A

PROJECT REPORT ON

AUTOMATIC RUBBER PIPE CUTTIG MACHINE

AT

MAFLOW INDIA PVT LTD

HINJEWADI 411057, PUNE

SUBMITTED BY
CHINMAY SUDHIR CHITRAKAR
T.E. PRODUCTION ENGINEERING (SANDWICH)
EXAM SEAT NO: T150087512

UNDER THE GUIDANCE OF

MR.J.M.KHADE

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 DEPARTMENT OF PRODUCTION ENGINEERING
D. Y. PATIL COLLEGE OF ENGINEERING,
AKURDI, PUNE – 411 044
2018-2019
D.Y.PATIL COLLEGE OF ENGINEERING,

AKURDI, PUNE – 44

DEPARTMENT OF PRODUCTION ENGINEERING

CERTIFICATE

This is to certify that, MR. CHINMAY SUDHIR CHITRAKAR of TE

Production S/W Engineering, [Exam Seat No.] has satisfactorily completed his
Industrial in Plant Training and Project entitled “AUTOMATIC RUBBER PIPE
CUTTIG MACHINE” at “MAFLOW INDIA PVT LTD” from 15th JULY 2018 to
15th DECEMBER 2018 in the partial fulfilment for the course of TE Production
(Sandwich) Course of Savitribai Phule Pune University during academic year 2018-
2019.

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Mr. J.M.KHADE Dr. V.A.KULKARNI
(In Plant Training Guide) (Head of Department)

Place : Akurdi, Pune. External Examiner

Date : Name:
Signature:

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 ACKNOWLEDGEMENT

With due respect and gratitude I convey my sincere thanks to the management of
MAFLOW INDIA PVT LTD. for giving me this opportunity to undergo my training
in quality department.
I present this report, a written testimony of my invaluable training. I was
privileged to work in the company’s Quality Section with the company officers.
It is my privilege to express my deep sense of gratitude, devotion and regards
to Mr.J.M.KHADE Dept. of Production (Sandwich) Engg. for consistent guidance
and for being a constant motivation. I owe all my respect to them for helping me to do
such inexhaustible work with fresh enthusiasm.
I also thank Mr.PANKAJ GHULE (HR -Department) for giving me this
golden opportunity of doing internship project in MAFLOW INDIA PVT LTD, Pune.
I thank the entire Quality Department team for their support and willingness to help
me out.

CHINAY SUDHIR CHITRAKAR

B.E (Production –Sandwich)

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 ABSTRACT
Training in a company like MAFLOW INDIA PVT LTD was truly a great experience
and an opportunity of lifetime skill improvements. The working environment and the
people with their unmatched knowledge, provide the perfect place for anyone to
complete their Industrial training.

MAFLOW INDIA PVT LTD is a bottomless well of knowledge and skill. The variety
of machines and equipment available in one roof is just not found anywhere else.
MAFLOW INDIA PVT LTD has always been up to-date with the latest technological
developments and does its best to implement them.

The general awareness of workshop ethics and work culture is imbibed in the
employees and distinctively felt all around. The training and assignment work gave
me an opportunity to be a part of this esteemed organization, thus absorbing me into
the area of discipline and technology.

In this report, I have written most of the things that I have done and studied during my
training, although quite a bit of it was practical and involved understanding and
grasping the basic fundamental concepts.

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SR.NO TITLE PAGE
NO.
1 Chapter 1: Introduction To Company 8
1.1 Company Profile
1.2 Company Business
1.2 Mission statement
1.3 Quality Policy
1.4 Environment Policy

2 Chapter 2: project 14
2.1 Background of Project
2.2 Motivation and Scope of Project
3 Chapter 3: Literature Survey 16
4 Chapter 4: Problem Statement 18
4.1 Current Scenario of Assembly Process
4.2 Assembly Quality Issues
4.3 Benefits after Implementation of Project
5 Chapter 5: Methodology 21
5.1 Data Acquisition System
5.2 Technology Used In Project
5.3 Machines Used In Assembly Process

6 Chapter 6: System Analysis 29

6.1 Processor Module
6.2 Ethernet module
7 Chapter 7: Testing And Result 32
8 Chapter 8: Advantages, Limitations & 38
Applications
9 Chapter 9: Assignments 40
9.1 Assignment No.1
9.2 Assignment No.2
9.3 Assignment No.3

10 Chapter 10: conclusion & future scope 41

11 Chapter 11: References 49

INDEX

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 LIST OF FIGURES

FIG. NO. FIGURE PG NO.

1 Greaves Cotton LTD 8
1.1 Petrol/Kerosene Engine 9
1.2 Diesel / Gasoline Engines 10
1.3 Gensets Dual Engines / Gensets 10
1.4 Concrete Pumps Concrete Mixers Concrete Batching 11
Plants
1.5 Diesel Engines 11
5.1 Proposed Architecture for Assembly Interlocking System 24
with Data Acquisition
5.2 Power Focus with DC Nut Runner and Socket selecto 25
6.1 Interfacing SPI-Ethernet to Microcontroller 30
6.2 Ethernet Module (ENC28J60) 31
7.1 Starting Window of Client Software 32
7.2 scanning of Engine Serial No 33
7.3 Resetting the Station 34
7.4 Parameter Feeding to DBMS Software 35
7.5 Changing the Sequence of Operations in Stage 36
7.6 Software for Report 37

LIST OF TABLES

4.1 List of Engine Defects 19

5.1 Details of SPM used in Assembly of Engine 27

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 CHAPTER 1
1.1COMPANY PROFILE
INTRODUCTION TO MAFLOW INDIA PVT LTD:

Fig. 1 Shows Maflow India pvt ltd.

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 MISSION
"To manufacture and market a wide range of Air conditining tubes for
passenger car and trucks, with systems of world class technology to the
total satisfaction of customers in domestic and overseas markets."

1.1 COMPANY PROFILE

The history of MAFLOW Group dates back to 1935 with the incorporation of
"Manuli", a company which focused on the production of rubber hoses for the
transmission of liquids within hydraulic systems. The company's activity in the
automotive sector started in 1983 when Manuli together with Uniroyal bought the
European part of one of the leading air-conditioning hoses producer – Stratoflex. A
significant development of the group took place in the 90s thanks to further
acquisitions of companies linked to the production of air conditioning tubes as well as
due to the launching of new plants. From 1994 till 2017, Maflow Group launched
eleven production plants in eight countries in four continents..

Maflow India Pvt Ltd, multi-product, multi-locational company is one of the leading
engineering companies in India with core competencies in air conditioning tubes and
hoses. The Company sustains its leadership through eight manufacturing units which
produce world class products backed by comprehensive marketing and service /parts
network throughout the country.

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10
Maflow Group consistently reinforces its presence and its competitiveness on the
global market of air-conditioning hoses. The potential for Maflow Group's further
development is significant, and the road to its realization is through maintaining and
continuously developing an effective organization, producing technologically
advanced air conditioning hoses as well as taking advantage of opportunities available
thanks to the worldwide growth of the automotive market.

1 VISION

Maflow will become an effective global group, specialised in manufacturing of air-

conditioning hoses for cars produced by various automotive groups. We want to
achieve this through the development of organization, technology, and external
expansion.

2 MISSION

Following the technological and locational changes in manufacturing world, to

design, produce and supply automotive parts, which fulfil demands of our Customers.

3 VAUES

- Trust. In relations with all stakeholder groups, we strengthen our credibility by

providing stable employment conditions for our employees, high-quality products to
our clients, increasing value of the Group's shareholders, local communities,
respecting the natural environment and supporting pro-development activities, and
partner-like cooperation terms. 

- Competences. We implement innovative production solutions, improve the

qualifications of the managerial staff and employees, and integrate research and
development work with the manufacturing process. 

- Development.We are looking for new business opportunities and new markets. We
constantly enrich and improve our product offer. We implement the policy of
expanding and diversifying our business segments, using the effects of synergy and
staying consistent with the principles of sustainable development.

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BORYSZEW GROUP OVERVIEW

Boryszew Maflow Branch in Tychy is part of Boryszew S.A., one of the biggest
industrial groups in Poland and the largest Polish producer in the automotive sector.
Boryszew Group specializes in the production of car components, processing of non-
ferrous metals and industrial chemicals. Boryszew Group is made up of 30
manufacturing plants and R&D Centers located in Europe, Asia and both Americas.
The Group’s success is owed to the passion, engagement and enthusiasm of the team
of 10,000 employees working on 4 continents.

AREAS OF ACTIVITY:

Automotive:

Boryszew Group is the largest Polish producer in the automotive sector. Its plants
manufacture plastic elements (lockers, cockpits, handles, engine covers, etc.) as well
as hydraulic break hoses and air conditioning tubes. One in every 10 cars in the world
and one in every 5 cars in Europe has parts produced in one of Boryszew factories.

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Non-ferrous metals:

Boryszew Group specializes in aluminium, copper, zinc, and lead processing. The
Group makes technologically advanced products for the automotive, electro-technical,
construction and packaging industries. Boryszew invests in environmentally friendly
solutions, believing that sustainable development is the key to building permanent
value chains.

Chemicals:

Boryszew Group manufactures fluids for de-icing of airplanes as well as polyester

fibres, PET flakes, polyamides and battlefield effects simulators, which are used for
special effects in the film industry as well. In Poland, Boryszew is best known for
Borygo, which is the best-selling radiator fluid produced in the Sochaczew plant.

MAFLOW COSTUMERS

We are one of the largest manufacturers of air conditioning tubes for passenger cars
and trucks, the leader in the production of rubber hoses. We supply our products to

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the greatest world car manufacturers, such as: Volkswagen Group, General Motors,
Renault Nissan, Jaguar Land Rover, PSA Peugeot Citroën, Volvo Car Corporation,
BMW, FCA as well as to the producers of truck vehicles, such as: Volvo GTT (Volvo
Truck, Renault Truck), Daimler Truck, Scania, Paccar Group (DAF, Leyland).

List of Customers:
1. Volkswagen,
2. Audi,
3. Seat,
4. Skoda,
5. Jaguar,
6. Land Rover,
7. Renault,
8. BMW,
9. PSA,
10. Bentley,
11. Lamborghini,
12. Porsche,
13. VOLVO,
14. Peugeot Citroën,
15. Aston Martin,
16. DAF, Leyland,
17. Daimler Truck,
18. Scania,
19. Volvo Truck,
20. Valeo,
21. Contitech,
22. Hanon,
23. Mirgor,
24. Changzhou Tenglong,
25. Delphi,
26. PARKER HANNIFIN,
27. Mahle,
28. EATON,

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 29. DENSO,
30. Nissan.

COMPANY BUSINESS

AIR-CONDITIONING TUBES FOR PASSENGER CARS

Maflow created solutions for air-conditioning hoses that allow to build air-
conditioning systems in any type of passenger car. The reduction of particular
elements’ size allows to develop modern systems for traditional cars as well as for
electric cars equipped with heat pumps. For more demanding customers, we have
created an efficient heat exchange system, which increases the cooling capacity. This
enables the use of low power compressors and, consequently, the reduction of CO2
emission.

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AIR-CONDITIONING TUBES FOR TRUCKS

Maflow manufactures air-conditioning hoses for the largest European truck producers.
Our hoses are made for a demanding, high intensity circumstances, which guarantees
a long, failure-free vehicle mileage. We also manufacture hoses for other commercial
vehicles and own ready-for-use solutions for any kind of air-conditioning application.

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

RUBBER AIR-CONDITIONING HOSES AND TUBES FOR

OTHER SYSTEMS
Maflow is one of the largest manufacturers of liquid transmission systems for the
automotive market. Maflow Group responds to the fast-growing demands of the
automotive market with its strengthened flexible rubber hoses. Our rubber hoses are
known for their high flexibility, resistance to air conditioning refrigerant factor, low
weight, high temperature resistance and the ability to absorb vibrations. In Maflow
Group’s rubber hoses portfolio, customers will also find other components used in the
most important car systems, such as tubes for: power steering, oil cooling system,

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active suspension, clutch control, fuel lines, LPG, CNG gases lines, brake system
assistance, brake hoses for trucks, turbocharger tubes, enginengine cooling tubes.

1.2 MISSION STATEMENT

“To manufacture and market a wide range of Air conditining tubes for passenger car
and trucks, with systems of world class technology to the total satisfaction of
customers in domestic and overseas markets..”

1.3 QUALITY POLICY

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“We at Maflow India Pvt Ltd are committed to innovate, design, source, manufacture
and supply Quality products and services to meet the Customer expectations and
demands of the Society by effective implementation of Quality Management System,
aiming at continual improvement, achieving product leadership through sustainable
business practices and providing a Healthy environment.”

1.4 ENVIRONMENT POLICY

One of our priorities is to assure a harmonious co-existence with the natural

management of materials, continuously monitors the production process and its
influence on the environment as well as promotes pro-ecological behaviors. Our
operations are based on a certified Integrated Environmental Management System,
which is consistent with the international norm ISO 14001.

DEPARTMENTAL PROFILE

Engineering:
This department is concerned for making the drawings according to customer’s
requirement which fits into IBR standards. This drawings r sent to R&D
department for checking after which they are sent to production department

Research &Development:
At R&D new product design and development is done so that the product is
meaningful for the organization. The customer needs put by marketing department are
fully considered for designing the products.

Maintenance:
The maintenance department is well developed to repair service and maintain
recreational areas, buildings, structures, supporting infrastructure of the built
environment, company is seen by this department. The department is having good
tools for respecting handling of the machines.

Quality:

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The quality department processes the after product engineering. Once the product
gets developed, all the physical tests are performed so that the quality of the
product is easy to define. Department consists of all important machines which
help to get accurate dimensions, angles

QUALITY DEFINATION:

1] American Society for Quality-"Meeting the requirements and expectations in

service or product that were committed to" and "Pursuit of optimal solutions
contributing to confirmed successes, fulfilling accountabilities".
2] Philip B. Crosby: "Conformance to requirements."
3] Joseph M. Juran: "Fitness for use."
4] Genichi Taguchi: "Uniformity around a target value."
5] Robert Pirsig: "The result of care."
6] Six Sigma "Number of defects per million opportunities."
7] Peter Drucker: "Quality in a product or service is not what the supplier puts
in. It is what the customer gets out and is willing to pay for."

QUALITY:

Q= Quality
P = Performance Q=P/E
E=Expectations

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1.6.3QUALITY INSPECTION:

Quality inspections are measures aimed at checking, measuring, or testing of one

or more product characteristics and to relate the results to the requirements to
confirm Compliance.

The importance of quality inspection

Quality inspection serves three main purposes:

1. Identification of the problem
2. Preventing its occurrence
3. Elimination of the problem

Stages of Quality Inspection: There are three stages of inspection of valves in

"MAFLOW"
1. Incoming Inspection
2. In-process Inspection
3. End of line & Testing.

INCOMING INSPECTION:

When the material arrives at store gate, it has to be inspected by the quality
department. If the material is accepted by the quality department, raw material is
delivered in stores location else it is informed to the purchase department and
material is returned to the vendor. Raw material delivered may be aluminium pipe
or rubber pipe depending upon the requirement. While inspecting the raw material,

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we check material of the component, dimensions, quantity, visible defects (surface
finish, burrs).

If received material we check,

 Description

 Size and class

 Material of component

 Dimensions

 Maflow logo

 Material using PMI

 Hardness

 Diameter

 If inspection is carried out at vendor’s premises, a complete record

of inspection and testing activities is collected and thoroughly
verified during in-coming inspection.

 Record of verification is maintained to evidence conformance with

purchase requirements.

 If the manufacturing process of the product purchased requires

validation, the required records are collected during the vendor
inspection or with the supply.

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 All the inspection reports, Material Test Certificates and dimensional reports are
verified and reviewed by a qualified QC person. The documents are stamped and
signed by him

 IN-PROCESS INSPECTION

 The in-process inspection of any product is done at different stages by

QC personnel. The documents are accordingly kept updated on
completion of inspection.

 All the procedure of acceptance / rejection is done by QC personnel

independently.

 Dimensional inspection of machined parts is carried out according to the

machining drawing.

 Edges, roughness of the machined parts is also checked.

INSTRUMENT USED FOR INSPECTION:

1] VERNIER CALIPER

 Vernier calliper consists of three main elements, viz. beam, fixed

jaw and movable jaw’s beam.

 Main scale is engraved on the beam and Vernier scale is engraved on

movable jaw beam.

 Main scale is the only true scale, and Vernier scale is designed scale.

 The sliding jaws moves along the beam.

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  By using Vernier, following measurement can be done.

1] Outside Dimensions (Outside jaws)

2] Inside Dimensions (Inside jaws)

3] Depth (using Depth bar)

4] Step measurement (Using step surface)

Dial Vernier Calliper: In this instrument, a small, precise rack and pinion drives
a pointer on a circular dial, allowing direct reading without the need to read a
Vernier scale. Typically, the pointer rotates once every inch, tenth of an inch, or
1 millimetre. The least count of dial Verniercallipers used in company was 0.02
mm. Two models were available. The range of one was 300mm while that of the
other was 600mm.

2] MICROMETER

 Micrometre screw gauge works on the principle of nut and bolt.

 Micrometre consists of a screw with fixed pitch and nut arrangement.

 The end of screw acts as a spindle/anvil in the base of frame.

 Spindle can be advanced or retracted by using thimble connected to spindle.

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 The barrel has engraved lines of main scale (LC=0.5mm) which is true scale.

 Thimble has circular scale with number of divisions engraved on it.

 A lock nut is provided for locking a dimension.

 Ratchet screw provides a stop, if excessive pressure is applied by the anvils,

which is one of the most important parts for avoiding errors.

 When two jaws touch each other, zero reading is excepted. If it is not
observed, error can be adjusted by rotating barrel itself.

] POSITIVE MATERIAL IDENTIFICATION (PMI) GUN

It is a specialized non-destructive testing method. The composition of alloys of

which the raw materials are made up of can be determined. It can be used to verify
if the material composition is same as that mentioned in the Material Test
Certificate (MTC). A number of similar looking materials which cannot be
distinguished visually are used in valve manufacturing. Hence, in such cases PMI
provides the solution

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 ASSIGNMENT NO 1

INTRODUCTION

2.1 Background of Project

Labour is a major problem for the industries. Many time’s situations happen that
labourers strike for their personal benefits which results in performance degradation
and loss in efficiency. As a result the company have to bear great loss and hence
cannot achieve their desired profit and goals .The system of automation in industry
can solve this problem in a very effective way.

The automation system solves labour problems which saves cost, increases
accuracy and decreases human errors. After surveying we conclude that, for some
basic processes which are time consuming like rubber tube cutting, packaging etc.
they use human resources. If we introduce automation to these basic processes then it
will be fruitful regarding the company’s development and profit gain as it improves
the system in many ways.

we found out our industry need a solution that is very efficient, fast and economical
for cutting various lengths of rubber tube which are required for producing hoses. So
we try to make cost effective rubber pipe cutting machine. Company is using
conventional method for pipe cutting from conventional method the production rate is
very low because they have to measure the length of pipe for every piece before
cutting which also take more time. Also sometimes pipe unequal length as well as
more man power is required.

A. Problems of Conventional pipe Cutting Method

Time required for pipe cutting is more.
1) More manpower is required.
2) More floor space is required.
3) t is required to measure every piece of pipe before cutting

Objective
The objectives of this project are to design and develop an automatic pipe cutting
machine to achieve low cost cutting. It works fast and reduces the cutting time. This
equipment is not designed using complicated components. This machine is simple and
portable. This machine is designed using angle bars, rollers, guide tubes, pneumatic
cylinder, cutter and controller unit to control the entire operation of machine
The practical objective of the automatic pipe cutting machine is to cut required

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length of wire in required number of pieces.
The objectives of the project are to design a system for an automatic pipe cutting
machine which is:
1) Automation
2) Efficient
3) User-friendly
4) Transportable
5) Cost-effective
6) Reduce strenuous and repetitive task
7) Functional requirement of proposed system
8) Respond as per user’s input.

METHODOLOGY
A. Defining the Specifications of Machine
The basic need of automatic pipe cutting is to cut the wire
of required length in required number of pieces, without
labour, efficiently. So we decided to make a project named ‘Automatic
Rubber pipe cutting machine. For that we decided some specifications
given
below:
1) To cut required length of pipe.
2) The diameter of pipe should be automatically adjustable.
3) The spool is provided to store pipe stock.
4) Guide tubes are provided to keep pipe in straight direction.
For making of the automatic pipe cutting machine we will follow
this procedure below:-So firstly we decided to make a virtual
design of the project and then we finalize that a final design for
project

B. Industrial pipe Cutting Machine Consist of Two Systems

1) Mechanical system
Electronics system

C. In Mechanical System Step by Step Done Procedure for on that Format of Design
Given Below
1) Making of a base of the mechanical part: fabrication work
2) Select the material for the fabrication work
3) Purchasing of required material from market
4) Checking of all loads acting on that frame

D. We Decided to Make Mechanical

System into Different Sub-Category

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1) Base
2) Rollers
3) Guide tubes
4) Sliding rails
5) Supports for mounting dc motors
6) Spring attachment
7) Pneumatic cylinder

CONCEPTUAL DESIGN

The base is made of angle bars of mild steel in a such a way that it can carry the
whole equipment. The bars are welded in a workshop on which metal sheet of mild
steel is welded. The first pair of rollers are attached to support in a order to uncoil the
rubber pipe from spool stock which are controlled by the dc motors which are further
controlled by the microcontroller. The pipe is passed through the guide tubes which
keeps the wire in straight direction in such a way that wire reaches exactly in between
the two rollers. After this the cutter is mounted. When pipe of required length is
passed the first pair of rollers are stopped and the movement of cutter is controlled by
Pneumatic cylinder which is mounted on the support arms. When the compressor is
switched ON, the compressed air is flow to inlet of the pneumatic cylinder.
The pipe is placed between the upper and the lower blade. The lower blade remains
stationary while the upper blade is forced downward. The upper blade is usually
angled so that the cut progresses from one end to the other, thus reducing the required
force.
When the pneumatic hand operated lever is moved forward, the piston starts moving
in the forward direction. The upper blade which are then forced against the pipe,
cutting the material. When the pneumatic hand operated lever is moved backward, the

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upper blade will come to the original position (i.e., the upper blade will move
upwards).
After the material is cut, adjust the pneumatic hand lever to the mid position (i.e.,
normal position) and then the compressor is switched off

Fabrication of Mechanical System:

We are started to manufacture the pipe cutting machine .At first we made base for
whole assembly on which different mechanical parts are assembled. Base is made up
of sheet metal which is capable of carrying load of all mechanical parts
.Manufacturing of base is done by spot welding process, which is commonly used
welding process.
Another important part of mechanical assembly is sliding unit .Sliding unit is
mounted on base by spot welding process. The main purpose of sliding unit is to
adjust the wire diameter.
Bracket support are used on which D.C. motors are mounted with diameter 13mm.
D.C. motors of 30RPM with 0.5N-m torque are mounted below the support. There are
four bracket support used in the system,out of which two are connected to sliding unit
and two are attached to base assembly. Rollers of diameter 35mmwith centre whole
6mm are mounted on the bracket Rollers are manufactured on lathe with different
operations such as outer diameter turning, facing, centering, growing of 0.5mm,
machining of raw material of diameter 40mm,driiling,tapping.The no of rollers used
in the system is four.

Specification:
Pneumatic cylinder
stroke length=150mm
Diameter=50mm
Pressure=10bar
pipe cutter=8inch

CONCLUSION
Automatic Rubber Pipe Cutting System” provides high level of accuracy and exact
cutting of wires than the present cutting system in the market. Thus due to this the
efficiency of production is increased. This system
gives exact number of wires with the required length.
The circuit complexity is reduced in this system. As the complexity in the circuit is
reduced, it is easy to understand. The main advantage of this system is that the
accuracy is increased and the required result
is obtained in very less time. The time required to cut pipe is less compared to the
manual cutting of wires. Due to simple hardware it is handy for the people. As the
price of the project is not high, it is economically affordable and has been successfully
implemented in the industry.

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