Manufacturing (acoustics) panels

FABRICATION SHOP: 1.Punching:

Metal used is CRCA cold rolled close annealed i.e cold rolled (brittle) and in close atmosphere of nitrogen(softens it) Mild steel of 1.6mm thickness is used for silent generators. A) Machine turret punch press.(TPP) It has C type frame. Table or bed with brushes or rollers to allow the sheet metal workpiece to traverse with low friction. Brushes are used where scratches on the workpiece must be minimized, as with brushed aluminium or high polished materials. Capacity/Force 200kN No.of turret stations: 34 Power:30kVA weight: 11tons

Other thickness used: 0.6, 0.8, 1

Approx.time : 3.40minutes

B) Cutting Machine: Gullatine Shear Mach y Used before bending y Max capacity : 120tons Max stroke 75mm y Max sheet thickness 15mm y Stroke here is Height of cutter

C) Bending: Hydraulic press brake Bends the corners of the sheets. CO2 welding: Co2 or MIG welding is done after bending to join and fill gaps. Copper coating over MS.

PRE-TREATMENT PROCESS (7 tank process) 1. Degreasing: To remove oil stains and grease over metal Chemical used Gardoclean 444 10-15 minutes at 60-65 *C Air agitation done 2. Water rinse 1 1-2 minutes or 2-3 dips inside industrial water at room temperature with air agitation. 3. Derusting: Gardacid 208 is used. Immersion time is about 5 to 10 minutes at room temp. To remove rust particles. 4. Water rinse 2 5. Activation 6. Phosphating 7. Water rinse 8. Passivation PAINTING For control panels Texture Coating since lot of grinding is involved.If powder coating done means all marks will be visible.

POWDER COATING: Green glossy 65 microns. Heated in oven Spraying pressure is important TEST ON PANELS: Bend test: This failure of improper adhesion is due to Too thick coating layer Inadequate baking of parts PEEL TEST: Failure due to improper pretreatment and inadequate baking.

POWERICA GENERATORS: a) Manual b) AMF ( automatic with failure control) switches off automatically when power comes. SERIES S 30 to 62.5 kVA X 15 to 25 kVA y y y y Noise becomes 100dB to 75 dB Anti Vibration Mounts (AVM pads ) are used to reduce vibrations at bottom Silicone sealants are used to fill gaps. Trial RUN 25% load 50% 75% upto 160kVA For above that 110% load is done for testing..