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MELSS
We offer World-Class Engineering & Technology Solutions. MELSS is an organisation with decades of experience in providing customers with state-of-the-art technology solutions in different domains and verticals.
To Know More, Visit: www.melss.com
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Automation is a necessity for industries to remain competitive.
Automation can be classified into Mechanical, comprising Robots, Cobots, Gantries, Conveyors etc and Digital, including IIoT networks, AI and Big Data.
Mechanical Automation allows us to perform manual, repetitive, time-consuming, hazardous and high-throughput operations in a cost-effective and safe manner. Digital Automation enables interconnectivity and autonomy of decisions on the shop floor.
Automation has not only increased productivity, it has improved quality, availability, timely delivery and safety wherever it has been implemented.
We offer a wide range of high-ROI automation solutions for industrial and manufacturing applications to drive efficiency, quality, productivity and safety.
For more Info: https://zurl.co/aqM6
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As per ABC News (Australia), fires caused by EVs need more water to be extinguished than those caused by IC engine vehicles.
Fire accidents in Electric Vehicles using lithium-ion batteries occur due to frequent charging, resulting in internal short circuits caused by lessening of effective distance between electrodes.
Insulation withstand voltage of #LithiumIonBatteries need to be tested by checking the distance between electrodes, instead of insulation resistance, at a voltage higher than 350V. Besides, self-discharge caused by leakage current inside the separator also needs to be tested at a lower testing voltage.
To solve this, we bring you the unique electrical #FlashoverDetection technology of the #Chroma11210#BatteryInsulation Tester with built-in +flash test.
For More Info: https://zurl.co/KTF8
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Solutions for the Rubber/Tyre Industry
Speak to MELSS for a wide range of solutions to monitor and improve the productivity and traceability of operations and finished goods for the Tyre & Rubber Industries!
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5 ways in which robotics helps to increase efficiency and reduce manpower
Skilled manpower need no longer be utilised in repetitive and mundane jobs, and can now be used in higher value tasks such as engineering and maintenance. Repetitive jobs are best handled by robots which also result in more throughput and efficiency. Precision handling eliminates many an imperfection in human handling, delivering higher quality. Also, moving manpower away from hazardous roles which can be handled by robots improves the safety level.
Here are just some of the ways in which robotics results in higher efficiency and lower manpower dependence. (5 ways in which robotics helps to increase efficiency and reduce manpower)
1. Repetitive Jobs Are Handled Better
Volume production often requires the same operation to be carried out at fast intervals, and this is best accomplished by robots. This helps industries achieve quicker turnaround time. The speed of operation is also attributed to robots nullifying human errors, and the time taken to complete each task is reduced. Precision is guaranteed by using robots. Besides, for ease in operations robots are deployed to handle components of complex jobs, such as lifting heavy loads and picking.
2. Metrics Are Maximised
A category of manufacturing where robots are being used exhaustively to improve efficiency is automobile manufacturing, calling for treatment as a special category for discussion. Each stage of automobile manufacturing has adopted robotics. The stamping stage which was earlier prone to human injuries, or even fatalities, has embraced robotics thereby eliminating the need for manning by humans. The body shop department uses robots for welding and punching. Assembly lines increasingly use robots helping to deliver world-class models.
Not only this, alternate handling of models is now possible, by programming the robot to handle that way, adding a new dimension to the whole manufacturing process. The latest models of most automobile majors have minimal involvement of humans and maximum involvement of robots.
3. Perfect Precision Is Now Possible
Miniaturisation is the norm in electronics manufacturing. Each unit is made up of smaller components which also need to be picked and placed precisely. High precision in operations is mandatory, and robots are a necessity. Mass production is needed to remain competitive without compromising on quality. Robotics plays a major role in achieving that. Efficiency and precision are increased with reduction in human participation.
4. Uniformity in Production Is Achieved
Healthcare industry requires help in various stages to ensure uniformity in batch production. Assembly after proper picking and placing resorts to robotics. Controlled and repeatable movement of the robotic arms ensures zero spills. Assembly inspection by in-built camera ensures zero errors and uniformity. Palletising robots help move human participation away from risky lifting operations. Proper labelling and printing are accomplished by the ever-so-efficient robots.
5. Safety to Manpower Is Ensured
Technological advancement to improve strength of materials has led to various industries using composite materials in the manufacturing process. Manufacture of composites is often in hazardous environments and deployment of robots helps reduce health issues. Also, composites are created with the same composition, time after time. Often requiring force, humans need breaks in between but a robot delivers the same quality 24×7 thus increasing efficiency.
Replacing or supplementing manpower with robots not only increases efficiency but is cost-effective in the long run and has many indirect benefits too such as being environment-friendly and adaptable to all-weather conditions.
MELSS delivers pioneering solutions in robotics to different industry segments, cobots (collaborative robots), end-of-line components for robots such as grippers, as well as highly reliable maintenance and service support.
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MELSS provides robotic solutions after careful study of your requirements and brings you a diverse range of solutions from the leading brands - Doosan and OnRobot . The range is also augmented by a set of tools and accessories.
The Lift100 from OnRobot is one such tool.
It increases the reach of a robot, enabling more cycles even in remote locations. Not only does the Lift100 offer the seventh axis to traditional six-axis robots, but it is also future-proof for palletising and other manufacturing applications. Its capability to handle high payloads with minimum deflection ensures precise positioning even at high speeds. Robustly built, it is reliable over a long period. Pallet stations for pallet positioning, along with #palletising software make it a complete package.
For more: https://zurl.co/qYEK
#Robotics#EndOfArmTool#Lift100
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Solder pastes offers formulations designed to deliver low-voiding, plus enhanced benefits such as improved response-to-pause, stability, HiP minimization, reliable in-circuit testing, and enhanced SIR performance.
Solder Paste ensure right Soldering. Soldering to perfection is no simple task. Anyone engaged in the process benefits immensely from having the right soldering paste.
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A video pattern generator is needed to test the quality of video input signals from different sources such as cable, HDMI or VHS – enabling root cause identification and rectification at the earliest.
The Video Pattern Generator-2238 from
Chroma ATE Inc. is studded with many advanced features such as:
• Modular Design housing 4 modules ranging from HDMI and USB-C to DVI and Analog, each with high-speed Graphics Core
• 7” Intuitive Touch Panel
• Range of communication interfaces including USB 3.0 Interface of 5Gbps bandwidth
• Smart I/O
• Simultaneous Signal Monitoring from multiple Chroma 2238 generators
• High service life of test equipment
For more info: https://zurl.co/tAXM
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Does your EV Battery Manufacturing unit use UV Curing?
The preserving properties of UV Curing have been used for a long time. UV Curing as a technology has been constantly researched and it is finding use in more industrial applications today. The list of such applications is exhaustive, and the technology has revolutionised many industries.
It has already been widely adopted across commonly used products such as eyeglass coatings, cell phones, all kinds of electronics, vinyl flooring, credit cards, and more as research progresses. Perhaps the largest beneficiary is the EV Battery manufacturing industry.
The Technology What exactly is UV Curing? Certain liquid monomers and oligomers when mixed with a small percent of photoinitiators, and then exposed to UV energy, initiate a photochemical process that instantly dries or cures inks, coatings, and adhesives. This technology has created a revolution with almost any industrial application benefitting from it.
Besides, UV-curable materials, from epoxies to urethanes, polyurethanes to acrylates, can be formulated into unique hybrids, thereby enabling UV coatings to be created by incorporating the best characteristics from each.
Not only are these solutions quick, but they bring many other benefits to the industrial table such as being environment-friendly, non-hazardous, and causing negligent waste.
Significance of UV Curing in EV Battery Manufacture
UV-curable materials have benefited multiple applications in electric vehicles, including electric vehicle (EV) batteries, LIB pouch cells, fuel cells, coin cells, and other geometries and chemistries, such as Li-iron phosphate (LFP), Li-nickel cobalt aluminum oxide (NCA), and Li-nickel manganese cobalt (NMC).
Challenges in EV Battery Manufacture
Reductions in manufacturing costs and improvements in reliability are the primary goals of EV battery research today. Traditionally, the battery’s electrode fabrication process was inefficient with the application and drying process being highly time-consuming using high energy, resulting in less yields.
Manufacturers face the challenge of preparing reliable EV battery packs capable of withstanding environmental extremes such as heat, corrosion, and vibration. While most battery packs include elaborate thermal management systems, short-term thermal shocks, and extreme vibration and shock levels continuously test the endurance of batteries. Better quality materials are needed in the manufacture of batteries to overcome these challenges.
The Solution
UV-curable binders combined with new electrode coating processes using lower energy UV LED curing systems reduce manufacturing costs by as much as 80%, thereby reducing electrode costs by more than 25%. Switching to UV-curable materials for battery pack assembly reduces VOC generation, speeds up assembly time, reduces assembly costs, and improves reliability. UV-curable adhesive is a natural choice which also meets the strict automotive standards for temperature extremes, high humidity, thermal shock, and extreme vibration levels.
MELSS brings you the OmniCure® SPOT and Area cure UV Curing Systems for precise curing of inks, adhesives and coatings. Selecting the ideal OmniCure system for a particular application depends on the physical, and chemical behavioral properties of the substrates.
Benefits:
Reduced process times, higher throughput with less rejection rates
Enhanced reliability of battery packs leading to reduced cost of manufacturing
Lower operational costs and resource consumption
Reduction or elimination of VOCs for environment–friendliness
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Predominantly used in all Electronic instruments, a Switched Mode Power Supply (SMPS) is also used in other applications such as Personal Computer, #RailwaySignaling, e-vehicle battery chargers, and #MobileChargers. Given its widespread applications, #Testing SMPS components is paramount - and this is best performed using an Automated Test Equipment (#ATE).
The SMPS ATE from #MELSS tests a range of parameters, from DC output voltage/current, regulation of voltage/current and turn-on/holdup time to short circuit tests, input power/current, efficiency and protection.
It has a range of features such as IPC based System, various programmable test and measurement instruments, customisable GUI and Reports, user authority control, activity log and comprehensive hardware modules.
For more Info: https://zurl.co/TmZ0
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Using data from Equipment Sensors, IoT has revolutionised manufacturing operations with a range of benefits such as:
• Better identification of trends and areas for improvement
• OEE for productivity monitoring - Machine/Shift/Variant/Operator wise
• Data logging with time stamp for reverse traceability and real-time trend analysis
• Implementation of foolproof Poka Yoke and 4M
• Elimination of data entry by humans and digitalisation of the data register
• Remote Monitoring of equipment
• Streamlined manufacturing process using IoT-enabled devices
• Predictive Maintenance to reduce unplanned downtime and increase productivity
• Better tracking of assets and locations including humidity, air quality and temperature
We provide a wide range of IoT Solutions for industry.
For More Info: https://zurl.co/sQP1
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Doosan collaborative robots
Are you making full use of your Collaborative Robot (Cobot)?
Ever since 1995, collaborative robots (cobots) have helped to spread robotics into many industrial segments which were earlier not considered due to concerns regarding prohibitive cost, space constraints or safety and operability issues.
Even when available, a cobot is often not properly utilised. The type of cobot selected could be incorrect for an application due to the limited range of cobot models and lack of awareness of requirements. A knowledgeable manufacturer of cobots is needed who offers a wide range of solutions suiting your specific application needs.
Doosan offers a wide range of cobots which can be used across applications and industries.
Why Doosan?
Within a span of 7 years, Doosan has captured 7% marketshare worldwide and is backed by the diversified 125–year legacy of the Doosan Corporation.
It has been researching the need for cobots and has been innovating by creating world-class cobot models with cutting-edge features. No wonder, it has been embraced by diverse industries. Doosan‘s innovations include:
Highest safety for operators
Operator safety is of utmost importance when it comes to cobots. Doosan’s H-Series boasts of the highest collision sensitivity in the industry, with six high-tech torque sensors. With Safety features that include Emergency Stop, Safe Torque Off (STO), and Safe Brake Control, a secure and safe work atmosphere for operators is ensured. The functional safety of the Doosan H-Series collaborative robots is certified as PL e-Cat 4 in accordance with ISO 13849-1. These cobots also feature a counterbalance mechanism to ensure their own safety, whereby the light-weight hardware reduces shock to improve the safety.
Zone-based operation
Each Doosan Cobot can be set into various zones according to the site application – Cooperation, Jam Prevention, Collision Sensitivity, Limited Tool Orientation and User-defined Zones. This ensures that the collaborative robot can work safely and efficiently alongside humans.
Highest payload capability
The Doosan range of collaborative robots can handle many payloads, and the H2515 boasts of the highest payload in any Cobot, easily handling up to 25kg payloads. Lower payload models in the H, M and A series are available depending on the application.
Flexibility
The Doosan H-Series cobots are very flexible due to their lightweight design which allows for free movement, flexible work settings and easy coupling with mobile robots such as AGV and AMR.
Applications
Doosan cobots find wide applicability in the manufacturing industry in applications such as Pick & Place, Assembly, Packaging and Palletising, Press Forming, Glueing and Bonding, Inspection, Injection Moulding, Polishing and Deburring, Air Blowing, Machine Tending and Heavy Object Handling.
Not only this, they also find applicability in the Service Industry in applications such as Food and Beverage, EV Charging, Video Shooting and Medical.
Common features
All Doosan cobots can be programmed by easy-to-complete, one-touch programming to automatically detect attached peripherals and suggest ideal work processes. On the operator’s side, it is easy to learn even for beginners. The in-built cockpit is handy to quickly and easily teach robots.
Compatibility
Doosan Mate comprises a variety of industry-leading partner products compatible with Doosan to provide the best automation solutions, optimised for customer needs.
Connectivity
Doosan cobots are capable of being connected even without a gateway, making it easy to interface with various types of industrial equipment and systems.
*Supported Communications: RS-232, RS-485, TCP/IP Socket, Modbus-TCP/RTU, PROFITNET, EtherNet/IP
Accessories
What’s more, it also comes with many user-friendly accessories such as
Mobile Base
Smart Vision Module
Protected AC Controller (CS-01P)
DC controller (CS-02)
DART-Platform
DC controller (CS-04)
Teach Pendant
ROS support for various platforms such as Windows and
Amazon AWS Robomakers
There is also a provision for Doosan ROS package
Continuing on the path of innovation, the Doosan Robot Controller can be connected to a Visual Components 4.7 model to visualise its utilisation in any industrial space which results in more productivity and profitability for the industry.
MELSS brings you the whole range of Doosan collaborative robots comprising the A, M and H Series, also including the E Series for the F&B industry. For more information on how we can help you automate with Doosan cobots, please visit: www.melss.com
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The Role of Industrial Automation and Robotics in Process Improvement
Industrial Automation is an umbrella term that refers to the improvement of processes by using any form of software and hardware to aid operators, including Robotics. After the start of the Industrial Revolution, the most important disruption has been the introduction of industrial automation.
The first attempt at industrial automation was made during World War 2 with the introduction of Computerised Numerical Control (CNC) machines. The CNC machines have evolved from basic equipment to those that minimized the need for human intervention and ensured higher levels of operational accuracy.
Industrial Automation also includes data acquisition systems, supervisory control, and Programmable Logic Controllers (PLCs). Supervisory Control and Data Acquisition (SCADA) systems collect data from various sensors and PLCs attached to the factory equipment. They not only collect data from the PLCs but also control their functioning.
The advent of Robots in the early 1970s has added a new dimension to Industrial Automation, while Collaborative Robots (Cobots) have added momentum to the adoption of Robotics. The vast range of End of Arm Tools (EOATs) available is often the distinguishing performance factor for robots and cobots.
Robots
Normally used to handle heavier or larger-sized objects with speed and precision, robots require dedicated space with limited human movement to avoid workspace injuries. This is achieved by using proper fencing in the enclosure where they are located. Lock Out Tag Out (LOTO) should also be applied to avoid any accidental operation which can lead to injury – only authorised persons should be allowed to set LOTO. In closed environments, floor space becomes critical for such an arrangement.
For external environments such as despatch bays of automobile plants or in cargo bays of seaports, there is a need to withstand adverse climatic conditions. Hazardous or continuous process environments also present their own unique challenges. Robots made of speciality materials are used in these cases.
In special cases Robots can also be equipped with special sensors, in which case a Robot performs its tasks in 3 stages of sense, plan, and act. In-built sensors enable robots to sense their environment. Based on this, the optimal route plan for the robot is prepared using the required programmable interface system. In the act stage, the robot performs the processes and sequences as determined in the planning stage.
Cobots
Unlike robots, Cobots can function alongside humans. They need less floor space, no safety fencing system and come with many in-built safety features to reduce collision or contact injury to humans. They can easily be moved from one application to another by simple reprogramming, and their movement is also easy due to lower weight. Additionally, they also cost less than their robot counterparts. Certain models can be mounted on Automated Guided Vehicles (AGVs) to augment pick and place operations in warehouses. Cobots are particularly useful in applications such as CNC, injection moulding, and welding which handle smaller objects.
Trends in Robotics
The field of Robotics today also encompasses Artificial Intelligence (AI) and Machine Learning using which robots can be programmed to perform advanced tasks. Advances such as open source Operating Systems like ROS (Robot Operating System) have made programming Robots accessible to the public at lesser cost. This drives innovation making Robots more agile and contributing to improved efficiency, quality, and productivity.
EOATs
The suitability of any Robot or Cobot to an application is determined by its EOAT (End of Arm Tooling). Different EOATs are available suiting different industries such as logistics, F&B, automobiles, avionics, shipping, medical, hospitality, and continuous process.
MELSS has provided many automation solutions for industry including SCADA, PLCs, Robots and Cobots. We provide complete solutions in Robotics and our experts suggest appropriate equipment based on your needs. We use an exhaustive range of Cobots from Doosan, Robots from Yaskawa/ Epson and EOATs from OnRobot. Our indigenously developed Solderbot helps in Robotic Soldering. MELSS repertoire of automation also involves electronic hardware developed in-house that allows our many customers to acquire data on the shopfloor for enabling traceability, data logging, warehouse automation and assembly-kitting activities.
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Have the HVAC units been tested before shipment?
The principal component in any HVAC unit is its compressor. The performance of this compressor is regulated by a VFD. The VFD helps in reducing its power consumption. Not only this, it helps in avoiding the wear and tear of equipment, thereby reducing the need for maintenance. By checking, analysing and then varying the input power, the Power PCB and Control PCB control the output from the VFD to always suit the load conditions optimally.
Why HVAC testing?
An HVAC normally handles heavy loads in large areas often with frequent footfalls such as commercial complexes, malls, airports, railway and metro stations. As such, their compressors along with their VFDs should perform at peak level always. It is therefore essential to test the VFD before checking the other components of the HVAC.
Tests performed on HVAC Power PCB
Some of the major tests performed on the HVAC are:
Isolation test: Each component of the HVAC is tested by isolating it from the rest of the system. This ensures the component works as designed under varying load conditions without impacting the performance of the other components in the process. With each component performing as required, the HVAC system as a whole function accordingly.
Short Circuit Test: A component will not turn on in spite of receiving the requisite power supply – this is attributed to either a short circuit in the line from the supply to the PCB or within the PCB itself. A non-functional component leads to a defective HVAC equipment causing improper usage which can further aggravate the problem and can have a cascading impact on the other components.
Current and Voltage Calibration/Measurement: Each component must receive the current and voltage as rated for it. The source power from the power supply must reach the component to match the rated. Any impedance causing it must be rectified to ensure proper functioning. It must be calibrated and measured.
IGBT/MOSFET Gate drive test: The switching of the HVAC must be proper. This is ensured by conducting the IGBT/MOSFET Gate drive test on the PCB. The power is calibrated and measured using an oscilloscope.
HVAC performance suiting the varying requirements is ensured by controlling its Variable Frequency Drive (VFD). The functionality of the VFD’s Control PCB must be thoroughly tested.
Tests performed on HVAC Control PCB
The Control PCB, which connects to the VFD’s main circuit via the gate drive board, is tested to ensure that its logic controls the VFD such that the VFD performs as desired. Towards this end, the following tests are performed:
Write FLASH Memory/EPROM data test to ensure the data and commands are stored properly in the main board
Communication test between the external equipment and operator interface components, and the VFD
Analog Input/output Calibration/Measurement of the main circuit parameters such as temperature, current and voltage
Testing the performance of other components
Besides the VFD, other components also need to be tested to ensure that the HVAC performs as desired. Components such as the thermostat, condenser coil and evaporator coil need to be tested before shipment.
Why Automated Test Equipment (ATE)?
The time taken to test the many parameters in an HVAC is greatly reduced by using an ATE. Besides an ATE provides efficiency and ease of use.
The use of an ATE makes it possible to customise the sequence of tests. The equipment used can be customised as per the requirements. Often the operation of HVAC is very complex with diverse sets of operating environments. Proper testing of the functionality of the HVAC is required which is provided by the ATE.
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