In automotive industry, coolant filling is a critical operation carried out in the assembly shop to ensure proper thermal management of vehicles. The process demands precise capacity handling and stable pressure control to avoid spillage, contamination, and safety risks.
Problem Description
The existing coolant filling machine was originally designed for earlier models with lower filling capacity, which created a fundamental limitation when applied to the new vehicle model. The mismatch in design capacity resulted in excessive back pressure during the coolant filling cycle. This abnormal pressure condition triggered the safety relief valve, causing coolants to be sprayed out of the system. The consequence was spillage within the machine area, contamination of critical components, and increased safety risks for operators. In addition to compromising workplace cleanliness, the issue highlighted a design inadequacy that required corrective action to ensure stable and reliable filling operations.
Solution
To overcome the limitation of the existing coolant filling machine, a corrective modification was implemented to address the issue of excessive back pressure during the filling cycle. An auxiliary vessel was integrated with the existing tank, equipped with a pressure relief at the top. This design enhancement increased the tank’s capacity by approximately 3 liters, thereby stabilizing pressure conditions and preventing the safety relief valve from opening and spraying coolant. The modification effectively eliminated spillage and contamination risks while ensuring a cleaner and safer operating environment. In addition, the solution avoided the need for costly OEM coolant tank modifications, resulting in a significant cost avoidance of 20 lakh rupees. By optimizing capacity and pressure management, the coolant filling process for the new model was made more reliable, efficient, and sustainable.
