Barani Hydraulics India Pvt. Ltd. (BHIPL) is one of the leading hydraulic press manufacturers and exporters in India, involved in designing and developing custom-built machines and meeting different customer requirements since 1988. The company has built over 900 machines so far for various engineering applications ranging from automobile, aerospace, solid tyres, refractories and abrasives, metallic components and so on. The speciality of BHIPL is that the products made are not standardized with each one coming with some unique features.
Wheels India Ltd. (WIL), leading wheel manufacturer, is one of its major customers in the automotive space. BHIPL has developed many turnkey projects for WIL and one such application is the Roll Former which has been recently made for earthmover wheels.
The Roll Former is used for profile forming and knurling operation on the wheels for tyre seating purposes. It is a completely automatic press starting from component loading to unloading where the component gets plunged in between two rotating spindles by a hydraulic cylinder through a mechanical link advantage concept called torque tube.
The torque tube is an integral part with the bottom spindle which multiplies the force of 60 T from the cylinder to 75 T to the bottom spindle, thereby achieving the required force with less input. The entire press is a stress-relieved, fabricated structure that results in minimal deflection under sudden loads.
Construction features
• Column type construction having more rigidity
• Both spindle housing are having the tilting facility and guide with 8 point jib guide assembly.
• Both the spindles are driven by hydro motor and planetary gear boxes and load transferring by a hydraulic actuator through Torque tube and linked mechanism.
• The force has been multiplied by mechanical advantage. The loading & unloading of the component is an automated facility
The Roll Former operates in a green energy concept. Its two spindles are operated through hydro motor and utilize only half the conventional power required for the rotation. This is achieved by integrating the spindles’ hydraulic connection. The output of the top spindle is given as an input to the lower spindle thereby synchronizing the speeds through proportional control valves. This enables to save 150 HP of power which translates into significant cost savings.
The accuracy levels of the operation is met out by an 8-point Gib guide system where the entire bottom spindle is moved with guiding at eight points in the frame, thereby enabling uniform geometrical tolerance on the component.
Some of the special features of the equipment include automatic loading and unloading to reduce operator fatigue and improve cycle-time. While the mechanical advantage in the design multiplies the transferring force with less input energy, the green energy concept enables the hydraulic input flow to use only 50 per cent energy, saving electrical energy to the tune of 120 KW.
80 T Hub assembly press
Yet another achievement by BHIPL is the development of a custom-built automatic press solution for truck wheel hub assembly for Wheels India.
Construction features
• 4 Pillar type construction; designed for three in one operation both stud pressing and top & bottom bearing pressing a processed simultaneously.
• A hydraulic equalizer assembly and 10 load cells are assembled in the pressing head which ensure 100% poke yoke system in the process.
• The transferring provision has been provided for the loading & unloading and ejection. With all that the press designed a complete automated customized solution.
The press comes with a unique construction, which, instead of processing at three different presses offers a combined solution, thereby saving directly on investment by reducing work space, electricity power and manpower. Another advantage of the machine is the reduced operator fatigue. By providing Scada software and creating different recipes, pre-determined data can be selected for each component which avoids time loss through manual setting and offers better consistency in the overall process.