Exhaust manifolds
4. Muffler
5. Catalytic convertor
6. Exhaust tubing
Muffler
Exhaust
Manifold
Resonator
Components
Catalytic
Convertor
Tail Pipe
Exhaust
Pipes
1.
It is a set of pipes that collect gases from the combustion
chamber and passes them to the exhaust pipes.
2.
They are made up of gray cast iron or nodular cast iron.
3.
They are mounted to the cylinder head’s exhaust ports. When
the engine works hard or has a lean air-fuel mixture, the
exhaust manifold runs red hot.
4.
The exhaust manifolds have a gasket between them and the
cylinder head. Gaskets are meant to prevent leakage of
air/gases between the manifold and cylinder head.
1. Steel tubing exhaust manifolds are
called headers. They tend to have a
shorter service life than cast iron
manifolds because they are thinner and
can rust through.
2. Headers are short and have a large
cross section to provide maximum
power at high rpm. The greater
backpressure that develops from longer
pipes tend to favour low rpm
performance.
1.
The main function of the muffler is to
quite the noise of the flow of the
exhaust gases.
2.
It is a combination of tuning
chambers, formed by partitions and
ventilated and solid tubes. It is
designed to effectively contain,
absorb and dissipate noise pulses
while moving the exhaust gases and
vapor smoothly through and
ultimately out of the tail pipe.
3.
The location of a muffler varies considerably depending on
the vehicle model, but most mufflers are located toward the
rear of the vehicle. The muffler can assume many shapes from
round to oval, to custom stamped.
4.
The muffler reduces the noise of exhaust by muffling the
sound waves created by the opening and closing of the
exhaust valves. When the exhaust valve opens, it discharges
the gases at very high pressure into the exhaust pipe which
itself is at low pressure. This creates a sound wave which the
muffler must silence. The wave energy is converted into heat
by passing the exhaust gases and it’s accompanying wave
pattern through perforated tubes and tuning chambers.
1. Louvered Tubes - These tubes provide better gas flow to maintain a
more uniform internal temperature. By avoiding cool spots within the
muffler, most acid condensation can be prevented.
2.
Internal Drainage System - A complete internal drainage system
prevents any acids from collecting between partitions or at the muffler
heads.
3.
Muffler Bushings - Road shock and vibration can cause early muffler
bushing breakage. Muffler bushings extend from the head into and
through the first internal partition. This two-point bridge contact gives
greater structural strength.
4.
Spot Welded Partitions - Spot welding is used to attach the partitions
to the muffler shell. This process provides more strength and rigidity
than other methods of attachment. Extra partitions are used where
additional strength is required.
1.
The Exhaust pipe carries the collected gases and vapor from the
exhaust manifold or header to another component further
downstream in the exhaust system.
2. The "Y" pipe is an exhaust pipe, which connects both exhaust
headers of a "V" engine to form a single exhaust system. It may
also be used to split a single exhaust system into a dual exhaust
system.
3. Balance pipes are used in many dual exhaust systems to merge
sound pulses from left-hand and right-hand sources. This helps
reduce harsh exhaust sounds, equalizes muffler and tail pipe life,
and can aid in improving mid-range torque output of the engine.
4. A "Crossover" pipe connects one exhaust header to the other, thus
creating the start of a single exhaust system combining multiple
exhaust outlets into one.
1.
2.
They are primarily used for
cleaning the pollutants
emerging from the exhaust
manifold.
Gasoline is a hydrocarbon
containing carbon and
hydrogen.
Since
combustion is never 100%,
some HC is still left.
Oxides of nitrogen are
caused by high cylinder
temperature.
3. Within the stainless steel shell of an aftermarket catalytic
converter lies a substrate that's coated with a combination of
platinum, palladium, and sometimes rhodium. These three
chemicals are frequently called precious, or noble, metals.
Typically, oxidation converters are loaded with platinum and
palladium. Three-way and three-way-plus converters are
loaded with platinum, palladium, and rhodium.
4.
5.
When the exhaust gas comes in contact with the precious
metals or catalyst, a chemical reaction takes place that
weakens the bonds of the polluting chemicals and allows
them to easily convert into the more desirable by-products of
combustion.
There are three types of convertor:- oxidation, three-way and
three-way plus oxidation convertor.
1.
2.
It oxidizes hydrocarbon and
carbon-monoxide emissions
only.
In this design, exhaust gases
are directed to flow over the
substrate where they come in
contact with the catalyst. The
exhaust gases increase in
temperature and continue to
oxidize. Hydrocarbon (HC)
and carbon monoxide (CO)
emissions are converted into
water (H2O) and carbon
dioxide (CO2) before they
enter the muffler.
1.
These converters reduce NOx emissions as well as oxidize
hydrocarbon and carbon monoxide.
2. Inside, a 3-way without air converter looks like a 2-way
converter. But, the 3-way without air substrate is coated with
rhodium and palladium.
3. If an engine's exhaust is high in hydrocarbons and carbon
monoxide, an air pump and tube feed extra oxygen directly to
the converter. Inside a 3-way with air-injection, there are two
substrates.
The front chamber is coated with rhodium and palladium.
Rhodium reduces NOx emissions into simple nitrogen (N2) and
oxygen (O2). This process is most effective when there's little
oxygen present. That's why this substrate is located upstream of
the air tube inlet.
5. A second substrate of palladium and platinum is located
downstream of the air inlet, so the increased oxygen enhances
the oxidation of hydrocarbons and carbon monoxide.
4.
1.
No matter what the converter design, they all fail for the same
reasons. Since there are no moving parts in a converter, the
most common cause of failure is contamination.
2.
When overly rich fuel mixtures or raw fuel is introduced into a
converter, its temperature can rise to the point that its substrate
will simply meltdown. This is known as thermal failure. Thermal
failure will deactivate the catalyst and, in extreme cases, block
exhaust flow through the unit.
3. Thermal shock occurs when an overheated converter is fed
cold raw fuel or comes in contact with winter elements. The
ceramic substrate cools too rapidly and contracts unevenly. It
starts to crack and break up. Normal exhaust system vibration
will cause it to disintegrate even further.
1. Silicone that has leaked into the exhaust from antifreeze or
sealants will similarly coat the catalysts, with the same result - a
non-functioning converter. In cases of serious contamination or
meltdown, the converter needs to be replaced.
2. Obviously, restrictions of any kind - inside the converter or
elsewhere in the exhaust system - will also affect converter
performance. If the restriction is internal, the converter needs to
be replaced.
3. Converters can also sustain physical damage. Body punctures or
weld cracks create leaks that require converter replacement.
S.No Accessories
Function
1.
Clamp
Used to provide gas- tight, leak-free connections at
points where two pipes or a muffler and a pipe are
joined together. Also used to attach the exhaust
system hangers.
2.
Gaskets
Sealing devices placed between two parts of that
exhaust system. The gasket assumes the shape and
size of the mating surfaces and often has provisions
for securing via multiple bolt holes punched through
the material. These devices may be made of
composition materials, formed metal, or a
combination of the two materials.
3.
Hanger
A hanger is a device with flexibility and noise isolating
qualities, which is used to attach exhaust system
components to the vehicle's underbody.
4.
Flange
It is a cast or formed part used to join two units of an
exhaust system to each other or to the exhaust header. A
flange may be a loose piece, "trapped" on a pipe, or
welded to the end of a pipe.
5.
Bracket
A Bracket is any metal protrusion, which is fastened to a
component of the exhaust system that is used in
suspending or reinforcing the exhaust system. These
devices are generally made of metal stampings, and often
use rubber components within their structure for vibration
control.
PART NAME : MUFFLER COMP.
MODEL : WAGONR
SPOT WELDING
OPN NAME : SPOT WELDING
AFTER WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : COILING & SPOT WELDING
AFTER WELDING
SPOT WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : OVAL SHAPING & FLANGING
AFTER FLANGING
OVAL SHAPING
& FLANGING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : SPOT WELDING
SPOT WELD
SHEEL+COVER
AFTER WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : BAFFLE PRESSING
BAFFLE
PRESSING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : CURLING & SEALMING
CURLING &
SEAMING
AFTER CURLING OPN
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : BENDING
AFTER BENDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : MIG WELDING
MIG WELDING
PIPE+FLANGE
AFTER WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
MIG WELDING
FRONT PIPE
+SILENCER
COMP.
OPN NAME : MIG WELDING
AFTER WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : BENDING
AFTER BENDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : MIG WELDING
MIG WELDING
TAIL PIPE
+SILENCER
COMP.
AFTER WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : MIG WELDING
MIG BENDING OF
STAY MTGS +BRKT
AFTER WELDING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : LEAKAGE
TESTING
PART NAME : MUFFLER COMP.
MODEL : WAGONR
OPN NAME : INSPECTION
FINAL ASSY.