industrial machines by microcon i2i

CORPORATE PRESENTATION2011

Microcon i2i Company Profile Started in 1983 Bangalore based Manufacturing Special Purpose Machines Specialised in Automotive Testing More than 300 machines for Auto ancillaries & OEMs Total Manpower -80 Employees Located About 10000 Sq. ft. facility in Bommasandra All under one-roof facilities for Custom-built machines

Mechanical Design Department Mechanical Manufacturing & Assembly Department Mechatronics Engineers with expert knowledge in Pneumatic,

Hydraulic & Motion Control Experienced Control & Instrumentation Engineers Well trained Software Engineers Dedicated technicians for Wiring & Panel building Good Mechanical Fabricators

Ownership

Promoted by Technocrat Mr. S.Ravi Narayanan Other companies in the Group Focuses on

Automotive, Aerospace Verticals Since 1983 Testing and Automation Solutions Since 1997 as a Separate Entity

Nature of Activities Design & Manufacture of Special Purpose Machines Manufacturing & Assembling Machines for Customers’

Design Test Rigs Vision based Inspection Systems Air Leak Testing in JV with ATC Inc., USA Building Electrical Control Panels Retro-fitment of old/imported SPMs and Refurbishing Manufacturing of Fixtures for customised applications Automation solutions for material handling Pneumatic Pick & Place systems, Customised Conveyors Service AMC for SPMs Testing services for Product Proto-typing Customers

Major Milestones 1988 – Bouquet of Clutch Testing Solutions 1988 – Rim Analyser –First of its kind in India 1989 – Inertia Dynamometer for Brakes Linings 1992 – Wheel Truth Analyser (WTA) 1992 – Seat Belt Solutions 1994 – Steel Pipe Mill Manufacturing Solutions 1998 – Crash Test -Integration 2000 – Fully Automatic Phosphating Plant 2002 – Fuel System Solutions 2004 – Indigenous Assembly Line and Flow Checking Test Rig for CRDi

based Fuel Injection systems 2006 – Focus on New Business Models, Strategic Tie-up 2007 – Promoting Micro-Flow based Air Leak Testing 2010 - Transition of Technology - Linear Servo Based G-Lock Testing

New Business Strategy Focus on Automobile Components Testing and Quality

Solutions Strategic Technology Tie-Up with Global Leaders for

Automobile Components Testing to provide Holistic support to our Customers

Provide Customers with world class solutions with Local Price Point advantage

Help Customers to compete globally with world class Quality Provide world wide cost effective support to our Partner To Provide Logistics Solutions to the Auto OEMs

Test Outsourcing(NEW BUSINESS STRATEGY)

We Manufacture & Assemble Test Systems for the Clients

The same Systems Installed in our Premises for Testing Customers’ Components (for Delphi and GE Medical).

JV with ATC Inc., USA (NEW BUSINESS STRATEGY)

Authorised partner in India for World’s largest leak test provider –ATC Inc., USA.

Set-up test lab with ATC’s demo units for testing components.

Providing on-line leak testing solutions to our Customers based on ATC’s technology.

Also Market ATC’s products in India

Logistics Solutions To Automotive Industry (NEW BUSINESS STRATEGY)

Design & Manufacture Re-usable Metal Pallets

To Design Specialised Packaging Solutions for Transportation of Auto Parts during inter-unit transfers or Sales

To tie-up with Flexol Packaging for these Solutions

To Market the Packaging Solutions with our Existing Customers

QUALITY POLICY

To excel in providing solutions, systems, and services of value that enhance the

quality and productivity in the field ofManufacturing, Testing and Development

Design and development facility located in Bommasandra, Bangalore with built in area of 5000 Sq.ft

Assembly and Testing facility located adjacent to Design with a built in area of 6,000 Sq. ft.

INFRASTRUCTURE

Special Purpose Machines

Image Processing Applications (Vision Based Equipments)

Machine design

Automation design and delivery

Test and Measurement systems

Process Automation

Quality, Tracking and Manufacturing Systems

On-Line SPC

PRESENT BUSINESS SENARIO

OUR ESTEEMED CUSTOMERS

Sl.No.

Name of the Auto-Components

Machines Built

1 Starter Motors 4 wheelers1.Alternator Test Rig

2 Starter Motors 2 wheelers1.OD turning m/c for stator cores.

3 Recliners 1.Torque Testing Machine2.Recliner Assy Machine

4 Seats1.Composite Durability Test Rig2.Abrasion Test Rig (Ingress & Egress)3.Rear-ward Load Testing 4.Front seat back-rest skinning m/c.5.Head rest trim inserting fixture

Projects at Glance

Sl.No.

Name of the Auto-Components

Machines Built

5 Motors (various)1.Washer Motor Armature Winding Machine2.Performance test rig for Blower and Radiator motors

6 Brakes1.Secondary Plunger sub-assy abd Plunger train assy cum Vision based Inspection Machine.2.Wheel Cylinder assy. cum Vision based Inspection Machine.3.Caliper Brake assy line consisting of Bore Cleaning m/c, Dummy Stroking m/c, Piston assy. m/c and Final Caliper assy & testing m/c.

7 Fuel Pumps1.Bearing Press Assy. Machine2.Metering Valve Assy. –Hydraulic as well as Servo motor based machines3.Canister Gluing Machine4.Filter –Crimping Machine

Sl.No. Name of the Auto-Components

Machines Built

8 Window Regulators1.On-line Window regulator Final test rig –PLC based2.On-line Window regulator Final test rig –PC based3.Off-Line Window Regulator Endurance Test Rig

9 ELR Seat Belts –(Emergency Locking Retractors)

1.G-Lock Testing Machine2.Pendulam Testing Machine (vertical dynamic test)3.Tilt-lock Testing Machine4.Extraction / Retraction Test Rig5.Spring force testing machine6.Retraction force testing machine7.Vision based Pin Measurement System

10 Steering Systems1.Steering column Endurance test rig2.Upper Bearing Press Assy. m/c3.Tolerance Ring Assy. m/c4.Spin Testing m/c for Bearing

11 Drive Shafts1. Ball Sorting Machine2. Intermediate Drive Shaft Assy. Line


Machines Built

12 Wheels On-line Wheel Run-out checking MachineOn-line Rim analyzerOn-line Air leak testing for butt-weldingWhole Wheel Air leak testing machineWheel truth analyser

13 Instruments Clusters/Dashboard Instruments

1.Performance test rig

14 Fuel Pumps (MRA series) 1.Pump Durability Test Rig2.Ceramic Card Durability Testing3.Height vs Resistance Test for Floats

15 Fuel Hoses 1.Burst Test Rig

16 Seating Systems 1.Tube swaging m/c.2.Front Seat Track adjuster (sliding) testing m/c


Machines Built

17 Gas Springs 1.Assy. Machine for 16 series Gassprings2.Gas Filling Machine3.Performance Test Rig.

18 Motor Bike Engines 1.Kick Starter Performance test rig

19 Radiators 1.Condenser End Cap Assy. m/c

20 Gaskets 1.Vision Inspection m/c for ‘O’ rings

21 CRDi (Common Rail Diesel Injection)

1.Jet Pressing Machine2.Jet Flow Checking Machine

22 Fuel Injection Systems (NLS Injectors)

1.Bobbin Assy. m/c2.Connector Crimping m/c3.Automatic Soldering m/c

23 Hydraulic Cylinder Assy. Line Manufactured Hydraulic cylinder Assy. Line for manufacturing cylinders used in Earth Moving Equipments


Machines Built

24 Fuel Injector Parts 1. High Pressure Flow Checking for Tubes

2. Orifice Plate Flow Checking

25 Leak Testing Application (Using ATC’s Micro-flow sensor)

1. Wheel Weld Joint2. Whole Wheel Rims3. Engine End-Cover Assembly4. Front Cover for Fuel Injection Pumps5. Speed Governors6. Filters

26 ELR (Seal Belts) NEW 1. G-Lock Testing Using Linear Servo Motor2. Dust Chamber Testing for ELR Assy.3. Micro-slip Testing for Seat Belt Adjusters4. Belt Adjuster Force Testing

27 Steering Wheels 1.Gripper Wear Resistance Checking2. Bending Load and Torsion Testing

Types of Machines Built

1. Testing Machines

2. Measuring & Inspection Machines

3. Assembly Machines

4. Combined Machines with Testing &

Assembly

Testing Machines

Testing done for Checking the Performance of a Component and also Its Endurance.

We do both On-line and Off-line (Lab.) Test Systems for various Auto Components.

Our Test Machines are based on Customers’ Requirement Specifications.

Our Capability on Testing MachinesUsed wide range of Instrumentations with various Precision Levels:

1. LVDTs2. Load Sensors with Programmable & Non-Programmable Signal

Conditioners3. Torque Sensors –various types based on the Applications4. Accelerometers 5. Flow Meters6. Micro-flow Sensors for Air Leak Testing7. Various Pressure Transducers and its Interface with various

Instruments8. Temperature Controllers9. Various Sensors from Proximity to Fiber Optic Sensors and Color

Sensors to Vision Sensors (Camera based Applications)10. Dynamo Meters, Magnetic Particle Brakes, etc11. Various Instruments used for Measuring Current, Voltage, etc12. Rotary and Linear Encoders used for Measurements13. Force Sensors

Our Methods of Integration

Control Systems of our Machines:

1. PLC based Controls with HMI based Operator Console

2. Computer based Controls with Data Acquisition System

combined with State of the Art SPCs

3. Simple Relay Logic based Systems for Simple Applications

4. SCADA based Communications

Important Test Rigs Developed for Auto Components

1. G-Lock Testing Machine for Seat Belts Using Linear Servo Motor having 5G Capacity which is 1st Indigenous Machine.

2. Engine Friction Test Rig developed for Two Wheeler Engines

3. Rotational Lash Testing for Half-shaft Assemblies

4. Inertia Dynamo Meter for Testing Brake Pads

Important Test Rigs Developed ……….

5. On-line Wheel Run-out Checking Machines for Car & Truck Wheels

6. Alternator Test Rig

7. Composite Car Seat Testing Machine

8. CRDi Jets Flow Checking

9. Pressure Sensor Calibration Test Rig

10. Recliner Torque Testing

Important Test Rigs Developed ……….

11. Throttle Body Torque Testing

12. Seat Belt Tilt Lock Testing

13. Vision based Inspection for Engine Gaskets

14. Valve Timing Test for Two Wheeler Engine

15. Window Regulator End of the Line Testing Machine

16. Endurance Test Rig for ‘C’ Arc Assembly of MRI Scanning Table

17. Pump Durability Test Rig

G-Lock Testing Machine

G_Lock Testing Machine is an on-line machine to test locking function of ELR (Emergency Locking Retractor) while subjected to specified level of acceleration. This machine is PC based to measure the Acceleration (g), Load (N), Distance (mm) and Time (mS) and record the Webbing payout during the locking operation. This machine computes Max ‘g’, Payout (mm) and Max ‘g’ reaching time from acquired data. The system uses Linear Servo Motor, Accelerometer, Load Cell, Potentio meter, Signal Conditioners and Data acquisition card to measure various parameters.

The software is developed in LabView 8.2 under Windows XP for Data Acquisition, Result Interpretation, File handling and Report generation.

Engine Friction Test Rig

The Engine friction Test Bench is semi-automatic Test Rig designed to carry out friction test on Two Wheeler Engine at various stages. The machine is constructed with High speed and high torque induction motor with variable frequency drive (VFD). A high accuracy Torque sensor with programmable signal conditioner is used to measure engine friction. A temperature sensor with signal conditioner is used to measure the engine temperature at various stages. A vibration sensor is used to measure engine vibration level at various rpm.

A separate high efficiency centrifugal air blower is place near the engine to cool the engine while on the test.

Rotational Lash Testing for Half-shaft

The Lash Test Machine is semi-automatic machine; is designed to test Rotational Lash for test limiting torque applied on the Half Shaft Assembly. The machine is constructed with Servo motor with Torque measuring / recording device with an accuracy of 5 Nm. The machine is designed for supplying an alternating force / moment upto 200 Nm.

The software is developed in Visual Basic under Windows XP for Data Acquisition, Result Interpretation, File handling and Report generation.

On-line Wheel Run-out Checking Machine

On-Line Run Out Measuring and Low Point Marking machine is fully automatic machine designed for inspection of automobile wheels. The machine is to measure Radial and Lateral runout, Tyre seat diameter and Width, Compute first harmonic from the measured average radial runout values and then hard mark the low point of the first harmonic amplitude.

The machine automatically takes care of Auto / Manual loading, Locating, Clamping by the fixture, Spinning, Measuring, Low Point hard marking and Unloading and segregation of PASS / FAIL wheel. The wheel is located on its bore by expanding multi jaws (Ten Jaw) chuck.


Alternator Test Rig

The Alternator Test Rig is designed to carry out the functional tests. This test rig essentially measures the alternator ( under test ) output under specified test conditions and compares the same to that of set master values. It also provides the user with the test status and automatically records the test results.

To test the performance and evaluation of the alternators used in automobiles.


Composite Car Seat Testing Machine

Composite Durability Test Machine is a semi automatic machine to test the total seat assembly for its reliability and functionality. This system is capable of checking for various tests like Arm Rest, Back rest forward, Back Rest Rearward, Cushion Height Checking, Head Rest Checking, Lever Recliner Test, Lever Recliner Mechanism Test, Slide Thrust Test, and Slide Track Test

The system is based on PLC programmable logic controller with Induction motor and pneumatic subsystems.

CRDi Jets Flow Checking

The Jet Flow Checking Machine is highly accurate Testing machine designed to check mass flow value through Jets and Rail fitted with jets (1 inlet jet + 4 Outlet jet). Station-1 for Checking Jet assembly. Station-2 for checking Rail fitted with jets. While checking Up stream pressure 100 bar 1.0 bar is maintained, down stream pressure 50 bar 1.0 bar is maintained. The parameter like Temperature, Mass flow, and Density of Oil value are acquired and is verified with set value. The Pass/Fail is displayed based on Mass Flow reading.


Pressure Sensor Calibration Test Rig

The Pressure Gauge Calibration Test Machine is designed to calibrate pressure gauge in production line. The calibration rig is semi-automatic type with proportional valve controller to carryout the calibration. The calibration procedure is done at of different set pressures using specific control switches mounted on the operator console. On successful calibration, locktite glue is to be applied to lock the calibrating screw. PC and DAQ are used to test equipment to read the applied pressure on the pressure gauge, Resistance value, Pressure controlling are done through proportional control valve. Programmable multi-meter is used for used for precise calibration of the pressure sensor and communication with the Data acquisition system through RS-232 port.


Recliner Torque Testing

The Trident Recliner Torque Testing Machine is semi-automatic testing machine designed for testing the performance of Recliner assemblies. This machine is PC based to measure the torque at various angle The system uses Servo Motor, Potentio meter, Signal Conditioners and Data acquisition card to measure various parameters.


Throttle Body Torque Testing

The Throttle Body Torque Testing Machine is semi-automatic testing machine designed for measuring the Torque Vs Shaft Rotation Angle This machine is PC based to measure the torque at various angle The system uses Servo Motor, Signal Conditioners and Data acquisition card to measure various parameters.


Seat Belt Tilt Lock Testing

The Tilt lock machine is a semi-automatic testing machine designed for functional verification of the Emergency Locking Retractors in various angles.

The tilting angles are programmable. Tilting of ELR is done through a Servo motor attached to a gear box unit. Lock testing arrangement is done through the servo motor and a fixture. Screw rod arrangement is provided to tilting the testing fixture for required angle as if vehicle mounting condition. This machine is capable of testing the ELR in all the four directions (in board, out board, front & rear) as in vehicle mounting conditions. The tilting angles are preset at +12 and +27 for RH and –12 and –27 for LH respectively.

The reeling fixture is designed to check the presence of pin during Buckle Head Assembly of ELR (Emergency Locking Retractor). The presence of the pin is measured using suitable sensor before assembly.

Vision based Inspection for Engine Gaskets

The Video Based Inspection System is On-line checking machine. It is designed for inspection of the presence of Fire Rings in individual Bores of the Gaskets used in Automobile Engines. The vision of the gasket bore is acquired by the camera and check for presence of fire rings.

Valve Timing Test for Two Wheeler Engine

The Valve Timing Testing Machine is semi-automatic Test machine designed to check the valve timing of the piston movement in the two wheel engine. The machine is constructed with Servo Motor, A high accuracy Linear probe with programmable signal conditioner is used to measure piston movement. A temperature sensor with signal conditioner is used to measure the engine temperature at various stages.

Window Regulator End of Line Testing Machine

The Window Regulator Testing machine is semi-automatic testing machine designed for functional testing the window regulators of both manual and powered type. This machine is capable of providing the user with the data of current drawn with respect to time (for the powered type) and also the torque (effort) required to wind / rewind the window regulator assembly under specified loaded condition.


C Arc Assembly of MRI Scanning Table

This system is to carryout the Endurance Test for C Arc Assembly of MRI Scanning Table used in the Medical Industries. This systems is capable of recording and display the following parameters

• RPM• Distance of Travel• Current applied• Temperature of Motor• Position of the Measurement• No. of Cycles Run

The required dead weights loading will be loaded before the test.


Pump Durability Testing Machine is specifically designed to test the durability of the Fuel pump. The system is capable of testing the following parameters

Test parameters Media – Gasoline Test pressure – 100 kPa, 200 kPa, 300 kPa,

350 kPa, 400 kPa, 500 kPa

Supply Voltage – 8 to 14V DC Temperature media – 60C, ±3C Flow – 75 g/sec.

This machine is capable of testing 6 Nos of Fuel pump at a time and also is capable of testing Diesel and Petrol fuel pumps.


CONTACT ADDRESS

MICROCON i2i PRIVATE LIMITED

NO. 110C, 8TH CROSS,

BOMMASANDRA INDL. AREA,

BANGALORE-560 099

KARNATAKA - INDIA

Phone : (+91) – 080 – 2783 6325 / 4260 4422 / 6559 3970

Mobile : 98860 41047 / 98860 82182

E-mail : [email protected]

Web : microconi2i.com

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