Prasad Tonape is a competent professional with over 13 years of experience in automation, control, and robotics projects. He has comprehensive experience in project planning, management, and ensuring timely completion. He is proficient in control system design, PLC programming, robotics, drives, and commissioning processes. He is seeking a senior level position in pre-sales, project design, engineering, and execution.

1. Prasad P. Tonape
Contact: 09881717015 / 020-25387453 ~ E-Mail: prasad_tonape@yahoo.co.in
Result-oriented professional targeting senior level assignments in Pre-sales Engg., Project Design, Engg.&
Execution, Commissioning, Vendor Development with a leading organization of repute in
Controls & Automation and Robotics Industry
P R O F I L E S U M M A R Y
• A competent professional with 13+ years of experience in Projects of Automation, Control & Robotics.
• Comprehensive experience in managing the plethora of operations pertaining to planning, arranging, directing
& controlling project related activities in instrumentation and control environment.
• Proficiency in all aspects of control & automation design activities encompassing process and analytical
instruments.
• Well versed with the concepts of handling Motion Controller & PLC, Servo Drives, Vector Drives,VFDs,CNC Front
End, etc., ABB PLC, Mitsubishi PLC, Unitronix PLC, ABB Robots, Siemens, VIPA PLC handling, etc.
• Resourceful in managing project erection / commissioning & start-up activities, including tuning of process
control loop design, simulation and loop checking of various instruments, implementation for smooth
operations in adherence to the company’s standards and specifications
• Skilled in directing process improvements & applying different employee participation tools as well as
techniques in different processes to enhance productivity
• Developed competency in establishing a performance-driven culture for ensuring accountability and personal
ownership, leading, developing, coaching and motivating all teams to achieve the goals
P R O F I C I E N C Y M A T R I X
Strategic Planning Project Management Quality Assurance
Technological Up-gradations Erection and Commissioning Budgeting & Cost Control
Instrumentation Engineering Vendor Development Material Management
Internal Auditing Safety Management Systems Liaising & Coordination
Lean Manufacturing Crisis Management Inventory Control Management
O R G A N I Z A T I O N A L E X P E R I E N C E
Since Nov’13 with EMTL Sales & Service Ltd., Pune as Asst. Manager (Project Leader) – Projects, Industrial
Automation
Nov’07-Oct’13 with Electronica Machine Tools Ltd., Pune as Asst. Manager (Project Leader)– Projects,
Industrial Automation
Aug’06-Nov’07 with Vega Controls Pvt. Ltd., Pune as Manager – Software & Key Account
Aug’00-Jul’06 with Electronica Machine Tools Ltd., Pune as Sr. Engineer- Projects Engg. - Industrial
Automation
Dec’99-Jul’00 with Scan Electronics Systems, Pune as Engineer - Production, Installation, Service
Key Result Areas: (across 13 years)
Project Management
• Overseeing the project activities involving working out various requirements with respect to utilities, machines,
manpower & monitoring overall project operations for ensuring timely completion
• Handling the documents, reports regarding maintenance and recording observations
• Carrying out discussion with vendors/customers and guiding technical bid evaluation
• Preparing Pre DAP & DAP document, Project Execution timeline/plan & presentation to customer for approval.
Vendor development for any new products, Conduction of FAT, Dispatch clearance, I& C, SAT, etc.
• Managing the process of scope definition and change control, including estimating and negotiations of contract /
scope variations (change orders)
• Interfacing with Customers, Project Management, Sales, Sales Support, Life Cycle Service, etc.
Automation & Control Operations
• Managing the process measurement, control instrumentation and services to monitor the operations
• Guiding the Automation and Instrumentation Department at corporate level
• Monitoring the design & engineering of process control instruments & control systems
• Liaising with life cycle services organization to ensure that projects are properly closed out
• Coordinating with sales to ensure that project proposals are supported with proposal deliverables e.g. risk /
opportunity, estimate, project plan, etc.
• Controlling financial status of project (EAC, billings, cost budgets, milestone payments, rebates, warranty, etc.)

2. • Assuring the quality of engineering services and timely delivery of deliverables
• Accountable for operations, maintenance and troubleshooting operations for:
o New and installed electrical systems to locate and correct malfunctions
o Control Panel/Console Panel design, assembly/wiring in house, In house Panel testing, Application S/W
Program development, Final program development
o Major/critical bought outs, Product selection, System architecture, Control system interface with
line/Mechanical unit, Electrical SLD, Panel GA/IGA, Detailed IO List, etc.
• Assigning staff to projects and manage the day-to-day resource conflicts; achieving meeting productivity /
utilization targets, OTTR and deliverable PPM targets within the Engineering Team
T E C H N I C A L P U R V I E W
• Programming- Delta Tau Products like Motion Controller & PLC, CNC Front End etc, ABB PLC, Mitsubishi PLC,
Unitronix PLC, ABB Robots, Siemens, VIPA PLC handling, etc.
• AC Servo Drive/Vector Control/VFD (Control Technique, Baldor, Siemens, Baumuller, Panasonic, HPB,
Mitsubishi, ABB, AB, ELMO, KEB, etc..) programming, interfacing with PLC/CNC,
• Induction Motors with Encoder/Without Encoder, AC Servo Motors tuning with Drives and with load.
• HMI (EXOR, Mitsubishi GOT, Unitronix, etc.) Programming, Interfacing
• SCADA scheme Design Interfacing with PLC,
• Different types of Sensors/Instruments (Inc/ABS Encoders, LVDT, LT, Pressure Transmitter, Load Cells,
Dosimeter, Photoelectric, Inductive, Safety Light Curtain, etc.) interface to system
• Different Types of Electro Hydraulic Servo/Prop Valves(Rexroth/Yuken), Electro Pneumatic Servo Valves
(Festo), Solenoid Valves etc interface to system,
• Positional Sensors like Incremental, ABS Encoders/Linear Scale interface to system
• Control System Interface to Mechanical Units like Hydraulic/Pneumatic Fixtures, Ball Screw/Lead Screw, Gear
Box, Pulley with timing belt, Conveyors, Machine Tool etc.
• Control System design in AutoCAD Electrical - Fabricated Panel/Console/Junction Box GA/IGA/SLD design
• Handling of ESAB, Sigma Make Mig Weld Power Source & its interfacing with ABB Robot
• AbiRob Binzel Torch (Mig Welding) interfacing with Robot
• Mig Welding Application programming/parameter setting for Robotic welding
• Front end S/W, SCADA (Wonderware, ABB, Ellipse Scada, User Defined VB/VC Scada, NI-Labview) handling,
Interfacing with PLC/Motion Controller
• Different types of CNC SPM, PLC & Drive, Robotics Line based application prove out from Presale Eng. to
Commissioning
• PMAC (Programmable Multi Axes Controller) and its peripherals Controller in brief
• PMAC1(Programmable Multi Axes Controller): is a family of high-performance servo motion controllers capable
of commanding up to eight axes of motion simultaneously with a high level of sophistication. Motorola's
DSP56001 is the CPU for PMAC, and it handles all the calculations for all eight axes.
• Turbo PMAC2 (Advanced Programmable Multi Axes Controller): is an advanced version of PMAC family &
capable of commanding up to 32 axes of motion simultaneously with a high level of sophistication. Motorola's
DSP56003 is the CPU for Turbo PMAC, and it handles all the calculations for all 32 axes, 16 co-ordinate systems.
It’s High-speed (160MHz), large memory.
• Electronic Gearing, Time Base, Electronic CAM, Axes Synchronization, Back lash compensation, Rotary Buffer
reqd for large NC Code etc.
A C A D E M I C D E T A I L S
• BE (Electronics) with First Class from Shivaji University (K.B.P. College of Eng., Satara) in 1999
• 12th from Kolhapur Board with 84% (G) (Y.C. College of Sciences, Karad) in 1995
• 10th from Kolhapur Board with 89.57% (Tilak High School, Karad) in 1993
A C A D E M I C P R O J E C T
• Microprocessor 8086 based D.R.O for Vertical Turret Lathe at Key Bouvet Eng. Ltd., Satara(Project was
sponsored by M/s Satara Tekniks, Satara)
P E R S O N A L D E T A I L S
Date of Birth: 28th September 1977
Address: C1-302, “Madhukunj” Coop Hsg Society, S.No.82/5, Near GuruGanesh Nagar, New DP Road,
Kothrud, Pune-411038, Maharashtra (INDIA)
(Pl Refer to Annexure for Project Details)

3. ANNEXURE
M A J O R P R O J E C T S
At ELECTRONICA Machine Tools Ltd., Pune/Saswad(Year 2008-till date)
Proposal Engg -> Design->Execution->Application Development->I & C :
• Control System for 1500 Tons Hydraulic SMC Press,
o 4 Axes Controller, 144DI/144DO, Rexroth Prop Valve, Lin Scale, etc
o Customer – BEMCO Hydraulics, End User- ACSI, Pirangut, Year – Dec 2007-Jan2008
o Achievement – Commissioning completed in 7 working days at site.
• Control System for 1000 Tons Hydraulic SMC Press,
o PMAC Axes Controller, 144DI/144DO, Rexroth Prop Valve, Lin Scale, etc
o Customer – BEMCO Hydraulics, End User- ACSI, Pantnagar, Year – Feb2008-March 2008
o Achievement – Commissioning completed in 7/8 working days at site by team member.
• Control System for 500 Tons Hydraulic SMC Press,
o PMAC Axes Controller, 144DI/144DO, Rexroth Prop Valve, Lin Scale, etc
o Customer – BEMCO Hydraulics, End User- ACSI, Pantnagar, Year – March 2008
o Achievement – Commissioning completed in 7/8 working days at site by team member.
• Control System for Wheel Press
o PMAC Axes Motion Controller with PLC, 72DI, 72DO, Sensors, PC Based HMI (VB), etc
o Customer – BEMCO Hydraulics, End User – Railways Work Shop, Chennai
& Dahod, DMRC, Delhi (3Nos), Year 2008-09
o Achievement – Commissioning completed in stipulated time days at site by team member.
• Revamp Control System for CH Spooler Winding Machine (Three nos.)
o PMAC 4 Axes Controller, 48DI/32DO, CLA Drives, Induction Motors, Load Cell, HMI etc
o Customer/End User – ICC Ltd, Pimpri, Year 2008
• Control System for PH Spooler Winding Machine
o GeoBrick 4 Axes Controller, 32DI/32DO, Induction Motors, Load Cell, HMI etc
o Customer/End User – ICC Ltd, Pimpri, Year 2008
o Achievement – Application development with new generation controller. Received the repeat orders.
• Control System for Cut to Length Line -GP Line
o PMAC 4 Axes Controller, VIPA PLC (214), SM221, SM222 144DI/144DO, Induction Motors, CLA, HMI etc
o Customer- HB EsMech Ltd. End User – Uttam Steel, Khopoli, Year –Dec 2008/Jan 2009
o Achievement – Application development with new H/W configuration
• Control System for PH Spooler Winding Machine (3Nos.)
o GeoBrick 4 Axes Controller, 32DI/32DO, Induction Motors, Load Cell, HMI etc
o Customer/End User – ICC Ltd, Pimpri, Year 2009
o Achievement – E & C completion in 20 working days at site.
• Scada Communication with Delta Tau Controller - trials
o Wonderware, Ellipse, Labview (NI) interface with DeltaTau controller In-house development activity for
future projects, Year -2009
• Scada Development in Labview for Wheel Press
o Resolved the issue of VB Based Scada by developing the Scada in Labview.
o Concept given to supplier & got it developed.
o Customer-BEMCO Hydraulics End User – Railways Workshops, Year 2009
o Achievement –Controller & Labview communication proved. Std Front End SW Product developed &
installed on all 7 sites.
• Control System for BSR Test Rig
o GeoBrick 8 Axes Controller, 32DI/32DO, Induction Motors, Ellipse Scada, HMI etc
o Customer/End User – TML Pimpri, Year 2009-10
o Achievement – Prove out of new application with new generation of Controller.

4. • CH Spooler Winding Machine (3Nos.)
o GeoBrick 4 Axes Controller, 16DI/16DO, VIPA PLC (214) 32DI/32DO, Induction Motors, Load Cell, HMI etc
o Customer/End User – ICC Ltd, Nalagadh (HP), Year 2009-10
o Achievement – Application development with new generation controller. Cost reduction in Project,
Received the repeat orders.
o E &C completion in 15 working days by team members.
• Control System for CNC Two Roller Vertical Flow Turning Machine (Hydraulic)
o UMAC 4 Axes Controller, 48DI/48DO, Yuken Prop Valve, Siemens VFDs, Induction Motor, ADV900 PC, Front
End in PHMI
o Customer- Excellent Engg, Sangli, End User – OFAJ, Nagpur, Year 2009-10
o Achievement –Studied the old Mechanical Machine. New product used for the first time in INDIA & proved
the Application.
o Appreciated by customer & GM, OFAJ.
• Control System for CNC Three Roller Flow Forming Machine (Electro-Hydraulic)
o UMAC 4 Axes Controller with Modbus TCP, 48DI/48DO, VIPA 313 PLC with Modbus
RTU, 96DI/96DO, Schneider Lexium AC Servo Drives, BSH Series AC Servo Motor, ABB VFD, Prop Valve,
VFDs, Induction Motor, ADV900 PC, Front End in PHMI
o Customer/End User - Paras Flow Form, Ambarnath, Year 2010-11
o Achievement – Studied the old Machine. Interfaced & proved the application with continuous efforts.
Appreciated by Paras Flow Form management team.
• XY Gantry System for Spot Welding Gun handling
o AB VFD, Induction Motors, Pendant, etc
o Customer/End User – L &T Ltd, Powai, Year 2010-11
o Achievement – Low cost control system. E & C completion at site in 1 day.
• CH Spooler Winding Machine (2Nos.)
o GeoBrick 4 Axes Controller, 16DI/16DO, VIPA PLC (214), 32DI/32DO, Induction Motors, Load Cell, HMI etc
o Customer/End User – ICC Ltd, Nalagadh (HP), Year 20010-11
o Achievement – E &C completion in 7 working days by team member.
• Robotics Pick/Place Line for Bottles – 80 Bottles/min
o ABB Robot IRB120, VIPAPLC 214 32DI/32DO, AB VFD, Conveyor, Schmaltz Vacuum System, Sensors, etc
o Customer/ End User – Emcure Pharma Ltd., Hinjwadi, Year 2010-11
o Achievement – First Robotic Project. Proved totally in house without external support. Achieved desired
cycle time & speed of 80 Bottle/Min. Special appreciations by Company Directors.
• Robotics Welding Station for SAFE
o ABB Robot IRB1600ID with Smartac, ESAB Mig 5000i, AbiRob A500, Sensors, etc, Learnt Robotic Welding
application & completed the task.
o Customer/ End User – Godrej & Boyce, Mumbai, Year 2011-12
o Achievement – First Robotic Welding Project. Proved totally without external support. Achieved desired
cycle time & weld quality. Received Robotics Mig Welding another order from same customer.
• Chiselling Machine Concept Proving
o Motion Controller, 16DI/16DO, CT Drive, EZ Motion Controller, Induction Motor, Sensors, etc
o Customer/ End User – JK Files Ltd., Chiplun Year 2012-13
o Achievement – Proved the new application & total M/C. Machine installed by customer w/o our support.
Recd repeat order for complete file manufacturing line.
• Robotics Welding Station with Fixture for FRFC (I & C - @ EMTL Sales & Service Ltd.)
o ABB Robot IRB1600ID, ESAB Mig 3000i, AbiRob A360,Mitsubishi FX 3U PLC, 112DI/64DO, 4 Axes- MRE
Super Drives, Servo Motors, HMI QSBD1055, Sol Volves, Sensors, etc
o Customer/ End User – Godrej & Boyce, Mumbai, Year 2012-13 In house fixture trials completed. System
dispatched in Oct13.
I & C in progress at site. Two variants are proved, Year 2014
o Achievement – Cost reduction in Project. Fixture made universal for 25 variants.
• New Generation Cutting Line for File Manufacturing
o Siemens 313 PLC, ET200 Remote IOs, 256DI/192DO, Yaskawa VFDs (6Nos.), Induction Motors, Festo Prop
Valves, Sol Valves, Sensors, etc.
o Customer/ End User – JK Files, Vapi, Year 2012-13
o Design Input prepared & offloaded to supplier for manufacturing.

5. o After management changeover, offloaded the Project to third party for interface and completion.
o Achievement – Cost reduction in Project. Overheads reduced.(Off loaded to third party for manufacturing)
• PLC Based Linear Auto Sampling Unit (DAP - @EMTL Sales & Service Ltd.)
o Schneider PLC BMX P342020, BMX DDI 3202/DDO3202 96DI/96DO,8AI, AC Servo Drives
o LXM32CD18M2, Servo Motors BSH055, Oriental Make AC Motors, HMI GTW7354, Sensors, ABS Encoders,
Valves, SS304L Mechanical Enclosure with SS Ball screw, etc
o Customer/ End User – BARC, Kalpakkam, Year 2012-13
o DAP is completed. QAP in process, Procurement started. Manufacturing to be started.
o Achievement – System reconfiguration made. RM cost reduced. DAP Approved as per new configuration.
• PLC Based Waste Inspection Tomography (Reconfig, Mfg, I &C- @ EMTL Sales & Service Ltd.)
o 6 Axes Motion Control, PMAC Controller, HPB Make Servo Drives, Unitronix Make PLC, 96DI/96D0, 4AI,
HPB Make Servo Motors, PC Based (VC) Scada, Loadcell, Dosimeter, Proxy Sensors, Conveyor, Machine Tool
assembly, ABS Encoders etc.
o Customer – IGCAR, Year- 2013-2014
o Achievement – Though not involved from Design, later involved for prove out after Management change.
System hardware and software wise reconfigured as per requirement and proved out in house by not
increasing/reducing additional material & labour cost without supplier technical support.
o System is dispatched to IGCAR after FAT in June 14 and I&C complete in Oct 14.
Engineering ->I &C (Contract Manufacturing):
• Force & Travel Test Bench –(2Nos)
o DAQ-NI PCI6224, Sensorex LVDT, Kistler Effort Sensor, Amplifier, Garos Load Cell, Conditioner, Labview
Front End etc.
o Customer- TCS, Pune, End User – Arvin Meritor, Year-2009
o Achievement – In stipulated time, completed the Projects. Received orders from same customer.
• Motor Test Bench
o DAQ-NI PCI6221, Lorenz Torque Sensor, Amplifier, Labview, Front End, etc
o Customer- TCS, Pune, End User – Arvin Meritor, Year-2009
o Achievement – In stipulated time, completed the Project.
• In Service Inspection Vehicle, Customer –IGCAR, Year -2011-13 & many more
• Now involved in ISI Vehicle Project Review and further trials from June 14 (@ EMTL Sales & Service Ltd.)
• CNC Wire Cut EDM Machine – New Generation of CNC Controller development work in H/W & S/W
(@ EMTL Sales & Service Ltd.),Year 2014-15
At ELECTRONICA Machine Tools Ltd., Pune/Saswad:
Proposal Engineering :
• Revamp of CTL – Control System (Approx 55 CTL Lines)
o 4 Axes Motion Controller with ModBus TCP, VIPA PLC with Modbus TCP, 144DI/144DO, CT UniSP Drives,
etc
o Customer-All End users of CTL like Bhushan Steel, Uttam Steel, Tata Steel, Abul Khair, PT Essar, Aarti Strips,
etc.
o Achievement – H/W configuration tested & proved in-house.
• Engine Assembly Line – 13 Press Stations & 2nos.- XY Servo Table, Conveyor Control System-
o Master PLC-Siemens S7 317 PN/DP, ET200S,
o Station PLC- IM151-1, Modules for 13 Stations 48DI/48DO each, 8AI/8AO each station, HMI MP277 (5nos),
OP 73 (8nos), Servo X Y Table with Simotion D425, Servo Motors 1FT/1FK, HMITP 177, Bar Code Scanner,
VFDs for Conveyor, Induction Motors, PC Based Scada (Wonderware), ATEQ-Leak Test Controller, LVDT,
Load Cells, Sensors, etc.
o Siemens Configuration + Scimetric- SigPod 1402 for Press Control (5nos)
o Master PLC – Q02H CPU, QJ61BT, CC Link, QJ71, DI/DO, Station PLC FX3U48, FX232, FX2N-32CCL, AI/AO,
QSBD1055 (8nos.) SigPod 1402 (5nos.), Servo Table- PLC Q01, QD75M2, DI/DO, Drive MRJ2S10, HCSFS102
Motors, etc.
o Customer-AVTEC, Indor
o Achievement – Extensive working done. Technically/commercially proposals are accepted by AVTEC.

6. • Parallel Manipulator- Control System
o UMAC 8 Axes Motion Controller with ModBus TCP, Faulbhaber Servo Drives/Motors, Fagor Linear
Encoders, GUI – Labview, etc
o Customer- BARC, Mumbai
• Wet Paint Application – Control System
o Siemens VFD MM440 with BOP 132KW, Flow Meter, etc
o Customer- JCB, Talegaon
• Shot Blasting Machine – SCADA
o Ellipse Scada 300 Tags with Hard Key
o Customer- JCB, Talegaon
• Pressure Testing Machine – Control System
o Mitsubishi FX1N PLC, 16DI/16DO, FX2N-4AD, Scada 20 Tags, Pressure Transmitter, etc
o Customer- JCB, Talegaon
• High Speed Cartoning Automation
o VIPA PLC 115, 32DI/32DO, VFD TDS V8, HMI ETOP05 Modbus RTU, 3.7KW Induction Motor, Sensors,
Valves, etc
o Customer- CIPLA, Patalganga, Goa
• Robotics Water Jet Cutting Machine
o ABB Robot 2400 with IRC5 Controller, CT Drive (5.5KW) for Indexing Motor, etc
o Customer- Grupo Antolin, Ranjangaon
o Achievement – Order received.
• Robotic Mig Welding + Fixture
o ABB Robot IRB1600ID, ESAB Mig 5000i, AbirRob Torch,
VIPA PLC 115, 24DI/24DO, JMD06 Drives, ESM85C (3.53NM) Servo Motor, HMI ETOP05, etc
o Customer- Premier Machines, Pune
• CTL – New Control System
o Motion Controller PMAC2 Clipper with Modbus TCP, VIPA PLC S7 Modbus TCP,
144DI/144DO, HMI ETOP05, KEB Servo Drive 90 Amp, Servo Motor 102NM,etc
o Customer- Tata Ryerson, Ranjangaon
o Achievement – H/W configuration tested in house.
• Seat Frame Assembly Work Stations
o Control System for 4 stations each - Siemens PLC 313-2DP, 32DI/32DO, CP343, CP340 for Scanner, ET200L
with 16DI/16DO, OP77B, etc.
o PC – Data base Station, Data base SQL Server, etc
o Customer- Tata Faurecia, Pune
• 5 Axes CNC Goniometer
o 6 Axes GeoBrick 8/16A, Modbus TCP, 32DI/32DO, ESM 85D Servo Motor, HMI ETOP05, PC, Scada- Labview
o Customer- Tata Motors, Pimpri
o Achievement – Techno-commercial proposal accepted by customer.
• Platform Levelling + Erecting System – 6 Axes
o UMAC 8 Axes Motion Controller, Modbus TCP, 72DI/72DO, High Speed AI Module, SSI Board, Baldor Drives
FDH4A27TR (6nos), Baldor Servo Motor BSM100C, HMI ETOP05, Netzer ABS Encoder with external SSI
Module, Load Cell28Tons, Tilt Sensor, etc, Stds-Mil Grade, JSS Penta 5, etc
o Customer- SEC, Hyderabad,
o Achievement – Extensive working done on this proposal.
• Servo Manipulator – 7 DOF (Master Arm 7 Axes, Slave Arm 7 Axes) , 3 Axes Gantry (Cross Travel, Vertical
Motion, Azimuth)
o Supervisory Monitor - Industrial PC, Profibus PCI Slot, Scada Labview, ETH Switch, Master/Slave Arm -7
Axes each- Configuration
o UMAC 16 Axes, 240Mhz Controller, Profibus, 72DI/72DO, AI/AO,
o Master Arm - Baldor Make Servo Drive 115V MDH 5A/10A (7nos), Servo Motor 2NM/4000 RPM BSM63N
(7nos),
o Slave Arm – Baldor Make Servo Drive 115V MDH 5A/10A (7nos), Servo Motor 3.2NM/4000 RPM BSM80N
(7nos),

7. o Gantry – Baldor Servo Drive 115V MDH 5A/10A (3nos) with Profibus DP, Servo Motor 3.2NM/4000 RPM
BSM80N (3nos), HMI – UniOP BKDC16+TCM08, Load Cells on joints, Clutch system on Master Arm, Thermo
Scientific Camera (3nos), etc.
o Customer- IGCAR, Kalpakkam
o Achievement – Extensive working done. Techno-commercial proposal accepted by customer. Technical
scheme appreciated by IGCAR Seniors. Prototype for single axis Master/Slave with Position & Torque loop
demonstrated to IGCAR Ass Director &team.
• Robotics Mig Welding Station for Chair
o ABB Robot 1410, ESAB 3000i, AbiRob A360 (3nos each), Torch cleaning station, Fume extractor, etc
o Fixture Control – Mitsubishi PLC Q0, 96DI/96DO, Device Net M/S, HMI QSBD 1055, Sensors, Sick Safety
Light Curtain (Type4), etc,
o Customer- Savera Engg, Aurangabad
o Achievement – Techno-commercial proposal accepted by customer.
• Robotics Mig Welding Station for Centre Frame & Side Frame (EX,ZX Models)
o ABB Robot 1600ID,80Ar20Co2, Track Motion, Smartac, Weld guide, Bulls eye, ESAB 5000i, AbiRob A500 ,
TSC, Fencing with Euchner -MGB Safety Gate Box Unit, etc Fixture Control – Mitsubishi PLCFX3U 128MT,
Device Net M/S, HMI QSBD 1055, Sensors, MRE Super Drive & 12NM Motor for Positioner, etc
o Customer- RSB Transmission, Dharwad
• Robotics Mig Welding Station for Fork Lift Main Chassis & Steering
o ABB Robot 2600, Smartac, Weld guide, IO Card, Device Net M/S, Kemppi, Syn 500 Water Cooled,
AbrRobW500, TSC, Fencing with Euchner –Type4 Switch, etc (02 each)
o Indexing Fixture Control – Mitsubishi 4.3 NM Servo Motor +MRE Super Drive, Sensors, etc
o Customer- Godrej & Bocye, Plant 16
• Robotics Bottle Cartoning Automation – Total Line
o ABB Robot IRB140, Schmalz Gripper, VFDs with Induction Motors for Bottle, Shipping, Rejection Conveyors,
Automatic Carton Erector, Sealing M/C, Label Application PRC, FX3U PLC 128MT+48DI+32DO+Device
Net+4AO Module, sensors, etc
o Customer- Zydus Cadila, Ahmadabad
o Achievement – Worked extensively. Quoted total line with tech details.
• Robotics Station for PCB Pick& Place on BBT Machine
o ABB Robot IRB120, 16DIO Card, Schmalz Gripper, Laser Sensors, etc
o Customer- Shogini Technoart, Pune
o Achievement – Worked extensively. Demo trials shown, Techno-commercial proposal accepted by
customer.
• 4 Axes Test Bench
o 4 Axes PMAC2 Clipper, LG Mecapion 2NM Servo Drive/Motor Set (4nos.), PC, HMI-ETOP05, etc
o Customer- D.A.R.E., Bangalore
o Achievement – Worked extensively. Quoted total line with tech details.
• Auto Scan for Pan & Tilt System
o 4 Axes PMAC2 Clipper, Modbus TCP, Baldor 750W Drive, 2NM Motor (2nos) PC, Scada Ellipse 75 Tags, etc
o Customer- LASTEC, Delhi
• Precision Position 11 Axes Table for Antenna
o UMAC Motion Controller, Modbus TCP, HMI Ev080, Baldor Servo Drives 750W (11nos,) , Baldor Servo
Motors 2NM/3000RPM, PC, Front End VB.NET, etc
o Customer- Defence Lab, Jodhpur
Vega Controls Pvt. Ltd., Pune (Year 2006-2007)
Project Engg->Execution->S/W Development->I&C :
• Gear Box Transmission Test Rig for ACE Vehicle –EOL
o Control System-Product Development- ABB PLC (AC500) 32DI/32DO, VFDs (ACS550), Wonderware Scada,
Induction Motors, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- Tata Motors Ltd, Pantnagar, Year 2006-07
o Achievement – Development of new Product for Gear Box Transmission-EOL Appreciation by VEGA
Management. Received repeat orders from TML.

8. • Gear Box Transmission Test Rig for Piaggio Vehicle –EOL
o Control System- ABB PLC, VFDs, ABB Scada , Induction Motors, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- Greaves Cotton, Aurangabad, Year 2006-07
o Achievement – E & C completion in 4 working days at site.
• Gear Box Transmission Test Rig for Endurance Test –R&D
o Control System-Product Development- ABB PLC, VFDs, ABB Scada, Induction Motors, Auto Gear Shifting, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- Greaves Cotton , R&D Centre, Aurangabad, Year
2006-07
o Achievement – Drive Parameter optimization as endurance trials were reqd. Auto Gear Shifting prove out
for first time.
• Gear Box Transmission Test Rig for EOL
o Control System-Product Development- ABB PLC (KT97), VFD (ACS550), Induction Motors, etc.
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- Hero Motors, Ghaziabad Year 2006-07
o Achievement – Low cost automation, Proved the System.
• Gear Box Transmission Test Rig for Nano Vehicle –EOL
o Control System- ABB PLC, VFDs, Wonderware Scada, Induction Motors, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- TML, Pantnagar, Year 2006-07
o Achievement – E & C completion in 2 working days at site.
• Gear Box Transmission Test Rig for Winger Vehicle –EOL
o Control System-Product Development- Siemens S7 313 PLC, Micromaster 440 VFDs, Wonderware Scada,
Induction Motors, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- Tata Motors Ltd, Pimpri, Year 2006-07
o Achievement – Development of System with Siemens Make Product for Gear Box Transmission-EOL,
Received repeat orders from TML.
• Gear Box Transmission Test Rigs for Winger Vehicle –Truck (2510)
o Control System-Product Development- Siemens S7 313 PLC, Micromaster 440 VFDs, Wonderware Scada,
Induction Motors, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- Tata Motors Ltd, Pimpri, Year 2006-07
o Achievement – E & C completion in 4 working days for two no. of systems at site.
• Gear Box Transmission Test Rigs for Pickup/Commander Vehicle –EOL Control System-
o ABB PLC, VFDs, ABB Scada, Induction Motors, etc.
o Customer – Ubique Controls Pvt. Ltd, Pune, End User- M & M, Kandivali, Year 2006-07
o Achievement – Completion of Total Project (2 nos) within 30 days of time after receipt of PO. Special
appreciation recd from VEGA, M&M management.
• Product Development – Single/Multiple Gear Roller Tester Control System
o ABB PLC (KT97), VFD, LVDT, etc
o Customer – Ubique Controls Pvt. Ltd, Pune, Year 2006-07
Electronica Machine Tools Ltd..(Year 2000 to 2006)
Project Execution->I&C :
• CH Spooler Winding Machine at ICC Ltd, Pimpri, Pune in year 2003
o Achievement – Critical parameter like desired accuracy of pitch & winding tension.
• Rotary Axis Controller at B.A.R.C., Mumbai in year 2004
• Telebreaker Racking Device (Embedded) at TISCO, Jamshedpur in year 2004.
• CTL Line at Bhushan Steel Ltd, Sahibabad in year 2005
• 2 WRA System at HLL Orai, 3 WRA System at HLL, Goa & HLL ,Baddi in year 2005
Project Design->Project Engg-> Execution->S/W Development->I&C :
• Control System for - 1000 Tons Hydraulic Press for SMC moulding (Servo & Prop valve controlled):
o 4Axes Motion Controller with PLC, 192 DI, 160DO,4AI, Rexroth Servo Valve, Linear Scale,.
o Customer - ISGEC, Yamunanagar, End User- ACSI Ltd., Pirangut, Year 2001-02
o Achievement – Proved Synchronization of RAM thru Control System, Controls of Hyd Cylinder Movement.
Special appreciation recd from ACSI, ISGEC, EMTL management.
Received orders from the same customer.

9. • CNC Engraving Machine for in house activities (Group Project Activity)
o 4 Axes Motion Controller, EMTL DC Drives, VFD for Spindle, etc
o Customer/End User – EMTL, Saswad, Year 2001
o Achievement-Development of G Codes, G00 to G84 (Pecking Cycle)
• Rotary Axis Controller for Wirecut Machine
o Single Axis Controller, Harshmann Rotary Table, Interface with CNC WireCut Controller
o Customer/End User – IGCAR, Kalpakkam, Year -2002
o Achievement – Made Standard product for WireCut Machine- Plug & Play
• All Electric Injection Moulding Machine
o 8 Axes Motion Controller with PLC, Current Loop Drives, 8AI, Induction Motor, PC Based HMI, Sensors, etc.
o Customer/End User – EPM Pvt Ltd, Pirangut, Year – 2002
o Achievement – Proved first Indian AE Injection Moulding M/C & presented at Plast Vision 2002.
Special appreciation by Management & visitors at Exhibition.
• Control System for 300 Tons Hydraulic Press for SMC moulding (Prop valve controlled)
o 4 Axes Motion Controller with PLC, 92DI,108DO , 4AI, Rexroth Prop Valve, Sensors, etc
o Customer – BEMCO Hydraulics, End User – ACSI Ltd., Pirangut, Year – 2003
o Achievement – Proved out the system in approx.28 days at site.
• Tele breaker Racking Unit
o 2 Axes Motion Controller with PLC, 4AI, CLA Drive, Induction Motor, HMI, etc
o Customer/End User - TISCO, Jamshedpur, Year – 2003
o Achievement – Developed & Proved very first product for TISCO-Automation. Special appreciation
By TISCO senior officials for successful & safe trials in Breaker. Recd repeat orders.
• Control System for 500 Tons Hydraulic Press for SMC moulding ( Prop valve controlled)
o 4 Axes Motion Controller with PLC, 92DI,108DO , 4AI, Rexroth Prop Valve, Sensors, etc
o Customer – BEMCO Hydraulics, End User – ACSI Ltd, Pirangut, Year – 2004
o Achievement – Proved out the system in approx. 20 days at site.
• Two Roller CNC Flow Forming Machine
o 8 Axes Motion Controller withPLC,96DI/72DO, CLA Drives, Induction Motors, PHMI, etc
o Customer – A.R.D.E, Pashan, Pune, Year – 2004-05
o Achievement – Developed & proved first indigenous product for ARDE.
First CNC Flow Forming M/C with Induction Motors in INDIA
• Control System for 500 Tons Wheel Press
o 2 Axes Motion Controller with PLC, 72DI/72DO, 4AI, Sensors, PC Based HMI (VB), etc
o Customer – BEMCO Hydraulics, End User – Northern Railways Work Shop, Amritsar, Year-2005
o Achievement-Developed & Proved first INDIAN Wheel Press based on Automation.
It was inaugurated by GM-Northern Railways in grand ceremony.
Recd repeat orders of 7 Machines for the same.
• Control System for Rotary Punching Line
o 4 Axes Motion Controller, Control Technique Drives, Servo Motors, HMI, etc
o Customer / End User – ICC Ltd, Pimpri, Year - 2005
o Achievement- New application proved out. Received repeat orders.
• Strip Magnetizing Machine
o 4 Axes Motion Controller, 24DI/24DO, DC Drives & Servo Motor with dual F/B, Sensors, Writer Head, etc
o Customer/End User – EMST Pvt Ltd, Pune, Year - 2005
o Achievement – Developed & proved first product for Linear Magnetic Scale manufacturing.
Appreciation by EMST Management.
• 3 WRA Program development
o 8 Axes Motion Controller, Control Technique AC Servo Drive, AC Servo Motors, Sensors, etc
o Customer/End User – HLL, Baddi, Year - 2005
o Achievement – Developed S/W keeping the same H/W by adding 3rd WRA system in 2nd WRA.
Enduser’s equipment cost reduced. Recd orders from customer.

10. • Control System for Fully Automated Bearing Cage Punching Line
o 8 Axes UMAC Motion Controller with PLC, 192DI/192DO, Vector Drives, Induction Motors, Sensors, HMI,
etc
o Customer – Prabodh Nirman, Pune, End User – Harsha Bearing Pvt Ltd, Ahmadabad, Year - 2006
o Achievement – Used advanced PMAC2 products for the very first time in INDIA & proved application on
site.Appreciated by Harsh Bearing Management. Recd repeat orders.
• Control System for Cable mat coiling Machine
o 8 Axes Motion Controller, Baldor Drives, Servo & Induction Motors, etc
o Customer/End User – Finolex Cables Ltd, Pimpri, Year -2006
o Achievement – Retrofitted the Control System & proved the application.
Scan Electronics, Pune (Year 1999-2000)
• Development & Installation of Ignition Key Test Rig
o Customer - Bajaj Auto Ltd, Akurdi, Pune, Year - 2000
• Installation & Commissioning SRC & RTCC for Transformer Tap changing
o Customer - Godrej & Boyce Ltd, Mumbai, Year - 2000
o Achievement – Completed the Project after rigorous trials as distance between SRC & RTCC was almost 2
Km.Communication thru telephone line.
• Installation & Commissioning of Data Loggers for Boiler Room
o Customer - L & T Ltd, Powai, Mumbai, Year - 2000
• Installation & Commissioning of Data Loggers
o Customer – S.A.S.E of D.R.D.O., Manali, Year - 2000
• Installation &Commissioning of Data Loggers
o Century Enka Ltd, Godrej & Boyes Ltd, Chemical Companies at Vapi, Year - 2000