1. MCM
Mech Consultants & Manufacturers
Challenges Spelt , Proved with Value Addition

2. Consultancy
 At Honeywell Tech. Soln. Lab; Bangalore .
1> Developed Prototype –Aircraft Engine Igniter Lead ends Connectors.
2> Guided Team for Intellectual Property Project – Patent Awarded.
3> Guided Team on Aero – Lighting Packaging - Boeing project.
4> Trained Mechanical team on DFM/DFA.
5> Supply chain empowered with technology inputs to make GONIOMETER – image
processor.
 At Modison Metals Ltd.- VAPI , Gujarat.
1> Imported total line for Moving Contact with contact Welding – Tool
Productionisation .
2>In-house tool design , making & maintenance capability with manpower & tool
Room set-up devlopment .

3. Total Solution with SPM, Tools & Handling
Automation
 Open Magnetic Ballast Assembly Line for Fluorescent/ CFL lamp.
 Multislide Shearing, Bending , Forming Press working Centre with On/ Off-line
Riveting, Tapping etc.
 Magnet Assembly making without back and center limb grinding with pole
faces finishing within 0.02 mm grinding – LV switchgear contactors .
 40 Ton Hydraulic Down stroking Press – 2 point Powered for Articulated
Urethene Foam Cutting.
 In Process – 5 Axis Pipe Bending M/c
 Glass Forming Lathe for Instruments.
 Transfer Line – 8 station with Pallet for 2 wheeler Silencer Pipe annular gap filling
with steel ball filling and one end swaging , open end Capping.
 Transfer Line – 10 Station with Pallet sub-assembly of Core-Coil of Open Ballast.

4. Project outputs
Assemblies, Intermediate sub-assemblies, Components.
Project outputs
Assemblies & Parts
Sr.No
4
Sr. No. 1
Sr. No.
2
Output of
project 6 –
intermediate
sub-assembly.
Output of project
No 5 : Sub – assembly.
Output of Project
no. 2 :
Components
Clutch rivet –Ford motors
Contact Terminals- rotary
Switch
Bus Bars (L,N&E types)-B.S. standard

5.  Quality
compatible to
international standards.
 Reliability
100% consistent &
Zero rejection.
Assemble your range of ballasts on our proven technology
and drive yourself to be most competitive at home and
international market
Our automated assembly line technology with first - time
developed pallet produces any variety of copper ballasts and
assures the QQR factor :
 Quantity
7 Assembled
ballasts/ min.
The S.P.M. hydraulics operated, automation pneumatics
operated, electrical controls along with the automatic wire
flattening with cut to length feature - the total unique product
from MCM
Ranges of Ballasts
Pallet
 Isostatic squaring and compression is possible
with pallet in tool on both ‘U’ & ‘T’ Laminations.
 Air gap spacer thickness control in within
+/-0.01 mm on our roll flattening machine.
 Independent gagging cyl. heads eliminates strict
control on gagging profile on laminations and
strongest holding of laminations.
Superb asthetics - as squared faces never have
distortions/warps.
 Input wastages are eliminated with Palletization.
MS laminations can replace Silicon steel keeping
performance unchanged.
 Electrical Parameters :
High Voltage Test ( 2 KVA )
 No Humming
 No coil insulation snapping.
Stable resistance at elevated temp.
Narrow three sigma limits of
Watt Loss ( 9 watts )
Short circuit & Running current
Productivity:
7 Nos. of Ballasts per minute
with min. manpower as highest
degree of automation with pallet
is possible. Hence cost
competitiveness.
PERFORMANCE BUILT UP ENGG.
Works : Mech Consultants & Manufacturers, 266, Whitefield Road,
Hoody, Bangalore 560 048. INDIA. (080)525 1197.

6. M/c Bed +Slides-view on left. M/c
with feeder+ straightener - view on
right.
Multislide Machine
Machine Bed

7. Flexible manufacturing in pressworking.
PLC sequence deletes cam making in mechanical multislides. Hence
reduced tooling investments and making time.
Quick setting of machine within 30 minutes.
Small lot production economics.
Advantage of clear view of logical sequence and what happens during the
entire cycle in each operation. This eliminates need of complex tool and
eases maintenance.
FEATURES
Flexible pressworking to
produce strip and wire parts
economically.
Product can be small, big
or bulky precision stampings,
multiple bending/forming
with the highest consistency
among all the other
pressworking processes.
Coiling of spring and pipe
bending.
Integration of operations
like Rivetting, Tapping,
Welding, Checking &
Sorting, Feeding of
secondary components and
assemblies etc.
In brief raw material can be
fed to produce finished parts
with precision and reliability
of the highest order over 24
hours
OPERATIONS

9. Project Serial No. 3 40 ton downstroking press for articulated foam cutting to shape and size
View 1 : Semi Aerial View from right left corner of machine. View 2 : Rear view of machine
- Fabricated structure of fixed m/c bottom platen and moving top platen ( up/ down ) .
-Two power transfer pivot points for Moving platen are seen in view 2 and
in view 1 power cylinders below pivot points at the bottom of m/c is seen.
- Ram travel sensor (electronic ) is seen in view 1
- PVC floating tool carrier bed , guided on four guide frames ( two on front and two on rear of of m/c bed)
is seen in both views. Floating PVC tool carrier supports are seen in view 2 at 4 locations fixed on m/c bed
- Hydraulic power pack with two pumps mounted on double ended electric motor shaft is seen .
these two pumps drive two power cylinders independently to ensure minimal phase difference in power motion.
- Electrical control cabinet is seen in view 1.
RAM
TOOL CARRIER
RAM PIVOT
POINTS
TOOL CARRIER PLATE FLOAT S
TOOL CARRIER GUIDES
SENSOR_RAM

10. CNC Pipe Bending Machine
TECHNICAL DATA
- Bending range- 32 mm Dia.
- Max Bend radius - 120 mm
- Control - CNC 5 Axes.
- No. Of bend angle - No limit
- Max.. bend angle - 180 deg.
- Cycle Sequence - Automatic
- Mandrel type - yes.
- Pipe feed - Automatic (programmed)
- Rotation of pipe - 360 deg.
- Power input - 7.5 HP, 440V; 50 Hz.
- Hydraulics - 30 lpm/120bar
- Pipe length over mandrel - 1.5 mtr
EQUIPMENT
Siemens System -for motion & signal
control to run programmed cycle to
make multibend part with six different
bend radius . MOTION control for
1> Feed pipe length over bend head
center; 2> rotate Pipe over its axis to
make pipe bending in ‘Z’ plane;
3> Bending head movement on ‘Y’ &
‘Z’ axes are to align bend-head center
with pipe feed center line. Bend-head
center line shifts up/down w.r.t. bend
rolls selection from six nos. on stack
tool. Thus 4 nos. of Servomotors are.
4> Bend angle is throu’ bend center
rotation done with servovalve & signal
comes from Simotion system - thus 5
axes control . Keyboard with display
screen is for operator interaction.
.

11. Project Sr. No. 6 - Exhaust Pipe Assembly( Cation Pipe – engine to silencer ) – Heat insulation by uniform air gap between inner & outer pipe .
System : 8 Station close loop transfer line – pneumatics driven and controlled .
System provision : 4 stations are in use to perform 3 different successive simultaneous operations to make output @ 6 nos. per minute and 4nos of
other successive stations are kept idle to be converted to similar working stations to multiply productivity , if situation demands.
Working Stations : 1> Two pipes, one in the other,is put manually throu’ top opening in the open jaws of the carrierand end cap for 4th station is put
in chute. 2> Bottom end of the two pipes are closed by flaring thinner tube to ID of outer tube upto 20mm on length. 3> Antistatic steel balls of
0.5mm dia. ,in measured Qty is filled in throu’ top annular opening. 4> End cap is pushed in the top annular gap of pipe assly and end product is
dropped throu’ the escapement chute for collection.OUTPUT IS TAKEN TO PIPE BENDING SUBSEQUENT OPERATION.
DIFFERENT VIEWS OF THE SYSTEM
VIEW 1
View from operator’s side .
Operator loads two tubes, one in the other , and the end cap is dropped
in escapement path for the 4th station.
Operator starts the cycle pressing two hand push button .
VIEW 2
Machine view from 90 degrees disposition wrt operator clockwise
From right : 1st station is for bottom end closing of pipes; next one is
for steel ball dosing and filling in throu annular top gap of
pipes; next is to push in end cap in top annulargap and release
the output for collection through escapement path at bottom.
At the back of all these stations carriers pitching cylinder is fited with
mechanism mounted on it to push middle statio carrier by one
pitch and first station ha s the stopper mechanism to ensure
positive stop on feed length. At each station carriers are
primarily located and successively tubes are finally located
prior to options simultaneously at stations.
Doser mechanism with steel balls hopper is visible in 3rd. Station wrt
operator.
VIEW 3 - View at 135degrees disposition clockwise wrt operator
VIEW 4 – Aerial view at 45 degrees disposition clockwise wrt
operator
1 2
3 4

12. Project sr.no.5
Core Coil sub assembly – intermediate sub-assly. Output for ballast product in project sr. no. 1.
View 1 & 2 shows system built-up and on View 1 left the intermediate output two views are shown.
• View 1 & 2 gives comprehensive understanding of the system
built. Fabricated modular structure; Track is built with hardened
and ground guides in modules; Transfer station move on chain
drive built with locators for pallets at pitches; Pallets are made
of hardened & ground Hchcr –modular built- and each one is
identical; pallets primary location is on chain and guided in
transfer line guide.
• Each station tool has locator for the pallets in station followed
by other activity elements & modular built.
• Pitchingcylinder with mechanism is below station 1 &2 in the
structure
• Drive and control mechanism is total pneumatics.
• View 1 is at 45 degrees disposition wrt operator –left.
• View 2 is at 180 degrees disposition clockwise .
• Station 1- U lamination loaded in chute is separated in
exact height and in nos. from chute column and is pushed in
pallet in the station on track.
• Station 3- T lamination loaded in chute above pallets movement
level, gets separated by height & nos. and gets pushed in carrier
pallet.This pallet is pushed down to level of primary pallets
moving in track and pusher pushes T lamination stack in 3rd
station pallet carrying U lamination,coil and spacer .
• Other side 4 station , kept idle can be utilised for doubling the
productivity.
1
2
Station 1-
’U’Stack
separates & is
pushed in
pallet
Station 3 – ‘T’Stack
separates & is pushed in
pallet-pallet comes down
& ‘T’ is pushed in main
pallet in track loaded
with ‘U’.coil & spacer.
Station 4 –
Ejection of
assembled
output
Station 2 –
Coil & ‘Al’
spacer is
loaded in
‘U’ stack in
pallet in
track.
Transfer line – 10 station track each with a
pallet in which on 4 working stations
successive operations are performed
simultaneously for the output in 5 second
Pallet
Output