Dango & Dienenthal (India) Pvt. Ltd. is a Germany-based company that manufactures furnace equipment and robots for advanced manufacturing industries. The document summarizes the company's products such as tap hole furnace drills, forging manipulators, transport manipulators, and charging machines. It then provides an in-depth analysis of the manufacturing process for their SAM-7 skimming machine, describing the assembly of parts, machining operations, and final assembly. The training concluded with acknowledgements to Dango & Dienenthal and MCKV Institute of Engineering for their support during the students' visit.

1. DANGO & DIENENTHAL (INDIA)Pvt. Ltd.
Duration of Training: 15/06/14 - 15/07/14
2014
MCKV INSTITUTE OF
ENGINEERING
7/15/2014
REPORT ON VACATIONAL
TRAINING

2. MCKV Institute of Engineering
Department of Mechanical Engineering
ABOUT THE COLLEGE: MCKV INSTITUTEOF ENGINEERING was established in
1999 as the pioneering self-financing degree engineering college in the district of Howrah, West
Bengal.
Contact:
MCKV Institute of Engineering.
243, G.T.Road(N),Liluah,Howrah-711 204.
Phone-(033) 2654 9315/17.
Fax-2654 9318.
Email:mckvie@vsnl.net
Website: www.mckvie.edu.in
The following students from the Department of Mechanical Engineering, MCKV Institute of
Engineering, were a part of the Vacational Training at Dango & Dienenthal (India) Pvt. Ltd.
 Asif Anwar
 Amit Kr. Pandit
 Amiyo Khanra
 Tanmoy Dey
 Srijan Roy
 Samaresh Samanta
 Sudipto Chakraborty
 Sujit Pal
 Umashankar Samanta
 Sudipta Jana

3. ABOUT THE COMPANY
Introduction:Dango&Dienenthal Pvt.Ltdisa
Germany basedcompanypopularforits widely
varyingproductsinthe fieldsof conventional&
nonconventional castingandforgingindustries.
Theyprovide personalizedfurnace equipments
and PLC controlledrobotsforadvanced
manufacturingindustries.
Services: The newmanufacturingandservice
facilities nearKolkatawere built in2001 and
extendedin2011. The plantIs locatedinthe
westernpartof the city.NexttoBombayroad at
JangalpurIndustrial Complex.Itisadequately
equippedtomanufacture,assemble andalso
testlarge machines.
The company hassuccessfully
manufacturedthe requiredproductsforthe
followingcompaniesoverthe years.

4. Products
1.Tap Hole Furnace Drill & Clay Gun
Furnace drill machine isusedtodrill pre determinedareaof a ladle furnace fordrainage of hotmolted
metal.
The clay gun isfollowedbythe drill tocoverthe drilledhole byspecial type of clay.
A tap hole drillingmachine,adrill bit and
a drillingmethod isused.A nitrogengas
supplyline forpressurizednitrogenasa
carrier gas anda coolingwatersupplyline
are providedtoformwatermistfor
coolingthe drill bit,the drill rod,the main
bodyof the drillingmachineandthe tap
hole.Thusthe drillingtime periodis
remarkably shortened,the molteniron
discharge time periodissignificantly
increased,andthe netconsumptionrate
of the refractorymaterial isconsiderably
decreased.Therefore,byproperly
adjustingthe amountof the moltenironexistingwithinthe lowerportionof the blastfurnace,the
conditionof the blastfurnace can be stabilized,andthe productivitycanbe improved.Advantageous
conditionscanbe providedforthe operationeven
undera highpressure anda hightemperature
environment.

5. 2.Forging Manipulator
Whenmaximumflexibilityintransportandhandlingcapabilitiesduringthe forgingprocessisimportant
a Mobile ForgingManipulatoris used.The compactdesignandmaneuverabilityof manipulatorsfrom
DANGO& DIENENTHALallowthe transportof workpieces whenspace islimited.
Whethersmall orverylarge handlingcapacitiesare neededDANGO&DIENENTHALoffersbothstandard
and customizedsolutions.The
machinesofferhighreliabilityas
well asgreat flexibility.The sturdy
and compact designisadaptedto
the special operatingconditions.
Economical aspectsandhands-on
experience are the decisive
factors forselectingandarranging
control levers,switchesand
buttons.
Characteristics:
1. Powerful tongs unitwithlarge grippingrange.
2. Multistage adjustmentof closingforce.
3. Springsystemsactingbothverticallyandhorizontallytoabsorbshockloads.
4. Highmaneuverabilitydue toquickandflexible travelling behavior.
5. Semi-automaticworkingcyclesatrequest.
6. Travel,steering,andtongsmotionscanbe carriedout at the same time excellentoperator's
viewinall directions.
7. Airconditioneddriver'scabinatrequest.
8. Pumpsdrivenbyelectricmotorordiesel engine.
9. Emergencyfunctions.

6. 3.Transport Manipulator
Transportationof coldor preheatedingots,discsorringsisperformedbyTransportManipulators
manufacturedbyDANGO& DIENENTHAL.Tool Manipulatorsguide andpositiontoolsatopen-die
forgingpresses.Bothmachine typeseithercanbe poweredby diesel-hydraulicorelectro-hydraulic
drives.
Characteristics:
1. Sturdydesignadaptedtothe conditionsinhotmetal formingplants.
2. Energy-savingtravellingwhile offeringhighcarryingcapacities.
3. Highmaneuverabilitydue toquickand flexible travellingbehaviortongschangingsystemon
request.

7. 4.Charging, Stoking & Distribution
Machine
Quite oftenthe space onthe furnace platformislimitedandcallsforcompact andmanoeuvrable
vehicles.Tomeetthisrequest,DANGO&DIENENTHALmachinesare equippedwithaspecial lever
systemwhichallowsashortmachine lengthwhenthe tool armisretracted.The machine travelswith
retractedtool.Onlyat the workingpositionatthe furnace the tool isextendedtoensure anutmost
reach intothe furnace.The operatordoesnotneedto leave the control standtochange the stokingtool
againstthe charging box.Bymeansof the box,chargingmaterial canbe broughtto specificpointsinthe
furnace.
In case of tube charging,the material
can be optimallydistributedbythe
stokingtool.Deepstoking,crushing
of slagbridgesandopeningof gas
bubblesiseasilypossible eitherby
meansof the leversystemwhenthe
machine isinrestingpositionorby
utilizingthe massenergywhenthe
machine istravelling.
Characteristics:
1. Electrohydraulicdrive withpowersupply viatrailingcable orcontactline ,alternativelyDiesel
hydraulicdrive.
2. The special leversystemensuresa shortmachine lengthwithretractedtool arm.
3. Changingof toolswithout manual assistance.
4. Low overall height.
5. Highmaneuverabilitydue toquick-reactingandflexible steeringandtravel performances.
6. Encloseddriver'scabinwhichcanbe equippedwith air-conditioningonrequesthermetically
sealedhydraulicsystem.

8. Skimming Machine
Skimmingmachine isaspecial kindof foundrymachine whichis used to skim away the slag over the
moltenmetal.This isbasicallyahydraulic operatedmachine whichgeneratesalarge amountof force
of skimmingfromanoticeable distance andoperatesthe mainbroomi.e.the partwhichextendsover
and carriesthe skimmingpoint.
SAM-7 and SAM-10 are the popularmachinesmanufacturedbythe company,providingskimming
solutions.

9. Heavy-Load Robot
A material handlingrobot movesselectsorpacks products.These robotsare alsousedto automate
feedingordisengagingpartsortoolsfromone locationto another.
Characteristics:
1. sturdydesignadaptedtothe conditionsinhotmetal formingplants.
2. Energy-savingtravellingwhile offeringhighcarryingcapacities.
3. Highmaneuverabilitydue toquickandflexible travellingbehaviortongschangingsystemon
request.

10. During our trainingperiodat the DDS factory,we observed the detailedmanufacturingoperationsof
the popularskimmingmachine, SAM-7.The step by step assemblyandproductionprocess of the
machineare describedin detailsas follows.
Orderis received Analysisof requiredproduct ProductDesign& validation Raw
material procurement Checkingof Raw materials DistributiontovariousMachiningshops as
perrequirement Parts are made usingspecializedmachineswithdetaileddrawing Assembly
of parts dispatching.
IN DEPTH ANALYSIS OF
MANUFACTURING OF “SAM-7”
INTRODUCTION: Skimmingisthe processof removal of slag floatingonthe moltenmetal surface.
Skimmingisdone bytiltingthe ladle andusingareciprocatingmotionincorporatedwiththe machine
arm.
WHY IT IS IMPORTANTIN FOUNDRYFIELD :
Previously,the skimmingwasdone manually.Inthissystemof manual skimming,we needextra
attention forthe safetyof the workmenandalsoitsuse is limitedforasmall processingunitonly.Large
amountof castingneeda large quantityof molten metal - sothe skimmingtobe done inhuge area.So if
manual operationisdone here itwill be more time takingand alsoa riskto the workmen.Toavoidthe
riskwe needto designaequipmentwhichsuitsthe needs.
SAM-7 isa miniature versionof the skimmingmachine SAM-30,produced bythe same company,with a
fewmodifications.

11. Hydraulic power pack:
HydraulicPowerUnitsare the maindriving componentsof hydraulicsystems.Consistentlymainlyof a
motor,a reservoirandahydraulicpump,these unitscangenerate atremendousamountof powerto
drive mostany kindof hydraulicram.HydraulicPowerUnitsare basedon Pascal'slaw of physics,
drawingtheirpowerfromratiosof area and pressure.
HydraulicPowerUnitscan generallybe usedinanyapplicationthatrequiresheavyandsystematiclifting
or otherrequirementsforthe repeateduse of powerful anddirectional force.
In SAM-7 the powerpack providesthe drivingmotionforthe Hydromotor.
Assembly of Power pack:
In SAM-7 the Motor, pump,heatexchangerandfilterare receivedandmountedasperdesign
dimensionsonthe oil tank.The oil tankis
separatelypreparedusingthe followingsteps.
 The structure steel ismarkedand
preparedforthe cutting
 Material iscut as perdimensions
 Thenthe structure steel platesare welded
to formthe oil tank.
SAM-7 Machine Body
HydraulicPowerpack
 Oil Tank
 Motor (30Hp)
 Pump(pistonpump)
 Heat Exchanger(cross
flow,watercooled)
 Oil filter
 Manifoldblock
 DC valves
 Pressure gauge
 Hose & Pipes
 Pipe fittings
 Skimmingarm
 Base
 Main body
 Supportingrollerfor
arm movement
 Hydro motor
 ChainSprocket
mechanismforarm
advancement

12.  Inspectionsare carriedoutto ensure thatthere isno leakage
The accessoriesare mountedseparatelyandfittedtothe tank.Pipesandhosesare connectedtothe
accessories.Holesare drilledonthe tankcoverto fastenthe mountedaccessoriesrigidlytothe tank.
Manufacturing ofmachine body:
We were able togo through manufacturingof the mainbodyand base of the skimmingmachinebody.
The detailsof the processesare described
below.
Structural steel work:
In thisprocesspartsof the structural steel were cut
out usinggascutter as perdimensions.
Welding:
The cut outparts are weldedtogetherbyMMAW.
The weldswere furthercheckedbyDPtesting.
Thenthe parts were sentfornormalizing.
Machining:
The parts are machinedtoget desireddimensional tolerance forvariousfitting.
The operationsandtoolsusedforthese purposesare explainedbelow.
Operation: Boring
Machine tool used: Horizontal
boring machine (Scharmann)
Boringmachine hasa longbedwhichis
usedto mountthe jobwithrespectto the
spindle.Properalignmentof the jobis
done byadjustingthe bedwithrespectto
Dye penetration test on welded part
Boring operation on machine body

13. the machine spindle bysome conventional mechanism.
Thismachine can be automatedthrougha huge extenttogetthe suitabilityof the
operation.AtDDS, PLC controlledboringmachine isavailablewiththe
conventional features.
 The normalizedbodywasmountedonthe machine bed.Thenthe boring
operationwas done usingasingle pointboringtool.
 Small sizedcylindrical partsare machinedbylathe machine,drilling
machine,PLCcontrolledvertical millingmachineetc.
 Electrical circuits forsupplyof electricity alsomade bythe engineersof the company.
The DOL starter, control panel are made by themforthe SAM-7.
Figure 5 liquid nitrogen cylinder
Figure 6 vertical milling machine (PLC controlled)

14. Additional Operations involvedin processing ofdifferent part bodies:
Alongwith the mainbody, differentnecessarysmall andmediumsizedpartbodies are alsoproduced
side byside usingthe followingoperationsandmachine tools
 Parts requiringsmoothsurface finishweremachinedbythe face millingmachine.Using
thismachine almostperfectdimensional accuracyisobtained.
 Mediumsizedjobswhichrequire certainturningandfacingoperationsweremachined
inthe conventionalengine lathe.
 The holeswere drilledusingradial drill.
 Relativelycomplex shapedpartswithintricate detailsare senttoCNC operatedlathe
and millingmachines.
 The pipesandhoses were tightly fittedintothe machine,includingthe power pack,
withthe helpof a hose crimpingmachine,pipeswerebentusingapipe bending
machine.
Duringmountingandtransportationof the assemblyparts,twoEOTcranes
were extensivelyused.
EOT CraneHose crimping machine

15. Final Assembly of skimming machine:
Afterthe machiningandpreparations
of separate bodypartsare finished,the
final assemblyisdone.The workmen,
underproperguidance,carryout this
job.
Whenthe assemblyisover,the final
inspectionsare made.The machine
thenundergoespaint-job.Finally,the
completedmachine isdispatchedto
the concerned customer.
Figure: Assembly of the boom

16. Acknowledgements
We sincerelyacknowledgethe supportandguidance of the following personalitiesandInstitutions .
Withouttheirhelp,this trainingwouldhave notbeenasuccess.
 Mr. AsishKumarGhosh (Manager),
and all the engineers&workmenof Dango& Dienenthal (India)Pvt. Ltd.forguidingusduring
thisperiodof trainingandprovidinguswiththe knowledge of differentindustrial processes.
 Prof.(Dr.) RanjibBiswas (H.O.D.,Mechanical EngineeringDept),
 Prof.(Dr.) Parasar Bandyopadhyay (Principal).
We,the studentsof Mechanical EngineeringDepartment,
MCKV Institute of Engineering ,sincerelythankall the membersandemployeesof Dango&
Dienenthal (India)Pvt. Ltdforthe support,and guidance providedtousduringthisperiodof
vacational training.