FORM 2
THE PATENT ACT, 1970,
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10; RULE 13)
"FAULT DETECTING SYSTEM ON ENGINE ASSEMBLY LINE AND THE METHOD OF TESTING THE SAME"
MAHINDRA & MAHINDRA LIMITED
A COMPANY REGISTERED UNDER THE
PROVISIONS OF COMPANIES ACT, 1956
HAVING ADDRESS AT R & D CENTER,
AUTOMOTIVE SECTOR,
89, M.I.D.C., SATPUR,
NASHIK - 422 007,
MAHARASHTRA, INDIA.
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES AND ASCERTAINS THE NATURE OF THIS INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF DISCLOSURE:-
The present disclosure relates to a testing arrangement, more particularly, the present disclosure relates to detecting faults in sensors and wiring fitted on Engine of vehicle on assembly line. Facilitation for testing of engine without being assembled on Vehicle.
BACKGROUND OF THE PRESENT INVENTION:-
In vehicle assembly process engine assembly plays an important role and a special part in the process. In the assembly process and vehicle level operation engine and engine component like sensor and actuators are control the operation and performance.
In the assembly process all the sensors and actuators get fitted on the engine one by one till the assembly process completed and engine get fitted on the vehicle frame. Which then get transported on conveyor to further processing.
While process several defects occurs like sensor connection not done, Sensor failure, Sensor connection loose, Sensor connection came out and all the above defects replicated on actuators also.
Efforts have been taken in process for the control on the manual processes by training and other systematic procedures, but still there are so many shortcoming in the processes which cannot controlled by humans working on the assembly line. Prior art US 5492006 is aimed to identify mechanical defects in the engine where it is not focusing or giving solution for the electrical defects on the engine.
(Method-of-testing-internal-combustion-engine-US 5492006 A) One of other prior are CA 2313436A1 (Method and system for determining proper assembly-of-engihe-components-CA 2313436 A1) is aimed at identifying the errors in the form of vibrations from the engine but it is limited to

mechanical part faults and errors and also not focusing anymore on the electrical components.
To overcome present prior art shortcoming the present invention is presented in the field of electrical component on the engine that to before actual assembly on the vehicle.
OBJECTIVE OF THE INVENTION:-
The main object of the present invention is to provide specialized apparatus and method for engine electrical component working and connectivity with minimum time as low as 10 sec.
Another object of the present invention to provide apparatus to check the all electrical component on the vehicle varying the number depending on the engine and controls on the engine.
Another object of the present invention is to provide procedure to assemble defect free product on the assembly line.
Still another object of the present invention is to arrest the defects on the assembly line in early stage of the product where rework cost will be 1% as of rectification of the same at end of the line.
STATEMENT OF INVENTION:-
Fault detecting system on engine assembly line comprising of a signal processing box capable of receiving the input signals from wiring harness socket on the engine; said socket connected to sensors and actuators which are mounted on the engine; once the power source passes 12 volts and 5 volts supply to the sensors and actuators, the input voltage will reach to the respective sensors through electrical circuit/ hard wire thereby activating the sensors which gives output to the transistor collector which gets powered to create passage to pass current; the said actuators and sensors are connected

serially to each other which on activation creates a complete conductive passage for current to pass to relay and gives the output signal in the form of audio and/or light emission diode (LED) facilitating for testing of engine without being assembled on the vehicle
DESCRIPTION OF THE FIGURES:-
Figure 1 describes locations of various sensors on the engine likewise
1 .Coolant Temp located at in front of the exhaust outlet manifold near the fuel injector area works on 5 volt power and give output in the form of voltage signal as 5 volt,
2. Fuel metering Sensor located on the fuel pressure pump (Not shown in the figure it is located on the hidden i.e. opposite side of the engine.) Work on 12 volt and gives output in the form of 12 volt voltage signal.
3. Rail Pressure Sensor located near injector number 1. (not seen in the figure as located near the bottom of the Injector number works on 5 volt power and give output in the form of voltage signal as 5 volt,
4. Fly Wheel Sensor also known as crank shaft sensor located on the bottom of the engine and on the front side in the figure works on 5 volt power and give output in the form of voltage signal as 5 volt,
5. Cam Shaft Sensor on the top and front side of the engine seen in the figure works on 5 volt power and give output in the form of voltage signal as 5 volt,
6. Speedo Sensor located on the bottom front side of the engine works on 5 volt power and give output in the form of voltage signal as 5 volt,,
7. GNS Sensor located on the transmission and below the gear lever (not shown in the figure as transmission not shown) works oh 5 volt power and give output in the form of voltage signal as 5 volt,
8. AC Compressor Signal sensor located below the exhaust manifold on the AC compressor works on 5 volt power and give output in the form of voltage signal as 5 volt,
9. Injector 1- located on top of the engine in line with the other 3 injector works on 5 volt power and give output in the form of voltage signal as 5 volt,,

10. Injector 2 - located on top of the engine in line with the other 3 injector works on 5 volt power and give output in the form of voltage signal as 5 volt,
11. Injector 3 - located on top of the engine in line with the other 3 injector works on 5 volt power and give output in the form of voltage signal as 5 volt,
12- Injector 4 - located on top of the engine in line with the other 3 injector works on 5 volt power and give output in the form of voltage signal as 5 volt,
13. Reverse Gear sensor Located near gear neutral sensor at the bottom of the gear lever works on 5 volt power and give output in the form of voltage signal as 5 volt,
14. HFM sensor located on the air inlet manifold of the engine works on 5 volt power and gives output in the form of voltage signal as 5 volt,
15. Oil Pressure sensor - located above the vehicle speed sensor works on 5 volt power and give output in the form of voltage signal as 5 volt,
16. Alternator - located on the opposite side of the AC compressor side of the engine above the starter of the engine works on 5 volt power and give output in the form of voltage signal as 5 volt.
Figure 2 explains the type of the component i.e. is it sensor or actuator.
Figure 3 explains internal circuit shortly explained how the electronic component is laid down in the processor for each sensor or actuator to check its electrical connectivity.
Figure 4 explains the block diagram of the total system explaining input for all the 16 sensors with different voltage. Power source gives output of 12 and 5 volts accordingly the sensors are connected with hard wire with the power source and then with circuit explained in fig 5 gives output for the relay located in the processing unit gives output to the Hooter device and Lightening device explain in the fig 6.

Figure 5 explains the flow of signals and power flow and how system is connected and integrated with each other.
Figure 6 explains the details of the processing box. The system is integrated with LED - Light emitting diode which when given 12 volt supply glows out red light, transistor is electronic part work as switch having 3 terminals one for input one for output and third one which is situated at the centre of the two other terminal when input voltage is given to the transistor it get switched on and creates passage for current and voltage to flow, and hard wire circuit on the board. A resistor is connected in between LED and transistor output to save LED to flow over current and get burn. Also this terminal gives the output to the next transistor collector and so on up to 16th transistor which finally gives output to the relay in the circuit to power up the relay coil to activate hooter for indication of the all connection and sensors on the engine are good.
A 12 volt input is given to 1st terminal of the transistor called as collector then on the second i.e. middle terminal called receiver is connected to the output from signal i.e 5 volt or 12 volt signal the transistor is selected such a that it will work on 12 volt and 5 volt input to the receiver terminal.
An engine system includes a several sensors listed below And all these sensors (1 TO 16) work with synchronization with Electronic control unit (ECU-17). They take power from ECU and give back feedback signals and or actuate themselves as per requirement. All these sensors work on 12 and 5 Volts.
WORKING -
ECU sends signals in form of voltage to sensors and actuators and they act in predefined format. It is necessary that all sensors and actuators must be connected to ECU through wiring and has firm electrical connection in between. To form the electrical connection wiring with copper threads is used.

On assembly line all sensors and Actuators are been fitted on Engine at various stages and wiring harness get connected after word. After connecting wiring harness it is important that all sensors are connected through the sockets and terminals with wiring harness. And it is not possible to identify the connection up to ECU get connected to Engine system which is getting fitted after assembly of vehicle and not possible till vehicle is power on.
To overcome the condition new system invented which fulfil the Sensor checking requirements on the line before final assembly of the vehicle. Which saves rework on the vehicle as well as scrap.
DESCRIPTION OF THE INVENTION:-
System consist of logical board (18) Power Source (19) Connector to wiring harness (20) Engine (21) Logical board is consist of electrical circuit which is includes 22.diodes, 23. Resisters, 24.transistor and 25.LEDs to indicate the status of connection.
Circuit diagram for the individual Sensor.
When the Engine wire harness connected, which is connected on other end with all sensors to 18.circuit board lights LED to indicate and confirm the connection is ok.
Process to check the sensors status -
Operator will connect the processing box socket to the wiring harness socket on the engine which is on other side connected on the sensors and actuators. When this connection happens the special power source will pass 12 volt and 5 volt supply to the sensors and actuators as listed in the fig.2, the given voltage will reach to the respective sensor through hard wire and activate the sensor which finally gives output to the transistor collector which get powered to create passage to pass current. Likewise from sensor number 1 to 16 the output comes up to the transistor number 1 to 16 which are serially connected to each

other on activation of all this create a complete conductive passage for current to pass to Relay.
If one of the sensor say sensor number 11 is malfunctioning or not connected to the opposite end of the engine wire harness loom it will result in the number 16 transistor will remain off that is current flow to the relay will disturbed and it will not activate to blow out the hooter. In this case operator/ workmen will immediately come to know that the system which he verifying has error and then he will check on the processing box which is a handy device with him in his hand where he can see all the 16 LEDs. Where he will find 11 numbers LED is not glowing. Afterward he will look at the board where details of numbers of the LED and corresponding sensors list is displayed. Now workman will check the connection of the 11 number sensor re check the system if it doesn't work then replace the said sensor and check it. After correcting the engine will pass to the next stage.
For the engine to check time required is 15 sec i.e. only picking up the processing unit along with socket and connect to the engine wire harness. Prior practise it was taking 4.5 minutes to check the whole engine sensors physically for electrical connections and that to workman is unable to see whether the sensors are working electrically or not.
TECHNICAL ADVANCEMENTS:-
Current process going on is manual checking of all the work done by operator but electrical proof is not possible and time consuming.
This invention overcome the problem and unable the process to check the electrical connections before vehicle final assembly resulting in ZERO defect vehicle.
Impact on customer and market for delivery of correct Product.

ADVANTAGES OF THE PRESENT INVENTION:-
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment. Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter. The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention.

WE CLAIM:-
1. Fault detecting system on engine assembly line comprising of a signal processing box capable of receiving the input signals from wiring harness socket on the engine; said socket connected to sensors and actuators which are mounted on the engine; once the power source passes 12 volts and 5 volts supply to the sensors and actuators, the input voltage will reach to the respective sensors through electrical circuit/ hard wire thereby activating the sensors which gives output to the transistor collector which gets powered to create passage to pass current; the said actuators and sensors are connected serially to each other which on activation creates a complete conductive passage for current to pass to relay and gives the output signal in the form of audio and/or light emission diode (LED) facilitating for testing of engine without being assembled on the vehicle.
2. Fault detecting system on engine assembly line as claimed in claim 1 wherein, the said processing box comprising of logical board (18) having diodes, resisters, transistors for processing of the inputs received from various sensors and actuators, and power source (19) connected to wire harness.
3. Fault detecting system on engine assembly line as claimed in claim 1
wherein, the actuators represents injector 1, injector 2, injector 3 and injector 4.
4. Fault detecting system on engine assembly line as claimed in claim 1 wherein, the sensors represents coolant temp, fuel metering sensor, rail pressure sensor, fly wheel sensor, cam shaft sensor, speedo sensor, GNS sensor, AC comp signal, reverse gear, HFM, oil pressure, alternator.
5. Fault detecting system on engine assembly line as claimed in claim 1 wherein, all the sensors wdrk'in synchronization with electronic control unit and works on 12 volts and 5 volts.
6. Fault detecting system on engine assembly line as claimed in claim 1 wherein, all the individual sensors will have their own electrical circuit.

7. Fault detecting method on engine assembly line as claimed in claim 1
wherein, the method of comprises of the following steps,
i) connecting the engine with the processor of fault detection system,
ii) the processor checks the inputs from all input sensors,
iii) then the processor receives the inputs, and processes it,
iv) while processing the inputs, the necessary coding and decoding is done in
the processor,
v) if there is the fault in the engine, the concerned input is noted by the
processor,
vi) the processor sends the processed output to the display board indicating the
faulty parameter in the form the flashing of light.