FACILITIES

Design and Engineering: With the assistance of design and engineering facilities along with unmatched human brilliance, our design team has successfully laid the basis for a variety of systems which has helped customers in achieving higher productivity and higher quality consistently. We have experience in developing systems to cater the needs of a wide variety of manufacturers-of Automotive components, FMCG goods, Electrical/Electronics Components, etc. Based on inputs from this detailed situation study, we prepare a Users Requirement, which clearly lists and describes each aspect, the constraints, and the technical details of the application. This User Requirement when approved by the customer, becomes the cornerstone of the design process. Upon completion of design, the designs are sent for manufacturing and then assembled in-house to make sub-systems. These sub-systems undergo tests to confirm that they meet the specifactions. System is run in conditions as close to the application situation with the actual components, etc.. The components after processing by our system are sent to the customer for inspection to ensure that no unacceptable damage has been made to the component and that the assembly meets their quality standards. Our conceptual design will enable the customer to clearly judge the feasibility of the system, from all technical and financial aspects.

Manufacturing: The projects that we handle are of developmental nature and hence they require a wide variety of machining and fabrication requirements. These include conventional machining in Lathes and Milling machines to sophisticated machines. Considering this nature of the machining requirement, we have tied up with some quality Tool Room units, which fabricate parts to our drawings and specifications. They integrate the operations required to fabricate the complex parts that go in our assemblies. Being tool rooms, they stress precision, with a high degree of adherence to the tolerances specified on the drawings, which is the basic requirement for our precision components.They also co-ordinate with finishing operation people like Chrome Plating, Powder Coating, Heat Treatment.

To monitor these activities, we have a Production team which is dedicated to monitoring the production and manufacturing related activities. They monitor the production of all the components to prevent any manufacturing errors.Thorough Inspection of components at the end stage is executed using precision gauges, and special inspection tools and documented accordingly.

Testing / Trials: All our systems, prior to despatch, undergo rigorous testing to ensure a guaranteed non-stop functioning at the customers' site. All possible uncertainties are identified and eliminated during these trials at our site.

Our testing start at a very early stage of the project, with the Mock Up testing, which helps to understand critical areas of the design and it provides valuable data for the design team on various parameters related to the process and the component that is being handled. It helps to validate the concept and to unearth any underlying uncertainties, which when removed at such early stage, saves development time and effort.

All individual subsystems, upon assembly are tested separately to ensure their proper functioning. This testing helps us in later identifying the problems that could arise during final assembly. This step-by-step testing of subsystems allows debugging, if any, at an earlier stage itself.

The full assembly is then tested for evaluating the overall performance such as functional requirements, cycle time, etc.. The Assembly is tested with dummy cycles to start with, and is then continued with components under the various possible operating conditions.

Following this, the electronic integration with the system is completed and the system is put to test under different conditions. The specific end user at the customers organisation is invited to monitor the continuous trials of the system so as to receive his inputs on any site related parameters which we have not taken into account so far. The system is put to continuous testing to gauge the reliability of the system before despatch. This also reduces the time it takes for installing and commissioning the system at our customer's site. Test reports are documented and sent to the customer for validation.

The parent machine to be integrated to our system, if any, is simulated at our site for the dimensional and functional requirements. This too helps in reducing the time taken for integration with the parent machine at the customers' site. The system is also put to accelerated testing to monitor the functionality of the systems under accelerated test conditions. This gives a better picture of the reliability of the system and the life of the system.

After Sales Service: We have an excellent after sales service team which is committed to having all our systems working perfectly at our customers' factories. They are in constant dialogue with the end user to monitor the working of the system. The service team always has a back up to attend any emergency break down call, in addition to routine visits.

All our systems come with a warranty for the performance of the system against design, workmanship, and material defects. The end-user is requested to follow a routine maintenance procedure and we render all other services.

Our service team monitors the system for one month after installation, training the end user in the setting and maintenance procedures. Our service team works round the clock, without disturbing the regular production to support the customer.

We concentrate more on training the customer in all the setting procedures and trouble shooting, to reduce the down time, which is very handy in the case of customers being at a remote place. Our service team works as a team with the end-user having an active participation in making the system functioning continuously. This approach has been the main reason for our many repeat customers.

PRODUCTS

Customised Engineering Solutions provides aids to problems due to low productivity, low quality and hazardous working environment. Take care of the whole process of providing solutions right from conceptualisation to installation and commissioning of system.

•  Welding Special Purpose Machines, a custom engineered solution for all welding related automation for achieving high productivity and quality for repetitive jobs. Our expertise includes in the area of Rail Wheel Re-building, Hard facing, Panel welding etc.

•  Material Handling Systems provides a wide range of engineering solution related to handling of components in different working conditions where high productivity, repeatability and accurate positioning is mandatory. Our custom built solution for material handling includes Loading and Unloading Systems, Pick and Place Systems and Transfer Lines.

•  Assembly Systems: Our Assembly Systems use various modular units like Pick and Place Systems to assemble components. The components are fed through feeder units (like Vibratory Bowl Feeders, Linear Vibratory Feeders, Hopper Magazine, Indexing Conveyor etc.). The assemblies are carried out on the Indexing Table (Rotary or Linear), which indexes from station to station receiving components for the assembly. The Assembly System may also have special units like Tapping Units, Online Crimping Unit, Fastening Units, Sealing unit, Weighing Units etc.. The assembly is sometimes carried out also fixed stations, where the Pick and Place Units transfer the components from one station to the next. Assembly of any number of components can be done using multiple tables, with primary assembly being done on different tables, and then being transferred to the main assemblies table, where the final assembly is done.

•  Machine Tool Loading and Unloading Systems: Our Pick and Place Systems are high precision, high speed, systems with 3 degrees of freedom. It has a vertical lifter and horizontal feed capabilities. The weight, nature and shape of the component determine the gripper choice. It could be Electro-magnetic, Vacuum, Mechanical, or a combination of the above. Our Pick and Place Systems can be used to feed components into machine tools, like Presses, Milling Machine, etc.

•  Inspection and Testing Systems: Our Inspection Systems use various Modular Units like Pick and Place Systems along with special units to inspect the components. These inspection units can be used to check dimensions, presence / absence of components, Electrical Properties, Mechanical Properties, Orientation and Strength.

Standard Welding Head - Job Manipulators aids in fabrication of tanks, barrels, pressure vessels and other engineering application where weld joints required controlled circular movement. Depending on the application one has to select suitable equipment from our wide range of products. Welding Head Manipulator brings the welding head to weld point. These equipments are suitable for long welds of repetitive work where high travel speed can give high productivity and better quality of welding is required. The coordinated movements of column and boom enable the welding head to reach intricate parts and inaccessible weld joints. This equipment can be ideally combined with Positioners and Rotators to build a comprehensive welding system.

•  Positioners

Light Duty Series

• Ideally suitable for small jobs in the range of 50kg to 150kg
• Designed to give accuracy and precision
• Job can be tilted to any side for convenient operation
• Face plate rotates with variable speed
• Available with optional accessories like torch stand, foot switch and pendant

Medium & Heavy Duty Series

• Covers wide range of jobs starting from 250kgs to 30,000kgs
• Designed and Manufactured for trouble free and easy operation
• Fabricated with heavy sections which avoids deflection under loaded conditions resulting in vibration free and smooth operation
• Anti-fall arrangement for face plates gives additional safety to work environment
• Positive locking tilting arrangement with instant braking arrangement ensures safety and accurate positioning
• Rotary drive unit with AC Variable Frequency Drive (VFD) provides steplessely variable speed from 0.1 to 1 RPM for face plate.
• Earthing Arrangement with wear compensation gives uninterrupted welding operation
• Tilting arrangement from horizontal 0º to 135º towards job side

•  Rotators

• Consists of Drive Unit and Idler Unit
• Frame and Roller brackets fabricated with heavy sections
• Overload disc to protect polyurethane roller
• Steplessely variable surface speed from 75 to 1500 mm/min controlled through AC Variable Frequency Drives
• Forward and Reverse rotation along with inching facility
• Operator pendant for forward , reverse and stop functions
• Self Aligning, Self Centering, Manual Adjusting, Coupling Shaft & Twin Drive classifications suits to different requirements and covers entire range up to 150MT capacity.

•  Column and Boom

• Vertical stroke ranges from 3000mm to 6000mm
• Horizontal stroke ranges from 3000mm to 6000mm
• Compatible with MIG/MAG, SAW and TIG welding equipment
• Fixed vertical lifting speed of 1200mm/min
• Steplessely variable horizontal speed ranges from 100 to 1500mm/min
• Operator's pendent with necessary controls such as vertical movements, horizontal movements etc.
• Manual or Motorised swiveling in 360º
• Motorised variable speed trolley for mechanical traveling of column and boom on rails
• Operator chair on the boom
• Ladder on column for maintenance purpose
• Provision for mounting welding power source on Column or Base
• Boom with special telescopic arrangement design adds advantage where space is a constrain