![Motor Parts](gifs/strip-application6.gif) |
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![Copper Parts Manufacturing at BMS](gifs/copper-parts-manufacturing-at-bms.gif) |
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![Our Engineering Capabilities](gifs/our-engineering-capabilities.gif)
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Development &
Production of High Precision Copper components
as per Custom Design, with
Intricate Shapes & Profiles having close tolerances &
Accuracy. |
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Expertise in Manufacturing
Engineering with subjective Knowledge of Standards,
Materials, Manufacturing Processes & Tool Making, to
produce Copper components for Electrical, High/Low Tension
Power Transmission & Electronics |
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Expertise in 3D & 2D
Software enable us to achieve successful results. |
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Controlling Wastage in Raw
material by Dexterously Designed Tooling &
Process Controls enable us to get optimized material
utilization. |
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Providing Total Solution
inclusive of Post-manufacturing
Processes like Surface Finishing, Coating / Plating,
Heat Treatment & Other allied
processes like Soldering, Silver soldering, Brazing,
etc. |
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Thorough Understanding
of Clients Design specifications &
functional requirements of the end product for Electrical &
Electronic Applications |
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Reverse
Engineering Services & Assistance in carrying out
Design Activities / Design Up-gradation & adopting
suitable manufacturing processes to achieve Clients desired
cost effective solutions. |
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Expertise in fault finding and
research capability, for applying corrective action.
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Copper Components
for Rotary Switches, Control Panels & Heavy Duty Current
Carrying Applications like Power Transformers, Switch gears etc.
like :
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CONTACTS |
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FUSE HOLDERS |
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BUS BARS |
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FASTENERS / WASHERS |
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TERMINALS |
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CLIPS |
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CONNECTORS |
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SPRINGS & WIRE FORMS |
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RELAYS |
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COPPER PIPES & FITTINGS |
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COMMUTATORS |
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CUSTOM
MADE COPPER
COMPONENTS & ASSEMBLIES
AS PER CLIENTS SPECIFICATIONS |
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ROTOR BAR |
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ELECTRICAL SWITCH GEARS
&
CONTACTORS
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ELECTRICAL HIGH/LOW TENSION
POWER
TRANSMISSION
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AUTOMOTIVE ELECTRICALS |
MARINE ELECTRICALS
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ELECTRONICS
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HARDWARE & FASTENERS
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REFRIGERATION &
TEMPRATURE
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We look at Copper from
the microscopic levels like grain homogeneity & orientation,
while manufacturing of components having extreme close
tolerances and finishes:
We are vertically
integrated with a team of various Associated ISO 9000 accredited
Manufacturing Units, each specializing in a specific field of
production Activity to ensure optimum quality with on time
deliveries:
![Precision Machined Shop](gifs/precision-machine-shop.gif) equipped
with CNC Turning and
Milling centers, SPMs, &
Automats like Traubs, Conventional Machines like Lathe &
Drilling, Grinding, Milling, Roll Threading Machines, Ultrasonic
Cleaning & Vibrator Deburring. Tool Room & Auxiliary
equipment facilities for Attachments & Fixtures.
![sheet metal press shop](gifs/sheet-metal-press-shop.gif) equipped
with Shearing Machines,
Power presses, Hydraulic
Power Presses, Press Brakes, CNC Turret Press, Vibrator Deburing
Machines & Fully Equipped Tool room with sophisticated
Measuring Instruments.
![forge shop](gifs/forge-shop.gif) equipped
with Induction Heating Facilities for small
Upset forgings,
Up-setters for head forming operations, Furnaces with Automatic
Temperature Controllers, Power Press (Pneumatic Hydraulic &
Mechanical) ,Friction Drop Hammers, Fully Equipped Die Shop &
Tool Room.
![soldering setup](gifs/soldering-setup.gif) equipped
with advanced Equipments
![Specialty Heat Treatments Facilities](gifs/speciality-heat-treatments-facilities.gif) We
have access
to facilites for
Specialized Heat Treatments like Nitrogen Annealing, Precipitate
Hardening, Homogenizing etc
![Specialty Surface treatments & Plating facilities](gifs/speciality-surface-treatments-planting-facilities.gif) We
have access to facilites
for surface treatments & Plating like Chrome, Gold, Silver,
Tin, Cadmium, Chrome, Nickel / Electroless Nickel, acid washing
etc. These units have Automatic Electronic controlled equipments
to regulate plating thickness.
![quality infrastructure](gifs/quality-infrastructure.gif) includes
Shophisticated Measuring
Equipments like Surface
table, digital height gauge, Digital Precision Micrometers,
Profile Projectors, Surface finish measuring gauge, sign bars,
bench centers and all other standard Inspection Equipments.
![consulting Testing & Metallurgical Laboratories & Agencies](gifs/agencies.gif) having
international accredition & equipped with advanced
facilities like
Computerised Spectrometer for chemical analysis, 3D Coordinate
Measuring Machines (CMM), Tensile and compressive load test
machines, NDT set up, etc.
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Inspection and identification
of the material at Electrolytic forming stage of Ingot to
ensure that the defective portions of the Ingots are
discarded correctly. |
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Chemical analysis for Purity, ensuring the
composition as per required grade. |
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Ultrasonic tests of Extrusion Bars &
Rods |
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Checks for Work Hardening of Rolled Sheet |
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1st piece Inspection. |
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Patrol inspection (SPC for critical close
controlled dimensions), |
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Final Inspection by SQC Method |
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Checks for Work Hardening of Rolled Sheet |
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Inspection for folds and
cracks |
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Inspection of grain
directions of formed profiles. (1st piece for corrective
action). |
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Testing of Ultimate
tensile/shear strengths to ensure Specifications. |
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Microscopic Inspection of sectioned pieces
for Electric Conductive and Current Flow Tests for Joints |
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We have developed various intricate Copper items requiring
sophisticated machines for processing and have operators with
good skills. Some of the products are listed below:
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![Precision Milled Collets](gifs/precision-milled-collets.jpg) |
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Slender 100mm Deep Milled
slits compared to Ø 35 mm and heavy thickness of the
Wall |
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Fine slit Milling with many inline slits,
alternate slits being in opposite directions. |
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![Precision Machined Contractor](gifs/precision-machined-contractor.jpg) |
![Precision Milled Collets](gifs/precision-machined-contactors.gif)
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Involves Precision Turning
and Eccentric Milling using Carbide Tipped Milling Cutters. |
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Required constant monitoring with special
purpose dedicated gauges |
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![Co-ordinate drilling-boring](gifs/coordinate-drilling-boring.jpg) |
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Co-ordinate drilling required
due to precision positioning of holes |
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Milling of the Slit done at the end of all
operations, to eliminate dimensional variations due to
springing open of the slit. |
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Deburring the Cross hole that is
intersecting the Milled Slit required high skills. |
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![ISOLATING CONTACTS](gifs/isolating-contacts.jpg) |
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8 Arms Contact required
development of dedicated Collapsible inserts form holder for
processing |
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The intricate shape calls for Skills &
care to eject the component from the tool. |
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The Operation is done on a Hydraulic
press, with variable controlled speeds, that are required at
various stages of the forming cycle. |
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Material saving is achieved by designing
the Blanking Tool to match intricate strip lay-out
consisting interlocked fingers. |
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![grip CONTACT](gifs/grip-contact.jpg) |
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Forming the 3 mm thick sheet
with 1.5 mm slit & Narrow U Bend of critical Inner
radius without springing back, called for a tool of unique
design |
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Slitting was done after complete forming
to avoid distortion. |
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Deburring of the slits was done by
Ultra-sonic cleaning, to avoid formation of inside burr. |
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![Switching Contacts with Smooth Dome Profiles](gifs/switching-contacts-with-smooth-dome-profiles.jpg) |
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Forming accurately Projected
Domes of exactly equal heights at the extreme edges, without
the plate bending, is a specialty in tool designing. |
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Precision Shearing free of burrs was also
a specialty in tool design |
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![Specialty Copper Cable Connectors](gifs/speciality-copper-cable-connectors.jpg) |
![Specialty Copper Cable Connectors](gifs/speciality-copper-cable-connectors.gif)
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2,5 mm Thick Main Connector
required Fine Blanking Tools & specialized Process. |
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Critical Bending of the Notched End
required extra care & presicion |
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Pressure spin riveting for Joining the
thin Copper Lug to the thick Thick Main Connector to ensure
solid joint without any air gap. |
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![Heavy-duty Copper contactors for Battery Switches](gifs/heavy-duty-copper-contactors-battery.jpg) |
![Heavy-duty Copper contactors for Battery Switches](gifs/heavy-duty-copper-contactors-battery.gif)
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Forged Contact, with large
eccentric upset wherein 7mm Ø bar is Spread to 452 sq
mm at 25mm eccentricity. |
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By our know-how we innovated a unique
process to achieve minimum waste, thus maximum cost saving.
Forming this profile by conventional Head Forging would
result in huge copper wastage due to large one sided Flanged
Head. |
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![Flat Angular Forged Terminals.](gifs/flat-angular-forged-terminals.jpg) |
![Flat Angular Forged Terminals.](gifs/flat-angular-forged-terminals.gif)
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Flat bar forged to form flat
tang of 8mm thickness with Forged bend to required angle. |
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Complex milling fixtures were made to
ensure high precision squareness and flatness at the desired
angle with respect to the rod |
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![Forged Heavy Terminals Bolt weighing 1 kg](gifs/forged-heavy-terminals-bolt-weighing-1kg.jpg) |
![Forged Heavy Terminals Bolt weighing 1 kg](gifs/forged-heavy-terminals-bolt-weighing-1kg.gif)
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1.25 bar upsetted to
2.5 Ø x 3/8 thick flattened top. |
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Then precision Machined to achieve various
Diameter on the Bolt Stem. |
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![3mm THIN COPPER BUSS BARS](gifs/3mm-thin-copper-buss-bars.jpg) |
![3mm THIN COPPER BUSS BARS](gifs/3mm-thin-copper-buss-bars.gif)
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Silver soldering of 3/8
UNC studs into 3mm thick copper Bus bars. |
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Capillary action of the silver solder
through the entire thread length maintained to achieve
Sturdy Joint while ensuring Perfect Conductivity. |
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![6mm to 10mm Thick Buss Bars Copper Bus](gifs/6mm-10mm-thick-buss-bars-copper-bus.jpg) |
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Silver soldering of 3/8
UNC studs into Tapped Holes of the 6 and 10mm thick copper
Bus bars. |
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Capillary action of the silver solder
through the entire thread lengths maintained to achieve
Sturdy Joint while ensuring Perfect Conductivity (To Carry
400 & 800 amps capacity) |
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![Heavy Duty Terminal Assemblies](gifs/heavy-duty-terminal-assemblies.jpg) |
![Heavy Duty Terminal Assemblies](gifs/heavy-duty-terminal-assemblies.gif)
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Large & Thick
Copper Flats are precision machined to flatness, parallelism
and thickness within 0.02mm T.I.R |
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Silver brazing the tang into a
rod involving complex fixturing to ensure that: |
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Alignment is within 0.05mm T.I.R. |
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The brazing through capillary action
covers the whole joint area giving strength and excellent
conductivity. (Being conductors for very heavy current
flows) |
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Co-ordinate drilling after
brazing to ensure accuracies |
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