ring plus aqua ltd
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Amaze, The Automated Assembly Machine For Integral Shaft Bearings
Engineering EXCELLENCE AWARDS 2013 Category: “Technology/Innovation”
“Implemented at: Ring Plus Aqua Ltd”
May 3, 2023 1
10th Oct’2013
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
May 3, 2023 2
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 ………….
May 3, 2023 3
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
Market growth & market share growth
● 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
Capabilities – supplement all the other growth drivers
● Ability to manufacture world class product using state of the art technology
● At competitive price
● World class quality standards
● Global SCM & VMI solutions
● Design engineering, validation & testing
Inorganic growth
● To use the inorganic route to enter into
New product line/ platform
New geographies
Acquire technology
Acquire customer
Conventional Bearing Assembly Processes !!!
INR200Mn
Automated Bearing
Assembly Machine
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 BinSignal to start next greasing
cycle
Grease Filling
Seal Fixing
Spinning
Weighing
`
May 3, 2023 5
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
May 3, 2023 6
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
May 3, 2023 7
Supplier Evaluation &
technical assessment
Automated Bearing Assembly Machine
Shaft Loading
Shaft insertion on fixture by tilting it 90 deg
Shaft Gauging
Sleeve Gauging & sleeve insertion on shaft
Continued …..May 3, 2023 8
Design Conceptualization
Auto Ball Selection & feeding Ball Cage pick up & fixing
Roller Cage InsertionBearing Assembly pick up & placing for clearance measurement
Continued …..
Automated Bearing Assembly Machine
May 3, 2023 9
Design Conceptualization
Grease Filling
WeighingUnloading on OK/NOT OK bin
Visual InspectionAntirust Application &
Packaging
Spinning
Manual Seal insertion
Auto seal fixing
Automatic Assembly - Features
Automated Bearing Assembly Machine
May 3, 2023 10
Design Conceptualization
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
May 3, 2023 11
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 3timesMay 3, 2023 12
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 / dayMay 3, 2023 13
PATENT APPLICATION
The First Ever Patent Application From Ring Plus Aqua Ltd For Automated Assembly Machine For Integral Shaft Bearings
May 3, 2023 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.”
Thank You!
May 3, 2023 15
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