Computer Aided Drawing
Our development team delves into every aspect of the new component to be manufactured. We use latest design tools to study the component model and design & develop jigs and fixtures to be used on the production line. This in-house capability helps speed up the process of sample component manufacturing. It gives clarity on how to manufacture the component exactly as per the drawing provided by the customer.
Fabrication entails a set of complementing and logically arranged processes. The first step is pressing, where the part is transformed from the basic condition to the required one. A number of operations – notching, piercing, blanking, forming – are carried out on various machines.
Welding at UACPL is a huge unit with several robotic arms. The programmed robots work with uniformity, consistency and speed to give a voluminous production of 800 parts per shift per robo. Every factor – the welding bead width, welding penetration, gas flow etc – is controlled automatically. The samples are first checked in welding penetration lab, a unique feature that allows an in-depth, graphical check. Another type of welding – Argon-CO2 welding – is carried out on SPMs, with a production of 1200 parts per shift.
Adding to the array, the profile bending machine is capable of 3-axes bending. Several components made from different tube profiles are manufactured for prestigious companies like Bajaj, BMW, Ducati and Jukova.
Surface Treatment of vehicle accessories is crucial for aesthetic appeal and corrosion resistance. Umasons has state-of-the-art facilities with 35 baths for Nickel-Chrome plating and standard 14-tank pre treatment procedure for Powder Coating.
For plating, a transporter wagon displaces the part from one tank to another. While the wagon is operated via a PLC, aspects like temperature of the bath, current for electroplating and time for which the component is dipped are precisely controlled.
For Powder Coating, an automated PLC controlled trolleys take the component through a phosphating line of 14 tanks containing various chemicals. This cleans the component surface from dust and oil. Clean components then are mounted to a conveyor that transports the parts through a coating booth where electronically charged powder is sprayed on the components and then further passes through an oven with the strictly controlled temperature for the optimum adhesion. Checking and keeping the process parameters as per the standard is critical to get the desired quality.
Product and Process Testing
At UACPL, some highly tenacious tests are used to rate the parts’ performance. After plating, a Salt Spray test deduces a part’s corrosion resistance and hence predicts its life. A Graphic Step Machine then measures if the thickness of the plating is adequate. For powder coated parts, a standard scratch test and then completely mechanical methods like flexibility test and impact test are used.
With conveyorised lines and productive techniques, the assembly lines at Umasons Auto produce 2400 parts per day. The processes are carried out on various SPMs and are built with the specialty of interlocking. Use of Poka-yoke technique at each assembly stage minimizes human error. A deviated part out from a process is not processed at the next stage. Features like Photo-Sensors, First In First Out and Auto Shutdown make the system highly efficient.