Amaze, The Automated Assembly
Machine For Integral Shaft Bearings
Engineering EXCELLENCE AWARDS 2013
Category: “Technology...
Introduction to Integral Shaft Bearings
Business Opportunities & Challenges
Conventional Bearing Assembly – Process Flow &...
Introduction To Integral Shaft Bearings
Integral Shaft Bearing has two widely spaced rows of rolling element, do not have ...
Business Opportunities & Challenges
Opportunity
Collective business potential of INR 200Mn
Challenge
Revamp of conventiona...
Conventional Bearing Assembly - Process Flow
All these Operations
are interlinked
Based on PLC logics
Ball Fillings
Cage F...
Limitations of Conventional Bearing Assembly
Conventional Assembly - Drawbacks
Shaft & Sleeve sorting at 2 different stati...
Automated Bearing Assembly Line - Conceptualization
Manufacturing
&
commissioning
of Bearing
Assembly Line
Define the
requ...
Automated Bearing Assembly Machine
Shaft Loading
Shaft insertion on fixture by tilting it 90 deg
Shaft Gauging
Sleeve Gaug...
Auto Ball Selection & feeding
Ball Cage pick up & fixing
Roller Cage InsertionBearing Assembly pick up & placing for
clear...
Grease Filling
WeighingUnloading on
OK/NOT OK bin
Visual Inspection
Antirust Application &
Packaging
Spinning
Manual Seal
...
Automated Bearing Assembly – Concepts & Error Proofing
Automatic Assembly - Features
•Auto gauging through LVDT probes & a...
Our Innovation – Automated Bearing Assembly Machine
Salient Features:-
• Bearing assembly within close tolerances
• Poka Y...
Automated Bearing Assembly Machine - Benefits
•Automated controls at each stage & linkage of all sub-assembly operations t...
PATENT APPLICATION
The First Ever Patent Application From Ring Plus Aqua Ltd For
Automated Assembly Machine For Integral S...
Thank You!
11 October 2013 15
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Ring plus aqua ltd

  1. 1. Amaze, The Automated Assembly Machine For Integral Shaft Bearings Engineering EXCELLENCE AWARDS 2013 Category: “Technology/Innovation” “Implemented at: Ring Plus Aqua Ltd” 11 October 2013 1 10th Oct’2013
  2. 2. Introduction to Integral Shaft Bearings Business Opportunities & Challenges Conventional Bearing Assembly – Process Flow & Limitations Automated Bearing Assembly Machine - Operations Error Proofing Benefits of Automated Bearing Assembly Machine Patent and National Level Recognition Contents 11 October 2013 2
  3. 3. Introduction To Integral Shaft Bearings Integral Shaft Bearing has two widely spaced rows of rolling element, do not have inner ring but raceways machined directly on the surface of the shaft. As a result there is more space available for the rolling elements, giving higher load carrying capacity with reduced price than conventional single row bearings. Water pump bearings are ready-to- fit bearing units. It comprises a shaft, an outer ring and rolling elements in between. The bearings are greased for its life and protected against environmental influences by two sealing rings. These bearing are being used in water pumps for automotive & non-automotive applications. Current major OEM customers are …………. 11 October 2013 3
  4. 4. Business Opportunities & Challenges Opportunity Collective business potential of INR 200Mn Challenge Revamp of conventional bearing assembly lines to eliminate manual intervention during bearing assembly processes to meet requirement of these customers Improve positioning ● Tier progression from current Tier 2 to Tier 1 for new products (forged components and transmission gears New products & accounts ● Enter into products currently being manufactured by OEMs themselves, due to presence of few quality suppliers ● High value fully machined forged components ● Fully finished transmission gears ● Diversification of customer base through new accounts, a key strategic growth driver ● Accelerate growth across base business segments (ring gears, bearings, pulleys and flexplates) through both ● Growth in domestic market of ~14% and export market of ~5% ● Increasing penetration and market share bilities – supplement all the other growth rs bility to manufacture world class product using ate of the art technology t competitive price World class quality standards lobal SCM & VMI solutions esign engineering, validation & testing ● To use the inorganic route to enter into  New product line/ platform  New geographies  Acquire technology  Acquire customer Conventional Bearing Assembly Processes !!! INR 200Mn Automated Bearing Assembly Machine
  5. 5. Conventional Bearing Assembly - Process Flow All these Operations are interlinked Based on PLC logics Ball Fillings Cage Fixing Clearances Measurement Manual Gauging of shafts Manual Gauging of sleeves ` Signal to start next greasing cycle OK Not OK Packing Rejection Bin Signal to start next greasing cycle Grease Filling Seal Fixing Spinning Weighing ` 11 October 2013 5
  6. 6. Limitations of Conventional Bearing Assembly Conventional Assembly - Drawbacks Shaft & Sleeve sorting at 2 different stations and offered for bearing assembly at the 3rd stn. Manual ball selection & filling Manual axial & radial inspection of bearings Manual intervention at each stage of bearing assembly, thus chances of incorrect assembly Inadequate error proofing, thus chances of wrong assembly Operator dominant process, thus high level of skill required for bearing assembly All the above results in process variation, thus inconsistent product quality Hesitation for the acceptance of our bearing assembly line from OEM Customers 11 October 2013 6
  7. 7. Automated Bearing Assembly Line - Conceptualization Manufacturing & commissioning of Bearing Assembly Line Define the requirements for machine Selection of supplier and sign-off Non- Disclosure Agreement (NDA) Release of PO with Statement Of requirements (SOR) Machine lay-out approval 11 October 2013 7 Supplier Evaluation & technical assessment
  8. 8. Automated Bearing Assembly Machine Shaft Loading Shaft insertion on fixture by tilting it 90 deg Shaft Gauging Sleeve Gauging & sleeve insertion on shaft Continued …..11 October 2013 8 Design Conceptualization
  9. 9. Auto Ball Selection & feeding Ball Cage pick up & fixing Roller Cage InsertionBearing Assembly pick up & placing for clearance measurement Continued ….. Automated Bearing Assembly Machine 11 October 2013 9 Design Conceptualization
  10. 10. Grease Filling WeighingUnloading on OK/NOT OK bin Visual Inspection Antirust Application & Packaging Spinning Manual Seal insertion Auto seal fixing Automatic Assembly - Features Automated Bearing Assembly Machine 11 October 2013 10 Design Conceptualization
  11. 11. Automated Bearing Assembly – Concepts & Error Proofing Automatic Assembly - Features •Auto gauging through LVDT probes & auto selection of correct number and size of balls through PLC logics.Gauging & Ball Selection •Correct orientation of ball cage & roller cage assembly through orientation fixture.Cage Orientation •Correct numbers of rollers which are weighed before assembly & inter-linked to rejection bin.Rollers •100% radial clearance measurement & NG bearings after this measurement are inter- linked to rejection bin thru PLC.Clearance Measurement •Volumetric dispensing for grease, thus better control.Grease Dispensing •Final weighing to detect any miss-out component and rejection is interlinked to rejection bin.Weighing •All sub-operations are performed sequentially & interlinked through in-built poka yoke’s at each stage.Poka-Yoke •Operator safety is also considered while designing this machineSafety 11 October 2013 11
  12. 12. Our Innovation – Automated Bearing Assembly Machine Salient Features:- • Bearing assembly within close tolerances • Poka Yoke at each assembly station • Segregation of NG parts at each assembly station • Higher Reliability • Productivity improvement by 3times11 October 2013 12
  13. 13. Automated Bearing Assembly Machine - Benefits •Automated controls at each stage & linkage of all sub-assembly operations thru Programmable Logic Controls. •Error proofing at each stage for defect prevention. •Productivity Improvement from 1500 to 4000 per day. •Effective space utilisation i.e. 50% space saving as compared to conventional assembly machine. •Auto segregation of Ok & Not ok products at different stages. •Saving of 12 man days per day. •Reduced Operator fatigue. •Manual intervention eliminated. •This idea gave us commanding position over the competitors, which helped to open the doors of potential OEM customers like Ford, Renault, Suzuki, Fiat, PSA, Hyundai, Pierburg, Sogefi, Magna etc •Capacity enhanced by 4000 pcs / day 11 October 2013 13
  14. 14. PATENT APPLICATION The First Ever Patent Application From Ring Plus Aqua Ltd For Automated Assembly Machine For Integral Shaft Bearings 11 October 2013 14 Complete patent application filed on 29th October 2012 and is published in the weekly journal of “India Patent Office on 30th November’2012”. No infringement objection received during the initial six months also as of Oct’2013. “Now it is under process for granting patent.”
  15. 15. Thank You! 11 October 2013 15

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