Projects - KVPM Automation
Learn more about KVPM Automation engineering solutions.
Project Case Studies
Automated Air Leak Testing SPM for Engine Blocks
Manual air pressure decay testing with soapy water led to inconsistent defect detection, human error, and high cycle times (4 minutes per component).
KVPM designed a Special Purpose Air Leak Testing Machine with differential pressure sensors, automatic clamping, pneumatic sealing jigs, and PLC-controlled Poka-Yoke interlocks.
Achieved 100% reliable leak detection with cycle time reduced to 45 seconds, zero false approvals, and digital logging of test results.
Ultrasonic Weld & Automated Assembly Rig for EV Battery Packs
Inconsistent manual soldering of copper battery interconnect cables caused high contact resistance, thermal hot spots, and scrap rates exceeding 8%.
Engineered an Ultrasonic Metal Welding Workstation with pneumatic positioning fixtures, automated clamp pressure monitoring, and vision verification.
Standardized weld joint quality across 10,000+ battery packs, reduced contact resistance by 35%, and eliminated scrap completely.
Automatic Shear Controller & Poka-Yoke for Steel Roll Mills
Manual blade actuation timing caused non-uniform cut lengths, severe steel coil wastage, and dangerous manual operator intervention near shear blades.
Installed a high-speed PLC-driven Shear Controller with optical rotary encoder length tracking, automated pneumatic stop guides, and light curtain safety interlocks.
Cut accuracy improved to ±0.5mm, material scrap reduced by 12 tons per month, and zero safety incidents recorded since commissioning.
Concentricity Alignment Jig for Precision Sleeve Mounting
Sleeve mounting onto precision shafts required multi-step trial-and-error measurement on dial gauges, taking 15+ minutes per unit with risk of shaft scoring.
Designed a single-setup concentricity fixture with quick-lock pneumatic collets and digital gauge integration for instant pass/fail readout.
Single-setup mounting achieved concentricity within 0.005mm in under 90 seconds, saving 12 minutes per assembly.
