Final Project Report1
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AUTOMATIC PROTECTIVE CAP PRESSING MACHINE
Design mainly refers to ‘mark out’ or to ‘designate.’
Protective cap pressing - Important operation done before dispatching the assembly.
Since this operation is considered as non-value added operation, the component of the equipment should be low.
This reduces man-power utilization & increases productivity, in turn results in cost benefits.
Protective caps protects the component from getting damaged.
Types of materials used for making protective caps.
In this regard low density polyethylene protective caps are used.
Applications- mainly protection of machined & polished surfaces, gripping, & etc.
Fig.1- Protective cap & its design
Presently in RML, protective caps are pressed manually, by placing & hammering them.
Protective caps are placed in the 8 holes & with the help of hammer force & pressure, it is inserted into the holes.
Even though man-power requirement is less, this is a time consuming process.
The figure of the component is as shown below:
8 holes where caps are inserted.
Componen t
Fig.2- Picture of the component
Cost saving is more.
Man power requirement is less.
Single
person can handle the whole process.
Skilled
persons are not required to carry out this
process. Damages
caused to the component is at a very
low rate.
Accuracy in placing the protective cap is more.
Variation
in the load, affects both cap &
component. Inspection
of hammer should be done each
time we use. Reliability Stress
is less.
on the worker is more.
Precise
working is required, which plays the
important role in maintaining accuracy.
One is having the Chute system with robotic base plate having X-Y axis to align the component.
Another option is that to make a hammer plate at the top which presses all the caps simultaneously.
Third option is having a automatic pressing machine actuated by pneumatic & electrical circuits.
First option- Easy to operate, handle, but require skilled workers, very high cost and consumes more time. Hence not feasible.
Second option- Easy to operate, handle, no need of skilled men, low cost but negligence wraths everything & its time consuming. So not feasible.
Third option- Feasible. Time consumed is less, easy to operate, no skilled workers needed, low cost.
ELEMENTS
MATERIALS USED
Component
SG Iron
Protective Cap
Low Density Polyethylene
Base Plate
Cast Iron
Pillars
C20(Carbon Steel)
Punching Plate
Tool Steel
Pusher Plate
Sheet Metal
Electrical System
Wires, Cables & Switches
Pneumatic System
C40 Steel
GROUPED SYSTEM
DIFFERENT ELEMENTS
Placing System
Conveyer, Pusher, Component loading.
Hammering System
Punching plate with piston-cylinder, pneumatic system used, Hinge (a 3 link system).
Stacking System
20 protective caps stacker, loading tray.
Miscellaneous System
Electrical, Electro-
Base Plate for placing
Stacking Sys
Miscellaneous Placing Sys
Fig.3- Pictures sys of all systems
Hammering Sys
Pneumatic refers to air pressure. Here Single acting cylinders are used to perform work.
We have one 200mm stroke cylinder & 8 block cylinders.
Electrical & logical circuitry is required to sequence the pusher & the actuator.
Thus, the operations can be carried out sequentially with out co-incidences.
Fig.4- Depicts a 200mm pneumatic Cylinder & Block Cylinder
SEQUENCE
OPERATIONS
First step
Component is loaded onto the fixture from the conveyer.
Second step
4 Pusher systems are actuated, such that it places caps from the stacker on the holes at a time.
Third step
4 Punching systems are actuated by the pneumatic cylinder to press the caps.
Fourth step
The component is taken out with the help of ejector.
Fifth step
The new component is ready for the same process to take place.
Fig.5- Complete design of the automatic
Automation increases productivity.
Easy to handle & operate.
No skilled worker is required.
Durability of the designed structure is more & is of low cost.
Pressurized air is readily available through air lines in factory, hence no extra cost.
Accuracy
& reliability is more.
Design mainly refers to ‘mark out’ or to ‘designate.’
Protective cap pressing - Important operation done before dispatching the assembly.
Since this operation is considered as non-value added operation, the component of the equipment should be low.
This reduces man-power utilization & increases productivity, in turn results in cost benefits.
Protective caps protects the component from getting damaged.
Types of materials used for making protective caps.
In this regard low density polyethylene protective caps are used.
Applications- mainly protection of machined & polished surfaces, gripping, & etc.
Fig.1- Protective cap & its design
Presently in RML, protective caps are pressed manually, by placing & hammering them.
Protective caps are placed in the 8 holes & with the help of hammer force & pressure, it is inserted into the holes.
Even though man-power requirement is less, this is a time consuming process.
The figure of the component is as shown below:
8 holes where caps are inserted.
Componen t
Fig.2- Picture of the component
Cost saving is more.
Man power requirement is less.
Single
person can handle the whole process.
Skilled
persons are not required to carry out this
process. Damages
caused to the component is at a very
low rate.
Accuracy in placing the protective cap is more.
Variation
in the load, affects both cap &
component. Inspection
of hammer should be done each
time we use. Reliability Stress
is less.
on the worker is more.
Precise
working is required, which plays the
important role in maintaining accuracy.
One is having the Chute system with robotic base plate having X-Y axis to align the component.
Another option is that to make a hammer plate at the top which presses all the caps simultaneously.
Third option is having a automatic pressing machine actuated by pneumatic & electrical circuits.
First option- Easy to operate, handle, but require skilled workers, very high cost and consumes more time. Hence not feasible.
Second option- Easy to operate, handle, no need of skilled men, low cost but negligence wraths everything & its time consuming. So not feasible.
Third option- Feasible. Time consumed is less, easy to operate, no skilled workers needed, low cost.
ELEMENTS
MATERIALS USED
Component
SG Iron
Protective Cap
Low Density Polyethylene
Base Plate
Cast Iron
Pillars
C20(Carbon Steel)
Punching Plate
Tool Steel
Pusher Plate
Sheet Metal
Electrical System
Wires, Cables & Switches
Pneumatic System
C40 Steel
GROUPED SYSTEM
DIFFERENT ELEMENTS
Placing System
Conveyer, Pusher, Component loading.
Hammering System
Punching plate with piston-cylinder, pneumatic system used, Hinge (a 3 link system).
Stacking System
20 protective caps stacker, loading tray.
Miscellaneous System
Electrical, Electro-
Base Plate for placing
Stacking Sys
Miscellaneous Placing Sys
Fig.3- Pictures sys of all systems
Hammering Sys
Pneumatic refers to air pressure. Here Single acting cylinders are used to perform work.
We have one 200mm stroke cylinder & 8 block cylinders.
Electrical & logical circuitry is required to sequence the pusher & the actuator.
Thus, the operations can be carried out sequentially with out co-incidences.
Fig.4- Depicts a 200mm pneumatic Cylinder & Block Cylinder
SEQUENCE
OPERATIONS
First step
Component is loaded onto the fixture from the conveyer.
Second step
4 Pusher systems are actuated, such that it places caps from the stacker on the holes at a time.
Third step
4 Punching systems are actuated by the pneumatic cylinder to press the caps.
Fourth step
The component is taken out with the help of ejector.
Fifth step
The new component is ready for the same process to take place.
Fig.5- Complete design of the automatic
Automation increases productivity.
Easy to handle & operate.
No skilled worker is required.
Durability of the designed structure is more & is of low cost.
Pressurized air is readily available through air lines in factory, hence no extra cost.
Accuracy
& reliability is more.
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