Machineries for Metal to Rubber Bonded Components World Class Automation & System Integration @ Affordable Price Our German Partner www.summitengineers.net
What really matters is that you have a competent partner for the job right from the planning stage. With so many options to choose from, we can offer you a customized solution. Opting for an experienced partner like SUMMIT provides you with: a broad product line, unmatched quality, international engineering expertise, and delivery of most machines within four weeks!! Since 1996 SUMMIT has been searching for new solutions to bonded component problems and has developed and manufactured machines for many trendsetting applications. Research and development is essential for the innovative products we have developed over the years. Our engineering experience and international support help keep SUMMIT on the leading edge of R&D. Metal to Rubber Bonding Process SELECT RUBBER Product Specification DESIGN BONDING AGENT SELECT SUBSTRATE CLEANING & PREPARATIONS Range of Services DILUTE AND MIXING COATING WITH BONDING AGENT CONSULTING CONCEPT DEVELOPMENT ENGINEERING HARDWARE PLANNING COMPOUND, MIXING, STRIP PROJECT MANAGEMENT PRODUCTION MOULDING SOFTWARE PROGRAMMING ASSEMBLY TESTING FINISHING COMMISSIONING TRAINING AFTER SALES SERVICE TESTING AND INSPECTION DISPATCH 2
Automated Coating System Two Station Conveyorised Two Station Conveyorised ID Spray System Spraying System for Flat and Irregular Components Automated Deflashing System ID Deflashing Machine OD Deflashing Machine Two Station Face Deflashing Machine Flash Cutting Machine Automated Finishing System Automated Grinding Line Swaging Machine Component Testing System Torsional Fatigue Testing Machine Online Bond Testing Machine Conical Fatigue Testing Machine Radial Fatigue Testing Machine Assembly Inspection & Poka Yoke System 3
Automated Coating System Your Areas of Concern Application of adhesive chemicals on the Metal Substrates before molding rubber has been one of the trickiest issues for Metal To Rubber Bonding industry. There have been various issues related to this activity, Manual labour: Inconsistent quality & Low Productivity. High labour attrition due to environmental issues. Limited productivity and labour issues hindering growth. Very expensive imported machines impacting bottom lines. Single Station ID Spray System Two Station Conveyorised ID Spray Our Breakthrough Solutions We at Summit Engineers & Consultants Ltd, have developed & patented automated machines for spraying primer & adhesive onto the metal components, either inside or outside surface, to the required specifications. The machines are capable of handling different sizes and shapes of the metal components & are being used for last 9 years by many companies in this industry such as: Bridgestone India Automotive Products Pvt. Ltd., Delhi Roop Polymers, New Delhi Sigma Corporation (I) Ltd., Bhondsi, Delhi Inarco Limited, Bhavnagar, Gujarat Jayashree Polymers, Pune Y Tech India Pvt Ltd, Alwar, Rajstan Varroc Elastomers, Aurangabad Innova Rubbers, Nasik And many smaller ones. These machines have only improved over the time. Technical Specifications Vertical ID Spray System Parameters Input Electric Supply Input pneumatic Supply Dryer Control Machine Output Cycle time per component And No. of components per 8hr shift 3- phase 440 volt 5-7 bar Specifications With or without heater/ dryer with temp. control PLC/ microprocessor Single/double coating of one type/ two types of adhesive of 15 to 50microns on cylindrical/ flat components. ID Spraying Single Stn. (Horizontal/Vertical) (Either primer or final coat) ID Spraying 2- Station Conveyorised (Both coats) 4 sec/job * 6000jobs/shift 2 sec/job * 14500 jobs/shift 4 Single Station OD Spray with canopy OD Spray Single Stn. (Horizontal/Vertical) (Either primer or final coat) OD Spraying Single Station Conveyorised (Either primer or final coat) OD Spraying 2- Station Conveyorised (Both coats) OD Spraying with X & Y axis spraying motion for flat components. (Either primer or final coat) 2 sec/job 14500jobs/shift 1 sec/job ** 30000 jobs/shift 1 sec/job ** 30000 jobs/shift 18 sec/cycle for Spray Area 300X300mmsq. (e.g. can spray 81 jobs of 1 dia in one cycle) Legend: * Depends on length of components Max spray length 150mm. ** Depends on length of components Max spray length 450mm OD Spraying: Coating outside surface of the metallic component. ID Spraying: Coating Inside surface of the metallic component
Salient Features & Advantages Quality: Convenience Savings: Uniform and accurate product coating. Wide range of flow rates, spray angle and drop size to suit customer requirement. Ensures quality with air and liquid control; eliminates quality problems due to uneven application of the spray solution due to changes in spray pattern or drop size. Variety of other controllable parameters to get desired results. Quality problems due to coatings that are too hot or too cold are eliminated through the use of closed-loop temperature control. Easy installation and operation compact unit requires just a few minutes for set-up. Reduces waste of costly coating chemicals. Rugged design & hence low maintenance quick change spray guns which can be easily removed from the coating station. The Summit Service: Spray nozzle gets very close to metal surface, very low misting & wastage. Custom built tooling & fixtures as per Component. We are only a phone call or an Email away, wherever you are in India. Full support for Commissioning & Operator Training. Easy to use Operations Manual complete with drawings, line diagrams, maintenance & fault finding guidance. While individual bought out components carry their own warranty, we provide one year full service warranty for any manufacturing defect. Summit machines are well proven, tough, specially built for the harsh adhesive paint application environment. They provide a series of benefits to the customer and are now considered a standard in the coating industry. Two Station Conveyorised OD Spray Single Station OD Spray (Non-Conveyorised ) Comparison Between Manual Adhesive Coating & Automated Coating Particulars Traditional Manual Coating (Single Coat) Single Stn. non-convey.m/c (Primer or final Coat) 2-Station Conveyorised m/c For 2 coats Coating of Inners Productivity per person 30 sec/job 4 to 8 sec/job about 2 sec/job* Jobs per hour Jobs per 8 hr. Shift 120 960 Coating of Outers/ flat jobs 240 1900 600 4800 1800 14500 1800 14500 Productivity per person 15 sec/job 2 sec/job about 1 sec/job* Jobs per hour Jobs per 8 hr. Shift Coating Thickness Coating Consistency Quality Advantage & Other Savings 3500 30000 Uneven Even Even Not assured Assured Assured Bond Strength Not assured Assured Assured Coating Thickness Control Not possible Possible Possible Adhesive Spillage Uncontrolled Controlled Controlled Space Health & Safety *(Depends on lenght of the component) High due to large no. of manpower Unavoidable exposure to a large no. of personnel 2 sq. meter including one operator Limited & controlled by exhaust ducts 3 sq. meter including bowl feeder Limited & controlled by exhaust ducts Vertical ID & OD Spray System X & Y Axis OD Spray System 5
Component Testing System SUMMIT have developed different types of component testing machines required for the Rubber to Metal bonded components by keeping in mind the higher productivity and the quality requirements by the automotive industries. Metal to Rubber bonded bushes/ components are frequently subjected to complex multiaxial stress and strain states in service. For certain applications, designs based on uniaxial materials data are insufficient. In these cases, radial, axial/torsional, conical testing simulates the multiaxial stress states of real-world operating conditions more accurately. SUMMIT offers all the technology that need to conduct highly accurate and repeatable radial/ axial/ torsional testing. Bond Testing Machine/Proof Load Testing Type of Test: Non destructive Purpose: % of Proof Load. Prime Mover: Compressed Air Brief Specifications: Maximum Load capacity-1000 kg Visual inspection of bond failure under proof load. Options: Digital display of Load. Vertical Load Deflection Test Rig Type of Test: Non destructive Purpose: Radial Load Vs Deflection Prime Mover: Compressed Air Brief Specifications: Maximum Load capacity- 1500 kg Digital display of load and deflection under specific load. Options: Data Acquisition System and PC software. Conical Endurance Testing Machine Type of Test: Destructive Purpose: Understand behaviour of component under Radial load with conical motion in cyclic pattern. Prime Mover: AC Induction Motor Brief Specifications: 3HP AC Induction Motor and VFD with Cam Mechanism to generate conical motion with Radial loading of 500Kg through Screw and Nut. Options: Digital display of Load. Torsion Endurance Testing Machine Type of Test: Destructive Purpose: Understand behaviour of component under Radial load with Torsional motion in cyclic pattern. Prime Mover: AC Induction Motor. Brief Specifications: 3HP AC Induction Motor and VFD with slider crank Mechanism to generate torsional motion with Radial loading of 500 Kg through Screw and Nut Options: Digital display of Load. Radial Load Fatigue Testing Machine Type of Test: Destructive Purpose: Understand behaviour of component under Radial load with constant displacement/ motion in cyclic pattern. Prime Mover: AC Induction Motor and hydraulic. Brief Specifications: 5 HP AC Induction Motor and VFD with slider crank Mechanism to generate sinusoidal motion with Radial loading of 1500Kg through Hydraulic system. Options: Heating Chamber. Servo Hydraulic Fatigue Testing Machine Type of Test: Destructive Purpose: Understand behaviour of component under Radial load with constant or variable displacement/ motion in cyclic pattern. Prime Mover: Servo Hydraulic Power Pack. Brief Specifications: 15 HP AC Induction Motor and Servo Hydraulic Power pack System with Two Pillar structure with micro controlled system to generate sinusoidal, Trapezoidal and square wave motion. Raw Material Cutting and Inspection System Raw Material Cutting And Inspection Systems: In order to cut the substrate we have developed automated tube cutting and inspection system 6
Automated Deflashing System Flash is excess rubber material left on rubber molded part after molding. Flash is result of rubber material or component migrating through the mold surface finish and mating surfaces. It can be removed by tear trimming, cryogenic deflashing, tumbling and other post molding operations. It is very costly, laborious, time consuming and tricky work of removing the flash on components after molding. Considering customer requirement, SUMMIT has developed different types of automated machines for deflashing of components considering the productivity, operator safety and quality. ID Deflashing Machine: Two station pneumatically operated system. Cleans ID thoroughly. Quick and effective operation. Quick changing fixtures to accommodate different components. Adjustable stroke depending upon length of the job. Adjustable cleaning stroke depending upon inside flash thickness. Can accommodate job from diameter 10 mm to 100 mm. Cycle Time < 5 sec. OD Deflashing Machine: Flash removal from outer of the bushings. Multiple numbers of components can be cleaned at a time. (Max. cleaning length-450 mm) Accommodates variety of components from diameter 10 mm to 100 mm by changing rods. Rod acts as gauge for ID bush. Cross slide with one grinding spindle. Localized and effective flash extraction canopy. Cycle time- Approx @ 20 sec for 450 mm length. Two Station Face Deflashing Machine: First station for deflashing of inner face and Second station for deflashing of outer face. Highly dynamic indexing table for quick loading, consisting of 6 nos of job holding fixtures. Quick changing fixtures to accommodate different sizes of components. Simultaneous fast and effective deflashing of inner face and outer face. Effective flash extraction. Cycle Time < 5 sec. Flash Cutting Machine: Simple, compact single station system to cut the extra flash from components outer face. Quick operation for flash removal. Quick changing fixtures to accommodate different components. Can accommodate job from diameter 10 mm to 100 mm. Cycle time < 5 sec. Automated Finishing System Swaging Machine Particularly for the rubber-metal bonded bushes it is necessary to enhance the strength by prestressing, which is called swaging. Summit have developed hydraulic operated Swaging Machine to accommodate bushes up to diameter 75 mm. Automation for Grinding line to achieve required Diameter of the Bushes: We support you with variety of feeding conveyors namely Loading, Intermediate and Accumulation in between your centre less grinding machines. This will eliminate manual intervention for loading of the components on to the grinding machine, thereby reducing the accidental hazards to the operators. It is possible to incorporate automatic gauging and inspection system in line with accumulation conveyor. Automatic Retapping and Plug Passing Machine: During moulding rubber flash occupies the threads of components having internal threads. It then becomes very tedious to remove the flash. These machines basically perform de-flashing by controlled re-tapping. Operator dependency is removed and consistency in the required quality is achieved with these machines. 7
About Us Summit Engineers and Consultants Pvt. Ltd." is engaged in manufacturing automation /Integrated systems, SPM's since 1995. We started operations with intention to support MSME sector in affordable solutions for Process automation. During our journey in SPMs & Automation we developed the know-how and expertise in various kinds of machines needed for the Metal To Rubber Bonding. With close association with many large industries like Innova Rubbers, Nasik & Varroc, Aurangabad, we have developed a well proven portfolio of automated machines catering to peculiar needs of the Rubber Industry, which are now in operation for last 7 years. As a result of this extensive product development, now summit has strategically standardized this product group and are offering these machines as standard solutions to the Rubber Industry. Partnership With Strama-MPS, Bavaria, Germany: In July 2012 we have signed a partnership agreement in Process Automation with Strama-MPS, worldwide leaders in Customised Machines in Metal Cutting Technology, Cleaning Technology, Assembly & Testing Technology, Automation in Photovoltaic Cell Mfg. Industry / Application Picture Component Description Commonly used Chemlok Grades Our Spraying Machine Bush: Inner Cylindrical Pipes. Coating from outside. Diameter & length varies. Ch205 PRIMER CH220, 252X, 6108, 6411 Bush: Outer Cylindircal Pipes. Coating from inside. Diameter & length varies Ch205 PRIMER CH220, 252X, 6108, 6411 ID Spraying Machine Product Code SEA0100, SEA0310 Mount: Top Bottom flat plates Flat components of different sizes & shapes Ch205 PRIMER CH220, 252X, 6108, 6411 Oil Seal Circular metal rings of different diameter for sealing purpose. Ch202 A/B, TS-167-13HS - NBR 607/ 608 - Silicone 5150, 5151- FKM Rollers Horizontal metal cylinders build with rubber as per application. Ch205, TS-1677-13HS - NBR 205/236A. 234BNW, 252X, NR, EPDM, CSM. 608- Silicone 219/218: PU Product Code SEA600 2-wheeler stay guard Zn-plated component for tail light indicator. Ch250- EPDM 481#44 - TPE Solid Tyres- Metal Different Dia Metal Bands. Size varies from 6 inch to 21 inch diameter CH205/220 - NR/SBR 219/218 OR CH213 for PU Rubberised Wheels (Plastic core) Plastic center cores of diameter 4 inches to 8 inches. CH205/220 or 250- NR/SBR Member of All India Rubber Industries Association Our German Partner F-93, MIDC, Ambad, Nashik-10, Maharashtra, INDIA Tel: +91-253-2380650 / 6640564 / 6640574 E-mail: sales@summitengineers.net / ravi.mahadeokar@summitengineers.net Web: www.summitengineers.net Ittlinger Str. 195 D-94315 Straubing Web: www.strama-mps.de Summit-Jan. 2014-Version 2. Given specifications are general in nature. Consult manufacturer to select suitable model for your product. Upgradation is a continuous process, we reserve the right to improve upon our specification.