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Machine Tools

We are a leading Exporter of Massive Forming Machines Tools, Mida Laser Tool Setting Application, Od Snap & Ring Gauges Machine Tools, Stamping Machines, Die Casting Machines and Leak Tests Leak Testing Machine Tools from Gurgaon, India.

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Marposs, though the acquisition of Brankamp in 2012, is the global market leader company for machine monitoring, offering a variety of monitoring solutions for every type of new forming machine or for retrofit in the user's plant. Our monitoring systems prevent process errors, protect the machine and tooling, and provide support for quicker machine set-up. When there are malfunctions, they switch off the system in time to limit costly damages. Cracks on formed parts represent a typical failure that often occur randomly in work pieces. The failures are only detected using in-process monitoring on all parts manufactured on various machines.

 The monitoring solutions offer an effective way to observe and control your machine by detecting, right at the deformation stage, part defect or abnormal conditions to prevent overload or fractures in the tool element. Additionally, the signals of sensors installed into the machine are elaborated with algorithms, which allow the improvement of machine efficiency and save machining time in setting operation.

 

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Marposs is able to offer measurement, monitoring and check solutions for any type of machine tool, such as: drilling and tapping machines, boring machines, sharpeners, gear cutters, machines for stonework, machines for glasswork, machines for woodwork.

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Stamping Machines

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Marposs, though the acquisition of Brankamp in 2012, is the global market leader company for machine monitoring, offering a variety of monitoring solutions for every type of new press or for retrofit in the user's plant. Our goal is to assist our customers in achieving the highest quality in stamping processes to help meet the rigorous demands placed on suppliers of automotive, aerospace, industrial electronics or telecommunication components. Advanced monitoring systems can provide the key to efficient quality and machine control whenever hundreds of millions of stampings are performed monthly on presses. By integrating sensors in the tool or in the supporting plate, it is possible to nip stamping problems in the bud. Production disruption caused by punching, cracks, double sheet metal or other faults can be detected and production immediately stopped.

Conditions:

Tools for producing car body parts on giant presses often measure several square meters. The requirement to produce millions of bodies and the need for manufacturing process flexibility imply almost daily tool change. The tool change represents a problem even when normal size objects are to be pressed. Incorrect alignment of the tool generates forces out of the bottom dead center, which results in an overcharged process and quick damage. Mass production and flexibility are also a way of life for other stamped car components. Gaskets and seals for all engines are only two example within the automotive industry. Billions of cans for food or pharmaceutical industries, as well as billions of connectors for electrical appliances and information technologies must be manufactured with an elevated quality standard (zero defects) to avoid contamination and guarantee safety and proper functionality. Cracks in the rivet head, pulled slugs, double thickness sheet metal, and inconsistent strip advance are some of the problems which could affect any stamping processes. Every production process has a weak point, but today there are solutions to monitor these problems and nip them in the bud, thereby reducing cost in stamping applications.

Solution:

Brankamp has been active in stamping process monitoring for nearly 40 years, and the sum of that experience is embedded into the monitoring solutions offered by the Company. The in-process monitoring system provides, directly on machine, the possibility for immediate identification of manufacturing faults. Using sensors inside the tools or within the machine structure, both tensile and pressure forces acting in any direction are measured in real time. The sensors recognize the slightest change in force that deviates from the normal pattern during production, signaling this to operator on the control monitor (Set up aide). A deviation exceeding the limits causes the machine to be automatically stopped. This allows for the identification of faulty parts (part quality) and to prevent damages (Tool and machine protection) . Additional functions including recognition of process fluctuations, visualization of curve details, parts counter and process data collection are available to improve machine productivity. (Machine efficiency)

Benefits:

  • Machine protection thanks to overload control
  • Reduction of unexpected machine crashes, breakage, down time, repair cost
  • Reduction of set up time
  • Better analysis of process failures to enable taking countermeasures and improve machine efficiency
  • Increase of production time due to minor and uncontrolled process stops
  • Reduction of scrap parts allowing zero defects batche

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Die Casting Machines

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Thermal Vision is an innovative technology for real time monitoring of the thermal map of a die surface for high pressure die cast processing of light alloys; a growing process in the automotive sector, which is strongly committed to reducing the weight of structures for improved fuel economy. The goal is to assist our customers in achieving the highest quality in their casting processes to meet the most rigorous demands, while providing, at the same time, an optimum die process monitoring solution together with best practice in die lubrication. Our equipment provides the key to efficient part quality and machine control in applications where thousands of die casts are performed monthly. A thermal map of the die surface is created by integrating infrared thermographic cameras in the machine, thereby making it possible to optimize the lubrication phase during the die casting cycle, and to obtain a deep knowledge of the process

Conditions:

Die surface temperature is crucial for high quality, efficiency and faultless processes. A majority of defects in die casting processes, such as shrinkage, porosity, cracks, and blisters, is caused by an out-of-control die temperature. To nip casting problems in the bud, it is mandatory to monitor, in real time and without interruption of the production cycle, the die temperature surface and related spray effect. High or cold die temperatures have a negative impact on tool life, start up and cycle time, as well as energy consumption and maintenance costs due to unnecessary use of thermal regulation, air pressure, and/or water based lubricant blow.

Solution:

Total Thermal Vision is a proven infrared thermography solution to capture and visualize the thermal map of the die surface. Years of experience and multiple applications in operations world wide make TTV the optimal solution to increase die casting quality and overall equipment effectiveness (OEE). At the core of the equipment are the high performance IR sensor and image elaboration devices, both protected by a cylindrical stainless steel housing. Germanium glass (transparent to IR), protected by an air operated shutter and an air cooling system, allows the cameras to operate in the aggressive foundry environment. Simple installation into machine and the friendly human interface allow casters to have immediate overview of die surface temperature distribution, without process interruptions. Max and Min surface temperature of Regions OInterest ( up to 10 R.O.I.s) of both half mold, trends and related alarms presented on the screen allow the operator to take appropriate countermeasure in the tool temperature setting and/or spraying optimization.
Single images are stored for post process "big data" analysis, die programs archive, part ID and history, making TTV the unique die surface monitoring solution for advanced die casting production in modern foundries.

Benefits:

  • Optimization of cycle time, thanks to spray lubrication and minimized tool cooling
  • Increased machine efficiency, thanks to reduction of production start time (warm up)
  • Increased die lifespan, thanks to optimal die surface temperature
  • Higher part quality, thanks to data analysis to set processes and a corresponding reduction of scrap
  • Cost savings due to less lubricant consumption and waste water
  • Better analysis of process failures to enable taking countermeasures and improving machine efficiency
  • Increase of production time due to minor and uncontrolled process stops
  • Process and part identification history

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