Specification: Brake Disk Shuffling System

Date 25/09/2018 Poclain Hydraulics PVT LTD.

From Jayakumar R,

Project Description
PLC Controlled Automated Brake disk shuffling – Standard GME Solution

Project Objective
To Study and standardize a “Turn-Key” solution to control & manipulate Brake disk shuffling
from F03, F05, F08 & F09 brake specification for motor. To purchase a device able to count,
shuffle & control for all Brake specification.

Functional Project Scope

Machine inputs:
 Motor part number. ( As per BOM part list preparation)
 Program selection based on Motor Part Number / bar code scanning.
 Stacking of External & Internal disk based on Brake specification.

Machine output:

 Selection of suitable hopper.

 Control of quantity.
 Control of thickness of the disk
 Shuffling of Brake disk in different sequence.
 Proper collection of disk counting.
 Unload of shuffled disk in respective disk holder.

Quote Details

This device concept is pilot project in PHPVT & based on principle concept to be deployed in other PH’s
other manufacturing facilities around the world. This device to be sourced with local source in India
with PLC setup to adapt future requirements in others Brake specifications. However, the device
parameters can be accepted in certain clause under Manufacturer standardization of device.

The machine should be supplied with technical documentation: mechanical, electrical drawings,
maintenance plan and testing reports whichever applicable. The supplier needs to furnish the controller
specification version and critical wear part list consumable like etc.,

Special Conditions

Commissioning acceptance is to be based on the following criteria:

 Maximum cycle time for shuffling of disks should be < 1 minutes. (Ignore-Manual sequence)
 No abnormal noise during operation.
 Automated disk collection and indexing with safety feature for operator handling.
 Set up change-over time between each models < 5 minutes.
 No physical damage for the brake disk shuffling ( Deep scratches / crack on edges etc)
 Flexibility to control the feed rate of shuffling.
 Poke-yoke interlocks for correct number of disk for each shuffling.
 Final reception with check list will be made (send to supplier prior to P.O).
With above features the process of the brake disk shuffling would be similar like below:

 The Process Starting

 The Operating mode (Normal mode)
 Auto-program starts
 Shuffling of disk
 Collection of shuffling disk
 Unload the disk
 Cycle status display
 Result.
 Unloading
 The Process End

Commissioning of the machine will take place at our site. . The conditions above will serve as the
acceptance criteria in both cases.

We, the undersigned, agree to these terms and conditions.

Poclain Hydraulics PVT Ltd.,