Torque Carrying Capacity Improvement Of Worm Drive

Torque Carrying Capacity Improvement Of Worm Drive


Requirements

To improve Torque carrying capacity of worm drive from 152 KNm to 350 KNm without changing the mounting hole details


Benefits

Increased range of product offerings

Design changes which were 10% compact

Improved Design with high torque carrying capacity to 350 KNm

Analytical tool developed for calculating torque carrying capacity of Work Drive


Our Solution

Generate multiple concepts within the boundaries of design constraints and by combination different techniques like

Tooth Profile geometry modifications

Enveloping of Worm gears to increase the tooth contact

Selection of High Strength Material

Optimum Gear Contact ratio

Change Splash lubrication with Pressure Lubrication

Design Verification thru Structural Analysis


Topology Optimization Of Eot Crane Girder

Topology Optimization Of Eot Crane Girder


Requirements

Reduce the weight of EOT Crane Drive by 25%

Functionalities to remain same

Use of Standard cross sections for easy availability


Benefits

Raw material Savings

Machining & Manufacturing cost Saving

Improved Strength to Weight Ratio


Our Solution

Loading Calculations for accurate boundary conditions

Design Verification with CAE and Hand Calcs with deviation under 10%

Check the Design compatibility with IS Standards

Followed AWS standards for maintaining robust welding joints


Structural Analysis Of Fixed And Movable Platform

Structural Analysis Of Fixed And Movable Platform


Requirements

Validate the customer design with regards to Safety norms

Certify the Product design

Calculate the Factor of Safety


Benefits

The Design of Fixed and Movable platforms has been Verified and Certified Safe.

The Factor of Safety calculated is 10 according to BIS Standards


Our Solution

Prepare Pre Processing Document by collecting all the Boundary conditions

Geometry Clean-up to speed up the Simulations

Defining Bolted and Welded joints

Define Meshing Criteria

Applying Proper Mesh for full Product

Solving the simulation to get the Maximum Stress and Deflections.

Fixture For Center Stand

Fixture For Center Stand


Requirements

To design an assembly line fixture for holding a 2 wheeler by using center stand

To prevent 2 wheeler from tilting during assembly processes on assembly line.

To clamp a 2 wheeler in 20 sec. on a fixture


Our Solution

Define the DOF of center Stand & Finalize the DOF to be restricted

Constrain all DOF of center stand.

Use of quick clamping & De-clamping mechanisms to achieve takt time of 20 Sec


Benefits

Restrict two wheeler movements during assembly

Created simulation videos for training of operators

Less Fatigue to Operator


Design Of Fuel Tank Holding Fixture

Design Of Fuel Tank Holding Fixture


Requirements

Flexible fixture to hold Multiple Bikes Fuel tanks

Reduced Setup Time

No Damage to Fuel Tanks, Paint and Geometry


Benefits

Fixture can hold tanks of different bikes (various shapes and size)

Reduced inventory cost as client need not design multiple fixtures

Easy to use and maintain


Our Solution

Field Visits to understand the problem statement clearly

Dimensional Inspection of Various Fuel Tanks to generate the Geometrical boundaries

Brainstorming on the Problem to generate alternative solutions

Evaluation of Concepts on Pugh matrix

Prepare Product Design 3D CAD Models

Production Drawings for Manufacturing

Device For Joining Dissimilar Metals

Device For Joining Dissimilar Metals


Requirements

To design a spool gun or solder wire feeder that dispenses flux and solder wire from the same device.

Fixture must not allow the un-welded part to change its orientation in relation to the welder during the welding operations

Ensure that the quality of parts to be joined is maintained (Dimensions, Tolerances, No Warpage)

Fixture must be compatible with straight and curved faces


Benefits

Portable Device designed for joining Aluminum with Cold Rolled Cold Annealed (CRCA) metal


Our Solution

Inductive Flux Heating Unit Design.

Design of Solder Wire Feeder Mechanism, Wire Heating Unit, Flux Heater and Feeder Mechanism.

Separate Heating control for Solder and Flux.

»  Wire Feed Rate Calculations to calculate Motor specifications and Worm Gear feeder mechanism

»  Calculations for Heat generated at the Tip to avoid metal and Solder from Burning

»  Electrical circuit design for Induction coils

»  Temperature Rise Calculations

Development Of Binderless Bricks

Development Of Binderless Bricks


Requirements

Speed up the constriction rate and build structures quickly.
Easy assembly with Interlocking


Benefits

Reduced Construction time
Eliminate need of mortar
Provides Flexibility in construction with Modular design


Our Solution

Patent filled novel Idea by Kalyani Studio team
Designed Interlocking Bricks with Flexibility in wall building
Wooden Mold for Bricks manufacturing
Use of 3D Printed table top models for design validation

Gear Casing Weight Optimization

Gear Casing Weight Optimization


Requirements

Design is safe or not against static load of 6000 Kgs

Weight optimization in the gear casing by 20%

Redesign Of Casing


Benefits

Operational life achieved of 10 Lakhs

Lifting

Reduced weight & material of gear casing


Our Solution

Perform Structural Analysis to obtain design information

Identified maximum stress area

Checked feasibility of casting design

Suggested changes in design

Metal Prototyping of Metal 3D Printing

Metal Prototyping of Metal 3D Printing


Requirements

Product manufacturing process planning

Product manufacturing as per production drawing given by client

Product quality check


Our Solution

List down critical dimensions

List down critical manufacturing features

Identify design standards for product manufacturing

Brainstorming for cost effective manufacturing process

Brainstorming for product quality improvement

Manufacturing of the component

Quality inspection and reports


Benefits

Cost effective manufacturing process

Product manufacturing as per manufacturing standards

Frequent PDCA (Plan Do Check Act) to get good product quality

Final full scale prototype with all features


Inspection and Welding Fixture for TIG welding Machine

Inspection and Welding Fixture for TIG welding Machine


Requirements

Combine horizontal and vertical welding operations

Avoid oxidation of the welding between Kovar to Kovar and SS to Kovar

Runout inspection in the same machine

Reduce rejection rate in runout (Current is 10 %)

Camera to monitor the welding process

Tack welding

Bluetooth or wireless dial gauge

Double hand operation for starting the process


Our Solution

Design of the mechanism to hold the electrode for horizontal + vertical welding

Design of a canopy for enclosing the components to be welded

Integrate inspection mechanism with the machine

Selection of dial gauges, pneumatic clamps, rack and pinion and motor

Prototyping and testing


Benefits

Reduced operator involvement.

In situ welding monitoring camera

Run out inspection can be carried out in the same setup

HMI with GUI for easy operations


2D-Production Drawings of Casting and Machining Components

2D-Production Drawings of Casting and Machining Components


Requirements

Prepare the production drawings for the casting and machining components


Our Solution

3D to 2D conversions

International standards followed for drawing creations

Prepare checklists for 100% inspection

Filled checklists with signoffs


Benefits

Production drawings complying with company and industrial standards (ASME, ISO)

Accurate dimensioning feature wise

2 levels of quality checks

100% quality checks of each drawing with a checklist

Interference checks for assembly CAD