AUTOMOTIVE – BIW FIXTURE ASSEMBLY LINE

E-mug Technologies provides end-to-end solutions for BIW welding fixture assembly Lines worldwide. Having completed over 1,00,000 hours of work on BIW domain, we have an capacity to take up any volume of work and deliver in time with best quality.

Body-In-White (BIW):

  • Passenger Car Bodies
  • Truck Cabins

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  • Complete BIW Assembly Line/ Main Line
  • Under Body
  • Engine Compartments
  • Body Sides
  • Wheel house/plenum
  • Dash board
  • Roof
  • Closures (Doors, Hood, Deck Lids )

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  • Automatic − Robotic Lines
  • Manual Welding Lines

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  • Spot Welding
  • MIG/Arc Welding
  • Stud / Nut Welding
  • Roller Hemming

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Manufacturing / Process Engineering

  • Production Volume − Takt Time Calculations
  • PPO (Pre Production Operations)
  • Part Study − Part Build ups
  • Process sheet
  • Weld points & Process Study
  • Weld Gun Selections
  • System Layouts − Conceptual Plant Layout
  • Clamping Plans
  • Build Sequence
  • Cycle Time Study
  • Ergo Study
  • Material flow simulation using EM-Plant
  • Pneumatic circuit Design
  • Documentation of the Process

Tools Used:

  • Process Designer
  • Microsoft Tools
  • Ergo web
  • eMplant
  • AutoCAD/Factory CAD

Simulation

  • Process Validation
  • Weld Point Segregation
  • Selected Weld Gun Study
  • Part Buildup, Parts Placement and Part Orientation
  • Reach ability of Robots check according to Layout
  • Fixture Validation
  • Gripper Validation
  • Payload Checks
  • Fine-tuning of the Placement
  • Process Path Creation
  • Kinematics
  • System Layout
  • SOP
  • OLP (Off Line Programming)

Tools Used:

  • RobCAD
  • Process Simulate
  • DELMIA V5
  • DELMIA D5 − IGRIP

3D Concept & 2D drafting

  • Clamp plan
  • Pre-Concept Fixtures
  • Geometric Stations (Spot Weld / Mig Weld
  • Re-Spot Fixtures
  • Checking Fixtures
  • Hemming Station
  • Marriage Station
  • Material Handling Grippers / Combo Grippers
  • End Effectors Geometry Stations with Dock and Lock
  • Conveyor Pallets and Pull off Cart Tooling
  • Pedestal Welding, Stud Welding and Gluing Stands
  • Loading and Passing Tables
  • Concept Design
  • 3D Finish
  • Manufacturing Drawings
  • Layout and Detailing
  • Pre BOM, Bill Of Materials (BOM)
  • Flame Cutting Details
  • Pneumatic Circuit Design
  • DXF/PDF/STEP/IGES format Output

Tools Used:

  • CATIA V5
  • UG NX
  • FIDES
  • Solid Works

INDUSTRIAL AUTOMATION ASSEMBLY LINE & SPM’s

e-mug tech is amongst the largest global automation companies with over 200 + employees and 6 facilities In India & abroad. The solid engineering strength enables e-mug tech to be a complete “Solution Provider”, from conceptualizing, designing, manufacturing (support), implementing and supporting advanced factory automation systems. It provides its customers with solutions to enhance productivity and achieve their manufacturing & Assembly goals.
E-mug design & delivers Special Purpose Machines, Leak Testing Machines, Automation Assembly Lines, Hydraulic Presses, Pneumatic presses, Test Rigs, Jigs & Fixtures, Industrial Washing Machines & Material Handling Systems.

Design & Development:

  • Component Study, Design of Alternatives
  • Mechanical Concept Design
  • Re-Engineering
  • Reverse Engineering
  • Tolerance Stack-up
  • Kinematic study
  • CAD data migration
  • Engineering Change Management
  • Sketch, Layout, Detail, Check
  • Should Costing
  • Product cost take out
  • Design Validation
  • Process Documents Human Ergo Study
  • Work Cell Layouts

Verification & Validation:

  • Static / Dynamic Analysis
  • Process Verification
  • Engineering Hand calculations
  • Stress Report
  • Design Validation
  • Multi- Body Dynamics
  • Pneumatic Controls
  • Electro Controls
  • Impact Analysis
  • Simulation for Motion/Reachability/ Collision etc

Production Support:

  • Process Planning
  • Work Instruction
  • SOP
  • Layout creation
  • Prototype design support
  • Vendor Development
  • Supplier Quality assessment support
  • Manual Creation

Platforms , Conveyors & Material Handling Equipment

E-mug tech is expertise in Designing ,Validating & Detailing various projects like Working Platform, Turn Tables, Conveyors and Material Handling Systems, Serving to different domains of Automotive, Aerospace, Industrial products, Mining, Pharma, Food Industries etc.

Conveyor and Material Handling Solutions:

  • Process Planning for Material Handling Activities
  • Assembly Line Conveyers / Application Study
  • Speed and Load Calculations
  • Selection of Standard Components
  • Support Structure Engineering
  • Pallet and Turn Table Concepts
  • Complete solution from concept generation to machining drawing
  • Solution to simplify the conveying operations
  • Manufacturing Cost Estimations
  • Manufacturing, Installation and Commissioning

Conveyor and Material Handling Systems:

  • Chain Conveyors
  • Belt Conveyors
  • Toe line Conveyors
  • Slat Conveyors
  • Gravity Rollers
  • Working Platforms ( I beam )
  • Fence
  • Turn Table
  • Cross conveyors
  • Eccentric Cross Conveyors
  • Hoppers and Chutes
  • Granulators
  • Food Processing Equipment’s
  • Vertical Elevators
  • Lift and Carry systems
  • Gantry



Aerospace

Aerospace industry is going through challenges which are multi faceted which includes the rise in the operating costs.

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Automotive

Automotive OEMs are globally competing to penetrate the market with new product lines, enhanced performance

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Appliance

Complex consumer habits, new cultural influences of global markets and rapidly changing technological

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Off Highway

Heavy Engineering industry is high risk, fragmented and highly competitive. Growing project complexities, fragmented business and

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Industrial Products

Industrial products are getting commoditized increasingly and OEMs and Tier 1 suppliers are looking ways to create differentiation

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e-mug Technologies Complete Engineering