This document summarizes an article that describes automating a milling machine using an electro-pneumatic system. Milling is a common metal cutting process where a rotating cutting tool removes material. The article discusses automating the milling process using pneumatic devices like cylinders, valves, and sensors combined with electrical components like relays and switches. It provides an overview of milling machines and their components. It also discusses the general concepts of designing and developing pneumatic control systems, including functional diagrams, circuit diagrams, and documentation. Finally, it analyzes the costs of manual versus automated milling machines and their production times.
Introduction to CNC machine and Hardware. aman1312
Complete detailing of cnc machine and its operations with its required hardware necessary for increasing its Automation and increasing its manufacturing capability. Also increase in complex shape manufacturing.
Introduction to CNC machine and Hardware. aman1312
Complete detailing of cnc machine and its operations with its required hardware necessary for increasing its Automation and increasing its manufacturing capability. Also increase in complex shape manufacturing.
Cnc tooling for cnc machine(130670119596)Kushal Shah
we have seen what the NC machine is and its various
parts, it is easier to understand what the CNC machine is. CNC is
the short form for Computer Numerical control. We have seen that
the NC machine works as per the program of instructions fed into
the controller unit of the machine. The CNC machine comprises of
the mini computer or the microcomputer that acts as the controller
unit of the machine. While in the NC machine the program is fed
into the punch cards, in CNC machines the program of instructions
is fed directly into the computer via a small board similar to the
traditional keyboard.
Simply put, CNC machines are programmed and controlled to carry out the following actions:
Positioning a tool in different axes
Motion-relative velocity of tool with respect to work piece
Switching function, for example, direction of rotation of spindle,
CNC systems use motor drives to control both the position and the velocity of the machine axes.
The open-loop system and the closed-loop system are two ways to activate the servo drivers.
Follow us on https://www.bpautomation.com/
GROW2012 - Harnessing the Crowd - Adam Chapnick IndiegogoDealmaker Media
Adam is a Principal at Indiegogo, where he also serves as CEO of Distribber.com, the new-model flat-fee distribution service that places independent films on VOD platforms while allowing filmmakers to keep 100% of their revenue. He was recently named one of “19 Brave Thinkers in Independent Film” by uber-producer Ted Hope’s Truly Free Film blog.
Cnc tooling for cnc machine(130670119596)Kushal Shah
we have seen what the NC machine is and its various
parts, it is easier to understand what the CNC machine is. CNC is
the short form for Computer Numerical control. We have seen that
the NC machine works as per the program of instructions fed into
the controller unit of the machine. The CNC machine comprises of
the mini computer or the microcomputer that acts as the controller
unit of the machine. While in the NC machine the program is fed
into the punch cards, in CNC machines the program of instructions
is fed directly into the computer via a small board similar to the
traditional keyboard.
Simply put, CNC machines are programmed and controlled to carry out the following actions:
Positioning a tool in different axes
Motion-relative velocity of tool with respect to work piece
Switching function, for example, direction of rotation of spindle,
CNC systems use motor drives to control both the position and the velocity of the machine axes.
The open-loop system and the closed-loop system are two ways to activate the servo drivers.
Follow us on https://www.bpautomation.com/
GROW2012 - Harnessing the Crowd - Adam Chapnick IndiegogoDealmaker Media
Adam is a Principal at Indiegogo, where he also serves as CEO of Distribber.com, the new-model flat-fee distribution service that places independent films on VOD platforms while allowing filmmakers to keep 100% of their revenue. He was recently named one of “19 Brave Thinkers in Independent Film” by uber-producer Ted Hope’s Truly Free Film blog.
CNC PART PROGRAMMING AND COST ANALYSIS ON VERTICAL MACHINING CENTRE (VTC)IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
DESIGN AND DEVELOPMENT OF SPECIAL PURPOSE MACHINE USING HYDROPNEUMATIC CYLIND...IAEME Publication
Piercing is a type of shearing operation which creates a open hole in sheet metal
by separating interior section. The removed metal is discarded as strap. In general
piercing operation is done in mechanical presses using piercing tool. Piercing tools
are developed with indexing method by piercing 1 or 2 holes at a time. To do 4 holes
the tool is allowed to do first hole and then the first hole is located to do piercing of
other holes. This special purpose machine using hydro pneumatic cylinders to pierce 4
holes and 2 holes at a time in a square tube. The productivity and quality of the work
is increased by this machine. The use of Special Purpose Machines minimizes
Possibility of Human Errors. These machines are Designed to Operate Continuously
for 24 hours a day, with Minimum Supervision
Esign and fabrication of a shearing machine for glass fiber sleeves using ste...eSAT Journals
Abstract
This paper gives the reader an insight in to the work we went through to invent the concept for an automated fiber glass sleeve cutting machine. The challenge given to us by the Industry was to design and fabricate the shearing machine that can cut fiber glass sleeves in a given desired length automatically on a large scale. The length of the sleeve given to us is in range of 20mm-50mm. We set out to invent a simple but strong concept resulting in a machine with minimal complexity which will reduce the cost of production, time required to cut the sleeve and also improve the ease of maintenance. This paper is testament to how we achieved a supposedly complex automation using simple mechanical automation. To support our concept we also set out to fabricate a proposed machine to prove this concept will work.
Keywords: Shearing, Plc, Fiber glass sleeves, Ladder programming, Hmi
DESIGN AND CONTROL OF ATC FOR SHORTER TIME INTERVAL IN CNC MACHINESIAEME Publication
This project focuses on the design and control of Automatic Tool Change (ATC)system in CNC machineries to reduce the time interval during tool change process.
Here three methods are used in this project, whereas the first method is the set of
mathematical logics is used to find the shortest distance in Tool magazine during toolchange.The second method is the use of Rotary encoder in the Magazine motor, In the
present system the digital input (count sensor) is used to count the pocket movement in
the magazine using Cam movement(Fixed position) from one pocket to another pocket,but the time interval between pocket to pocket is more. Hence to reduce this time,rotary encoder is being used to read each pocket positions through high pulse input.The third method is the creating and interfacing the Tool change database in Auto mode during machining, the detailed analysis of these three methods is shown below.
Geometric modeling: Wire frame, surface and solid modeling - Engineering analysis;
design review and evaluation, automated drafting.
Numerical control: Need - advantages and disadvantages – classifications – Point to
point, straight cut and contouring positioning - incremental and absolute systems – open
loop and closed loop systems – DDA integrator and Interpolators – resolution – CNC and
DNC.
Programmable Logic Controllers (PLC): need – relays - logic ladder program –
timers, simple problems only - Devices in N.C. systems: Driving devices - feed
back devices: encoders, moire fringes, digitizer, resolver, inductosyn, and
tachometer.
A Novel Method for Prevention of Bandwidth Distributed Denial of Service AttacksIJERD Editor
Distributed Denial of Service (DDoS) Attacks became a massive threat to the Internet. Traditional
Architecture of internet is vulnerable to the attacks like DDoS. Attacker primarily acquire his army of Zombies,
then that army will be instructed by the Attacker that when to start an attack and on whom the attack should be
done. In this paper, different techniques which are used to perform DDoS Attacks, Tools that were used to
perform Attacks and Countermeasures in order to detect the attackers and eliminate the Bandwidth Distributed
Denial of Service attacks (B-DDoS) are reviewed. DDoS Attacks were done by using various Flooding
techniques which are used in DDoS attack.
The main purpose of this paper is to design an architecture which can reduce the Bandwidth
Distributed Denial of service Attack and make the victim site or server available for the normal users by
eliminating the zombie machines. Our Primary focus of this paper is to dispute how normal machines are
turning into zombies (Bots), how attack is been initiated, DDoS attack procedure and how an organization can
save their server from being a DDoS victim. In order to present this we implemented a simulated environment
with Cisco switches, Routers, Firewall, some virtual machines and some Attack tools to display a real DDoS
attack. By using Time scheduling, Resource Limiting, System log, Access Control List and some Modular
policy Framework we stopped the attack and identified the Attacker (Bot) machines
Hearing loss is one of the most common human impairments. It is estimated that by year 2015 more
than 700 million people will suffer mild deafness. Most can be helped by hearing aid devices depending on the
severity of their hearing loss. This paper describes the implementation and characterization details of a dual
channel transmitter front end (TFE) for digital hearing aid (DHA) applications that use novel micro
electromechanical- systems (MEMS) audio transducers and ultra-low power-scalable analog-to-digital
converters (ADCs), which enable a very-low form factor, energy-efficient implementation for next-generation
DHA. The contribution of the design is the implementation of the dual channel MEMS microphones and powerscalable
ADC system.
Influence of tensile behaviour of slab on the structural Behaviour of shear c...IJERD Editor
-A composite beam is composed of a steel beam and a slab connected by means of shear connectors
like studs installed on the top flange of the steel beam to form a structure behaving monolithically. This study
analyzes the effects of the tensile behavior of the slab on the structural behavior of the shear connection like slip
stiffness and maximum shear force in composite beams subjected to hogging moment. The results show that the
shear studs located in the crack-concentration zones due to large hogging moments sustain significantly smaller
shear force and slip stiffness than the other zones. Moreover, the reduction of the slip stiffness in the shear
connection appears also to be closely related to the change in the tensile strain of rebar according to the increase
of the load. Further experimental and analytical studies shall be conducted considering variables such as the
reinforcement ratio and the arrangement of shear connectors to achieve efficient design of the shear connection
in composite beams subjected to hogging moment.
Gold prospecting using Remote Sensing ‘A case study of Sudan’IJERD Editor
Gold has been extracted from northeast Africa for more than 5000 years, and this may be the first
place where the metal was extracted. The Arabian-Nubian Shield (ANS) is an exposure of Precambrian
crystalline rocks on the flanks of the Red Sea. The crystalline rocks are mostly Neoproterozoic in age. ANS
includes the nations of Israel, Jordan. Egypt, Saudi Arabia, Sudan, Eritrea, Ethiopia, Yemen, and Somalia.
Arabian Nubian Shield Consists of juvenile continental crest that formed between 900 550 Ma, when intra
oceanic arc welded together along ophiolite decorated arc. Primary Au mineralization probably developed in
association with the growth of intra oceanic arc and evolution of back arc. Multiple episodes of deformation
have obscured the primary metallogenic setting, but at least some of the deposits preserve evidence that they
originate as sea floor massive sulphide deposits.
The Red Sea Hills Region is a vast span of rugged, harsh and inhospitable sector of the Earth with
inimical moon-like terrain, nevertheless since ancient times it is famed to be an abode of gold and was a major
source of wealth for the Pharaohs of ancient Egypt. The Pharaohs old workings have been periodically
rediscovered through time. Recent endeavours by the Geological Research Authority of Sudan led to the
discovery of a score of occurrences with gold and massive sulphide mineralizations. In the nineties of the
previous century the Geological Research Authority of Sudan (GRAS) in cooperation with BRGM utilized
satellite data of Landsat TM using spectral ratio technique to map possible mineralized zones in the Red Sea
Hills of Sudan. The outcome of the study mapped a gossan type gold mineralization. Band ratio technique was
applied to Arbaat area and a signature of alteration zone was detected. The alteration zones are commonly
associated with mineralization. The alteration zones are commonly associated with mineralization. A filed check
confirmed the existence of stock work of gold bearing quartz in the alteration zone. Another type of gold
mineralization that was discovered using remote sensing is the gold associated with metachert in the Atmur
Desert.
Reducing Corrosion Rate by Welding DesignIJERD Editor
The paper addresses the importance of welding design to prevent corrosion at steel. Welding is
used to join pipe, profiles at bridges, spindle, and a lot more part of engineering construction. The
problems happened associated with welding are common issues in these fields, especially corrosion.
Corrosion can be reduced with many methods, they are painting, controlling humidity, and also good
welding design. In the research, it can be found that reducing residual stress on the welding can be
solved in corrosion rate reduction problem.
Preheating on 500oC and 600oC give better condition to reduce corosion rate than condition after
preheating 400oC. For all welding groove type, material with 500oC and 600oC preheating after 14 days
corrosion test is 0,5%-0,69% lost. Material with 400oC preheating after 14 days corrosion test is 0,57%-0,76%
lost.
Welding groove also influence corrosion rate. X and V type welding groove give better condition to reduce
corrosion rate than use 1/2V and 1/2 X welding groove. After 14 days corrosion test, the samples with
X welding groove type is 0,5%-0,57% lost. The samples with V welding groove after 14 days corrosion test is
0,51%-0,59% lost. The samples with 1/2V and 1/2X welding groove after 14 days corrosion test is 0,58%-
0,71% lost.
Router 1X3 – RTL Design and VerificationIJERD Editor
Routing is the process of moving a packet of data from source to destination and enables messages
to pass from one computer to another and eventually reach the target machine. A router is a networking device
that forwards data packets between computer networks. It is connected to two or more data lines from different
networks (as opposed to a network switch, which connects data lines from one single network). This paper,
mainly emphasizes upon the study of router device, it‟s top level architecture, and how various sub-modules of
router i.e. Register, FIFO, FSM and Synchronizer are synthesized, and simulated and finally connected to its top
module.
Active Power Exchange in Distributed Power-Flow Controller (DPFC) At Third Ha...IJERD Editor
This paper presents a component within the flexible ac-transmission system (FACTS) family, called
distributed power-flow controller (DPFC). The DPFC is derived from the unified power-flow controller (UPFC)
with an eliminated common dc link. The DPFC has the same control capabilities as the UPFC, which comprise
the adjustment of the line impedance, the transmission angle, and the bus voltage. The active power exchange
between the shunt and series converters, which is through the common dc link in the UPFC, is now through the
transmission lines at the third-harmonic frequency. DPFC multiple small-size single-phase converters which
reduces the cost of equipment, no voltage isolation between phases, increases redundancy and there by
reliability increases. The principle and analysis of the DPFC are presented in this paper and the corresponding
simulation results that are carried out on a scaled prototype are also shown.
Mitigation of Voltage Sag/Swell with Fuzzy Control Reduced Rating DVRIJERD Editor
Power quality has been an issue that is becoming increasingly pivotal in industrial electricity
consumers point of view in recent times. Modern industries employ Sensitive power electronic equipments,
control devices and non-linear loads as part of automated processes to increase energy efficiency and
productivity. Voltage disturbances are the most common power quality problem due to this the use of a large
numbers of sophisticated and sensitive electronic equipment in industrial systems is increased. This paper
discusses the design and simulation of dynamic voltage restorer for improvement of power quality and
reduce the harmonics distortion of sensitive loads. Power quality problem is occurring at non-standard
voltage, current and frequency. Electronic devices are very sensitive loads. In power system voltage sag,
swell, flicker and harmonics are some of the problem to the sensitive load. The compensation capability
of a DVR depends primarily on the maximum voltage injection ability and the amount of stored
energy available within the restorer. This device is connected in series with the distribution feeder at
medium voltage. A fuzzy logic control is used to produce the gate pulses for control circuit of DVR and the
circuit is simulated by using MATLAB/SIMULINK software.
Study on the Fused Deposition Modelling In Additive ManufacturingIJERD Editor
Additive manufacturing process, also popularly known as 3-D printing, is a process where a product
is created in a succession of layers. It is based on a novel materials incremental manufacturing philosophy.
Unlike conventional manufacturing processes where material is removed from a given work price to derive the
final shape of a product, 3-D printing develops the product from scratch thus obviating the necessity to cut away
materials. This prevents wastage of raw materials. Commonly used raw materials for the process are ABS
plastic, PLA and nylon. Recently the use of gold, bronze and wood has also been implemented. The complexity
factor of this process is 0% as in any object of any shape and size can be manufactured.
Spyware triggering system by particular string valueIJERD Editor
This computer programme can be used for good and bad purpose in hacking or in any general
purpose. We can say it is next step for hacking techniques such as keylogger and spyware. Once in this system if
user or hacker store particular string as a input after that software continually compare typing activity of user
with that stored string and if it is match then launch spyware programme.
A Blind Steganalysis on JPEG Gray Level Image Based on Statistical Features a...IJERD Editor
This paper presents a blind steganalysis technique to effectively attack the JPEG steganographic
schemes i.e. Jsteg, F5, Outguess and DWT Based. The proposed method exploits the correlations between
block-DCTcoefficients from intra-block and inter-block relation and the statistical moments of characteristic
functions of the test image is selected as features. The features are extracted from the BDCT JPEG 2-array.
Support Vector Machine with cross-validation is implemented for the classification.The proposed scheme gives
improved outcome in attacking.
Secure Image Transmission for Cloud Storage System Using Hybrid SchemeIJERD Editor
- Data over the cloud is transferred or transmitted between servers and users. Privacy of that
data is very important as it belongs to personal information. If data get hacked by the hacker, can be
used to defame a person’s social data. Sometimes delay are held during data transmission. i.e. Mobile
communication, bandwidth is low. Hence compression algorithms are proposed for fast and efficient
transmission, encryption is used for security purposes and blurring is used by providing additional
layers of security. These algorithms are hybridized for having a robust and efficient security and
transmission over cloud storage system.
Application of Buckley-Leverett Equation in Modeling the Radius of Invasion i...IJERD Editor
A thorough review of existing literature indicates that the Buckley-Leverett equation only analyzes
waterflood practices directly without any adjustments on real reservoir scenarios. By doing so, quite a number
of errors are introduced into these analyses. Also, for most waterflood scenarios, a radial investigation is more
appropriate than a simplified linear system. This study investigates the adoption of the Buckley-Leverett
equation to estimate the radius invasion of the displacing fluid during waterflooding. The model is also adopted
for a Microbial flood and a comparative analysis is conducted for both waterflooding and microbial flooding.
Results shown from the analysis doesn’t only records a success in determining the radial distance of the leading
edge of water during the flooding process, but also gives a clearer understanding of the applicability of
microbes to enhance oil production through in-situ production of bio-products like bio surfactans, biogenic
gases, bio acids etc.
Gesture Gaming on the World Wide Web Using an Ordinary Web CameraIJERD Editor
- Gesture gaming is a method by which users having a laptop/pc/x-box play games using natural or
bodily gestures. This paper presents a way of playing free flash games on the internet using an ordinary webcam
with the help of open source technologies. Emphasis in human activity recognition is given on the pose
estimation and the consistency in the pose of the player. These are estimated with the help of an ordinary web
camera having different resolutions from VGA to 20mps. Our work involved giving a 10 second documentary to
the user on how to play a particular game using gestures and what are the various kinds of gestures that can be
performed in front of the system. The initial inputs of the RGB values for the gesture component is obtained by
instructing the user to place his component in a red box in about 10 seconds after the short documentary before
the game is finished. Later the system opens the concerned game on the internet on popular flash game sites like
miniclip, games arcade, GameStop etc and loads the game clicking at various places and brings the state to a
place where the user is to perform only gestures to start playing the game. At any point of time the user can call
off the game by hitting the esc key and the program will release all of the controls and return to the desktop. It
was noted that the results obtained using an ordinary webcam matched that of the Kinect and the users could
relive the gaming experience of the free flash games on the net. Therefore effective in game advertising could
also be achieved thus resulting in a disruptive growth to the advertising firms.
Hardware Analysis of Resonant Frequency Converter Using Isolated Circuits And...IJERD Editor
-LLC resonant frequency converter is basically a combo of series as well as parallel resonant ckt. For
LCC resonant converter it is associated with a disadvantage that, though it has two resonant frequencies, the
lower resonant frequency is in ZCS region[5]. For this application, we are not able to design the converter
working at this resonant frequency. LLC resonant converter existed for a very long time but because of
unknown characteristic of this converter it was used as a series resonant converter with basically a passive
(resistive) load. . Here, it was designed to operate in switching frequency higher than resonant frequency of the
series resonant tank of Lr and Cr converter acts very similar to Series Resonant Converter. The benefit of LLC
resonant converter is narrow switching frequency range with light load[6] . Basically, the control ckt plays a
very imp. role and hence 555 Timer used here provides a perfect square wave as the control ckt provides no
slew rate which makes the square wave really strong and impenetrable. The dead band circuit provides the
exclusive dead band in micro seconds so as to avoid the simultaneous firing of two pairs of IGBT’s where one
pair switches off and the other on for a slightest period of time. Hence, the isolator ckt here is associated with
each and every ckt used because it acts as a driver and an isolation to each of the IGBT is provided with one
exclusive transformer supply[3]. The IGBT’s are fired using the appropriate signal using the previous boards
and hence at last a high frequency rectifier ckt with a filtering capacitor is used to get an exact dc
waveform .The basic goal of this particular analysis is to observe the wave forms and characteristics of
converters with differently positioned passive elements in the form of tank circuits.
Simulated Analysis of Resonant Frequency Converter Using Different Tank Circu...IJERD Editor
LLC resonant frequency converter is basically a combo of series as well as parallel resonant ckt. For
LCC resonant converter it is associated with a disadvantage that, though it has two resonant frequencies, the
lower resonant frequency is in ZCS region [5]. For this application, we are not able to design the converter
working at this resonant frequency. LLC resonant converter existed for a very long time but because of
unknown characteristic of this converter it was used as a series resonant converter with basically a passive
(resistive) load. . Here, it was designed to operate in switching frequency higher than resonant frequency of the
series resonant tank of Lr and Cr converter acts very similar to Series Resonant Converter. The benefit of LLC
resonant converter is narrow switching frequency range with light load[6] . Basically, the control ckt plays a
very imp. role and hence 555 Timer used here provides a perfect square wave as the control ckt provides no
slew rate which makes the square wave really strong and impenetrable. The dead band circuit provides the
exclusive dead band in micro seconds so as to avoid the simultaneous firing of two pairs of IGBT’s where one
pair switches off and the other on for a slightest period of time. Hence, the isolator ckt here is associated with
each and every ckt used because it acts as a driver and an isolation to each of the IGBT is provided with one
exclusive transformer supply[3]. The IGBT’s are fired using the appropriate signal using the previous boards
and hence at last a high frequency rectifier ckt with a filtering capacitor is used to get an exact dc
waveform .The basic goal of this particular analysis is to observe the wave forms and characteristics of
converters with differently positioned passive elements in the form of tank circuits. The supported simulation
is done through PSIM 6.0 software tool
Amateurs Radio operator, also known as HAM communicates with other HAMs through Radio
waves. Wireless communication in which Moon is used as natural satellite is called Moon-bounce or EME
(Earth -Moon-Earth) technique. Long distance communication (DXing) using Very High Frequency (VHF)
operated amateur HAM radio was difficult. Even with the modest setup having good transceiver, power
amplifier and high gain antenna with high directivity, VHF DXing is possible. Generally 2X11 YAGI antenna
along with rotor to set horizontal and vertical angle is used. Moon tracking software gives exact location,
visibility of Moon at both the stations and other vital data to acquire real time position of moon.
“MS-Extractor: An Innovative Approach to Extract Microsatellites on „Y‟ Chrom...IJERD Editor
Simple Sequence Repeats (SSR), also known as Microsatellites, have been extensively used as
molecular markers due to their abundance and high degree of polymorphism. The nucleotide sequences of
polymorphic forms of the same gene should be 99.9% identical. So, Microsatellites extraction from the Gene is
crucial. However, Microsatellites repeat count is compared, if they differ largely, he has some disorder. The Y
chromosome likely contains 50 to 60 genes that provide instructions for making proteins. Because only males
have the Y chromosome, the genes on this chromosome tend to be involved in male sex determination and
development. Several Microsatellite Extractors exist and they fail to extract microsatellites on large data sets of
giga bytes and tera bytes in size. The proposed tool “MS-Extractor: An Innovative Approach to extract
Microsatellites on „Y‟ Chromosome” can extract both Perfect as well as Imperfect Microsatellites from large
data sets of human genome „Y‟. The proposed system uses string matching with sliding window approach to
locate Microsatellites and extracts them.
Importance of Measurements in Smart GridIJERD Editor
- The need to get reliable supply, independence from fossil fuels, and capability to provide clean
energy at a fixed and lower cost, the existing power grid structure is transforming into Smart Grid. The
development of a smart energy distribution grid is a current goal of many nations. A Smart Grid should have
new capabilities such as self-healing, high reliability, energy management, and real-time pricing. This new era
of smart future grid will lead to major changes in existing technologies at generation, transmission and
distribution levels. The incorporation of renewable energy resources and distribution generators in the existing
grid will increase the complexity, optimization problems and instability of the system. This will lead to a
paradigm shift in the instrumentation and control requirements for Smart Grids for high quality, stable and
reliable electricity supply of power. The monitoring of the grid system state and stability relies on the
availability of reliable measurement of data. In this paper the measurement areas that highlight new
measurement challenges, development of the Smart Meters and the critical parameters of electric energy to be
monitored for improving the reliability of power systems has been discussed.
Study of Macro level Properties of SCC using GGBS and Lime stone powderIJERD Editor
One of the major environmental concerns is the disposal of the waste materials and utilization of
industrial by products. Lime stone quarries will produce millions of tons waste dust powder every year. Having
considerable high degree of fineness in comparision to cement this material may be utilized as a partial
replacement to cement. For this purpose an experiment is conducted to investigate the possibility of using lime
stone powder in the production of SCC with combined use GGBS and how it affects the fresh and mechanical
properties of SCC. First SCC is made by replacing cement with GGBS in percentages like 10, 20, 30, 40, 50 and
by taking the optimum mix with GGBS lime stone powder is blended to mix in percentages like 5, 10, 15, 20 as
a partial replacement to cement. Test results shows that the SCC mix with combination of 30% GGBS and 15%
limestone powder gives maximum compressive strength and fresh properties are also in the limits prescribed by
the EFNARC.
Event Report - SAP Sapphire 2024 Orlando - lots of innovation and old challengesHolger Mueller
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The 10 Most Influential Leaders Guiding Corporate Evolution, 2024.pdfthesiliconleaders
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Top mailing list providers in the USA.pptxJeremyPeirce1
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Recruiting in the Digital Age: A Social Media MasterclassLuanWise
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In the Adani-Hindenburg case, what is SEBI investigating.pptxAdani case
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LA HUG - Video Testimonials with Chynna Morgan - June 2024Lital Barkan
Have you ever heard that user-generated content or video testimonials can take your brand to the next level? We will explore how you can effectively use video testimonials to leverage and boost your sales, content strategy, and increase your CRM data.🤯
We will dig deeper into:
1. How to capture video testimonials that convert from your audience 🎥
2. How to leverage your testimonials to boost your sales 💲
3. How you can capture more CRM data to understand your audience better through video testimonials. 📊
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Anny Serafina Love - Letter of Recommendation by Kellen Harkins, MS.AnnySerafinaLove
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IJERD (www.ijerd.com) International Journal of Engineering Research and Development
1. International Journal of Engineering Research and Development
e-ISSN: 2278-067X, p-ISSN: 2278-800X, www.ijerd.com
Volume 2, Issue 9 (August 2012), PP. 04-09
Automation of Milling Machine Using Electro Pneumatic System
Pragnya Pradeep1, Siddharam Patil2, R M Lathe3
1
Pda College of engineering Gulbarga
2
HKES- BOSCH Rexroth centre Gulbarga
Abstract––Milling is a metal removal process by means of using a rotating cutter having one or more cutting teeth. A
milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms
horizontal and vertical. This refers to the orientation of the main spindle. At all types of milling machines, the cutting tool
performs a rotational motion that is the cutting motion. The rotation axis of the tool could be horizontal or vertical,
depending on machine tool version. The feeding motion is achieved either by part or tool, or both; usually on three
perpendicular directions. Milling machine is automated using Electro pneumatic system. Milling process is the second
most common method (after turning) for metal cutting and especially for the finishing of Machined parts. In modern
industry the goal is to manufacture low cost, high quality products in short time.
Keywords––Milling, Electro pneumatic, cutting tool, cutter, automated.
I. INTRODUCTION
Milling machines were first invented and developed by Eli Whitney to mass produce interchangeable musket parts.
Although crude, these machines assisted man in maintaining accuracy and uniformity while duplicating parts that could not
be manufactured with the use of a file. Development and improvements of the milling machine and components continued,
which resulted in the manufacturing of heavier arbors and high speed steel and carbide cutters. These components allowed
the operator to remove metal faster, and with more accuracy, than previous machines. Variations of milling machines were
also developed to perform special milling operations. During this era, computerized machines have been developed to
alleviate errors and provide better quality in the finished product.
A simple milling machine such as a milling machine is converted into an automatic machine by using the
pneumatic devices such as: Double acting Cylinder, Flow Control valves, Direction Control Valves, sensors (reed type )
and the Electrical devices are also used in combination with the pneumatic devices are such as: Relays, Push button
switches, Reed switch and solenoid valves. The main aim of this project is to have the complete know how of the pneumatic
devices, Electrical devices and the machines by which the manually operated machine can be converted into a semi-
automatic or fully automatic machine.
II. AN OVERVIEW OF MILLING MACHINE
Fig.1 Milling Machine
Milling is one of the basic machining processes that allow large amount of material to be removed quickly.
At all types of milling machines, the cutting tool performs a rotational motion that is the cutting motion. The rotation axis of
the tool could be or vertical, depending on machine tool version. The feeding motion is achieved either by part or tool, or
both, usually on three perpendicular directions.
A. Types of Milling Machine
The milling machine may be classified in several forms covering a wide range of work and capabilities, but the
choice of any particular machine is determined primarily by the nature of work to be undertaken both in relation to the size
and operation to be performed. The usual classifications according to the general design of the milling machine are:
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2. Automation of Milling Machine Using Electro Pneumatic System
1. Horizontal milling machine
(a) Hand milling machine.
(b) Plain milling machine.
(c) Universal milling machine.
(d) Vertical milling machine.
2. Manufacturing of fixed bed.
(a) Simplex milling machine.
(b) Duplex milling machine.
(c) Triplex milling machine.
3. Planer type.
4. Special type.
(a) Rotary table milling machine.
(b) Drum milling machine.
(c) Planetary milling machine.
B. Parts of Vertical Milling Machine
Base: The base of the machine is gray iron casting accurately machined. It carries the column at its one end.
Column: The column is the main supporting frame mounted vertically on the base. The column is box shaped, heavily
ribbed inside and houses all the driving mechanism for the spindle and table feed.
Knee: The knee is a rigid grey iron casting that slides up and down on the vertical ways of the column face.Table: The table
rests on ways on the saddle and travels longitudinally. The top of the table is accurately finished and T-slots are provided for
clamping the work and other fixture on it.
Spindle: The spindle of the machine is located in the upper part of the column and receives power from the motor through
belts, gears, clutches and transmits it to the cutter.
III. GENERAL CONCEPTS ON DESIGN AND DEVELOPMENT OF PNEUMATIC
SYSTEMS
A. Development of Pneumatic System
The solution to a control problem is worked out according to a system with documentation playing an important
role in communicating the final result. The circuit diagrams are drawn using standard symbols and labeling. Comprehensive
documentation is required including most of the following
Function diagram
Circuit diagram
Description of the operation of the system
Technical data of the components.
Supplementary documentation comprising
Parts list of all components in the system
Maintenance and fault-finding information
Spare parts list
There are two primary methods for constructing circuit diagrams:
The so-called intuitive methods
The methodical design of a circuit diagram in accordance with prescribed rules and instructions.
Fig. 2 Functional Diagram
Whereas much experience and intuition is required in the first case and above all, a great deal of time where
complicated circuits are concerned; designing circuit diagrams of the second category requires methodical working and a
certain amount of basic theoretical knowledge.
Regardless of which method is used in developing the circuit diagram, the aim is to end up with a properly
functioning and reliably operating control. Whereas previously emphasis was placed on the least expensive hardware
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3. Automation of Milling Machine Using Electro Pneumatic System
solution, more importance is now attached to operational reliability and ease of maintenance by a clear layout and
documentation5.
This inevitably leads to increased usage of methodical design processes. In such cases, the control is always
constructed in accordance with the given procedure and is less dependent upon personal influences from the designer. In
many cases, however, more components will be required for the methodical solution than in a circuit devised by the intuitive
method.
This additional material requirement will usually be rapidly compensated for by time-saving at the project stage
and also later in terms of maintenance. Generally, it must be ensured that the time spent in project design and particularly in
simplifying the circuit, is in reasonable proportion to the overall effort.
Regardless of which method and which technique is used to produce a circuit diagram, the basic requirements are
sound fundamental knowledge of the devices concerned and knowledge of the switching characteristics of the components
used.
In majority of the pneumatic applications more than one cylinder is used. The movement of these cylinders is
coordinated as per the required sequence.
The activation of the limit switches of different cylinders will provide set or reset signal to the final control valves
for further controlling the movement of various cylinders. The limit switches have to be arranged in the proper location with
the help of motion diagram.
In order to develop control circuitry for multi cylinder applications, it is necessary to draw the motion diagram to
understand the sequence of actuation of various signal input switches-limit switches and sensors. Multi cylinder applications
with three cylinders A, B and C:The status of the cylinder displacement and actuation of set and reset signals at double
piloted directional control value is shown by functional diagram.
IV. OPERATIONAL AND ANALYSIS
A. Cost Analysis of Manual and Automated Production Machine
The machine taken for comparison is a milling machine. Depending upon the size of the machine the cost varies.
Taking a minimum size of the machine the analysis is done.For manually operated milling machine the cost of minimum
operated milling machine the cost of minimum size machine is approximately around80000/-. For automatically operated
milling machine the cost of minimum size machine (after conversion) is approximately around 200000/-.
Production time: Let us consider a milling machine which is used for milling a 5cm length in a mild steel piece.
Manually operated milling: The time needed for machining manually operated milling machine is about 2mins. The
total time needed including the loading and unloading is about 2 minutes. Therefore in 1 hour 30 jobs are made. There is one
day (5 hours) 150 work pieces are completed. (Total machining time taken in a day is 5 hour).
B Automated Milling
The time needed for machining work piece on an automated milling machine is about 1 minute. In one hour 60
work piece are produced. Therefore in one day (5 hours) 300 work pieces are completed.
To know the productivity of both the machines it can be understood from the graph.
Fig. 3 Graph Showing Productivity Of Two Machines (Milling)
AUTOMATED M/C MANUAL OPERATED M/C
1 HOURS-60 UNITS 1 HOURS-30 UNITS
5 HOURS-300 UNITS 5 HOURS-150 UNITS
As seen from the graph the rate of production is very high in case of automated milling machine as compared with
the manually operated machine. Hence, the productivity is high on the automatic machine.
Break Even Analysis: In decision making breakeven analysis assumes an important place it helps its decision maker in the
choice of the optimal price, cost and output levels of each products. Whatever may be objective of the firm profit
maximization is the basic objective. The firm is interested in finding out the sales volume which will bring it to the
maximum profit or for that matter the minimum loss. It is therefore interested in preparing chart to find out the areas of
profit and loss in its operational process. The chart is called “Breakeven chart”.
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4. Automation of Milling Machine Using Electro Pneumatic System
Fig. 4 Break Even Chart
The BEP is defined as that level of output where total revenue is equal to total cost. The point is a point of no profit,
no loss. This point shows where loss stops and the profit starts. Increase in the sales beyond this point would result in profit.
Decrease in sales below this point a result in loss of course the firm is interested in operating beyond the breakeven point
(BEP). The firm will be most happy once it crosses. The BEP the firm incurs two types of cost
1. Fixed cost
2. Variable cost.
The rental of a machine, building furniture etc is fixed cost.
Cost of labor, raw material, fuel, etc are variable cost.
A break even chart is a graphical representation of the relationship between the cost and revenue at a given time.
It is a graphic device employed to determine the breakdown point (BEP) and profit potential under varying
conditions of outputs and costs. While preparing break even chart we will assume that the firm incurs some fixed cost and
some variable cost. This will give us the total cost function which may be either linear or non-linear. If the average variable
cost is assumed to be constant over the range of output the cost function would be as shown in figure.
Cost, variable cost and rate of production
A business can work out how what volume of sales it needs to achieve to covers it costs. This is known as the
breakeven point.
The key to break even is to work out the contribution made from the sale of each unit. The amount of money each
unit sold contributes to pay for the fixed and indirect cost of the business14.
Manually operated machine (milling):
Fixed Cost of machine (FC) : Rs. 80,000/-
Variable Cost (VC) : Rs. 200,000/-
Rate of production : 54750 units / year
Sales (considering the : Rs. 273750/- Year
Cost of machining Rs 5 per unit) (Machining time is taken 5 Hours per day)
Scale: X AXIS 1CM=10000
Y AXIS 1CM=40000
Fig. 5 Manual Operated Machines’ Bep
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5. Automation of Milling Machine Using Electro Pneumatic System
Scale: X AXIS 1CM=4000
Y AXIS 1CM=10000
Fig. 6 Automated Machine’s BEP
Automated machine milling:
Fixed Cost of machine (FC) : Rs. 80,000/-
Variable Cost (VC) : Rs.200,000/-
Rate of production : Rs.109,500 units / year
Sales (considering the : Rs. 547,500/-
Cost of machining is Rs 5/- per unit)
(Machining time is taken 5 Hours per day)
From the BEP we can conclude that even though the initial investment is high but the returns of the investment is
very quick as compared to the manual operated machines and also the profits are more in case of the automated machines
when compared with the manual operated machine with in the same period of time.
From the BEP chart of both the machines we come to a conclusion that why the automated machines are the first
choice.
Conventional Machine (Milling):
150 units are produced in one day,
No. of days required to produce 29000 units (From the BEP of conventional machine BEP chart)
Approximately 193 days are required.
Automated Machines (Milling):
300 units are produced in One day,
No. of days required to produce approximately 128000 units. (From the BEP of Automated machine BEP chart)
Approximately 427 days are required.
From the statistics, it shows that even though the initial investment is high, but the BEP would be reached
approximately 427 days. In case of conventional machine the initial investment is low as compared to the automated
machine, but to obtain the breakeven point it takes more number of days approximately 193 days and the profit is less.
If there is a need of a production machine (Milling) for mass production, opting to a automated machine is must or
else the existing conventional machines can be converted into automated machines, so the goal can be achieved i.e. Less
time more profit.
Hence it can be concluded that automated machines are better than the manual operated machines both in
productivity and accuracy areas.
V. CONCLUSION
The manual controlled machine is converted into automatic machine by which maximum operating time will be
saved. Thus the output will be more. The human intervention is minimized. As far as this project is concerned the machine is
not fully automatic. It may be called as semi automatic because the loading of the sheet metal is done manually.
But this machine can be made fully automatic by using more number of cylinders by which the machine is loaded
automatically. So that the machine may run for longer time and unloaded without stopping the machine. Thus there will be a
increase in the output. The number of workers is also minimized by which number of machines can be handled by a single
operator.
To conclude, this project is made keeping in mind that any manually operated machine can be converted to
automatic machines by using these devices. For these purpose one should have the full knowhow of the devices which are
being used. By doing so the existing old machines can be modified and made automatic by which the initial cost, to procure
new automatic machines may be minimized. Thus there is a lot of scope in this area (automation).
Further in this project the wiring is very much complicated, if any troubleshoot occurs then the fault cannot be
easily found, for this the interface with the PLC can be used, by which the wiring is minimized and the fault can be easily
detected without waste of time.
Hence there is still wide scope in the automation area where lots of improvement can be made with the help of the
latest technology.
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6. Automation of Milling Machine Using Electro Pneumatic System
REFERENCES
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[2]. S. R. Majumdar, Pneumatic Systems , Tata McGraw-Hill , 1996
[3]. W. Bolton,Mechatronics,4 Ed.,Pearson Prentice hall, 2008
[4]. Bosch-Rexroth, Manuals of Pneumatics.
[5]. P. Croser, F.Ebel, Pneumatics, Festo, 10, 2002
[6]. Robotics and Automation by R.K Rajput
[7]. www.omega.com , air-preparation
[8]. www.wikipedia , chapter7, aircompressor-airfilters-lubricator
[9]. www.en.wikipedia,relay
[10]. www.britannica.com,automation,advantages&disadvantages
[11]. www.jrank.org,pages,677,automation&application
[12]. www.netviewforz,os,automation,guide,objectives
[13]. www.enwikipedia,ladderdiargam
[14]. www.enwikipedia,breakeven
[15]. www.answer.com,industrialautomation,scope
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