Abstract The scope of this research is to design an automated system by which stapling of box is done. Automation is key subject for this project. Machine Design and Manufacturing Process were also subjects of interest. Accuracy in manufacturing was necessary for proper functioning of system. First of all various design of system was carried out. After comparing various possibilities in every aspect, final efficient design is selected. Design includes Scissors mechanism, Z- Shaped Base and Robot slide base. Design and selection process includes LM Guides, Actuators, Shock Absorber, Robot, and Indexer. Design stage involved basic machine design techniques and force analysis
IRJET- Design of Manufacture of Fixtures for CNC Machine to Improve Productiv...IRJET Journal
This document discusses the design of a fixture for a CNC machine to improve productivity using the SMED (Single Minute Exchange of Die) concept. It begins with an introduction to setup time reduction and the SMED methodology. It then describes the objectives of the project, problem statement, and methodology. The design of the new fixture is explained along with dimensions and assembly drawings. Testing shows the new fixture reduces setup time by 52.5% (105 minutes) and increases production capacity. The conclusions are that SMED facilitates fast changeovers and improved efficiency.
In this presentation, we will talk about the importance of technology and factory automation, along with automated manufacturing systems, types of automation, automation principles and strategies.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
Low-cost and portable automatic sheet cutterIJECEIAES
Process automation is crucial to increase productivity, more efficient use of materials, better product quality, improved safety, etc. In small-medium enterprise (SME) businesses related to household retailing, one of the process automation needed is the measurement and cutting of the mat or sheet, made of rubber or polyvinyl chloride (PVC) materials. Most of the household retailers that selling the sheet, the process of measuring and cutting according to the customer’s requirements are manually performed using a measuring tape and scissors. These manual processes can cause inaccuracy in length, inefficient use of material, low productivity and reduce product quality. This paper presents a low cost and portable automatic sheet cutter using the Arduino development board, which is used to control the process of measuring and cutting the materials. The system uses a push-button where the user can set the required length and quantity of the sheet. Once the required information is set, the stepper motor rolls the sheet until the required length is satisfied. Subsequently, another stepper motor moves the cutter horizontally and cut the sheet. With the automatic sheet cutter, the material is cut with acceptable precision. The design of the automatic sheet cutter is low cost and portable which significantly suitable to be used by SME household retailers.
Modeling and Manufacturing of an Aerospace Component by Single Point Incremen...IRJET Journal
The document describes modeling and manufacturing an aerospace component using single point incremental forming process. It discusses modeling the component and fixture in Solidworks. A static structural analysis was performed in ANSYS to study stresses and deformations on the fixture under different forming loads. The component was then manufactured using a CNC milling machine with a hemispherical forming tool following the tool trajectories from the CAD model. Analysis of stresses, strains, and deformations helped understand how process parameters affect shape accuracy in single point incremental forming.
This document summarizes research measuring tool flank wear when machining Inconel 825. The research was conducted in two stages:
1. Dry turning of Inconel 825 was performed on a CNC machine using uncoated carbide tools. Tool flank wear was measured under varying spindle speeds from 300-900 RPM and feeds of 0.06, 0.08, and 0.1 mm/rev.
2. Dry turning of Inconel 825 was also performed on a conventional lathe under varying cutting conditions. Tool flank wear was again measured.
The goal of the research was to compare tool flank wear when machining Inconel 825 on a CNC machine versus a conventional
Implementation and Selection of Optimum Layout Design in Cellular Manufacturi...AM Publications
Laying out a factory involves deciding where to put all the facilities, machines, equipment and staff in the
manufacturing operation and layout determines the way in which materials and other inputs flow through the operation.
The objective of this work is to find the best layout designs with an intention of minimize the material movement and cost
to improve the over efficiency of a diligence and such extension of our work is we planned to implement this optimized
layout design in any of the industry to achieve some good results in their production. In this paper we proposed to make
a deliberate case study in a process industry to study the existing layout design. We have design the optimum layout
considering different layouts like with an aim of minimize the cost by reducing the total travelling distance of materials
and change the existing layout design for selected process industry this optimum layout design is executed using through
ARENA simulation software with different form of machine layouts.
IRJET- Effect of ICT Application in Manufacturing IndustryIRJET Journal
This document discusses the application of information and communication technologies (ICT) in manufacturing industries. It begins by defining industrial informatics as the application of IT tools and techniques to solve real-world problems in industrial settings. It then discusses how ICT can be applied across different types of industries from primary to quaternary. Key applications of ICT in manufacturing mentioned include process modeling, production scheduling and control, and knowledge management. The document also examines communication requirements and challenges at different industrial levels from machines to components. It explores opportunities for using wireless technologies and computational intelligence techniques to improve real-time capabilities and decision making in industrial settings.
This document provides a summary of a minor training report on production technology. It discusses the various departments within a production unit cell, including the material selection, testing, designing, and manufacturing departments. The material selection department chooses between metals, alloys, and plastics. The testing department evaluates materials through destructive tests like tensile and impact tests, as well as non-destructive tests. The designing department uses CAD and CAM software. Finally, the manufacturing department machines parts using CNC lathes, mills, drills, and other tools programmed based on the CAD/CAM designs.
IRJET- Design of Manufacture of Fixtures for CNC Machine to Improve Productiv...IRJET Journal
This document discusses the design of a fixture for a CNC machine to improve productivity using the SMED (Single Minute Exchange of Die) concept. It begins with an introduction to setup time reduction and the SMED methodology. It then describes the objectives of the project, problem statement, and methodology. The design of the new fixture is explained along with dimensions and assembly drawings. Testing shows the new fixture reduces setup time by 52.5% (105 minutes) and increases production capacity. The conclusions are that SMED facilitates fast changeovers and improved efficiency.
In this presentation, we will talk about the importance of technology and factory automation, along with automated manufacturing systems, types of automation, automation principles and strategies.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
Low-cost and portable automatic sheet cutterIJECEIAES
Process automation is crucial to increase productivity, more efficient use of materials, better product quality, improved safety, etc. In small-medium enterprise (SME) businesses related to household retailing, one of the process automation needed is the measurement and cutting of the mat or sheet, made of rubber or polyvinyl chloride (PVC) materials. Most of the household retailers that selling the sheet, the process of measuring and cutting according to the customer’s requirements are manually performed using a measuring tape and scissors. These manual processes can cause inaccuracy in length, inefficient use of material, low productivity and reduce product quality. This paper presents a low cost and portable automatic sheet cutter using the Arduino development board, which is used to control the process of measuring and cutting the materials. The system uses a push-button where the user can set the required length and quantity of the sheet. Once the required information is set, the stepper motor rolls the sheet until the required length is satisfied. Subsequently, another stepper motor moves the cutter horizontally and cut the sheet. With the automatic sheet cutter, the material is cut with acceptable precision. The design of the automatic sheet cutter is low cost and portable which significantly suitable to be used by SME household retailers.
Modeling and Manufacturing of an Aerospace Component by Single Point Incremen...IRJET Journal
The document describes modeling and manufacturing an aerospace component using single point incremental forming process. It discusses modeling the component and fixture in Solidworks. A static structural analysis was performed in ANSYS to study stresses and deformations on the fixture under different forming loads. The component was then manufactured using a CNC milling machine with a hemispherical forming tool following the tool trajectories from the CAD model. Analysis of stresses, strains, and deformations helped understand how process parameters affect shape accuracy in single point incremental forming.
This document summarizes research measuring tool flank wear when machining Inconel 825. The research was conducted in two stages:
1. Dry turning of Inconel 825 was performed on a CNC machine using uncoated carbide tools. Tool flank wear was measured under varying spindle speeds from 300-900 RPM and feeds of 0.06, 0.08, and 0.1 mm/rev.
2. Dry turning of Inconel 825 was also performed on a conventional lathe under varying cutting conditions. Tool flank wear was again measured.
The goal of the research was to compare tool flank wear when machining Inconel 825 on a CNC machine versus a conventional
Implementation and Selection of Optimum Layout Design in Cellular Manufacturi...AM Publications
Laying out a factory involves deciding where to put all the facilities, machines, equipment and staff in the
manufacturing operation and layout determines the way in which materials and other inputs flow through the operation.
The objective of this work is to find the best layout designs with an intention of minimize the material movement and cost
to improve the over efficiency of a diligence and such extension of our work is we planned to implement this optimized
layout design in any of the industry to achieve some good results in their production. In this paper we proposed to make
a deliberate case study in a process industry to study the existing layout design. We have design the optimum layout
considering different layouts like with an aim of minimize the cost by reducing the total travelling distance of materials
and change the existing layout design for selected process industry this optimum layout design is executed using through
ARENA simulation software with different form of machine layouts.
IRJET- Effect of ICT Application in Manufacturing IndustryIRJET Journal
This document discusses the application of information and communication technologies (ICT) in manufacturing industries. It begins by defining industrial informatics as the application of IT tools and techniques to solve real-world problems in industrial settings. It then discusses how ICT can be applied across different types of industries from primary to quaternary. Key applications of ICT in manufacturing mentioned include process modeling, production scheduling and control, and knowledge management. The document also examines communication requirements and challenges at different industrial levels from machines to components. It explores opportunities for using wireless technologies and computational intelligence techniques to improve real-time capabilities and decision making in industrial settings.
This document provides a summary of a minor training report on production technology. It discusses the various departments within a production unit cell, including the material selection, testing, designing, and manufacturing departments. The material selection department chooses between metals, alloys, and plastics. The testing department evaluates materials through destructive tests like tensile and impact tests, as well as non-destructive tests. The designing department uses CAD and CAM software. Finally, the manufacturing department machines parts using CNC lathes, mills, drills, and other tools programmed based on the CAD/CAM designs.
Study of Manufacturing of Multi-Saddle ClampIRJET Journal
The document discusses the design and manufacturing of a multi-saddle clamp die. Previously, single cavity dies were used to manufacture individual saddle clamps through bending or blanking operations. However, this was an inefficient process. The proposed multi-saddle clamp die allows for multiple clamps to be manufactured simultaneously through bending and blanking operations in the same die, improving productivity. Key requirements for the die design include producing quality products efficiently while minimizing manufacturing costs and scrap material. The methodology involves identifying the problem, collecting information, and developing a solution to design a die that can manufacture multiple saddle clamps in a single cycle through different operations like surface grinding, drilling, tapping, and wire drawing.
This document summarizes a research paper about developing an intelligent saw cutter system using image processing for safety. The system aims to prevent accidents and injuries that commonly occur when operating wood cutting saws. It works by using a camera and image processing software to detect the presence of hands near the saw blade in order to automatically stop the saw before injury occurs. The proposed system is intended to improve safety in woodworking industries and workshops by minimizing accidents caused by common human errors or lapses in concentration when using saw cutting equipment.
Design Optimization of Display Unit Supporting Structure Under Static and Spe...IRJET Journal
This document describes the design optimization of a display unit support structure using finite element analysis. A 3D model of the display unit was created and imported into Hypermesh for meshing. An initial analysis found failure in some components under the design loads. Design optimization was then performed through Ansys' design optimizer module to vary the thickness of 7 components. 21 optimized design iterations were obtained with stresses below allowable limits and increased structural safety for the given loads. The final optimized design had higher thickness values for critical components and improved stress distribution compared to the initial design.
Chapter 1 introduction to agricultural machinery designElmanTorres5
This document contains lecture notes on agricultural machinery design. It outlines the current state of agricultural machinery in the Philippines, which focuses on developing tillers, pumps, transplanters and other equipment. It then discusses the classifications, general considerations and procedures for machine design, including standards, economics, stresses, uncertainties and units. The notes provide an introduction to the topic and outline the key aspects that will be covered.
IRJET- Modelling & Analysis of Drill Bit with Different MaterialsIRJET Journal
This document analyzes the modeling and performance of drill bits made from different materials, including high-speed steel (HSS) and two types of titanium alloy (alpha and beta). A twist drill bit model with dimensions of 8mm diameter and 80mm flute length is created in SOLIDWORKS. Finite element analysis is performed in ANSYS to compare equivalent stress, strain, and deformation between the materials when subjected to torque loads. The results show that the beta titanium alloy exhibits the highest effective strain but lowest equivalent stress compared to the other materials.
RECENT DEVELOPMENTS AND DESIGN OF TOOLS FOR PUNCHING AND CUTTINGIAEME Publication
Intensive utilization of computers is especially emphasized in the field of industrial
production, where use of computer applications achieves significant savings in regard
to the time required for manufacturing of products. Shortening of the production time
decreases the production costs and new products are faster introduced to the market,
thus making the company more competitive. In addition to the shorter time for
production, better precision and accuracy is also accomplished, resulting with better
product quality at the end.
Due to the fact that, for the reason of cost-effectiveness of manufacturing of tools,
processing of sheet metal on presses is primarily performed in the course of serial
production, this paper focuses on an analysis of the use of computers in the process of
design of tools for punching and cutting of sheet metal on presses. The presented
methodology encompasses all phases in the process of design of tools – from planning
the work piece until the final design of the tool for punching and cutting, with an
emphasis on the activities performed exclusively by computer applications.
The result of this research is a 3D geometrical model of a tool for punching and
cutting, with an explanation of characteristics of its construction parts, calculation of
its executive parts, analysis and simulation of operation of the tool, and finally the
conclusion on the representation and importance of the utilization of computer
applications in the process of design of such tools
Design of computer aided process plan for a casing cover plateIAEME Publication
This document describes the design of a Computer Aided Process Plan (CAPP) for manufacturing a casing cover plate using NX 7.5 software. The CAPP design considers various process planning activities including layered manufacturing, interpreting product design data, selecting machining processes, tools, and machines, determining setup requirements, sequencing operations, and generating process sheets. Specifically, it involves generating a 3D model from 2D drawings, creating an NC program, selecting cast aluminum material, and using a 5-axis milling machine with tools like slot drills and end mills to machine the casing cover plate.
IRJET- Static Structural Analysis of Roll Cage for Self Propelled Onion Harve...IRJET Journal
1) Researchers designed and analyzed the roll cage for a self-propelled onion harvester to maximize safety, comfort, and performance.
2) The roll cage was modeled in Solidworks and analyzed using ANSYS to evaluate stresses and ensure a safety factor above requirements. Low carbon steel was selected for its strength and affordability.
3) Static structural analysis found the maximum von Mises stress to be 150.59 MPa and maximum principal stress to be 101.41 MPa, below the material yield strength, indicating the design would safely withstand loads.
IRJET - A Systematic Review on Powder Mixed Electric Discharge Machining (PME...IRJET Journal
This document provides a systematic review of the Powder Mixed Electric Discharge Machining (PMEDM) process. PMEDM is an advanced EDM technique that improves process efficiency by mixing electrically conductive powder additives into the dielectric fluid. This decreases the dielectric strength and increases the inter-electrode gap, resulting in improved surface finish and material removal rate compared to conventional EDM. The document discusses the working principles of PMEDM, effects of different powder additives, applications, and conclusions that PMEDM enhances EDM performance and machining capabilities for difficult-to-machine materials.
Implementation of a Cellular Manufacturing Tool for Minimization of Non Value...IJERA Editor
The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to reduce wastes in the system; increasing profit and reducing lead-times. Current state and future state of manufacturing of a firm are compared and witnessed: 50 percent reduction in lead time, 4 percent reduction in processing time, 58.5 percent reduction in WIP and 22 percent reduction in manpower required to perform same amount of work.
This document provides a report on an embedded systems industrial training submitted by Islam Nabil Mahmoud. The report covers several topics related to embedded systems including microcontrollers, system on chip, differences between microprocessors and microcontrollers, microcontroller CPU architectures, memory types, real time systems, simulators vs emulators, C programming, data structures and algorithms, computer architecture, and several labs completed during the training. The training was supervised by Dr. Mohamed Ali Torad and took place from May to August 2017 at the Higher Technology Institute.
A Review on System-on-Chip (SoC) Designs for Real-Time Industrial Applicationijtsrd
Now-a-days System-on-a-chip (SoC) technology is used in small, increasingly complex consumer electronic devices. A system-on-a-chip (SoC) is a microchip with all the necessary electronic circuits and parts for a given system, such as a Smartphone or wearable computer, on a single integrated circuit (IC). Day by day the scope & use of the electronics concepts in industrial field is increasing step by step. In this paper the review of newly developed concepts is done for the SoC design for real time industrial application. This paper also reviews a power and area efficient for industrial application. Further the study of SoC designs for real time industrial application has been carried out. Mr. Abhijit Patil | Mr. A. A. Shirolkar"A Review on System-on-Chip (SoC) Designs for Real-Time Industrial Application" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-1 , December 2017, URL: http://www.ijtsrd.com/papers/ijtsrd7077.pdf http://www.ijtsrd.com/engineering/electronics-and-communication-engineering/7077/a-review-on-system-on-chip-soc-designs-for--real-time-industrial-application/mr-abhijit-patil
IRJET- AODV and DSR Routing Protocol Performance Comparison in MANET using Ne...IRJET Journal
This document compares the performance of two mobile ad hoc network (MANET) routing protocols: Ad hoc On-Demand Distance Vector (AODV) and Dynamic Source Routing (DSR). The protocols were evaluated using the Network Simulator 2 (NS2) across three simulation scenarios with varying time durations. The results showed that AODV had lower initial packet loss compared to DSR. However, at longer simulation times both protocols performed similarly with comparable packet delivery ratios. In conclusion, AODV is more suitable when the MANET needs to be established quickly, while both protocols can be used for longer-term MANETs as their performance converges over time.
Abstract: This Project presents the Design of Machining Fixture for Support Bracket for Machining on VTC (Vertical Turning Centre). Fixture Design consists of High product rate, low manufacturing operation cost. The fixture should be designed in such-a-way that part/product change overtime is very less. The report consists of study of input data from customers like Part drawing and Assembly drawing. The fixture design begins with part modeling, Machining and Analysis of various parts in the fixture assembly using AutoCAD and Solid works, for a analysis ANSYS Software package is used. The actual design begins with study details of project proposal summary from customer. After that machining fixture concept is done. Locating and clamping points are decided. This also includes accessibility, loading and unloading sequence of parts, required material for this fixture is selected, and Fixture is designed at HMT MACHINE TOOL, KALAMASSERY using Industrial application standards. Locating accuracy and machined part quality tested and found that the fixture is as good as any dedicated fixture in production.
The present paper deals with development of Computer Govern Maintenance System (CGMS) for a Process
Industry. The developed software is easy to use, less complicated, less costly and less time consuming and
consisting of number of modules like detailed information of equipment, procedures of maintenance tasks,
employees, work order, and calendar facility etc. The software has been developed in Microsoft Visual Studio.NET.
The development of CGMS Software i.e. ‘IOCL CGMS’ at “IOCL Panipat Refinery”, Panipat, may furnish good
results. The currently developed CGMS aims to reduce total downtime, overall annual maintenance cost, frequency
of failures of the machines, to get day-by-day maintenance schedule, maintenance policy.
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
SSIP's T-shaped movement is about open innovation for people's knowledge (what), skills (how), attitudes (why), and networks (who) - know what, know how, know why, know who.
This document discusses different types of timber flooring, including solid wood, reclaimed timber, multi-layered or engineered wood, vinyl, and laminate flooring. It provides details on the construction and characteristics of each type. Advantages include durability, ease of installation, and longevity. Disadvantages include potential noise, inability to repair damage via sanding, and imperfections in reclaimed timber. A range of costs for different flooring options is also presented.
This document summarizes various woodworking techniques including lathe/wood turning, joinery, CNC cutting, carving, and wood bending. It describes the key aspects of each technique such as the different methods of wood turning including spindle and faceplate turning. It also outlines the process of CNC cutting using CAD/CAM software and machines, provides examples of joints used in joinery, and explains the tools and techniques used in wood carving. Price ranges for CNC cutting of wood boards are also included.
Study of Manufacturing of Multi-Saddle ClampIRJET Journal
The document discusses the design and manufacturing of a multi-saddle clamp die. Previously, single cavity dies were used to manufacture individual saddle clamps through bending or blanking operations. However, this was an inefficient process. The proposed multi-saddle clamp die allows for multiple clamps to be manufactured simultaneously through bending and blanking operations in the same die, improving productivity. Key requirements for the die design include producing quality products efficiently while minimizing manufacturing costs and scrap material. The methodology involves identifying the problem, collecting information, and developing a solution to design a die that can manufacture multiple saddle clamps in a single cycle through different operations like surface grinding, drilling, tapping, and wire drawing.
This document summarizes a research paper about developing an intelligent saw cutter system using image processing for safety. The system aims to prevent accidents and injuries that commonly occur when operating wood cutting saws. It works by using a camera and image processing software to detect the presence of hands near the saw blade in order to automatically stop the saw before injury occurs. The proposed system is intended to improve safety in woodworking industries and workshops by minimizing accidents caused by common human errors or lapses in concentration when using saw cutting equipment.
Design Optimization of Display Unit Supporting Structure Under Static and Spe...IRJET Journal
This document describes the design optimization of a display unit support structure using finite element analysis. A 3D model of the display unit was created and imported into Hypermesh for meshing. An initial analysis found failure in some components under the design loads. Design optimization was then performed through Ansys' design optimizer module to vary the thickness of 7 components. 21 optimized design iterations were obtained with stresses below allowable limits and increased structural safety for the given loads. The final optimized design had higher thickness values for critical components and improved stress distribution compared to the initial design.
Chapter 1 introduction to agricultural machinery designElmanTorres5
This document contains lecture notes on agricultural machinery design. It outlines the current state of agricultural machinery in the Philippines, which focuses on developing tillers, pumps, transplanters and other equipment. It then discusses the classifications, general considerations and procedures for machine design, including standards, economics, stresses, uncertainties and units. The notes provide an introduction to the topic and outline the key aspects that will be covered.
IRJET- Modelling & Analysis of Drill Bit with Different MaterialsIRJET Journal
This document analyzes the modeling and performance of drill bits made from different materials, including high-speed steel (HSS) and two types of titanium alloy (alpha and beta). A twist drill bit model with dimensions of 8mm diameter and 80mm flute length is created in SOLIDWORKS. Finite element analysis is performed in ANSYS to compare equivalent stress, strain, and deformation between the materials when subjected to torque loads. The results show that the beta titanium alloy exhibits the highest effective strain but lowest equivalent stress compared to the other materials.
RECENT DEVELOPMENTS AND DESIGN OF TOOLS FOR PUNCHING AND CUTTINGIAEME Publication
Intensive utilization of computers is especially emphasized in the field of industrial
production, where use of computer applications achieves significant savings in regard
to the time required for manufacturing of products. Shortening of the production time
decreases the production costs and new products are faster introduced to the market,
thus making the company more competitive. In addition to the shorter time for
production, better precision and accuracy is also accomplished, resulting with better
product quality at the end.
Due to the fact that, for the reason of cost-effectiveness of manufacturing of tools,
processing of sheet metal on presses is primarily performed in the course of serial
production, this paper focuses on an analysis of the use of computers in the process of
design of tools for punching and cutting of sheet metal on presses. The presented
methodology encompasses all phases in the process of design of tools – from planning
the work piece until the final design of the tool for punching and cutting, with an
emphasis on the activities performed exclusively by computer applications.
The result of this research is a 3D geometrical model of a tool for punching and
cutting, with an explanation of characteristics of its construction parts, calculation of
its executive parts, analysis and simulation of operation of the tool, and finally the
conclusion on the representation and importance of the utilization of computer
applications in the process of design of such tools
Design of computer aided process plan for a casing cover plateIAEME Publication
This document describes the design of a Computer Aided Process Plan (CAPP) for manufacturing a casing cover plate using NX 7.5 software. The CAPP design considers various process planning activities including layered manufacturing, interpreting product design data, selecting machining processes, tools, and machines, determining setup requirements, sequencing operations, and generating process sheets. Specifically, it involves generating a 3D model from 2D drawings, creating an NC program, selecting cast aluminum material, and using a 5-axis milling machine with tools like slot drills and end mills to machine the casing cover plate.
IRJET- Static Structural Analysis of Roll Cage for Self Propelled Onion Harve...IRJET Journal
1) Researchers designed and analyzed the roll cage for a self-propelled onion harvester to maximize safety, comfort, and performance.
2) The roll cage was modeled in Solidworks and analyzed using ANSYS to evaluate stresses and ensure a safety factor above requirements. Low carbon steel was selected for its strength and affordability.
3) Static structural analysis found the maximum von Mises stress to be 150.59 MPa and maximum principal stress to be 101.41 MPa, below the material yield strength, indicating the design would safely withstand loads.
IRJET - A Systematic Review on Powder Mixed Electric Discharge Machining (PME...IRJET Journal
This document provides a systematic review of the Powder Mixed Electric Discharge Machining (PMEDM) process. PMEDM is an advanced EDM technique that improves process efficiency by mixing electrically conductive powder additives into the dielectric fluid. This decreases the dielectric strength and increases the inter-electrode gap, resulting in improved surface finish and material removal rate compared to conventional EDM. The document discusses the working principles of PMEDM, effects of different powder additives, applications, and conclusions that PMEDM enhances EDM performance and machining capabilities for difficult-to-machine materials.
Implementation of a Cellular Manufacturing Tool for Minimization of Non Value...IJERA Editor
The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to reduce wastes in the system; increasing profit and reducing lead-times. Current state and future state of manufacturing of a firm are compared and witnessed: 50 percent reduction in lead time, 4 percent reduction in processing time, 58.5 percent reduction in WIP and 22 percent reduction in manpower required to perform same amount of work.
This document provides a report on an embedded systems industrial training submitted by Islam Nabil Mahmoud. The report covers several topics related to embedded systems including microcontrollers, system on chip, differences between microprocessors and microcontrollers, microcontroller CPU architectures, memory types, real time systems, simulators vs emulators, C programming, data structures and algorithms, computer architecture, and several labs completed during the training. The training was supervised by Dr. Mohamed Ali Torad and took place from May to August 2017 at the Higher Technology Institute.
A Review on System-on-Chip (SoC) Designs for Real-Time Industrial Applicationijtsrd
Now-a-days System-on-a-chip (SoC) technology is used in small, increasingly complex consumer electronic devices. A system-on-a-chip (SoC) is a microchip with all the necessary electronic circuits and parts for a given system, such as a Smartphone or wearable computer, on a single integrated circuit (IC). Day by day the scope & use of the electronics concepts in industrial field is increasing step by step. In this paper the review of newly developed concepts is done for the SoC design for real time industrial application. This paper also reviews a power and area efficient for industrial application. Further the study of SoC designs for real time industrial application has been carried out. Mr. Abhijit Patil | Mr. A. A. Shirolkar"A Review on System-on-Chip (SoC) Designs for Real-Time Industrial Application" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-1 , December 2017, URL: http://www.ijtsrd.com/papers/ijtsrd7077.pdf http://www.ijtsrd.com/engineering/electronics-and-communication-engineering/7077/a-review-on-system-on-chip-soc-designs-for--real-time-industrial-application/mr-abhijit-patil
IRJET- AODV and DSR Routing Protocol Performance Comparison in MANET using Ne...IRJET Journal
This document compares the performance of two mobile ad hoc network (MANET) routing protocols: Ad hoc On-Demand Distance Vector (AODV) and Dynamic Source Routing (DSR). The protocols were evaluated using the Network Simulator 2 (NS2) across three simulation scenarios with varying time durations. The results showed that AODV had lower initial packet loss compared to DSR. However, at longer simulation times both protocols performed similarly with comparable packet delivery ratios. In conclusion, AODV is more suitable when the MANET needs to be established quickly, while both protocols can be used for longer-term MANETs as their performance converges over time.
Abstract: This Project presents the Design of Machining Fixture for Support Bracket for Machining on VTC (Vertical Turning Centre). Fixture Design consists of High product rate, low manufacturing operation cost. The fixture should be designed in such-a-way that part/product change overtime is very less. The report consists of study of input data from customers like Part drawing and Assembly drawing. The fixture design begins with part modeling, Machining and Analysis of various parts in the fixture assembly using AutoCAD and Solid works, for a analysis ANSYS Software package is used. The actual design begins with study details of project proposal summary from customer. After that machining fixture concept is done. Locating and clamping points are decided. This also includes accessibility, loading and unloading sequence of parts, required material for this fixture is selected, and Fixture is designed at HMT MACHINE TOOL, KALAMASSERY using Industrial application standards. Locating accuracy and machined part quality tested and found that the fixture is as good as any dedicated fixture in production.
The present paper deals with development of Computer Govern Maintenance System (CGMS) for a Process
Industry. The developed software is easy to use, less complicated, less costly and less time consuming and
consisting of number of modules like detailed information of equipment, procedures of maintenance tasks,
employees, work order, and calendar facility etc. The software has been developed in Microsoft Visual Studio.NET.
The development of CGMS Software i.e. ‘IOCL CGMS’ at “IOCL Panipat Refinery”, Panipat, may furnish good
results. The currently developed CGMS aims to reduce total downtime, overall annual maintenance cost, frequency
of failures of the machines, to get day-by-day maintenance schedule, maintenance policy.
Sand casting conventional and rapid prototyping manufacturing approacheseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
SSIP's T-shaped movement is about open innovation for people's knowledge (what), skills (how), attitudes (why), and networks (who) - know what, know how, know why, know who.
This document discusses different types of timber flooring, including solid wood, reclaimed timber, multi-layered or engineered wood, vinyl, and laminate flooring. It provides details on the construction and characteristics of each type. Advantages include durability, ease of installation, and longevity. Disadvantages include potential noise, inability to repair damage via sanding, and imperfections in reclaimed timber. A range of costs for different flooring options is also presented.
This document summarizes various woodworking techniques including lathe/wood turning, joinery, CNC cutting, carving, and wood bending. It describes the key aspects of each technique such as the different methods of wood turning including spindle and faceplate turning. It also outlines the process of CNC cutting using CAD/CAM software and machines, provides examples of joints used in joinery, and explains the tools and techniques used in wood carving. Price ranges for CNC cutting of wood boards are also included.
Bearing joints are used at right angles where two members meet to provide strength. Various bearing joints are described including the chase-mortise joint, cogged joint, double tenon joint, dovetailed joint, halved joint, housed joint, and joggle tenon joint. The most common bearing joint is the mortise and tenon joint, which involves cutting a tenon on one member that fits into a corresponding mortise cut into the other member. Other joints like the notched joint, tusk-tenon joint, and oblique shouldered joints are used when members meet at obtuse or acute angles.
This document provides instructions for installing sheet wall panelling. It includes a list of required materials and tools, as well as steps for estimating quantities, preparing the wall surface, and fitting the wall panels using either nails or adhesive. Key points covered are checking for a flat surface, attaching horizontal and vertical battens, applying adhesive, and securing panels starting from the center and working outwards. The goal is to provide easy to follow guidance for giving walls a new look using wall panelling.
1. Wood is a natural material composed mainly of cellulose that is used widely in building, tools, vehicles, and decorative objects. It is composed of fibers that transport water and provide mechanical strength.
2. There are various terms used to describe wood depending on its application, such as carpentry, timbering, joinery, and cabinetry. Knots will affect the properties of sawn wood.
3. The density, strength, and other properties of wood vary depending on factors like species, moisture content, and processing. Both hardwoods and softwoods have distinct characteristics and applications.
The document provides information on various types of timber finishes including stains, paints, and clear finishes. It discusses factors that affect finish performance such as wood type and grain, moisture, surface preparation, and weathering. The purpose of finishes is to both protect the timber from the elements and add aesthetic qualities. Proper selection and application of finishes is important for durability.
The document discusses various types of wood joints used in furniture making, including butt joints, dowel joints, biscuit joints, tongue and groove joints, mortise and tenon joints, dovetail joints, housing joints, rule joints, and knuckle joints. It also introduces modern techniques for wood joining like dowels, biscuits, dominos, beadlock pro, and slip slot mortise mills that use machines and jigs.
Wood flooring is made from timber and designed for use as flooring. It is a common choice due to its environmental profile, durability, and ability to be restored. There are two main types: solid wood flooring made from a single piece of timber, and engineered wood flooring composed of two or more wood layers for increased stability. Wood flooring provides acoustic benefits, natural beauty, sustainability as a renewable material, and good insulation properties. It requires regular maintenance like polishing but can last a lifetime if properly cared for.
The document discusses the process of manufacturing plywood. It begins with logging operations such as debarking and cutting logs. The logs are then heated and sliced/peeled into veneers. Veneers are dried and laid up in alternating perpendicular layers, with glue spread between layers. The laid up assembly is pressed under heat and pressure to bond the layers. Plywood is then cut and finished, with applications including construction, furniture, flooring, and more. Benefits of plywood include uniform strength, dimensional stability, and efficient wood utilization, while disadvantages include susceptibility to water damage if unprotected.
Plywood is a manufactured wood panel made of thin layers of wood veneer glued together. It was invented in the 19th century by Immanuel Nobel as a stronger alternative to solid wood. Plywood has face veneers of higher quality wood and core veneers to increase bending resistance. Common dimensions are 1.2m x 2.4m or 4ft x 8ft, with ply thicknesses ranging from 1.4mm to 4.3mm depending on the number of plies. There are several types including softwood, hardwood, tropical, decorative, and marine plywood used for various construction and industrial applications.
Does specifying wood seem like a foreign language? Then this presentation is for you. You'll receive an overview of wood terminology, applications of wood materials, production of wood, characteristics of wood and relationship with properties, grading, durability, specification and handling as well as an overview of manufactured wood products such as laminated veneer lumber (LVL)
This document describes several common types of wood joints:
Dowel joints use dowels inserted into drilled holes for strength. Dado joints cut away wood to hold shelves without fasteners. Rabbet joints cut wood at specific lengths then glue them together. Lap joints overlap cut wood and glue or nail them together. Dovetail joints cut interlocking wood shapes to join drawers strongly. Mortise and tenon joints cut a tenon that inserts into a mortise for a very strong connection. Miter joints at corners can be strengthened with hidden wood splines. Tongue and groove joints insert a tongue into a groove to join flooring or panels edge to edge into a flat surface.
Aggregate are important constituents in concrete, making up 70-80% of its volume. Aggregates can be classified in several ways: by size (coarse or fine), source (natural or manufactured), unit weight (lightweight, normal weight, or heavyweight), shape (rounded, angular, flaky), and surface texture (smooth, granular, crystalline). Ideal aggregates are hard, strong, durable, dense, clean, and free of materials that could compromise the concrete. Tests are conducted on aggregates to determine properties like particle size, impact value, crushing value, and abrasion value to ensure good quality for use in concrete.
This document discusses different types of wood joints used in furniture and woodworking. It describes various butt, edge, halving, housing, bridle, finger, mortise and tenon, dovetail, screw, plug, block, mitre, and dowel joints. Each joint type has different strengths and suitable applications. The document provides examples of describing suitable joints for joining furniture parts like table rails and legs or shelf units. It also includes a quiz to test the reader's knowledge of different joint names and parts.
IRJET- Role of Artificial Intelligence in Flexible Manufacturing Process - A ...IRJET Journal
This document discusses the role of artificial intelligence in flexible manufacturing processes. It begins by introducing the topic and defining key terms like artificial intelligence, sensors, and flexible manufacturing. It then discusses how AI can enhance manufacturing by using sensors to detect defects on production lines in real-time and make immediate adjustments to schedules and orders. The document reviews different applications of AI in manufacturing processes. It provides an overview of flexible manufacturing systems and their three main subsystems: fabrication, machining, and assembly. Finally, it presents a simple model of AI and discusses how AI can help address computational problems in manufacturing planning and scheduling.
“Remedies over the obstacles in implementing automation in indian infrastruct...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The document provides an introduction to Advance Technology in Chandigarh, which offers technical education solutions and products. It then discusses Geeta Institute of Management and Technology in Kurukshetra, which offers various degree programs and has excellent infrastructure for training and student placement. The rest of the document covers topics on industrial automation, including an introduction to programmable logic controllers (PLCs), their history and need, basic PLC architecture, and components like the CPU and I/O interfaces.
1) The document describes the design and development of a forging hammer machine. The machine is intended to replace manual hammering and increase efficiency in forging processes.
2) The forging hammer machine is designed to have a hammer that is powered by a motor and pedal system to perform automated hammering. The hammer will provide repetitive blows to shape metal between dies.
3) Testing of the forging hammer machine showed that it can reduce the time and effort required for hammering processes compared to manual hammering. The machine also allows for a more consistent and operator-independent hammering process.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IRJET- Design Development and Analysis of Low Pressure Bladeless TurbineIRJET Journal
This document discusses the design, development, and analysis of a bladeless turbine. It begins by providing background on Tesla turbines, which use boundary layer effects rather than blades. The proposed design aims to recover low pressure energy in process industries as an alternative to using throttle valves.
The design process is divided into system design and mechanical design. System design parameters like component arrangement and interaction with operators are considered. Mechanical design involves analyzing forces and selecting materials. Applications discussed include using compressed air/steam as a power source, waste pumps, and centrifugal blood pumps. The document concludes that the project helped apply engineering concepts to practical problems and learn teamwork skills.
IRJET- Six Axis Pneumatic Materials Handling Robotic ArmIRJET Journal
This document describes the design of a six-axis pneumatic robotic arm for materials handling. It begins with an abstract that outlines the goals of reducing costs associated with materials handling through automation. It then provides background on pneumatic systems and their suitability for automation in manufacturing. The document describes the design methodology, including a flow chart, and provides details on the proposed robotic arm system, including definitions of key parameters like workspace, payload capacity, accuracy and repeatability. It also defines the problems the robotic arm aims to address in materials handling. The document gives objectives to reduce time and costs of materials handling. It provides details on materials selection, frame design, selection of standard pneumatic components like cylinders and control valves. Calculations are shown
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction.
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction.
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction.
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction.
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
This document discusses the design and development of custom change management workflow templates and handlers for vehicle design release using PLM software. It describes how change management workflows can be implemented to manage the complex assembly structures of vehicles, which contain thousands of parts. Customizations are made to the PLM software using integration toolkits to track part level properties like make/buy indicators and ensure they are updated correctly. The workflows aim to efficiently manage the design change process from need for change to final released designs, while minimizing errors and manual work.
IRJET-Production of Hybrid Aluminium Matrix Composite with Welding Slag and F...IRJET Journal
This document describes the design and fabrication of a multi-purpose tooling machine. The machine allows five operations - drilling, shaping, cutting, buffing, and grinding - to be performed simultaneously using a single machine. This is more efficient than separate machines for each operation as it saves space, time, and costs for industries. The machine uses a belt drive system connected to pulleys and bevel gears to transfer power from an electric motor to shafts that drive the various tools. A scotch yoke mechanism is also used to convert rotational motion to reciprocating motion for shaping. The machine aims to improve productivity while reducing production costs for industries.
Study of Fabrication of Multipurpose Tooling MachineIRJET Journal
This document describes the design and fabrication of a multi-purpose tooling machine. The machine allows five operations - drilling, shaping, cutting, buffing, and grinding - to be performed simultaneously using a single machine. This is more efficient than separate machines for each operation as it saves space, time, and costs for industries. The machine uses a belt drive system connected to pulleys and bevel gears to transfer power from an electric motor to shafts that drive the various tools. A scotch yoke mechanism is also used to convert rotational motion to reciprocating motion for shaping. The machine aims to improve productivity while reducing production costs for industries.
RESEARCH ON PLANT LAYOUT AND PRODUCTION LINE RUNNING SIMULATION IN PISTON FAC...IAEME Publication
The aim of this paper is to create a better understanding of how simulation is used in industry especially in the area of facility layout planning. The project in which this paper is based upon concerns the development of a factory layout which will be created in a production line simulation. Background research was conducted in the field of simulations including the history, advantages, current capabilities, steps of development, and current uses. Research also concerning layout planning will also be reported in the research sections of this paper.
This document discusses using simulation software to model and optimize a production line layout for a piston factory. It begins with background on simulation software and how it is used for facility layout planning. It then describes modeling the layout and production process of a piston factory in the Arena simulation software. The simulation is used to analyze material flow and optimize the layout to improve production rates by minimizing bottlenecks. The goals are to better understand how simulation can be applied to layout planning and prove its benefits for increasing efficiency in a factory setting.
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction.
DESIGN AND DEVELOPMENT OF CUSTOM CHANGE MANAGEMENT WORKFLOW TEMPLATES AND HAN...ijcax
A large no. of automobile companies finding a convinient way to manage design changes with the use of
various PLM techniques. Change in any product is something that should occur on timely basis to match
up with customer requirement and cost reduction. The change made in the vehicle designs directly affects
various concerned agencies. Automobile Vehicle structures contains thousands of parts and if there is any
change is occurring in child parts then it becomes important to track that impacted part, propose a solution
on that part and release a new assembly structure with feasible changes such that all efforts need to be
done for cost reduction.
IRJET- Design, Development and Manufacturing of Dedicated Fixture for the...IRJET Journal
This document describes the design and development of a dedicated fixture for drilling and tapping operations on an NRV body component using a 4th axis rotary table VMC machine. It involves studying the component features, conceptualizing and detailing the fixture layout in Solidworks. Each fixturing component is designed and analyzed in ANSYS for deflections and stresses. The objectives are to design a fixture for drilling 4 holes of 11mm diameter and tapping 5 holes of M6x1 to a depth of 10mm in a single setup. The methodology involves component study, fixture planning, individual element design, assembly, manufacturing, and finite element analysis verification. Literature review discusses approaches like using genetic algorithms to optimize locator and clamp positions, reducing cycle times
Similar to Design and fabrication of automation for stapling of wooden supports to corrugated boxes (20)
Mechanical properties of hybrid fiber reinforced concrete for pavementseSAT Journals
Abstract
The effect of addition of mono fibers and hybrid fibers on the mechanical properties of concrete mixture is studied in the present
investigation. Steel fibers of 1% and polypropylene fibers 0.036% were added individually to the concrete mixture as mono fibers and
then they were added together to form a hybrid fiber reinforced concrete. Mechanical properties such as compressive, split tensile and
flexural strength were determined. The results show that hybrid fibers improve the compressive strength marginally as compared to
mono fibers. Whereas, hybridization improves split tensile strength and flexural strength noticeably.
Keywords:-Hybridization, mono fibers, steel fiber, polypropylene fiber, Improvement in mechanical properties.
Material management in construction – a case studyeSAT Journals
Abstract
The objective of the present study is to understand about all the problems occurring in the company because of improper application
of material management. In construction project operation, often there is a project cost variance in terms of the material, equipments,
manpower, subcontractor, overhead cost, and general condition. Material is the main component in construction projects. Therefore,
if the material management is not properly managed it will create a project cost variance. Project cost can be controlled by taking
corrective actions towards the cost variance. Therefore a methodology is used to diagnose and evaluate the procurement process
involved in material management and launch a continuous improvement was developed and applied. A thorough study was carried
out along with study of cases, surveys and interviews to professionals involved in this area. As a result, a methodology for diagnosis
and improvement was proposed and tested in selected projects. The results obtained show that the main problem of procurement is
related to schedule delays and lack of specified quality for the project. To prevent this situation it is often necessary to dedicate
important resources like money, personnel, time, etc. To monitor and control the process. A great potential for improvement was
detected if state of the art technologies such as, electronic mail, electronic data interchange (EDI), and analysis were applied to the
procurement process. These helped to eliminate the root causes for many types of problems that were detected.
Managing drought short term strategies in semi arid regions a case studyeSAT Journals
Abstract
Drought management needs multidisciplinary action. Interdisciplinary efforts among the experts in various fields of the droughts
prone areas are helpful to achieve tangible and permanent solution for this recurring problem. The Gulbarga district having the total
area around 16, 240 sq.km, and accounts 8.45 per cent of the Karnataka state area. The district has been situated with latitude 17º 19'
60" North and longitude of 76 º 49' 60" east. The district is situated entirely on the Deccan plateau positioned at a height of 300 to
750 m above MSL. Sub-tropical, semi-arid type is one among the drought prone districts of Karnataka State. The drought
management is very important for a district like Gulbarga. In this paper various short term strategies are discussed to mitigate the
drought condition in the district.
Keywords: Drought, South-West monsoon, Semi-Arid, Rainfall, Strategies etc.
Life cycle cost analysis of overlay for an urban road in bangaloreeSAT Journals
Abstract
Pavements are subjected to severe condition of stresses and weathering effects from the day they are constructed and opened to traffic
mainly due to its fatigue behavior and environmental effects. Therefore, pavement rehabilitation is one of the most important
components of entire road systems. This paper highlights the design of concrete pavement with added mono fibers like polypropylene,
steel and hybrid fibres for a widened portion of existing concrete pavement and various overlay alternatives for an existing
bituminous pavement in an urban road in Bangalore. Along with this, Life cycle cost analyses at these sections are done by Net
Present Value (NPV) method to identify the most feasible option. The results show that though the initial cost of construction of
concrete overlay is high, over a period of time it prove to be better than the bituminous overlay considering the whole life cycle cost.
The economic analysis also indicates that, out of the three fibre options, hybrid reinforced concrete would be economical without
compromising the performance of the pavement.
Keywords: - Fatigue, Life cycle cost analysis, Net Present Value method, Overlay, Rehabilitation
Laboratory studies of dense bituminous mixes ii with reclaimed asphalt materialseSAT Journals
Abstract
The issue of growing demand on our nation’s roadways over that past couple of decades, decreasing budgetary funds, and the need to
provide a safe, efficient, and cost effective roadway system has led to a dramatic increase in the need to rehabilitate our existing
pavements and the issue of building sustainable road infrastructure in India. With these emergency of the mentioned needs and this
are today’s burning issue and has become the purpose of the study.
In the present study, the samples of existing bituminous layer materials were collected from NH-48(Devahalli to Hassan) site.The
mixtures were designed by Marshall Method as per Asphalt institute (MS-II) at 20% and 30% Reclaimed Asphalt Pavement (RAP).
RAP material was blended with virgin aggregate such that all specimens tested for the, Dense Bituminous Macadam-II (DBM-II)
gradation as per Ministry of Roads, Transport, and Highways (MoRT&H) and cost analysis were carried out to know the economics.
Laboratory results and analysis showed the use of recycled materials showed significant variability in Marshall Stability, and the
variability increased with the increase in RAP content. The saving can be realized from utilization of recycled materials as per the
methodology, the reduction in the total cost is 19%, 30%, comparing with the virgin mixes.
Keywords: Reclaimed Asphalt Pavement, Marshall Stability, MS-II, Dense Bituminous Macadam-II
Laboratory investigation of expansive soil stabilized with natural inorganic ...eSAT Journals
This document summarizes a study on stabilizing expansive black cotton soil with the natural inorganic stabilizer RBI-81. Laboratory tests were conducted to evaluate the effect of RBI-81 on the soil's engineering properties. The tests showed that with 2% RBI-81 and 28 days of curing, the unconfined compressive strength increased by around 250% and the CBR value improved by approximately 400% compared to the untreated soil. Overall, the study found that RBI-81 effectively improved the strength properties of the black cotton soil and its suitability as a soil stabilizer was supported.
Influence of reinforcement on the behavior of hollow concrete block masonry p...eSAT Journals
Abstract
Reinforced masonry was developed to exploit the strength potential of masonry and to solve its lack of tensile strength. Experimental
and analytical studies have been carried out to investigate the effect of reinforcement on the behavior of hollow concrete block
masonry prisms under compression and to predict ultimate failure compressive strength. In the numerical program, three dimensional
non-linear finite elements (FE) model based on the micro-modeling approach is developed for both unreinforced and reinforced
masonry prisms using ANSYS (14.5). The proposed FE model uses multi-linear stress-strain relationships to model the non-linear
behavior of hollow concrete block, mortar, and grout. Willam-Warnke’s five parameter failure theory has been adopted to model the
failure of masonry materials. The comparison of the numerical and experimental results indicates that the FE models can successfully
capture the highly nonlinear behavior of the physical specimens and accurately predict their strength and failure mechanisms.
Keywords: Structural masonry, Hollow concrete block prism, grout, Compression failure, Finite element method,
Numerical modeling.
Influence of compaction energy on soil stabilized with chemical stabilizereSAT Journals
This document summarizes a study on the influence of compaction energy on soil stabilized with a chemical stabilizer. Laboratory tests were conducted on locally available loamy soil treated with a patented polymer liquid stabilizer and compacted at four different energy levels. The study found that increasing the compaction effort increased the density of both untreated and treated soil, but the rate of increase was lower for stabilized soil. Treating the soil with the stabilizer improved its unconfined compressive strength and resilient modulus, and reduced accumulated plastic strain, with these properties further improved by higher compaction efforts. The stabilized soil exhibited strength and performance benefits compared to the untreated soil.
Geographical information system (gis) for water resources managementeSAT Journals
This document describes a hydrological framework developed in the form of a Hydrologic Information System (HIS) to meet the information needs of various government departments related to water management in a state. The HIS consists of a hydrological database coupled with tools for collecting and analyzing spatial and non-spatial water resources data. It also incorporates a hydrological model to indirectly assess water balance components over space and time. A web-based GIS portal was created to allow users to access and visualize the hydrological data, as well as outputs from the SWAT hydrological model. The framework is intended to facilitate integrated water resources planning and management across different administrative levels.
Forest type mapping of bidar forest division, karnataka using geoinformatics ...eSAT Journals
Abstract
The study demonstrate the potentiality of satellite remote sensing technique for the generation of baseline information on forest types
including tree plantation details in Bidar forest division, Karnataka covering an area of 5814.60Sq.Kms. The Total Area of Bidar
forest division is 5814Sq.Kms analysis of the satellite data in the study area reveals that about 84% of the total area is Covered by
crop land, 1.778% of the area is covered by dry deciduous forest, 1.38 % of mixed plantation, which is very threatening to the
environmental stability of the forest, future plantation site has been mapped. With the use of latest Geo-informatics technology proper
and exact condition of the trees can be observed and necessary precautions can be taken for future plantation works in an appropriate
manner
Keywords:-RS, GIS, GPS, Forest Type, Tree Plantation
Factors influencing compressive strength of geopolymer concreteeSAT Journals
Abstract
To study effects of several factors on the properties of fly ash based geopolymer concrete on the compressive strength and also the
cost comparison with the normal concrete. The test variables were molarities of sodium hydroxide(NaOH) 8M,14M and 16M, ratio of
NaOH to sodium silicate (Na2SiO3) 1, 1.5, 2 and 2.5, alkaline liquid to fly ash ratio 0.35 and 0.40 and replacement of water in
Na2SiO3 solution by 10%, 20% and 30% were used in the present study. The test results indicated that the highest compressive
strength 54 MPa was observed for 16M of NaOH, ratio of NaOH to Na2SiO3 2.5 and alkaline liquid to fly ash ratio of 0.35. Lowest
compressive strength of 27 MPa was observed for 8M of NaOH, ratio of NaOH to Na2SiO3 is 1 and alkaline liquid to fly ash ratio of
0.40. Alkaline liquid to fly ash ratio of 0.35, water replacement of 10% and 30% for 8 and 16 molarity of NaOH and has resulted in
compressive strength of 36 MPa and 20 MPa respectively. Superplasticiser dosage of 2 % by weight of fly ash has given higher
strength in all cases.
Keywords: compressive strength, alkaline liquid, fly ash
Experimental investigation on circular hollow steel columns in filled with li...eSAT Journals
Abstract
Composite Circular hollow Steel tubes with and without GFRP infill for three different grades of Light weight concrete are tested for
ultimate load capacity and axial shortening , under Cyclic loading. Steel tubes are compared for different lengths, cross sections and
thickness. Specimens were tested separately after adopting Taguchi’s L9 (Latin Squares) Orthogonal array in order to save the initial
experimental cost on number of specimens and experimental duration. Analysis was carried out using ANN (Artificial Neural
Network) technique with the assistance of Mini Tab- a statistical soft tool. Comparison for predicted, experimental & ANN output is
obtained from linear regression plots. From this research study, it can be concluded that *Cross sectional area of steel tube has most
significant effect on ultimate load carrying capacity, *as length of steel tube increased- load carrying capacity decreased & *ANN
modeling predicted acceptable results. Thus ANN tool can be utilized for predicting ultimate load carrying capacity for composite
columns.
Keywords: Light weight concrete, GFRP, Artificial Neural Network, Linear Regression, Back propagation, orthogonal
Array, Latin Squares
Experimental behavior of circular hsscfrc filled steel tubular columns under ...eSAT Journals
This document summarizes an experimental study that tested circular concrete-filled steel tube columns with varying parameters. 45 specimens were tested with different fiber percentages (0-2%), tube diameter-to-wall-thickness ratios (D/t from 15-25), and length-to-diameter (L/d) ratios (from 2.97-7.04). The results found that columns filled with fiber-reinforced concrete exhibited higher stiffness, equal ductility, and enhanced energy absorption compared to those filled with plain concrete. The load carrying capacity increased with fiber content up to 1.5% but not at 2.0%. The analytical predictions of failure load closely matched the experimental values.
Evaluation of punching shear in flat slabseSAT Journals
Abstract
Flat-slab construction has been widely used in construction today because of many advantages that it offers. The basic philosophy in
the design of flat slab is to consider only gravity forces; this method ignores the effect of punching shear due to unbalanced moments
at the slab column junction which is critical. An attempt has been made to generate generalized design sheets which accounts both
punching shear due to gravity loads and unbalanced moments for cases (a) interior column; (b) edge column (bending perpendicular
to shorter edge); (c) edge column (bending parallel to shorter edge); (d) corner column. These design sheets are prepared as per
codal provisions of IS 456-2000. These design sheets will be helpful in calculating the shear reinforcement to be provided at the
critical section which is ignored in many design offices. Apart from its usefulness in evaluating punching shear and the necessary
shear reinforcement, the design sheets developed will enable the designer to fix the depth of flat slab during the initial phase of the
design.
Keywords: Flat slabs, punching shear, unbalanced moment.
Evaluation of performance of intake tower dam for recent earthquake in indiaeSAT Journals
Abstract
Intake towers are typically tall, hollow, reinforced concrete structures and form entrance to reservoir outlet works. A parametric
study on dynamic behavior of circular cylindrical towers can be carried out to study the effect of depth of submergence, wall thickness
and slenderness ratio, and also effect on tower considering dynamic analysis for time history function of different soil condition and
by Goyal and Chopra accounting interaction effects of added hydrodynamic mass of surrounding and inside water in intake tower of
dam
Key words: Hydrodynamic mass, Depth of submergence, Reservoir, Time history analysis,
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DEEP LEARNING FOR SMART GRID INTRUSION DETECTION: A HYBRID CNN-LSTM-BASED MODEL
Design and fabrication of automation for stapling of wooden supports to corrugated boxes
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DESIGN AND FABRICATION OF AUTOMATION FOR STAPLING OF
WOODEN SUPPORTS TO CORRUGATED BOXES
Aakash Todakar1
, Siddharth Patil2
, Ashish Shejwal3
, Omkar Barve4
1
B.E, Mechanical, M.I.T., Maharashtra, India
2
B.E, Mechanical, M.I.T., Maharashtra, India
3
B.E, Mechanical, M.I.T., Maharashtra, India
4
B.E, Mechanical, M.I.T., Maharashtra, India
Abstract
The scope of this research is to design an automated system by which stapling of box is done. Automation is key subject for this
project. Machine Design and Manufacturing Process were also subjects of interest. Accuracy in manufacturing was necessary for
proper functioning of system. First of all various design of system was carried out. After comparing various possibilities in every
aspect, final efficient design is selected. Design includes Scissors mechanism, Z- Shaped Base and Robot slide base. Design and
selection process includes LM Guides, Actuators, Shock Absorber, Robot, and Indexer. Design stage involved basic machine
design techniques and force analysis
-------------------------------------------------------------------***------------------------------------------------------------------
1. INTRODUCTION
With ever increasing demand for goods and services,
constant pressure to cut down costs, improve product quality
and consistency as well as to improve the worker safety
automation has now become a norm in the industries
throughout the world. Automation is helping companies to
streamline their operations and helps the companies in
gaining an edge over their competitors in terms of quality
and consistency of the product as well as in terms of
customer satisfaction. Automation can be defined as the
technology used for the application of integrated
mechanical, electronic and computer based systems in the
operation and control of production systems. Automation
covers a wide range of area ranging from manufacturing,
packaging, and transportation. The basic objective of
automation is to streamline and synchronize various
activities within the industry as well as reduction in the
workforce requirement which help in minimizing the errors
and maximizing the profits.The Indian motorcycle giant
Bajaj Auto Ltd. which is headquartered in Akurdi, Pune
with its recent takeover of the Austrian two wheeler
manufacturer KTM as well as the collaboration with
Kawasaki has seen an increasing demand for two wheelers
abroad. Some of these vehicles are exported as Completely
Built Units (CBU’s) which are packed in corrugated boxes
with a wooden support structure. With increasing volumes
there developed need for automation to staple wooden
supports to the corrugated boxes which was earlier carried
out manually.It basically consists of a wooden framework
on the top and bottom. This wooden framework along with
wooden pillars that are stapled to the corrugated boxes form
a sturdy structure which supports and safeguards the vehicle
during transportation.
1.1 Objective
The pneumatic stapling gun used for the stapling operation
comes with a built in safety mechanism that prevents the
trigger operation until and unless the stapling gun has been
pressed against the object to be stapled. But despite this
pneumatic stapling guns are a safety hazard if handled
improperly. These stapling guns are responsible for lots of
accidents globally. In case of humans there is always a
tendency to find ways to reduce the efforts and break the
rules of safety. There were a couple of accident encountered
in the company and the primary reason observed was the
very human tendency to reduce efforts that resulted in the
operator bypassing the safety mechanism. As a result of
these incidents a primary need was recognized to improve
the safety during this operation. Also this activity carried out
manually was quite labor intensive requiring three people in
order to complete the operation. And as in case of any
system man being the biggest variable there was a need
recognized to reduce the manpower for this operation.Also
cutting costs was also another objective. Another area for
improvement was the time required for stapling one box or
simply said the cycle time of the stapling operation.
Summary of the objectives:
1) Improving operator safety
2) Reducing manpower requirement
3) Cutting down the costs
4) Reducing the cycle time
1.2 Constraints
The following are the constraints for designing the system:
1) Floor space availability = 4000mm X 5000mm
2) Targeted cycle time = 60 seconds
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1.3 Current Scenario
MANUAL STAPLING OPERATION
Various activities involved in the manual stapling operation:
1) Loading of the box on fixture
2) Placing of wooden supports in the fixture
3) Manual stapling by one worker using a pneumatic
stapling gun
4) Unloading of the box from the fixture
2. LITERATURE SURVEY
2.1 Automation
Automation can be defined as the technology used for the
application of integrated mechanical, electronic and
computer based systems in the operation and control of
production systems. Automation is not new but has been in
industry for quite some time. The automation seems to be a
feasible solution for improving the productivity, quality and
economy. Manual operations lead to many accidents, poor
quality, manpower requirement. Hence automation is best
option for efficient process and more productivity.
Automation is not feasible in low scale production system
but however as the volumes goes on increasing automation
becomes more and more economically feasible. Here we are
using a fixed automation system. Technical limitation of
automation are minimal but there are social and financial
limitations, social related are that job opportunity are
reduced and that with financial are automation have high
initial cost.
2.2 Product Life Cycle of any Automation Project
1) Project Concept or ‘Need’
2) Initial Specification
3) Front End Engineering Design (FEED)
4) Detailed Engineering Design
5) Build & Delivery
6) Installation & Commissioning
7) Support
Brief explanation of the various stages:
Project Concept or ‘Need’: The birth of any project comes
from its need. Need arises either from any inherent problem
that is being faced or from the need to improve any process.
Initial Specification: It is basically a list of all the things
that would be included in the project. It is mainly aimed at
telling the customer something about the product. The
specification again may be developed as you work through
your project. Changes that may be needed during the project
have an effect on the specification, you may want to remove
some part of the design and change something else.
Front End Engineering Design (FEED): The FEED is
basic engineering which comes after the Conceptual design
or Feasibility study. The FEED design focuses the technical
requirements as well as rough investment cost for the
project.
Detailed Engineering Design: The detailed design portion
of the engineering design process is the task where the
engineer can completely describe a product through solid
modeling and drawings. Some specifications include:
Operating parameters
Operating and non-operating environmental stimuli
Test requirements
External dimensions
Maintenance and testability provisions
Materials requirements
Reliability requirements
External surface treatment
Design life
Packaging requirements
External marking
Build & Delivery: Based on the drawing that are released as
an outcome of the detailed design process the various
components are manufactured as per the specifications and
are further assembled based on the design guidelines. Once
the entire assembly is completed functionality tests are
carried out and once the product passes all tests the product
is ready to be delivered.
Installation & Commissioning: In practice, the
commissioning process comprises the integrated application
of a set of engineering techniques and procedures to check,
inspect and test every operational component of the project,
from individual functions, such as instruments and
equipment, up to complex amalgamation such as modules,
subsystems and systems.Commissioning activities, in the
broader sense, are applicable to all phases of the project,
from the basic and detailed design, procurement,
construction and assembly, until the final handover of the
unit to the owner, including sometimes an assisted operation
phase.
Support: This process mainly consists of providing training
to the on field workers required for the operation of the
equipment as well as provide any technical help required
during the operational life of the product.
2.3 Industrial Robot
Robot is defined as a reprogrammable multifunctional
manipulator designed to move materials, parts, tools, or
specialized devices through variable programmed motions
for performing a variety of tasks. It is designed for highly
repetitive jobs, like in our case the stapling process is a
repetitive process which instead is done by robot. The robot
technology has established over the period of time. It has
taken more than half a century. The first generation robots
are referred as dumb robots. These robots strictly work in a
fixed sequence. They do not have any sensors which can
take corrective action in case of deviations. Then came
second generation which was referred as clever robots. They
come with a number of sensors which can take corrective
action in case of deviations. They are capable of taking
logical decisions. The third generations of robots are
referred as intelligent robots. They are still in design stage
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they can important decisions. They are designed by using
the concept of artificial intelligence. Here we have used
universal robots which is modern and flexible industrial
robot. They are extremely compact and can be used without
any safety guarding. Any faculty with repetitive task is done
efficient by these robots. They are light weight and can be
moved to some place other easily. Programming is done
intuitively. Simply grab the robot arm and show it the
desired movement. The robot will then remember the
movements. The robot is controlled from a handy, touch-
sensitive screen with a graphical user interface. On the
screen, you can choose from a wide range of useful
functions (Teach Pendant.)
Robot Specs:
6-axis robot arm with a working radius of 850 mm / 33.5 in
Weight 18.4 kg / 40.6 lbs
Payload 5 kg / 11 lbs
Reach: 850 mm / 33.5 in
Joint ranges: +/- 360° on all joints
Speed: Joint: Max 180°/sec. Tool: Approx. 1 m/sec. /
Approx. 39.4 in/sec.
Repeatability: +/- 0.1 mm / +/- 0.0039 in (4 mil)
Footprint: Ø149 mm / 5.9 in
Degrees of freedom: 6 rotating joints
Control box size (WxHxD): 475 mm x 423 mm x 268 mm /
18.7 x 16.7 x 10.6 in
I/O ports: 10 digital in, 10 digital out, 4 analogue in, 2
analogue out
I/O power supply: 24 V 1200 mA in control box and 12
V/24 V 600 mA in tool
Communication: TCP/IP 100 Mbit: IEEE 802.3u,
100BASE-TX
Ethernet socket & Modbus TCP
Programming: Polyscope graphical user interface on
12 inch touchscreen with mounting
Noise: Comparatively noiseless
IP classification: IP54
Power consumption: Approx. 200 watts using a typical
program
Collaboration operation: Tested in accordance with sections
5.10.1 and 5.10.5 of EN ISO
10218-1:2006
Materials: Aluminium, ABS plastic
Temperature: The robot can work in a temperature range of
0-50°C
Power supply: 100-240 VAC, 50-60 Hz
Calculated Operating Life: 35,000 Hours
6 metre / 236 in cable between robot and control box
4,5 metre / 177 in cable between touchscreen and control
box.
3. DESIGN
3.1 Initial Layout Plan
As it has been decided that two robots will be allotted for the
project, the entire layout development centered on the two
robots. Therefore it was decided that we will be having two
stations, one for loading and unloading of the boxes and
another for stapling. The only thing that was needed to
decide was the way the boxes will travel from one station to
another.
Fig-1: Layout of loading and unloading station.
Based on the above comparisons it is observed that the
Layout 2 using the indexer is suitable for our application.
Therefore the design is started with Layout 2.
3.2 Major Subassemblies
3.2.1 LM Guides
The linear motion bearings allows a type of linear motion
which uses rolling elements like balls or rollers. By using
rolling elements between the rail and block high precision
motion is achieved. Compared to traditional slides the
coefficient of friction in these is only 1/50. Because of the
restraint motion it can take up loads in up/down as well as
left/right direction. This greatly helps in enhancing the
moving accuracy.
Detailed Selection Process: First we begin with
determining the required length based on the geometry of
the entire assembly as well as the various constraints.
Therefore, approximate length of the rails = 1800 mm
Next important dimension required is the spacing between
the rails. The spacing between the rails depends upon the
dimensions of the mounting plate. The dimensions of the
mounting plate depend upon the robot mounting
considerations as well as the other things that are to be
mounted.
Plate dimensions (approx.) = 260 mm × 260 mm
Assuming block width as 60 mm
We get the rail spacing as 200 mm
Next based on the guidelines in the catalogue we select the
HG series of the LM guides
Further based on the configuration that would be used we
determine the loads on the guide blocks.
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Fig-2: Position where force is acting
Total weight (W)
= weight of the robot + weight of the mounting column +
weight of the mounting plate
= (18 + 18 + 12) kg
= 48 kg
Fig-3: Free body diagram.
Based on the above figure, we have:
F = 10 × 9.81 N; L = 1180 mm
Assuming d = 100 mm
Based on the load equations shown above,
Maximum load acts on blocks 2 & 4
Therefore,
P2 = P4 =
𝐖
𝟒
+ 𝐅 × 𝐋/(𝟐 × 𝐝)
P2 = P4 = 698.96 N
Selecting a load factor, FSL = 3
Max. Load = 698.96 × 3 = 2096.88 N
Based on the standard lengths available, we select the model
HG30. Further we select the CA category indicating heavy
load. Therefore the selected model is HG30CA.
Basic Static Load Rating (C) = 52.19 kN
Basic Dynamic Load Rating (C0) = 38.74 kN
Expected life of the LM guides = 5 years
Calculating the total distance travelled during the lifetime
Distance travelled per cycle = 3000 mm = 3 m
Targeted cycle time = 60 sec
Total distance travelledper day = 3 × 10 × 60 = 1800 m =
1.8 km
Therefore, total distance covered in 5 years = 1.8 × 30 × 12
× 5
= 3240 km
Calculating the required dynamic load rating: 𝐋 =
𝐂
𝐏
𝟑
× 𝟓𝟎
Where,
L = Nominal Life of the LM bearings
C = Dynamic Load Rating
P = Max. Load
Substituting the values in the above equation, we get
C (Required) = 8.4223 kN
C (actual) = 38.74 kN
Therefore we observe that the selected model of the LM
guides is safe.
Model of the Guide and block selected: HGH-30CA.
3.2.2 Actuator Selection[7][8]
The major constraint in the selection of the actuator for this
application is the space constraints. The desired feature for
the probable actuator is compactness. The most widely used
actuators on such Special Purpose Machines are
conventional pneumatic and hydraulic actuator. The
problem with conventional actuators is that they have a large
footprint which contradicts to our requirements. Therefore
on looking into the various actuators available we could find
two actuator that suited our application. First a ball and
screw mechanism and second a rodless pneumatic
cylinder.However as the compressed air is readily available
on the shop floor we zeroed in on the rodless pneumatic
cylinder.
Rodless Pneumatic Cylinder: Rodless cylinders are linear
devices that use pressurized fluid to move a load within
power transfer operations. A rodless cylinder should be used
if the footprint of the area is small, when the load needs to
be moved some distance from the cylinder itself, and when
the load must move within the length of the cylinder.
Fig-4: Rodless pneumatic cylinder
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Selection of Rodless Pneumatic Cylinder: The selection
process for the rodless pneumatic cylinders is similar to that
of the conventional pneumatic cylinders.
We begin with the force that is required to be supplied by
the actuator.
This force can be divided into two parts:
1) The frictional resistance on account of the movement of
the robot assembly on the LM rails. It is determined by the
standard formula:
[1] 𝐅 = µ × 𝐍
Where,
F = Frictional force µ = Coefficient
of friction N = Normal Reaction
Accordingly the various values are as follows:
µ = 0.05 (Standard value supplied by the LM rail supplier)
N = 49 kg (The total weight supported by the LM rails)
2) The second force will be the external resistance due to the
robot drag chain. (The drag chain is a flexible chain that
carries the various wires that are required for the functioning
of the mobile equipment.)
Fext. = 10×9.81 N (Assumed)
Therefore the total force is the addition of the two forces
above
Ftotal = 122.1345 N
We further select a Factor of Safety (FOS) as 4,
To determine the desired bore of the cylinder we use the
formula:
Force = Pressure × Area
Pressure = 5×105
N/m2
(Available system pressure)
Area = Π /4 × D2
(Area for a circle)Where, D = Bore
Diameter
On substituting the values in the above equations, we get:
D = 35.2711 mm
On referring the catalogue for the Rodless Pneumatic
Cylinders Supplied by Festo Pneumatics, the standard sizes
of bore available are as follows: 18, 25, 32, and 40 (mm)
Therefore we select the bore size as D = 40 mm
Accordingly the model is designated as: DGC-40-1550-G-
PPV
Further we move on to the selection of shock absorbers.
3.2.3 Shock Absorber
The basic purpose of the shock absorbers is to dampen the
impact between the sliding robot assembly and the position
stops mounted on the supporting structure. The absence of
the shock absorber will result into a severe impact loading
on the entire robot assembly which is not desirable. [8][9]
The selection of the shock absorber is carried out using the
software provided by the manufacturer Festo. Below are the
snapshots from the selection software. Therefore based on
the output provided by the software the model number of the
selected shock absorber is as given: YSRW-16-26
4. WORK PRESENTATION SYSTEM
The basic purpose of the work presentation system is to
present the work to the robot in a proper a proper position
and orientation. The work presentation system is important
from the point of view of the efficient functioning of the
automation system. The various components that form a part
of our work presentation system are as follows:
4.1 Scissor Fixture
[9] A scissor lift is a device used for lifting purposes, its
objectives is to make the table adjustable to desirable height.
A scissor lift provide the most economic dependable and
versatile methods of lifting loads, it has few moving parts,
which may only require lubrication. This lift table raises the
load smoothly to any desired height. Elements of scissor
mechanism are top and bottom frame, Scissors arms,
cylinder, shafts and bearings. The frame is made up of the
scissor arms which are acting as the support to the entire
structure. A table bed platform will be at the top of the
scissor link arm. Forces and moment, but only few will be
taken into consideration because of the symmetry of various
joint and parts of the structure, i.e. reaction forces at similar
but opposite point will also be similar but might be of
different direction when all conditions are met. M will stand
for the moment about any point, while ω will be the weight
inherent in the system (i.e. weight). Also W will be used to
represent applied load i.e.Wx,Wy, Wz & in the X, Y, & Z
directions.
Fig-5: Scissor mechanism.
6. IJRET: International Journal of Research in Engineering and Technology eISSN:2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 11 | Nov-2014, Available @ http://www.ijret.org 357
Now, since in our case scissor mechanism is used for just
support, the load acting on it will be self-weight of scissor.
This will be in negative y- direction i.e. downward direction.
This is two stage scissor mechanism, with load acting
vertically downward.
Free Body Diagram:
Fig-6: Free body diagram of scissor fixture
Total Load on the system will be applied load plus self-
weight.
I.e. Total Load = Applied load + Self weight
= W + Wg = Wy
From FBD,
2Fy - 2(W/4) – (Wg/2) = 0;
Fy = (W + Wg)/4;
Fy = Wy/4;
Also summation of Moment about point C = 0;
2 (Wy/4) (d/2) cos A = (d/2) sin A (Fx – Ix);
Since one end of arm is sliding joint, hence let Ix =0;
Therefore,
Fx = Wy/ (2tan A);
Now,
Cx = Fx + Ix;
Cx = Wy/tan A;
Calculation: In our case,
Fx = Wy/ (2tan A) = 294.3N;
Fy = Wy/2=1378.6N;
Where,
Wy= self-weight of scissor=120kg.
Shaft: According to A.S.M.E code,
Material selected: 20MnCr5 with Sut = 1200 N/mm2;
Justification: Has core tensile strength, good wear
resistance;
Diameter of shaft = 10.86mm;
From design table, we select 12mm as diameter of shaft.
Bearing: Bearing selected is 6201z.
D = 32; d = 12;
Pneumatic Cylinder:
Fig-7: Pneumatic cylinder arrangements
Pneumatic cylinder arrangement: Pneumatic cylinder is
used to lift the scissor whenever the box is to be loaded. The
sequence is like, first of all scissor is lifted, then box is
mounted and then wooden pillars are placed accordingly.
The cylinder is lifted up with help of pressurized air, having
a pressure of 5 bar.
Calculation:
Weight to be lifted approx. = 90kg.
Angle of inclination (B) = 22.778deg.
Force needed to lift = W x g/ sin B = 2280.443N
Pressure available = 5 bar.
Pressure = Force / Area;
Area = Force / Pressure = 2280.443/ 5 × 105
= 4.56 × 10-3
;
Area = Π/4 × d2
;
d = 76.2 mm
Based on the standard sizes of the cylinders available as per
the Festo catalogue, the pneumatic cylinder with a bore size
of 100 mm is selected.
2) Rotary Indexer: The indexing mechanism is required in
order to carry a newly loaded box from the
loading/unloading station to the stapling station and carry
back the stapled box from the stapling station to the
loading/unloading station. The application demands the
indexing to be carried out back and forth through an angle of
180 degrees in order to prevent the twisting of the cables
and pneumatic hoses. The indexing mechanism can be
basically classified as mechanical cam driven systems and
servo motors based indexing systems. But as the angle
through which indexing is to be done is 180 degrees it
makes selection of cam based indexing system viable.
Moreover there many other advantages of a mechanical cam
based system which are given as follows:
Inertia and weight capacity: They can handle the highest-
inertia systems.
Repeatability: They are extremely repeatable and give
consistent results.
Speed: They move heavier loads at faster speeds than most
electronic systems.
7. IJRET: International Journal of Research in Engineering and Technology eISSN:2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 11 | Nov-2014, Available @ http://www.ijret.org 358
Reliability: High reliability is because of fewer components
to fail.
Repetitive motion: This is good for systems requiring
accurate repetitive cycles.
Cost effectiveness and simplicity: They can be maintained
and operated by less skilled factory personnel, but are
impervious to tampering.
Calculations and selection: The indexer is selected
according to its inertia capacity. Thus the inertia can be
calculated assuming the scissor fixtures as rectangular
volume and determining its moment of inertia about an axis
perpendicular to the plate and passing through its center and
further using the parallel axis theorem to determine the
moment of inertia about the indexer axis.
Moment of inertia of a single scissor fixture about indexer
axis = 141.186 kg-m2
Total moment of inertia for two fixtures = 282.373 kg-m2
Whereas, for the z shaped structure the moment of inertia is
determined by assuming it to be a rectangular plate and
further determining its moment of inertia.
Therefore, Moment of inertia of the z shaped structure about
the indexer axis = 264.07 kg-m2
Total moment of inertia = 282.373 + 264.07
= 546.433 kg-m2
Thus referring to the catalogue supplied by CDS Indexers,
based on the required index angle and the inertia capacity
the indexer model CDS TR315is selected which has an
inertia capacity of 697 kg-m2
, thus suitable for our
application.
Project Outcomes:
1) Reduction in the worker fatigue: As the worker is
relieved of the highly monotonous and tiring job of stapling
manually there is significant reduction in the fatigue as the
only job that is now required to be carried out by the
workers is to place the corrugated box on the scissor fixture
followed by placing the wooden supports in place and the
unloading of the stapled box after cycle completion.
2) Improved worker safety: As now the stapling activity is
carried out by the robots the workers now do not come
across the pneumatic stapling gun which is the major source
of hazard in the entire operation. Thus operating conditions
of the workers are safer.
3) Comparable cycle times: Achieving the desired cycle
time for any operation that is automated is one of the biggest
challenges faced by the designer. However in this case we
have been successful in achieving cycle times comparable to
that of the manual activity. The tables shown below:
Manual Activity:
Table-1: Manual activity chart
Activity Time (sec)
Loading box on fixture 6
Placing wooden supports 20
Stapling 60
Unloading of box from
fixture
6
Total time required =
92 sec
Automated Activity:
Table-2: Automated activity chart
Activity Time (sec)
Loading of box on scissor
fixture and raising the fixture
10
Placing wooden supports 70
Indexing 8
Stapling by robots 90
Indexing 8
Lowering of scissor fixture
and unloading the box
10
Total time
required = 98 sec
In case of the automated activity as the loading/unloading as
well as the support placement is being carried out
simultaneously with the stapling activity by the robots the
effective cycle time is the sum of the time required for
stapling or the time required for loading, unloading and
pillar placement the greater of the two and the time required
for indexing.
5. CONCLUSION
Incorporating maximum design principles for our objective
to have maximum safety of worker. Here the stapling
process needs maximum safety, because some accidents
have occurred in past, during stapling due to mishandling of
stapling gun by worker. Hence this incident is avoided here
because the staple gun and stapling is totally handled by
robot. Secondly the stapling is done with high accuracy. But
we observe here that time required for process increases by
some seconds, but that can be avoided, since our prior goal
is safety of worker. In this system worker required will be
only one, which in early stage was two. Cost of project is
also high, mainly because of robots. Nowadays companies
are investing on robots to increase the quality of work,
productivity. Hence our research is justified.
REFERENCES
[1] Design of machine elements by V.B. Bhandari,
TataMcGRAW HILL publication.
[2] PSG Design Data Book, PSG College of
Technology, 2010 Edition.
[3] Fluid Power and Application, Anthony Esposito,
Pearson Publication.
[4] Hiwin Linear guideway catalog_G99TE13-0809.
8. IJRET: International Journal of Research in Engineering and Technology eISSN:2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 03 Issue: 11 | Nov-2014, Available @ http://www.ijret.org 359
[5] Indexing and transfer, Cam Driven System
Catalogue.
[6] Shock Absorber Selection Tool, version 5.10.1.8 by
FESTO
[7] Rodless Pneumatic Cylinders, FESTO Pneumatics
catalogue.
[8] United States Patent – Pneumatic Nail Gun by We_
Chou Chang, Patent No: US 6533156 B1, March
18,2003.
[9] Scissor Lift design for use in automotive Industry
presented by Macaulay Oletu Stanley UG/07/0898.
BIOGRAPHIES
Aakash Todakar, born in Maharashtra,
India in 1992. He secured his degree in
B.E.- Mechanical from Maharashtra
Institute of Technology, pune , in 2014.
He is currently working in Bajaj auto..
He has interest in Future studies and
his interested field is Design field
Siddharth Patil, born in Maharashtra,
India in 1992. He secured his degree in
B.E. Mechanical from Maharashtra
Institute of Technology, pune , in 2014.
Future studies and interest in Design
field andprocess industry.
Ashish shejwal, born in Maharashtra,
India in 1993. He secured his degree in
B.E. Mechanical from Maharashtra
Institute of Technology, pune , in 2014.
He has completed his project and
worked as Intern at varroc polymers
pvt. Ltd. And interned in mahindra and mahindraand
volkswagon. Future studies and interest in Design field and
metallurgy.
Omkar Barve, born in Maharashtra,
India in 1993. He secured his degree in
B.E. Mechanical from Maharashtra
Institute of Technology, pune , in 2014.
Future studies and interest in aerospace
field.