STONA

INDIA WOOD exhibition

SANSERA

SANSERA

Started in 1987.

Key sectors: 2 wheelers, automotives, heavy commercial vehicles, aerospace, engine services

Business area: Precision forging and machining.

Uniqueness: Manufacturing of CNC SPMs for cost and productivity competitiveness

Work force: 1900

Product Range:

-CONNECTING ROD

Split,Fractured

-SHAFT

Balance, Crank, Rocker, Cam

-GEAR SHIFTER FORM

-ARM RELAY

-ROCKER ARM

Sintered, roller, rocker arm assy., chrome plated

Customers: India; Bajaj, Honda, GM, Maruti, Suzuki, Yamaha, Hero, TVS, Mahindra

World;Ducati, FPT, MBK, Motorart, Harley Davidson

Types of design:

Process design

Fixture design

Machine design

Tool design

Forging tools design

3d modelling and tool path generation

Forging simulation

Aerospace part modelling

DIFFERENT DEPARTMENTS AT THE FACTORY:

1. Machine

2. Fixture

3. Operator

4. Cutting

5. Machine operator

8 STATION MACHINES: The whole operation is completed in this machine as there are 8 operations working on the product simultaneously.

BOARING MACHINE: Enlarging hole

Heat treatment: carbon deposition on rockerarm to improve the hardness. It is passed through 930 degees. It changes into HS(Hard steel)

Milling operation: One mark is made as the reference point for all the next operations.0

Coolants: oil +water

Grinding

Different materials are used for one rockerarm. Parts which should not wear out easily will have harder steel, other parts milder steel.

Each rockerarm=Rs 60. They send out 60 lakh pieces to Maruti in one month.

Featherlite

FEATHERLITE

Punching machine (bought from Italy):

Different shapes and sizes of punches available. Three parts to the machine. Feeder works on a pneumatic operation. After completion of the job, there are two deviators which takes the metal either to the uploading area or the stacking area(24 different positions).

Multi head area:

48 stations.;48 tools can be loaded and punched simultaneously

SHEETS: Maximum size of the sheet is 8’x4’

1)CRCA(Cold rolled cold annealed iron)

2)GALVANIZED IRON

3)PRE COATED MS

For shearing:

2500 mm(max length)

4mm(max thickness)

Folding machines:

RAS folding machine- you get a radius at the edge

Bending machine- sharper edge

Fabrication area:

Welding, sanding

Powder coating area

WOOD

Pre laminated board(PLB)

- Raw material from supplier, 18-25 mm, different shape, colour and thickness

Particle board

ROVER C MACHINE

- It does cutting

- Out of waste wood, making drawers and storage

- sawdust- giving to agarbatti makers

Edge banding machine

PLT(both sides same colour laminate)

PLB(both sides different colour laminate)

Pre laminated tin board

Stretch warping machine

Avoids dust, scratch. Puts plastic laminate

Honeycomb Factory

Honeycomb Factory

To make veneers:

-Boil timber for three days- reduce moisture level to 15%

-slice it in wet condition- .3 thickness. The width of the slices is the width of the timber.

-pass it through a dryer

-parallel clipping so that the different layers are joined to form a veneer with the help of a gluing machine

-taken to the press (first cold and then hot)

-last stage-white belt sander to give a smooth finish

Other activities, machines or types of wood found at the factory:

Edge banding

Bamboo veneers: the width of the slices are much thinner according the width of naturally found bamboo)

Press membrane used for raised surfaces: MDF is cut and shaped on the machine with raised surfaces and then the veneer is cut accordingly and pressed on to it. The air is sucked out first and with high pressure, the veneer is pressed on the sides and top surface of the MDF.

Honeycomb paper

The hexagon is the strongest shape, especially a grid/or tessellation of hexagons.

For opening/expanding the honeycomb structure it is heated with a machine and stretched. Once, opened, it permanently remains stretched.

Multiple circular saw

Like the circular saw in college, this machine has 4-5 circular saws operating at the same time, located parallel to each other. A big piece of wood can be sliced into 4 equal parts in one go, when passed through this machine.

REVA

The Reva factory

Reva factory plant which is in the process of being built has been designed in order to minimise waste of existing resources(green design). The roof is covered with insulation material(possibly glass wool or PUF) so it doesn’t let heat pass through. But strips are left uncovered to let sufficient amount of sunlight pass in order to light up the whole space. There are also solar panels which will be converted into electricity to charge the cars. There will also be a rainwater harvesting area.

Some of the Reva models are designed according to European specifications, for eg the cold climate in Norway has different requirements as compared to the summers of Rajasthan. (The extremes range from minus 20 degrees to plus 40 degrees) A chassy is the basic skeleton of the car. It is designed in such a way that it has sufficient strength to hold people, engine, etc. There are also crumple zones on the car which take the stress/damage in case of an accident, bef on it matters. 500 gms of added weight can make a huge difference affecting how much or how well it drives.

The Reva is meant to be charged overnight. There are talks of using solar energy for the same purpose of charging but it hasn’t yet been used at the Reva factory.

Hauling power is the pulling capacity of a car. The Reva runs on an electric motor driven by battery. It is designed in a frugal manner such that only basic amount of power is utilised as per the need. In a Reva, every ounce of weight that you exert

The Reva weighs 40 kilos more than a Maruti car.

The 2 seater costs 3.25 lacs whereas the 4 seater is around 6.5 lacs or 8000 euros. The four seater was launched in 2010.

How the Reva came into being: There was a particular students project which created a solar car. This project was sponsored by General Motors and came 3^rd in a competition. This inspired the makers of Reva to make an electric car. They started in 1994 in California and shifted to India in 1999.

It has 2 markets, Bangalore and London.

The Reva is not yet popular among car buyers. The early adopters of the Reva are mainly innovators and people who are conscious about saving the environment and having a green lifestyle.

The Chevrolet Spark car has been designed by the same makers in order to make it into an electric car as well.

These factory plants are localised where the cars can be customised according to the customers taste.

Mobile interaction with the car: by sending an sms you can tell how much charge is left or how much time it will take to charge the rest of the battery. One can even known the cabin temperature b just sending a text msg.

Revive: In case you run out of charge and you are stranded, you sms the Reva head office. They can activate the battery(RESERVE) which allows you to drive up to 8-10 kms more to reach the nearest charging station.

The batteries used are lithium batteries which can be charges anywhere. Usually they come with 5 m cables(15 feet).

What is a regenerative shock absorber? What is a regenerative break?

The latter, which is the regenerative break is used in a Reva. Both are new technologies that are coming up in order to regenerate power.

Assembly line:

The Reva assembly line comprises of 15 stages which are manually accomplished.

First the motor, transmission, cable and wheels are put together. Then come the electronics, then harness, then body panels. Once the wheels are assembled, moving the car from one stage to another is done just by pushing it ahead. Each stage takes 15-20 min. It takes 3 days for one car to reach the final stage. Here, 8 cars are assembled in one day.

Under chassy and break bleeding tests are carried out in the assembly line.

Earlier an alternating current(AC) motor was used to run the Reva but it has now been replaced by a direct current(DC) one. It has 8 batteries inside. The DC current from the motor is converted into AC. The power is calculated in kilowatts.

Final inspection: A quality control team checks the car at each stage and at the last stage if the car is approved, it puts 4 stickers on it to pass it.

We also saw the open air Reva design prototype.

The charging cost of Reva is 45 paisa per km.

New battery: One charging gives 80 km, after 2 years or so the battery begins to deteriorate.Batteries are called deep discharge batteries.

Maintenance: Once in a month, the battery required water. There is a nozzle at the charging point on the car through which water can be supplied to the batteries.

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RAK MULDER

RAK MULDER PERCELAIN PVT LTD

Stoneware

Bonechina

Ceramic

Porcelain

Cold transfer: cups/plates etc made of bonechina that haven’t faded even after 50 -60 years were printed with image (sticker) using the cold transfer method.

PREPRESS : First the designer creates the artwork, then it is scanned and put on the computer, then you get positives for printing. After the artwork is scanned and put on the software, they separate it colour wise according to which the screen printing is done. For this colour separation the positives are used. They prepare shade cards in order to get the perfect shade of ink.

SCREEN PRINTING: Silk screen is prepared and then the positives are exposed.a film coat is applied after screen printing.

What is capillary film?

Heat transfer: It is used mainly for transferring/printing the image on cloth directly, through the effect of heat.

Tiles: Screen printing on tiles was being done manually, applying colour wise directly on the tiles. After the tiles are printed, to give the emboss effect, it is coated with glass powder, in the parts to be embossed. Then it is passed through high temperature for 2-24 hours, depending on the material.