Twin Engineers is known for its expertise in Meter Mix Dispensing, Oil Filling, and Robotic Sealant Dispensing. The company has over two decades of expertise in automating a range of mixing and dispensing processes, one of which is Potting.
Twin’s machines have been used to automate 100+ niche and proven potting applications in various industry verticals from transformers to auto parts and temperature sensors to capacitors.
Consider our experience of developing a fully integrated plant for one of the world’s leading Japanese auto-electronic part manufacturer. The client was not just able to automate the electronic potting process with enhanced efficiency and throughput, but could do so with a complete control on the quality and safety. Twin has also been a major provider of process automation solutions for global automobile manufacturers such as Harley Davidson, Toyota, Volvo, and Honda.
Here are the notable benefits of automation the potting processes where Twin’s technology can help to create a competitive edge for you-
Optimized – Tapping opportunities to reduce cycle time where there were none
From dual potting heads to integrating pre-heating and potting stations on a single Machine, Twin has offered several innovative automation solutions to significantly reduce the cycle time of the process. In a machine that was supplied recently to a large transformer manufacturer based in Turkey, Twin was able reduce the cycle time by 20% as compared to the German machines which the customer was already using. This was achieved by optimising the size of the vacuum chamber to accommodate double the number of components and thus effectively reduce the time required to create and kill the vacuum by almost 50%.
Seamless – towards lean production lines
Twin’s fully automated potting lines are well proven in simplifying the potting process as a whole. The entire process of pre-heating with curing is accomplished in a sequential manner to ensure less processing time and desired quality. Clients have earned dividends in multiple ways from space and cost savings due to optimised layouts, seamless production flow without manual intervention and an accurate control over the entire production process, including potting.
Consistent – improved quality and control
In an extremely competitive environment, the quality of the product can become a significant competitive advantage. Be it the high-volume assembly operations like creating small automotive sensors or the potting process of motor windings installed in submersible pumps. Automation of tasks like potting will help in maintaining a consistently high quality as this allows greater control over dispensing conditions like temperature, mixing ratio, and dispensing volume.
Flexibility – The key to modern-day success
Driven by processes that have proven successful internationally, globalised production centres, and shorter product life-cycles, manufacturing companies are seeking more flexibility. To go-to-market faster and address the needs of their demanding customers, they need to be able to change layouts, materials, and even key processes like potting.
These changes should be easy to make and should be inexpensive, so they don’t make a dent on investment budgets. This is where Twin’s designs have been making a mark. Our solutions for automating potting are modular. They allow fast, easy, and economical adoption. This allows manufacturing companies to automate their potting tasks quicker and get the benefits faster.
The next wave of automation is already knocking on the doors of the manufacturing industry. The Internet of Things has brought with it sensors that can provide much more intense and real-time monitoring of every phase of the production process. This will allow the triggering of better predictions of downtimes promoting better quality and faster production. But, that’s the subject of another blog -so do stay tuned!
Twin Engineers is a 25-year old Indian supplier, manufacturer, and exporter of some innovative equipment that addresses key industry segments like Automotive, Electrical and Electronics, Composites, Packaging and PU Products. The organization offers its best-in-class products in Meter Mmix Dispensing, Single-Component Dispensers, Robotic sealant dispensers, Oil and Fluid filling, and Adhesive Dispensers. The company has a reputed global clientele in its years of service with clients including much of India’s Automotive sector Tata Motors, Ford, Suzuki,Honda, Volvo, etc.
Back in 2008, the Indian automotive parts market was estimated to be nearly US $26B. The nation has continued experiencing persistent growth in the sector for a decade after that too. Around that time, an automobile filter manufacturer from Delhi had connected with us for its aftermarket products. The dealer wanted to introduce a process strong-enough to increase manufacturing efficiency tenfold so they could make a real impact in the growing Automotive business.
How we confronted this challenge
The automotive parts dealer was looking to manufacture filters with a semi-automated machine capable of PU Foam dispensing. But it was not easy to convince them to adopt our solution. Filter prices were subject to intense competition and labour was cheap -not a situation conducive to large budgets. We faced rejection on our first quote but with persistence, several meetings, and visits to the factory, we helped define a new understanding of the value of automating the meter mix dispensing process for the customer.
The solution suggested by Twin Engineers
Based on our understanding the market demand and growth opportunities for the business, Twin’s team suggested to the customer to think big. We recommended that they drop the idea for a basic machine and, instead, we suggested that they go in for a fully-automated dispensing system.
The new proposal did not get a positive response for months. The Sales team continued discussions and spent more time to grasp the customer’s concern. The customer was concerned about support and we instilled the confidence that we would support them till the machine proved itself on the production line. With the risk of failure now greatly reduced the customer decided to go ahead.
The first machine for the company went operational in about 3 months. Our team was actively involved in training the unskilled operators at the company to ensure proper quality and throughput. Handholding by Twin’s team ensured a confident Operator and Production staff that felt ready to take-off with their new Machine.
The next step
One year down the line the Machine had paid itself off. The customer got back to us, this time with lots of ideas to further advance thed automation and features in the Machines.
We were only happy to oblige. The second machine went operational .. then the third and the journey has continued over the past decade. The client’s business expanded, profits increased, and capacities increased. This helped to transform the company into a leading brand in aftermarket filters in the extremely competitive North Indian territory.
Last year, the customer invited us to help assess their expansion plan. With help from Twin’s innovative machines, the Client’s operations have always been among the most profitable in the industry. In a wonderful moment, the founder of the company thanked our team while proudly mentioning that he had bought his first Mercedes recently.
“Automation is a prerequisite for quality-controlled and efficient manufacturing!”
Automation, once it became the cornerstone of manufacturing, has the potential to make a significant contribution to the expansion plans of small and medium-sized companies. Further, automation brings several advantages such as increased production rate without any compromise on the quality, economical and efficient use of raw materials at every stage of production, and enhanced safety procedures.
Traditionally, small and medium enterprises have been held back from their Automation plans through fear of making a sizeable investment. However, as this story shows, taking the plunge in a planned manner can help recoup the investment with time. In that quest, innovative manufacturers such as Twin Engineers who have helped more than 250 small and medium entrepreneurs, can help prove that automation is not a luxury -in fact, it could help these businesses get a little bit of luxury (like a Mercedes) into their lives.
Electric Vehicles are disruptive in more ways than we think. It’s not just the change of fuel, but a re-engineering of an entire value chain. From a mixing and dispensing technology view, adhesives will replace the traditional welded and riveted parts in the electric vehicles. At the same time, there is a demand for serving several new applications such as sealing in batteries, specialised dispensing in rotor motors, adhesive dispensing in composite or new age materials and much more.
For the last few years, Twin Engineers has enabled several applications for the Electric Vehicles using cutting-edge solutions.
Dispensing technology for the heart of EVs
Magnets form the heart of the motors in Electric Vehicles. Recently, the team at Twin Engineers developed an Epoxy dispensing Machine for sealing a set of magnets in the rotor of EV motor.
Void-free sealing with under vacuum dispensing
The job involved dispensing of 2 Part Epoxy (shot size of 150 gm) inside the cavity of the rotor holding the magnets. The sealing operation prevents the magnets from displacement under the rotational forces inside the motor. Accurate filling of quantity, mixing ratio accuracy are highly critical to ensuring the proper functioning of the EV motor. The material was dispensed under vacuum to ensure void-free sealing of multiple magnets through the deep cavity inside the rotor.
Meeting the specific needs of the process
Twin’s team designed the dispensing set-up by a careful consideration of the smallest details expected to be at play in the application. Starting from the selection of materials in the machine to programming the dispensing path, everything was designed to meet the highly specific needs of the process.
Charged for a high-speed production
Twin’s team helped the customer to achieve the desired cycle time, thus ensuring a high-speed production for a critical process. The Machine, build on Twin’s Intellomix platform comes with important interlocks for process parameters to ensure absolutely no deviation in end product quality.
Twin has been a partner to develop mixing and dispensing technology to some of the largest OEMs and Suppliers of Electric Vehicles in India. If you are looking for an expert partner in developing parts or components for Electric Vehicles that use sealants or adhesives, speak to one of Twin’s representatives to explore new possibilities.
Euro VI necessitates several fundamental changes in technology for Two Wheelers. To comply to the Euro VI norms, Two Wheeler manufacturers are likely to phase out CDIs and Carburettor whose functions will be carried by the new Magneto coil designs and ECUs.
When one of world’s top Auto-Electronic manufacturer was looking for a reliable solution to dispense single component epoxy on the winding (12 to 18 poles) of its newly designed Magneto coil, it selected Twin’s Machine for the job.
The process uses a single component epoxy in order to insulate and bond the winding and prevent its fly-off under high rotational forces. With a decade-long relationship and a strong reputation earned from Twin’s previous projects, the Client entrusted the task of developing the machine for this new application to Twin’s team.
The single component Epoxy Dispensing Machine equipped with dual-head Robotic Dispensing, designed by Twin, serves the specific needs of the application including accurate shot size and desired cycle time. The dual dispensing heads on the Machine improve the productivity of the process by enabling simultaneous dispensing in two coils. The highly compact design, coupled with the most advanced controls has helped the client to save space and costs while providing total assurance to achieve the product quality, as desired.
Over the last two decades, Twin has developed specialized mixing and dispensing machines to cater to over 120 applications in a variety of electronic and electrical products.
For more information write to us at firstname.lastname@example.org
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