Jendamark India has designed and developed a new suspended backlash measuring machine for our axle assembly customers using trolley-based systems instead of conveyor lines.
Measuring the amount of backlash is important to reduce power transmission losses in the gear train. More backlash means more power lost, while reduced backlash indicates that the distance between the meshing gears is reduced, which could lead to gear jams and increased mechanical wear and tear.
While backlash measurement machines are generally mounted on a fixed base machine, our new innovation – suspending it from our JTM hanging tool – allows us to perform this technically challenging activity without removing the axle from the continuously moving trolley.
Suspended systems are usually reserved for tightening or pick and place processes but this novel solution allows Jendamark to save both time and costs, while meeting the customer’s specific requirements.
The backlash measurement process is completely automated, with no human interference once the part is clamped.
The precise encoder has an accuracy of 0.001 degrees, and measurement happens at three points 120 degrees apart, which gives the final accurate output. Specially designed holders and adaptors compensate for external variables such as a slightly uneven floor or worn trolley wheels.
The suspended backlash machine with a built-in change-over concept is capable of handling seven different variants.
Determined to create a more conducive environment for learning, Jendamark India recently partnered with the new Zilla Parishade (District Council) School in Velu to fund the building of a classroom.
This newly built, government-run school serves 300 pupils, whose families hail from a mainly rural, agricultural community.
Jendamark India’s Pranjali Valavade says before its establishment, there were no district schools in the area.
“Education is essential for development and we really wanted to give something back to the community in which we are operating our business,” says Valavade, adding that one of these children could be the next tech leader.
“It is very important to have clean and spacious infrastructure for learning. We are so proud that we were able to give some small help in building a bright future for these children.”
This year, Jendamark Techcellency (JMKT) delivered a first for India and its biggest order to date – an innovative engine assembly line that uses augmented reality to guide its operators.
In May, this line was installed in the Skoda plant in Aurangabad, where it is being used to assemble four-cylinder R4 and six-cylinder V6 engines. The €2.5 million production line, which took 10 months to complete, has successfully produced the pilot series of engines and is currently gearing up for a ramp up in volumes.
JMKT operations director Himanshu Jadhav says the Industry 4.0-driven project was not just a first for the JMKT
team but for the customer too.
“As a turnkey project, it was extremely complex and many of the aspects had never been done before. Our engineers spent a considerable amount of time understanding the requirements, coming up with innovative solutions and making it work.
“This line has several unique solutions – from a mechanical, electrical and IT point of view – which showcase our
capabilities as a leading tech-oriented company,” says Jadhav.
First among these is the use of augmented reality glasses in the production environment to guide the operator through the assembly process. There is also the extensive use of tools and gauges that transfer critical production data via a wireless network.
“All of these Industry 4.0 solutions are based on our Odin software platform,” says Jadhav.
“We also gave our customers a realistic feel for the line and a chance to suggest improvements – before a single part was manufactured – using THEIA, our virtual reality solution.”
The complete line entailed the design and manufacture of more than 300 items required for the assembly of the engine in the most cost-effective way, without compromising on quality.
Teams from South Africa, Germany and India were involved in every aspect of the project from design to execution.
“The whole global team put in long, hard hours but our passion to deliver and an uncompromising approach towards results saw us execute this project to the best of our abilities and ensure customer satisfaction.”