Paiyanoor
TURBO ENERGY LIMITED
Old Mahabalipuram Road,
Paiyanoor - 603104.
Kanchipuram District.
Tamil Nadu.
Manufacturing Activities
TEL has set up a fully automated assembly plant at Paiyanoor about 50 kms from Chennai. TEL also has a full fledged R&D facility at the site, recognized by the Department of Science & Technology (Govt. of India) since 1985. TEL is accredited to TS 16949:2002 & ISO 14001:2007 standards.
Assembly
The turbocharger assembly mainly has the following stages:
- Core assembly
- Balancing
- Assembly of Housings
- Waste Gate Actuator setting
- Final Inspection
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The individual components are stored in Heavy duty storage Rack systems & automated Vertical storage systems. These parts are moved to the assembly using conveyors systems and other lean management material handling systems.
Core Assembly
Core assembly can be called as a heart of the Turbocharger, The Core assembly provides supports for the journal bearings and provides lubrication to the rotary parts. There are semi automatic core assembly stations with special controls for error proofing.
TEL is also equipped with automatic core assembly line for passenger cars which has higher operational speed. There are controls at each stage for ensuring Zero defects.
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Balancing
In addition to individual component level balancing, based on the application balancing is also done as a core assembly. The balancing helps in reducing the vibrations and noise levels during operation. TEL has facility for fully automatic high speed core balancing and semi automatic balancing. These machines are a master piece demonstration of the collaboration’s technological competence. The cores can be balanced to higher speeds up to 200,000 RPM based on the application requirement.
Assembly of Housings
The Core Assemblies are mounted and fastened at required orientation on the Compressor housing & turbine housing. These operations are done in individual work stations with error proofing control. TEL also has a semi automatic conveyor assembly line for assembling the housings to the core assembly .This has pallet mechanism for feeding the materials and assembly is done on the pallet. The traceability is established by interfacing 2D readers which reads the unique turbocharger serial no. at each station and records the parameters and values at that stage. The tightening process is controlled with a DC tightening tool, the feedback is monitored and the torque values are stored in the data base. The assembly line also has sensors and vision systems to detect the presence of various components.
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Waste Gate Actuator setting
The Waste Gate Actuator setting is done to enable the waste gate flap to open at the required operational boost pressure. TEL uses a custom built Setting Rig made by the technology development wing for performing this operation. There are various controls like data traceability, characteristic monitoring, error proofing control etc in these rigs.
TEL also has the state of art Flow setting rig for Variable geometry Turbochargers
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Final Inspection
Final Inspection of turbochargers is carried out at the End of each line to ensure the compliance of the Turbocharger to the specified requirements. Final Inspection acts as a firewall to improve the rapid detection and control mechanism. Final Inspection is done manually by trained personals and with the aid of automated vision system.