Overview

The plant is fully equipped for high performance gears and components suitable for NVH requirements using disruptive technologies required by CVT, DCT & EV transmissions.

High Speed Turning & Gun Drilling

Make & Specialty

  • WMZ Turning Machine
  • Country: Germany
  • OP10 –Facing & Gun drilling, OP 20 -
  • Outer turning
  • Centre Drive Head clamping

Capability

  • Facing & Centering, Gun drill, OD Turning in single Setup.
  • Maximum work piece length 1400 mm
  • Concentricity with respect to OD will be maintained at maximum 0.05 mm

Automation

  • Preloaded Z-axis with heavy duty roller bearing resulting highest turning accuracies with two center drive heads for simultaneous end machining of shafts
  • Various type of poka yoke line work
  • Piece alignment sensor, air seat sensor, part traceability

Hobbing & Chamfering Machine

Make & Specialty

  • Felsomat FHC 180
  • Country: Germany
  • High Speed Dry Cutting
  • Integrated Chamfering & Deburring
  • In-built intelligent software for easy operator interface

Capability

  • DIN Class 7
  • Cm/Cmk < 3
  • Fr-DINClass8
  • Max Lead Variation - 10μ

Automation

  • Meshing unit poka yoke for part loading
  • Component loading stacker cell
  • Dynamic feedback control system

High Speed Shaping

Make & Specialty

  • Liebherr LS180
  • Country: Germany
  • Combines flexibility with productivity
  • Automatic changeover from internal to external gear

Capability

  • DIN Class 7
  • Cm/Cmk < 2
  • Fr-DINClass7

Automation

  • Serial production runs are processed very economically through use of internal automation in the form of a ring loader
  • Meshing unit poka yoke for correct part loading & Air seat sensors.
  • Fully automated part loading & unloading with conveyor automation

Spline Rolling

Make & Specialty

  • Rollex S HP
  • Country: Germany
  • Special drive chain for spline rolling
  • Multi-axes CNC
  • Data management
  • High Precision version with servo-mechanical drives

Capability

  • Helical spline rolling Max helix angle 23.
  • DIN Class 7
  • Fr in Class 7
  • Double incremental rolling up to120mm.
  • Cm/Cmk < 2

Automation

  • Auto Door for operator safety

Gear Grinding

Make & Specialty

  • Reishauer RZ-260
  • Country: Switzerland
  • Dual spindle technology with high cutting speed
  • Line dressing, multi-rip full profile dressing & topological dressing

Capability

  • Twist control grinding within ±0.005 mm
  • CmCmk <3
  • Fr in single digit.
  • Fha & FHb within ±0.004 mm.
  • Ra within 0.3.
  • Cm/Cmk < 2

Automation

  • Fully automated part loading & unloading facility to improve the productivity.
  • Meshing unit Pokayoke for correct part loading.
  • Air seat sensor

Gear & Shaft Honing Machine

Make & Specialty

  • Praewema
  • Country: Germany
  • Single & Dual Spindle Machine  Shorter through-put times
  • Higher precision
  • Dual Spindle Machine

Capability

  • Cm/Cmk< 3.1
  • Fr in Single digit
  • Fr in Class 7
  • Consistent Lead Variation result  Surface Finish 0.2
  • Twist Control within +/- 0.005

Automation

  • VSD Dressing Technology.
  • Twist control as per requirement
  • Poka yoke like Part presence sensor, Part orientation Sensor.
  • Meshing unit poka yoke for correct part loading & Air seat sensors.
  • Auto rolling with master gear

Hard Turning

Make & Specialty

  • Felsomat FTC 180
  • Country: Germany
  • Single spindle with double work bed  ID & Cone turning.

Capability

  • Cm/Cmk< 2
  • Fr & Fp AsperDINclass8
  • Multiple Operations can be performed in single setup.

Automation

  • With Auto loading unloading stacker cell.
  • Poka yoke like Part presence sensor, Part orientation Sensor.
  • Meshing poka yoke to avoid wrong part selection & Air seat sensors
  • Meshing unit poka yoke for correct part loading & Air seat sensors.

Laser Welding

Make & Specialty

  • Felsomat FLW 180
  • Country: Germany
  • Supported with ultrasonic testing with weld seam quality
  • 2 Station indexing dial work bed.

Capability

  • Welding depth up to 8 mm.
  • Preheating & Ultrasonic testing with 1% acceptance criteria.
  • Consistent quality without manual intervention.

Automation

  • Poka yoke like Part presence sensor, Part orientation Sensor.
  • Meshing unit pokayoke for correct part loading & Air seat sensors.
  • Established Pressing, Induction heating & Ultrasonic testing

Differential Assembly

Make & Specialty

  • Tox PressoTechnik
  • Servo pressing, travel can be controlled up to 10 Microns
  • Drag torque test – 1N-m to 100N-m torque can be measured

Capability

  • Blot tightening range = 45 - 280 Nm.
  • Drag torque testing range = 0 – 100 Nm. Full Pokayoke from OP 10 to OP 60 with Data monitoring

Automation

  • Poka yoke – Scanner on each station for traceability
  • Various types of pokayoke like Load cell for pressing load calculation, Torque sensor for measuring the torque
  • Part mixing, pick to light & sequencing pokayoke.
  • Defective assembly process aborted through Logic controls

Ultra-Sonic Washing

Make & Specialty

  • Durr – Eco clean HP
  • Country: Germany
  • Ultrasonic washing
  • Hot air drying, vacuum drying
  • Twin working chamber

Capability

  • IN - Cleaning – Rinsing (in WT1) – Ultrasonic washing - Final Rinsing – Hot air drying – Vacuum Drying (in WT2) - OUT
  • Millipore value can be achieved up to 0.1 mg/kg

Automation

  • Leakage warning sensor.
  • Temperature measuring sensor.
  • Fluid Level Sensors.
  • Basket count & efficiency calculation system.
  • Auto Pull-push system of basket

Videos

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Other Manufacturing Capabilities

Tool and Die Manufacturing

Safety Measures

Tool and Die Manufacturing

Inspection and Testing

Tool and Die Manufacturing

Specialised Heat Treatment

Tool and Die Manufacturing

Transmission Components Technology

Tool and Die Manufacturing

Tool and Die Manufacturing

Tool and Die Manufacturing

Development and Engineering

Tool and Die Manufacturing

Forging