Case Studies

Problem: During Application study we found out that there was a variety of name plates to be marked. Data on each name plate was more and that had to come from an ERP.
Solution: The problem was solved by developing a simple auto name plate feeding system. The large variety of name plate sizes was reduced to just 5 sizes. A custom software to take the data from the ERP and present it to the operator was created. The software also communicated with the automatic name plate feeder for fully automatic operation. The operator now loads a big bunch of name plates on the stacker, then selects many nameplates to mark and gives start marking command. The system automatically marks all the name plates one after the other and stops with an audio visual alarm after completing operation. A single operator easily handles more than 4 marking stations and also some other work.
This same solution with some minor variations have been implemented at many customers.
Problem: The Customer had marking to be done on flanges and similar components and there was a variation in positions.
Solution: We deviced a simple rotary attachment for the existing 2 axis machine where the operator could manually rotate the component and clamp it in place for marking.
Typically name writing machine on steel could be a challenge. Here the fast Pneumatic marking machines are more suitable than the electrical machines. We have given solution to hundreds of customers for name plate marking with the standard Hybrid marking machine.
Problem: The Piston is made either flat or has a circular dome shape. The marking is supposed to be done on the dome of the piston.
Solution: We used the dot type of Pneumatic stylus assembly which has a long stroke of 15mm. As a result, the dome of the piston could be marked in a single setting.
Problem: The marking was supposed to be done on inside surface of a ball. The surface was cylindrical in shape… just like doing marking on wall of the hole.
Solution: We had to put an extension on the marking machine so that the marking stylus could protrude out of the marking machine. Then a dotted type stylus was used to take care of the irregular surface on the inside of the ball. The marking which also involved a logo was done very effectively using this trick.
Problem: The Marking was to be done in a circular fashion. Though that is a standard feature, the circular marking was required to be done inside a groove as well as over a tapered surface.
Solution: We used the most versatile dotted stylus with long stroke of 15mm to take care of marking inside the groove as well as the tapered surface.
Problem: The flanges for marking had large tapered surfaces. The Marking was supposed to be done on these tapered surfaces with a rotary marking machine. There were more than 5 different tapers.
Solution: We deviced a rotary attachment with a facility to tilt the component. There are finite positions on the tilting attachment to ensure the exact angle of tilting each time the job is loaded. So the marking can be done in such a way that the taper face is not perpendicular to the stylus and marking takes place really well.
Problem: The customer had asked for a common machine for marking on rings which are used as gaskets where the diameter was varying from 25mm to 1.2m. The challenge was to make a common machine.
Solution: We deviced a custom rotary device for the moving the rings. The device can take the rings from 25mm diameter to 1.2m diameter and the marking was done on the top using the stationary mode of marking.
Problem: The application involved marking on large flanges and flywheels which weighted from 20kg to 100kg. The marking was required on periphery and in some cases timing diagrams that look like a scale were to be marked.
Solution: A large component handling machine was made. The component can be loaded on the machine and made to rotate. the machine head had adjustment of accomodating diameters from 100mm to 600mm.
Problem: The component had two faces to be marked at different heights. Also, there were different components of different heights and height adjustment of the machine was required to be automatic.
Solution: Motorized Column Frame was our solution for both these problem. The Z Co-ordinate can be entered into the controller or software and when the design is marked, it automatically moves the marking head as per the entered co-ordinate.
Problem: A lot of cylindrical components were to be marked and the marking was to happen in a synchronised manner on the periphery.
Solution: The Rotary Marking attachment to the 3 axis controller is meant for marking on cylindrical components. There is a Normal way for synchronised marking ideal for marking of logos and text alike and there is a Stationary mode which is suitable for marking most of the text blocks.
Problem: application involved marking on hexagonal components of different sizes. The marking was supposed to be done on the flat face of the hexagon which required a flat marking but for moving the component to mark on all the faces, that required a rotary movement.
Solution: The Rotary marking attachment to the 3 axis controller is meant for marking on hexagonal components also. The controller or Software is provided with a Block Station mode which has similar characteristics that are useful when marking hex components. This solution has been implemented with a number of engine parts manufacturers as well as fittings makers.
Problem: Application involved marking on the top cover of the battery. Most important was that the manufacturers wanted to mark their company logos or some other logos on the top face.
Solution: the Standard Flat Marking machine with the software or controller has the facility to mark logos on the components. This was used to give a effective solution to many plastic parts manufacturers.
Problem: The customer had marking to be done on cylindrical surface of different components. Usually, that was done with a rotary attachment but here, he wanted a 2 axis solution.
Solution: The most versatile dotted type stylus was used here. The large stroke enables us to mark on a surface irregularity of over 10mm. This was used to do the marking on the components.
Problem: Different components especially with our customers from aerospace industry, are required to be marked with a Datamatrix Barcode. This barcode is required to be scanned so that the data is available on a computer.
Solution: The software and controllers are capable of marking a Datamatrix as well as QR Code barcodes. This facility and scanning ability was demonstrated.
Problem: For many applications of name plate marking, the volume of name plates were not so high to justify a fully automatic system and not low enough for a manual device. A semi-automatic solution was required.
Solution: A Pneumatic holding device for name plates was the solution. The operation of clamping and de-clamping was done pneumatically and fast where as the nameplates are required to be placed manually.