Iapl presentation 26.6.2014 (2)
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The document describes the history and operations of Integral Group, an engineering company that started as a component manufacturer in 1989 and diversified into manufacturing special purpose machines and automation equipment. It discusses key milestones such as taking over management in 2002 and manufacturing over 200 machines for automotive companies. It also outlines the group's capabilities in design, manufacturing facilities, and projects completed for clients in various industries.
Iapl presentation 26.6.2014 (2)
- 1. 1 Integral Group Sharing Wisdom and Wealth
- 2. 1989- Started as component manufacturer, supplying precision machined parts to auto industries. 2002- Management was taken over by new set of entrepreneurs headed by Mr. K Elango and diversified into SPM and Special Purpose Testing equipment manufacturing. 2003-Till now- Manufactured over 200 Special purpose machines, assembly lines and testing equipment's to various leading automotive companies. 2 Integral Group Sharing Wisdom and Wealth
- 3. 2007- Established sister concern, M/s Jaysen Engineering pvt ltd at Jigani Industrial area, Bangalore, to expand manufacturing facilities. 2011-2012- Designed and Commissioned major processing projects for ITC ltd-Mysore. Group turnover INR 80 million (2011-12) 3 Integral Group Sharing Wisdom and Wealth
- 4. K Elango Director (IAPL) S Ravichandran Director (IAPL, JEPL) S Senthil Murugan Director(JEPL) 4 Integral Group Sharing Wisdom and Wealth
- 5. Sharing knowledge ,wisdom to create wealth & employment 5 Integral Group Sharing Wisdom and Wealth
- 6. To excel and sustainTo excel and sustain growth in the field of manufacturing engineering and automation solutions, at most competitive price, quality and service. 6 Integral Group Sharing Wisdom and Wealth
- 7. INEL Integral Group Sharing Wisdom and Wealth Our Clients
- 8. Strengths of IAPL Structured Project Execution from Concept to Commissioning 8 Integral Group Sharing Wisdom and Wealth
- 9. Two industrial sheds of total built up area of 12,000 sq ft at Bommasandra industrial area. 6000 sq ft at Jigani industrial area 9 Integral Group Sharing Wisdom and Wealth
- 10. Fully equipped machine shop for supporting SPM manufacturing operational needs (turning, milling, boring, surface grinding etc) 10 Integral Group Sharing Wisdom and Wealth
- 11. Design office with experienced engineers supported with drafting software like AutoCAD-2D and modeling IronCAD-3D. Trained and experienced engineers to execute projects on PLC, SCADA, HMI. 11 Integral Grup Sharing Wisdom and Wealth Integral Group Sharing Wisdom and Wealth
- 12. Integral Automation pvt ltd provides Strong Combination of Process and technology in identifying right solution for automation. Low cost solutions for improved quality and productivity. Special purpose machines. Custom built test rigs for testing auto components. Professional after sale Service. 12 Integral Group Sharing Wisdom and Wealth Focus of Integral Groups
- 13. 13 INTEGRA L Integral Group Sharing Wisdom and Wealth Butt Welding Machine Butt welding machine is used to weld the strip of sheet to form basic structure for rim. Sequence of operation is controlled through a PLC system. Hydraulic actuators are used to perform all movements. Pneumatically operated automatic lubrication system is provided wherever required We have successfully executed more than 200 projects for various industries across INDIA.
- 14. Conditioning Cylinder Conditioning Cylinder of Stainless steel is designed to add moisture and temperature to the tobacco product of capacity 7000 Kgs/Hr. The tobacco leaf gets opened while tossing inside the shell. * Shell size of 1800mm X 7500mm lg * Adjustable shell speed & Angle * Auto Moisture & temperature Control. * Noiseless drive system. Features INTEGRA L Integral Group Sharing Wisdom and Wealth
- 15. 15 INTEGRA L Integral Group Sharing Wisdom and Wealth The PC Based Stainless Steel Pellet Coating Machine is designed for adding the starch syrup and essence on to the pellet (chewing gum) Spraying, Drying & pause time are Programmable for each spray. Coating capacity is 350 Kgs. This machine is controlled through a highly reliable PC based data acquisition system. Features: . No of spray & pan speed programmable Dosing syrup temperature controlled Hot air inlet & vapor outlet controlled.
- 16. INTEGRA L Integral Group Sharing Wisdom and Wealth Wheel Cylinder Piston Assembly Machine is a SPM designed to assemble piston into the wheel Cylinder body. Before assembling the piston into wheel cylinder, seal assembly, removing debris, Lubrication & identifying any damages to the piston has been ensured. Sequence of operation is controlled through a PLC. Seal Assembly & Orientation ensured. Forced Methanol washing on piston Thin layer of grease applied on piston. Piston passed through a gauge for identifying any damages on the piston. Features Wheel Cylinder Piston Assembly Machine 16
- 17. INTEGRA L Integral Group Sharing Wisdom and Wealth TMC Assembly & Testing Machine Tandem Master Cylinder assembly machine consists of four different stations namely PP assy, SP assy, TMC assy & testing and Reservoir assy & Testing. This machine is used to assemble the TMC assy of 3 models namely auto, car and van. Features Height controlled screw tightening Thread identification and piston assy. Torque controlled screw tightening Leak detection & vacuum test in the TMC body and Reservoir. 17
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- 23. INTEGRA L Integral Group Sharing Wisdom and Wealth Frame Revising Machine-N40 Frame revising machine is a semi automatic machine to measure Head pipe tilt & offset, Shock absorber LHS & RHS and Tail lamp mounting of the Bike chassis and it is revised within the specified tolerance limit. Head pipe tilt & offset, Shock absorber LHS & RHS and Tail lamp mounting are measured and calculated with the help of LVDTs interfaced to the DAQ system. Features Deflect. of max. 3mm shall be revised Revising accuracy is 賊0.4mm. Servo hydraulics are used for revising Machine sequence is controlled by PLC & high speed DAQ system. The operator interface is through highly interactive GUI. 23
- 24. INTEGRA L Integral Group Sharing Wisdom and Wealth PP and SP Assembly Testing Machine PP &SP machine designed to check 4nos of holes presence, identify the model of piston, Assemble the seal into the piston, automatic screw tightening, piston sleeving & washing the piston Features Piston height is measured using LVDT 4holes presence checking with air back pressure principle. Forced fluid removes debris on the component 24
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- 27. Washing Machine Flywheel Cup The Washing machine for Flywheel cup is a SPM designed to remove the coolant oil and the debris present in component after the machining and pressing operations. Flywheel cup rotated while washing and drying. Sequence of operation is controlled through a PLC. Features Washing & Drying time is 18 Secs. Washing solution Temperature is 80属C Moisture removed by compressed air. Temperature & Water level is controlled automatically. VFD is used for varying washing & drying speed. Integral Automation (Pvt.) Ltd.
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- 30. Cutting Machine Cutting machine designed to cut the braided and formed rope as per the predefined distance. Sequence of operation is controlled through a PLC and pneumatic actuators perform all the movements. Features Lead 4mm Cycle time 5sec/cycle Holding torque of 112kg/cm Man machine interface is provided to set the predefined counter value Integral Automation (Pvt.) Ltd.
- 31. INTEGRA L Integral Group Sharing Wisdom and Wealth Caliper Housing Inspection Machine Caliper housing final inspection machine is a semi automatic machine to check thread of M10x1, M10x1.5, Hole checking and twin bore measurement within the specified tolerance limit. Accepted components are soft marked using marker pen. Sequence of the machine is controlled by a PLC. Features Hole check by back pressure method Bore measurement accuracy is 賊2袖 Thread check by tapping attachment Air electronic gauges are used to check two bores simultaneously. Floating mechanism to accept dimensional variation of component 31
- 32. INTEGRA L Integral Group Sharing Wisdom and Wealth Latch Assembly Line Latch assembly machine is a special purpose automated machine designed to apply grease for pawl, claw & rivet, Riveting of pawl & claw rivets, Height checking of Retention plate & Back plate assembly, Vision inspection system to identify the component presence and Cable press & Actuator assembly. Latch assembly machine is divided into three control circuits namely Retention plate assembly, Vision Inspection machine and Back plate assembly machine. 32
- 33. INTEGRA L Integral Group Sharing Wisdom and Wealth Testing Machine End Of Line Testing Machine for Latch 33
- 34. 34 Jaysen Engineering pvt ltd-Jigani . Developing assembly lines for manufacturing industries and custom built control panels for Automation Industry. New business division is into Renewable Energy, manufacturers and commission Micro Wind mills and Hybrid Solar/Wind systems for Rural application. INTEGRA L Integral Group Sharing Wisdom and Wealth
- 35. Played a major role in erection and commissioning of entire plant for processing tobacco for ITC ltd-Mysore. (2010-11) Designed and manufactured Conveyors and Intermediate processing machines. 35 INTEGRA L Integral Group Sharing Wisdom and Wealth
- 36. Designed and Commissioned an entire conveyor line for baling of metal scrap capacity 100 tons/day To M/s Toyota Kirloskar-Bidadi. 36 INTEGRA L Integral Group Sharing Wisdom and Wealth
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- 38. Renewable Energy division. Designed and erected community street lighting system for rural places with LED lights and Hybrid wind solar system 1.5 kW Hybrid system feeding 20 street lamps of 12W LED 38 INTEGRA L Integral Group Sharing Wisdom and Wealth Thali near Dankanikota, Tamilnadu (2011)
- 39. SPM division: Integral Automation (Pvt) ltd B-17, KSSIDC Industrial Estate Bommasandra, Bangalore- 560099 Tele Fax : (91) 080 2783 2398, 2783 5826 E-mail : iapl@vsnl.net Website : www.iapl.net.in Assembly line for automobile industry: Jaysen Engineering Pvt Ltd Q4- KSSIDC Industrial Area 1st main road, Jigani 2nd phase Bangalore 562106 Tele Fax : (91) 080 2782 5160 39 INTEGRA L Integral Group Sharing Wisdom and Wealth
- 40. INTEGRA L Integral Group Sharing Wisdom and Wealth 40 Thank you