TWIN ENGINEERS PVT. LTD.

(An ISO 9001:2008 Certified Company) WORKS: J-524, MIDC, BHOSARI, PUNE – 411 026.

TEL.: (020) 27130626, 27130118

1

TECHNICAL SPECIFICATIONS FOR

BRAKE OIL FILLING & LEAK TESTER MACHINE

Reference photograph for Brake Oil Filling System

Reference photograph for Pumping System

TWIN ENGINEERS PVT. LTD.

(An ISO 9001:2008 Certified Company) WORKS: J-524, MIDC, BHOSARI, PUNE – 411 026.

TEL.: (020) 27130626, 27130118

2

BRAKE OIL FILLING MACHINE

SPECIFICATIONS

Description

Equipment Name Brake oil leak tester Filling Machine

Dimension L 1500 x H 1800 x W 1500

Cycle Time Max 3-4 min for complete cycle including loading & unloading

Oil type DOT 3 / 4 (Machine suitable for both oil types)

Filling Customer to specify

Capacity Pressure up to 2 bar

Filling Gun

Master adaptor provided with manual arrangement to clamp as

per specific vehicle model. (Currently single adapter considered

for all models). Master adaptor will get clamped & sealed to the

vehicle reservoir pneumatically. Handle provided for filling gun.

Filling gun provided with cycle start button (green colour), cycle

stop button (red colour), & cycle ON Green Colour LED.

Vacuum Pump

As per system requirement (Twin to provide Laybold China Make

Pump)

Utility Primary power ~ AC 380V, 3 Phase, 50Hz

Primary pressure ~ Compressed Air 5 bar

PLC Siemens / Mitsubishi Suitable Series

HMI Siemens / Mitsubishi (5” – 7” whichever is suitable)

Storage tank Capacity 35 Ltr, SS 304

Filling Pump Electrical Gear Pump Capacity max 6 L/min

Fluid Supply

Customer Oil drums of 200 liter. Transfer pump provided by TWIN

with flow regulators/monitoring, 10 mtr max supply hose length.

Operating Automatic mode for production

Mode Manual mode (step by step) for maintenance (checking purpose).

Drier

Provided to avoid air contamination while entering drum/reservoir

Oil filter 10 micron

Control Panel Rittal Make Explosion proof panel with Gun parking

TWIN ENGINEERS PVT. LTD.

(An ISO 9001:2008 Certified Company) WORKS: J-524, MIDC, BHOSARI, PUNE – 411 026.

TEL.: (020) 27130626, 27130118

3

PRINCIPLE OF OPERATION: -

The offered Brake Fluid Filling Machine works on the principle of Evacuation and pressurized oil filling &

leveling the volume in the bowl.

BASIC SEQUENCE OF OPERATION: -

• EVACUATION

• LEAK TEST

• PRESSURE FEEDING

• FLUID LEVELLING

COMPONENTS OF BRAKE OIL FILLING SYSTEM:

Basically the proposed automatic brake fluid filling machine is designed for assembly line applications. The

machine is modular; besides the basic equipment different accessories or attachments could be selected to

facilitate the assembly line operations.

The components of the system are:

1. BASIC SYSTEM UNIT WITH CONSOLE

2. FILLING ADAPTOR OR GUN

BASIC SYSTEM UNIT WITH CONSOLE:

This is further divided into following subcomponents: -

Evacuation Line: - This consists of the source of evacuation, i.e. the vacuum pump, vacuum line piping

connected to the adaptor or gun. The evacuation of brake system will be carried through this line. During leak

test the system tries to maintain certain level of vacuum in a specified time span in the vacuum line for

EQUIPMENT DESCRIPTION

TWIN ENGINEERS PVT. LTD.

(An ISO 9001:2008 Certified Company) WORKS: J-524, MIDC, BHOSARI, PUNE – 411 026.

TEL.: (020) 27130626, 27130118

4

detection of any leak in the system.

Filling Line: - This consists of storage tank of 35 ltr capacity with degassing chamber in built in the tank,

pumping device ( Gear Pump) and fluid Piping connected to the filling adaptor or gun. The brake system after

evacuation will be filled through this line with the help of New generation Gear Pump. The feeding pressure

inside the brake system will be sensed & then filling cycle will be cut off. The pressure can be adjusted

according to the requirement.

Rigid SS Piping

Fluid leveling line: - After sensing the fluid pressure in the vehicle reservoir (bowl), the excess volume of fluid

will be sucked and forwarded to the machine fluid tank.

Fluid transfer system: - The facility is provided to transfer the brake fluid from 200 ltr barrel to the storage

tank automatically by vacuum pump. Min & Max level sensor is provided in the machine tank. On achieving

the low-level signal fluid will get transferred automatically by pressure difference. If the fluid is not

transferred within the specified time, machine will give indication of storage tank empty. Buzzer will indicate

this. The 200 ltr barrel should be placed near to the machine (1 mtr area).

Fluid transfer from 200 ltr barrel will pass through the filter; the de-aerator provided in the system will

remove the air/moisture entrapped in the fluid. Hence the conditioned fluid is available for filling.

Fluid transfer logic as per requirement of oil from TAL 200 ltr barrel to machine after every cycle.

OPERATING CONSOLE: - This consists of the number of user-friendly operating options, including auto cycle,

manual cycle options, various displays for alarms and fault indicators. The operating console also has the

digital vacuum controller L.C.D. display for indicating the vacuum levels achieved and the limits set. The

operating console will mainly indicate the functional status of the system through the M.M.I. (Man Machine

Interface) of the P.L.C.

TWIN ENGINEERS PVT. LTD.

(An ISO 9001:2008 Certified Company) WORKS: J-524, MIDC, BHOSARI, PUNE – 411 026.

TEL.: (020) 27130626, 27130118

5

Electrical Panel Digital display

FILLING ADAPTOR OR THE GUN: - This is the important component of the system, which comes directly in

contact with the brake system. This adaptor is mounted on the bowl (Bowl design to be specified as per

model by TAL) of the brake system and all operations i.e. evacuation, filling are operated through this

adaptor.

At present it is considered that one adaptor will work for all the variants. Additional adaptors would be

provided at extra price.

This adaptor is connected to the various lines (vacuum, filling) through flexible piping.

� Connect the Gun to the Reservoir Tank

� Push the Cycle Start button on the Gun

Pre Vacuum and Vacuum

Leak Test (Major and Minor)

Filling of Brake Fluid

Re-suction and Leveling

� Completion of cycle will be indicated by Buzzer and Lamp

� Press Gun remove acknowledgement button on the Gun

� Remove the Gun

� Park the Gun on the gun stand provided on the Machine

OPERATION PROCESS:

TWIN ENGINEERS PVT. LTD.

(An ISO 9001:2008 Certified Company) WORKS: J-524, MIDC, BHOSARI, PUNE – 411 026.

TEL.: (020) 27130626, 27130118

6

A D V A N T A G E S O F T E P L B R A K E O I L F I L L I N G M A C H I N E :

� Very short cycle times. 120 Sec. minimum.

� Only one operator is required for complete fill and top off procedure.

� No loss of fluid with clean and drip-free operation.

� Degassing of new oil in separate tank and then transferred to storage tank hence, very little or no

contamination.

� Positive displacement pump (Gear Type) used for filling hence; required pressure can be

developed in less time.

� Continuous flow of oil is achieved during filling no air bubble.

� Testing the security of the brake system before filling.

� Self-contained and compact in size. Excellent access for maintenance with all components tagged

for ease of identification.

� Most component parts are easy to source. Some valves are multi-purpose, which reduces the

variety to hold as spares.

� Vacuum at gun tip 2 mbar.