Etm Chapter 3 4 5

Recent Trends in Mechanical
Engineering
Unit III : Recent Trends in Manufacturing in
Industry
CO III
Cite examples of Modern
Manufacturing in Industry
XX Month 200X
Agenda
Key takeaways
Interpret the “Automation” in Mechanical
Industry. Needs.
Basic Elements of Automated systems.
RAJESH KALE
Workshop Superintendent
Page 3 9 March 2021 Presentation title

Automation
► Smart manufacturing is a convergence of modern data science techniques and artificial intelligence to form the factory of the
future.
► Smart manufacturing is about increasing efficiency and eliminating pain points in systems.
► It‘s characterized by a highly connected, knowledge-enabledindustrial enterprise where all organizations and operating
systems.
► Giving enterprises or business - enhanced productivity, sustainability, and economic performance.
► Smart factory is actually an Industry 4.0 that demands smart systems integrated with intelligence to have a better human-
machine interface.

Smart Manufacturing Processes: Three Dimensions:
(1) Demand Driven and Integrated Supply Chains : It includes - Digital Tools, Product Representation and Exchange Technologies
and Standards, Agile (Additive) Manufacturing Systems and Standards. Mass Customization, Smart Machine Tools, Robotics
and Automation, Smart Communication systems Information, Mobility, Communication Technologies, Protocols, Cyber Physical
Systems.
(2) Dynamically Optimized Manufacturing Enterprises (plant + enterprise operations): It includes - Online Predictive Modeling,
Monitoring and Intelligent Control of Machining/Manufacturing and Logistics/Supply Chain Processes, Smart Energy
Management of manufacturing processes and facilities.
(3) Real Time, Sustainable Resource Management :It must have - Eliminating Errors and Omissions,Improving Speed/Agility,
Improving Information Capture/Traceability, Improving Intelligent Decision Making under uncertainty Assisted/Augmented
Production, Assisted/Augmented Assembly, Assisted/Augmented Quality, Assisted/Augmented Maintenance.
Historical Development of Smart Manufacturing: Fig is shown below
Industrial Revolutions:
First : Conventional product cycle,
Second : CAD/CAM product cycle in which single alone CNC technology
Third : Rise of computers, computer networks (WAN, LAN, MAN), the just rise of robotics
Fourth : Internet of Things, Big Data, cloud, advanced robotics and AI /cognitive.
Footnotes

Elements of Smart Manufacturing:
 Internet of Things(IoT): The IoT is the infrastructure of interconnection among objects. In manufacturing systems, each device is
embedded with electronic software. Sensors, and Actuators is connected to Internet networks.
Footnotes

Internet of Things characteristics:
• Connectivity: This doesn‘t need much further explanation. Devices, sensors, they need to be connected to an item, to each
other, actuator, a process and to the Internet‘ or another network.
• Things: From sensors and household appliances to tagged livestock. Devices can contain sensors or sensing materials can
be attached to devices and items.
• Data: Data is the glue of the Internet of Things, the first step towards action and intelligence.
• Communication: Devices get connected so they can communicate data and this data can be analyzed.
• Intelligence: The aspect of intelligence as in the sensing capabilities in IoT devices and the intelligence gathered from data
analytics (also artificial intelligence).
• Action: The consequence of intelligence. This can be manual action, action based upon debates regarding phenomena (for
instance in climate change decisions) and automation, often the most important piece.
• Ecosystem: The place of the Internet of Things from a perspective of other technologies, communities, goals and the
picture in which the Internet of Things fits. The Internet of Everything dimension, the platform dimension and the need for solid
partnerships.
Footnotes

IoT – Example
Manufacturing: “IoT Manufacturing”. Below Fig will explain .
Footnotes

IoT Applications:
• Predictive and preventative maintenance

• Supply chain management
• Inventories and logistics.
• Factory floor efficiency will have the largest impact
• Increasing productivity by as much as 25 percent.
• Iot + data analytics + machine learning
Footnotes

Digital Transformations:
 Digital transformation is the process of using digital technologies to create new or modify existing business
processes, culture, and customer experiences to meet changing business and market requirements.
 The branch of scientific or engineering knowledge that deals with the creation and practical use of digital or
computerized devices, methods, systems, etc. advances in digital technology.
 Digital technologies are electronic tools, systems, devices and resources that generate store or process data. Well
known examples include social media, online games, multimedia and mobile phones.
Digital Twin: The applications of DT in Smart Manufacturing are directed as below.
Designing and verifying of products :Enables the iterative optimization of design
Monitoring product over production life-cycle: digital representation of product from the early design stage to the end of product life-cycle.
Designing and verifying of processes and production lines: DT
to assist the design of process function and production line capabilities
Enhancing resources overhaul maintenance:DT to trace resources digital behavior to diagnose and prognosticate faults, failure,
and performance deviation.
Following figure will explain the concept of DIGITAL TWIN
Footnotes

Digital Twin:
Footnotes

Artificial Intelligence:
Artificial intelligence (AI) is an area of computer science that emphasizes the creation of
intelligent machines that work and reacts like humans. For example, speech recognition,
problem-solving, learning and planning. Theoretical AI says that Intelligence (be it natural or artificial)
has three types.
 Artificial Narrow Intelligence ( ANI )
 Artificial General Intelligence ( AGI )
 Artificial Super Intelligence ( ASI )
Disadvantages of Artificial Intelligence:

• High Cost; No Replicating Humans ; No Improvement with Experience; No Original Creativity & Unemployment
Footnotes

Cloud computing:
In the simplest terms, cloud computing means storing and accessing data and programs over the Internet
instead of your computer's hard drive.
With cloud computing, users can access files and use applications from any device that can access the
Internet. An example of a Cloud Computing provider is Google's Gmail.
Benefits of cloud computing:
• Reduced IT costs.
• Scalability.
• Business continuity.
• Collaboration efficiency.
• Flexibility of work practices.
• Access to automatic updates.
Footnotes

has three types.

Footnotes

has three types.

Footnotes

Thank you
AUTOMATION – PRINCIPLES
&STRATEGIES
Introduction-04-02-2021
Agenda
Key takeaways
Interpret the “Automaion” in
Mechanical Industry AUTOMATION – PRINCIPLES & STRATEGIES
Understand –USA principle
Benefits
RAJESH KALE

Automation Principles and Strategies
The USA Principle : USA stands for-

1. Understand the existing process: Understand the current process in all of its details
a. What are the inputs? What are the outputs?
b. What exactly happens to the work unit between input and output?
c. What is the function of the process?
2. Simplify the process: Checklist of questions about the existing process
a. What is the purpose of this step or this transport?
b. Is this step necessary?
c. Can this step be eliminated?
d. Is the most appropriate technology being used in this step?
e. How can this step be simplified?
3. Automate the process: Once the process has been reduced to its simplest form, then automation can be considered.
Thepossible forms of automation include strategies discussed below.
TEN Strategies for Automation and Process Improvement
► Specialization of operations: Involves the use of special—purpose equipment & labor specialization-employed to
improve labor productivity.
► Combined operations: Involves reducing the number of distinct production machines by performing more than
one operation at a given machine through which the part must be routed.
Cont..
► Simultaneous operations: simultaneously perform the operations that are combined at one workstation
► Integration of operations :link several workstations together into a single integrated mechanism
► Increased flexibility :to achieve maximum utilization of equipment for job
► Improved material handling and storage: reduced work-in-process and shorter manufacturing lead times.
► On-line inspection:. Incorporating inspection into the manufacturing process permits corrections to the process as the
product is being made.
► Process control and optimization: the individual process times can be reducedand product quality improved.
► Plant operation control: concerned with control at the plant level
► CIM: involves extensive use of computer applications, computer data bases, and computer networking throughout
the enterprise.
Automation Migration Strategy: A typical automation migration strategy is the following:
Phase 1: This is used for introduction of the new product for reasons already mentioned: quick and low cost tooling to
get started.
Phase 2: Single stations are automated to reduce labor and increase production rate.
Phase 3: Automated integrated production using a multi-station automated system with serial operations and
automated transfer of work units between stations.

Merits of Automation
Merits -
► Increased throughput or productivity.
► Improved quality or increased predictability of quality.
► Improved healthiness of processes or product.

► Increased consistency of output.
► Reduced direct human labor costs and expenses.

► Installation in operations reduces cycle time.
► Can complete tasks where a high degree of accuracy is required.

► Replaces human operators in tasks that involve hard physical or monotonous work ,Example: Fork lift truck.
► Reduces some work-related injuries (e.g., fewer strained backs from lifting heavy objects)
► Replaces humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities,
underwater, etc.)
► Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
► Frees up workers to take on other roles.
► Provides higher level jobs in the development, deployment, maintenance and running of theautomated
processes.

Demerits of Automation
Demerits –
► Possible security threats/vulnerability
► Due to increased relative susceptibility for committing errors.
► Unpredictable or excessive development costs.

► High initial cost.
► Displaces workers due to job replacement.

ASSESSMENT - QUESTIONS
Which device is mostly associated with automation?
a) flexible manufacturing
b) robots
c) computer graphics workstation
d) NC machine
Choose the basic element for an automated machine tool
a) logic
b) NC tape programming
c) software
d) workstation

Thank you
AUTOMATION – BASICS
3b. Interpret the Automation in Mechanical
Industry
Automation: Need, Basic elements of
automated systems.
04-02-2021
Agenda
Key takeaways
Interpret the “Automation” in
Mechanical Industry • Need of Automation
• Basic elements of automation
RAJESH KALE

AUTOMATION
► It is the technology by which a process or procedure is performed with nominal human assistance.
► For example : Control systems for operating equipment such as machinery, processes in factories, boilers and heat
treating ovens, aircraft (Auto Pilot mode) & Driverless vehicles.
► In other word automation yields increased safety, reliability, and profitability.
Needs of Automation
To satisfy customers demanding premium quality products and services that can only be supplied by a high level of
productivity. Following are the some of the important points due to which it(automation) is needed in industrial
workplace.
► Globalization – Global industrial automation market demands superior and practical services.
► Productivity – Automation enhances the productivity of Industry.
► Industrial Automation – Industrial automation refers the categorization of software and hardware and a
mechanism that combines them.
► Reduce Worker Fatigue and Effort or Labor Intensive Operation –If the task requires conditions not suited to
human comfort or focus, consider automation.
► Prevent Products or Materials from Being Damaged or Destroyed –
► Prevent Non-conforming Product from Shipment –
► Save Money –Inventing in industrial automation yields cost savings through making processes more regular and
collecting data for making confident decisions.
Elements of Automated system
An automated system consists of three basic elements:
(1) Power to accomplish the process and operate the system.
(2) Program of instructions to direct the process, and
(3) Control system to actuate the instructions.
The relationship amongst these elements is shown below

Basic elements of automated system
► Power source : Electricity (power is required to drive the process as well as controls.)
► Program of instructions: The actions performed by an automated process are defined by a set of instructions
known as process. The programmed instructions determine the set of actions that is to be done automatically by the
system.
1. Control system : These executes the program of instructions. The control element of the automated system
executes the program of instructions. The controls in an automated system can be: Closed loop & Open loop.
Closed loop control system: It is also known as a feedback control system. In this system the output variable is
compared with an input parameter and any difference between the two is used to drive the output into agreement with
input.
1. Input parameter: as set point, represents the desired value of output.
2. Output variables: actual value of parameter.
3. Sensors: A sensor is used to measure the output variable and close the loop
4. Between input and output: It performs feedback function.
5. Controller: The controller compares the output with the input and makes the required adjustment in the
process to reduce the difference between them.

6. Actuator: The adjustment being done with one or more actuator which are the hardware devicesthat
physically carry out the control actions such as electric motor, cylinder etc.
Closed loop control system: Mini CNC

Elements of Automated system
Open loop control system:
• It is without the feedback loop.
• In this case the controls operateswithout measuring the output variables, so no comparison is made between the
actual value of the output and desired input parameters.
• There is always risk that the actuator will not have intended effect on the process.
e difference between them.

6. Actuator: The adjustment being done with one or more actuator which are the hardware devices that physically
carry out the control actions such as electric motor, cylinder etc.

Automation Principles and Strategies
The USA Principle : USA stands for-

1. Understand the existing process: Understand the current process in all of its details
a. What are the inputs? What are the outputs?
b. What exactly happens to the work unit between input and output?
c. What is the function of the process?
2. Simplify the process: Checklist of questions about the existing process
a. What is the purpose of this step or this transport?
b. Is this step necessary?
c. Can this step be eliminated?
d. Is the most appropriate technology being used in this step?
e. How can this step be simplified?
3. Automate the process: Once the process has been reduced to its simplest form, then automation can be considered.
Thepossible forms of automation include strategies discussed below.
TEN Strategies for Automation and Process Improvement
► Specialization of operations: Involves the use of special—purpose equipment & labor specialization-employed to
improve labor productivity.
► Combined operations: Involves reducing the number of distinct production machines by performing more than
one operation at a given machine through which the part must be routed.
Cont..
► Simultaneous operations: simultaneously perform the operations that are combined at one workstation
► Integration of operations :link several workstations together into a single integrated mechanism
► Increased flexibility :to achieve maximum utilization of equipment for job
► Improved material handling and storage: reduced work-in-process and shorter manufacturing lead times.
► On-line inspection:. Incorporating inspection into the manufacturing process permits corrections to the process as the
product is being made.
► Process control and optimization: the individual process times can be reducedand product quality improved.
► Plant operation control: concerned with control at the plant level
► CIM: involves extensive use of computer applications, computer data bases, and computer networking throughout
the enterprise.
Automation Migration Strategy: A typical automation migration strategy is the following:
Phase 1: This is used for introduction of the new product for reasons already mentioned: quick and low cost tooling to
get started.
Phase 2: Single stations are automated to reduce labor and increase production rate.
Phase 3: Automated integrated production using a multi-station automated system with serial operations and
automated transfer of work units between stations.

Merits of Automation
Merits -
► Increased throughput or productivity.
► Improved quality or increased predictability of quality.
► Improved healthiness of processes or product.

► Increased consistency of output.
► Reduced direct human labor costs and expenses.

► Installation in operations reduces cycle time.
► Can complete tasks where a high degree of accuracy is required.

► Replaces human operators in tasks that involve hard physical or monotonous work ,Example: Fork lift truck.
► Reduces some work-related injuries (e.g., fewer strained backs from lifting heavy objects)
► Replaces humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities,
underwater, etc.)
► Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
► Frees up workers to take on other roles.
► Provides higher level jobs in the development, deployment, maintenance and running of theautomated
processes.

Demerits of Automation
Demerits –
► Possible security threats/vulnerability
► Due to increased relative susceptibility for committing errors.
► Unpredictable or excessive development costs.

► High initial cost.
► Displaces workers due to job replacement.

ASSESSMENT - QUESTIONS
Which device is mostly associated with automation?
a) flexible manufacturing
b) robots
c) computer graphics workstation
d) NC machine
Choose the basic element for an automated machine tool
a) logic
b) NC tape programming
c) software
d) workstation

Thank you
3.3 TYPES OF AUTOMATION
What are different types of
Automation?
1.Fixed automation,
2.Programmable automation, and
3.Flexible automation.
TYPES OF AUTOMATION
Automated production systems are classified into three basic types:

❑ Fixed automation,
❑ Programmable automation, and

❑ Flexible automation.
Fixed Automation:
It is a system in which the sequence of processing (or assembly) operations is fixed by the equipment configurations.
Examples are Paper mill, Steel mill & Printing press.
Typical features of fixed automation are:
► High initial investment for custom–Engineered equipment.
► High production rates.
► Relatively inflexible in accommodating product changes.
Paper Mill
TYPES OF AUTOMATION
Programmable Automation:
Capability to change the sequence of operations to accommodate different product configurations.
Operation sequence is controlled by a program, which is a set of instructions coded so that the system can read and
interpret them.
Features that characterize programmable automation are:
► High investment in general-purpose equipment.
► Low production rates relative to fixed automation.

► Flexibility to deal with changes in product configuration.
► Most suitable for batch production.
Fig. Home Automation an example

Cont.
Flexible Automation:
► It is an extension of programmable automation.
► A flexible automated system is one that is capable of producing a variety of products with virtually no time lost for changeovers
from one product to the next. There is no production time lost while reprogramming the system and altering the physical setup.
Consequently, the system can produce various combinations and schedules of products instead of requiring that they be made in
separate batches .
► System can produce various combinations and schedules of products instead of requiring that they be made in separate batches.
Features of flexible automation
a. High investment for a custom-engineered system.
b. Continuous production of variable mixtures of products.
c. Medium production rates.
d. Flexibility to deal with product design variations.
The relative positions of the three types of automation
for different production volumes and product
variations are depicted in the figure.
The essential features that distinguish flexible automation from
programmable automation are:
1. The capacity to change part programs with no lost production time; and
2. The capability to changeover the physical setup, again with no lost production time.

Cont.
▪ The relative positions of the three types of automation for different production volumes and product variations are
depicted in the following figure.
▪ .

Hard and Soft Automation
Soft or Programmable Automation is the more developed cousin to Hard Automation. It includes equipment that
has been designed to accommodate a variety of product configurations. If you have facility that manufactures a limited
range of similar products that are run in batches, Soft Automation may be your best choice.
Hard and Soft Automation
Hard automation is used for a specific production purpose where the processes are fixed. It is best suited for automated
equipment that mass-produced high-volume products with few alterations or little changeovers.
This type of automation has a high initial investment and high production rates, most typically automated assembly line
machines.

SOFT AUTOMATION
Soft automation can be used to produce a variety of parts with virtually no time lost for changeovers from one
part style to another or for multiple small batches of a single product.
Advantages -
► Continuous production of variable mixtures of product &
flexibility to accommodate varying product designs.
Disadvantages -
► Medium production rate,
► High long term production costs and
► A high unit cost compared with hard automation.
Soft Automation

Recent and Emerging applications of Automation.
Automated power production

Technologies like solar panels, wind turbines, and other renewable energy sources, together with smart grids,
micro-grids, battery storage - can automate power production.
Automated retail Food and drink industry
The food retail industry has started to apply automation to the ordering process; McDonald's has introduced touch
screen ordering and payment systems in many of its restaurants, reducing the need for as many cashier employees.
Automated mining
Automated mining involves the removal of human labor from the mining process. The miningindustry is currently in
the transition towards automation.
Automated video surveillance
Automated video surveillance monitors people and vehicles in real time within a busy environment.
Automated highway systems
As demands for safety and mobility have grown and technological possibilities have multiplied, interest in
automation has grown.
 Automated waste management
► Automated waste collection trucks prevent the need for as many workers as well as easing the level of labor
required to provide the service.
Cont.
► Business process automation

It can help to streamline a business for simplicity, achieve digital transformation, increase service quality, improve servic e delivery or
contain costs.
► Home automation
Home automation designates an emerging practice of increased
automation of household appliancesand features in residential dwellings,
particularly through the use of “Electronics”.
► Laboratory automation
Automation is essential for many scientific and clinical applications. Therefore, automation has been extensively employed
in laboratories.
Cont.
Industrial automation
► Industrial automation deals primarily with the
automation of manufacturing, quality control
and material handling processes.
► General purpose controllers for industrial processes
include Programmable logic controllers,stand-alone
I/O modules, and computers.
► Industrial automation is to replace the decision
Making of humans and manual command-response
Activities with the use of mechanized equipment
and logical programming commands.

Industrial Robotics
3d. Select Robot for given application
3.4.1 Industrial robotics: Robot’s anatomy

Agenda
ROBOTS ANATOMY
To study structure of Robot
Understand the following :
1. Manipulator
2. Links, types
3. Joints, types
4. Degree of freedom, types
5. Work space &
6. Wrist assembly

INTRODUCTION - Industrial Robotics
► Industrial robots (tough and tireless) are capable of handling a variety of jobs right from material handling to
complex assembly tasks.
► They perform hazardous and monotonous tasks with
tireless precision.
► They improve productivity and reduce manufacturing costs.
► Perform complex jobs.
► Can even cope with changing conditions in the workplace,
when fitted with sensors and adaptive controls.

Robot anatomy
► The anatomy of robot is also known as structure of robot.

► The RIA (Robotics Industries Association) has officially given the definition for Industrial Robots, ―
► A general-purpose,programmable machine possessing certain anthropomorphic characteristics ―
Importance of robotics:
► Robots can substitute for humans in hazardous work environments.
► Consistency and accuracy not attainable by humans.

► Can be reprogrammed.
► Anatomy of industrial robots deals with the assembling of outer components of a robot such as wrist, arm and
body components of a robot.
Manipulator-
► The manipulator comprising of base, arm and wrist are the most obvious parts of the robot.
► Robot‘s movements are executed by the mechanical parts like links, power joints, and transmission system along
with internal sensors housed within the manipulator.

JOINTS
• Joints provide relative motion. Fig below shows different types of joints.
Compare with your HAND . It also has 3 joints – SHOULDER,ELBOW & WRIST joints respectively.

LINKS
• Links are rigid members between joints
Dear students , move your own hand (either left or right ) and u can understand the concept .

DEGREE OF FREEDOM-LINEAR & ROTORY
• Each joint provides a ― degree-of-freedom
VIDEO LINK:https://www.youtube.com/watch?v=QAby_ilhoDQ
Robot manipulator –Body and Arm
 Robot manipulator consists of two sections:

 Body-and-arm – for positioning of objects in the robot's work volume.
VIDEO Link: https://www.youtube.com/watch?v=fLTdIqn0Tao

WRIST ASSEMBLY OF ROBOT
► Wrist assembly – for orientation of objects.
VIDEO LINK: https://www.youtube.com/watch?v=pa5_tudyAF8

End effector- In robotics
► End effector- In robotics, an end effector is the device at the end of a robotic arm, designed to
interact with the environment. The exact nature of this device depends on the application of the
robot.
► Types of End effectors -
► Impactive –jaws or claws which physically grasp by direct impact upon the object.
► Ingressive –pins, needles or hackles which physically penetrate the surface of the object (used in
textile, carbon and glass fiber handling).
► Astrictive –suction forces applied to the objects surface (whether by vacuum, magneto–or electro
adhesion).
► Contiguities –requiring direct contact for adhesion to take place (such as glue, surface tension or
freezing
VIDEO Link: https://www.youtube.com/watch?v=Jua8LnGk-wc

Emerging Trends in Mechanical
Engineering
Unit III : Recent Trends in Manufacturing in
Industry
CO III
3d. Select Robot for given application
3.4.2 Robot control systems.

Agenda
1. Robot Control system Key takeaways

2. Methods
3. Languages Understand concept of the following
Methods of programming
& Languages used for programming
RAJESH KALE

► The controller is the "brain" of the industrial robotic arm and allows the parts of the robot to operate together. It works as a
computer and allows the robot to be connected to other systems. The robotic arm controller runs a set of instructions written
in code called a program. The program is inputted with a teach pendant. Many of today's industrial robot arms use an
interface that resembles or is built on the Windows operating system
► Robot Programming -

PROGRAMMING LANGUAGES – ROBOTS
a. Lead through programming - work cycle is taught to robot by moving the manipulator through the required
motion cycle and simultaneously entering the program into controller memory for later playback.
b. Robot programming languages - uses textual programming language to enter commands into robot
controller.
c. Simulation and off-line programming – program is prepared at a remote computer terminal and
downloaded to robot controller for execution without need for lead through methods.
Programming Languages used for Robot controlling

 C/C++ - C and C++ is the best start for an aspiring robotics as it is a general purpose programming language
that contains imperative, object-oriented and generic programming features. C++ allows interaction with low
level hardware, and also real time performance. C and C++ are very mature programming languages. To
ensure the best performance of a robot, it will be better to use C++.
Footnotes

PROGRAMMING LANGUAGES – ROBOTS
A. Python- Python is the high-level programming language and it plays a key role in building and testing
robots. Python is a good platform to automate, teach, and post-process robot programs.
B. Java- To perform human-like tasks, robotics systems must be included with functions via programming
languages. To enable robots with these functions, Java language can be used as it offers an array of APIs
that are tailor-made to the needs of the robotics realm.
C. MATLAB - MATLAB is not a programming language but it is a tool with which you can find engineering
solutions based on mathematics. Robotic developers need to learn MATLAB if they want to analyze data,
produce advanced graphs or implement control system.
Footnotes

Thank you
Industrial Robotics
Prof. KALE RAJESH. DAMODAR

MAEER’ MIT POLYTECHNIC.PUNE-38
Flexible automation are
ROBOTS,COBOTS.
Why Industrial Robot(IR)
are to be used in industry
today?
Contents/agenda slide
1. Sensors Key words

2. TYPES
3. APPLICATIONS 1. Understand different types of sensors for ex.:
2. Light sensors,
3. proximity sensors,
4. acceleration &
5. temperature sensors
6. Applications
Job Title to go here

Sensors:
❑ They sense the environment are essential for intelligent robots.

❑ • Light Sensor - Light sensor is a transducer used for detecting light and creates a voltage
difference equivalent to the light intensity fall on a light sensor. The two main light sensors
used in robots are Photovoltaic cells and Photo resistor.
❑ • Proximity Sensor- Proximity sensor can detect the presence of nearby object without any
physical contact. The working of a proximity sensor is simple. In proximity sensor transmitter
transmits an electromagnetic radiation and receiver receives and analyzes the return signal for
interruptions. Therefore the amount of light receiver receives by surrounding can be used for
detecting the presence of nearby object

ROBOT SENSORS -
 Sound Sensor- Sound sensors are generally a microphone used to detect sound and return a voltage
equivalent to the sound level. Using sound sensor a simple robot can be designed to navigate based
on the sound receives.
 Temperature Sensor- Temperature sensors are used for sensing the change in temperature of the
surrounding. It is based on the principle of change in voltage difference for a change in temperature this
change in voltage will provide the equivalent temperature value of the surrounding.
 Acceleration Sensor- Acceleration sensor is used for measuring acceleration and tilt. An accelerometer is a
device used for measuring acceleration.

Industrial Robot Application-
1. Arc Welding- Robot welding is improving the safety of workers from arc burn and inhaling hazardous fumes.
2. Spot Welding – Robotic Spot welding joins two contacting metal surfaces by directing a large current through
the spot, which melts the metal and forms the weld delivered to the spot in a very short time (approximately
ten milliseconds).
3. Materials Handling - Materials handling robots are utilized to move, pack and select products. They also can
automate functions involved in the transferring of parts from one piece of equipment to another. Direct labour
costs are reduced and much of the tedious and hazardous activities traditionally performed by human labour
are eliminated.
4. Machine Tending - Robotic automation for machine tending is the process of loading and unloading raw
materials into machinery for processing and overseeing the machine while it does a job.
5. Painting- Robotic painting is used in automotive production and many other industries as it increases the
quality and consistency of the product. Cost savings are also realized through less rework.

Industrial Robot Application-
1. Picking, Packing and Palletizing - Most products are handled multiple times prior to final shipping. Robotic
picking and packaging increases speed and accuracy along with lowering production costs.
2. Assembly- Robots routinely assemble products, eliminating tedious and tiresome tasks. Robots increase
output and reduce operational costs.
3. Mechanical Cutting, Grinding, Deburring and Polishing - Buffing and polishing a hip joint by hand can
normally take 45-90 minutes while a robot can perform the same function in just a few minutes.
4. Gluing, Adhesive Sealing and Spraying Materials -Sealer robots are built with numerous arm configurations
that enable the robot to apply adhesives to any type of product. The primary benefit in this application is
increased quality, speed and consistency of the final product.
.VIDEO LINK:FROM AUTOMOBILE SECTOR SHOWING U COMPLETE APPLICATION UNDER ONE ROOF

3e. 3D printing technology.
3.5.2 3D scanning Technology- Function, Applications

4D PRINTING
Prof. KALE R.D

WORKSHOP SUPRIENTENDENT
MAEER’S MIT POLYTECHNIC ,PUNE-38
Agenda
1. 3D printing Key takeaways

2.
3. Understand concept of the following
3D scanning Technology
- Function,
- Applications.
RAJESH KALE

3.5.2 INTRODUCTION – “3D” SCANNING TECHNOLOGY
A 3D scanner is a device that analyzes a real-world object or environment to collect data on its shape and its
appearance (i.e. color). The collected data then can be used to construct high resolution, accurate, digital 3D models.
3D Scanning
3D scanning is a technique used to capture the shape of an object using a 3D scanner. The result is a 3D file of the
object which can be saved, edited, and even 3D printed. Many different 3D scanning technologies exist to 3D
scan objects, environments, and people. Each 3D scanning technology comes with its own limitations,
advantages, and costs.
Creaform Metra SCAN optically tracked 3D scanning and probing system

3D scanning working-
► There are two major categories of scanners based on the way they capture data:
 White-light and structured-light systems that take single snapshots/scans
 Scan arms and portable handheld scanners that capture multiple images continuously. Scanning results are
represented using free-form, unstructured three-dimensional data, usually in the form of a point cloud or a
triangle mesh. Certain types of scanners also acquire color information for applications where this is
important.
 3D scans are compatible with Computer Aided Design (CAD) software and also 3D printing, after a little
preparation on the computer software. A 3D scan can give a lot of information about the design of an object,
in a process called reverse engineering.
 Triangulated mesh representation shown in figure --

Functions of 3D scanning
▪ The purpose of 3D scanning is
▪ To collect data of a real-world object or environment
▪ To recreate design in the form a digital 3D model.
▪ It bridges a gap between Physical world and Digital world.
▪ This 3D model has many applications, ranging from industrial product design to production quality control and
movie productions. 3D scanners are powerful tools for professionals in several industries, such as automotive,
aeronautics, dental, jewelry making, as well as video gaming specialeffects, and animation movies.

Types of 3D Scanning Processes
1) Contact
2) Non-contact
a) Active
(i) Time-of-flight
(ii) Triangulation
(iii) Structured light
(iv) Industrial Computed Tomography (CT)
a) Passive
(v) Stereoscopic
(vi) Photometric
(vii) Silhouette
Fig .: Non contact type 3D Scanner

Contact type 3D Scanning
► 3D contact scanners, generally calibrated to operate on a fixed platform, often contain a probe located at the
end of an articulated mechanical arm. The arm may be robotically or manually manipulated over the part's
surface. As the probe contacts the object's surface the scanner records the X,Y,Z position of the probe by taking
positional measurements of the armature. The recorded positions form a point cloud, which can be used to
calculate a 3D mesh. Some highly accurate 3D scanners called Coordinate Measuring Machines (CMMs) are
often used by the manufacturing industry to inspect parts for early indications of assembly problems. This device
is used for measuring the physical geometrical characteristics of an object. Measurements are defined by a probe
attached to the third moving axis of this machine. Probes may be mechanical, optical, laser, or white light,
amongst others.
► Non-Contact Active type 3D Scanning
In Non-Contact Active Scanning processes, scanners emit some kind of radiation or light and detect its reflection
or radiation passing through object in order to review an object or environment. Possible types of emissions used
include light, ultrasound, or x-ray.

▪ Non-contact passive type 3D Scanning
▪ Passive 3D imaging solutions do not emit any kind of radiation themselves, but instead depend on detecting
reflected ambient radiation. Most solutions of this type detect visible light because it is a readily available ambient
radiation. Other types of radiation, such as infra-red could also be used. Passive methods can be very cheap, because
in most cases they do not need particular hardware but simple digital cameras.
► Applications of 3D Scanning
a. Education
► 3D scanning is starting to become predominant in classrooms all around the world. By using shaping clay or a
similar medium, students with very limited 3D CAD modelling skills are able to create and 3D print completely
unique models that would be near impossible to produce using software only.
a.Mechanical Engineering / Reverse engineering
► Another area with huge potential for 3D scanning is engineering. The ability to scan any object and then use
CAD for modification makes both reverse engineering and rapid prototyping an extremely streamlined process.
Detailed measurements can be performed and investigation in to mechanical properties is simplified.

Cont.
a. Design process
 Increasing accuracy of working with complex parts and shapes,
 Coordinating product design using parts from multiple sources,
 Updating old CD scans with those from more current technology,
 Replacing missing or older parts,
 Creating cost savings by allowing as-built design services, for example in automotivemanufacturing plants,
 "Bringing the plant to the engineers" with web shared scans, and
 Saving travel costs.
a. Law enforcement
► 3D laser scanning is used by the law implementation agencies around the world. 3D Models areused for on-
site documentation of:
 Crime scenes
 Bullet trajectories
 Bloodstain pattern analysis
 Accident reconstruction
 Bombings
 Plane crashes, and more

Assessment – Questions
1. What Is 3d Printing?
2. How Does 3d Printing Work?
3. What Are The Limitations Of 3d Printing?
4. Is There A Difference Between 3d Printing And Additive Manufacturing?
5. What Is The Difference Between 3d Printing And 4d Printing?
6. Who Invented 3d Printing?
7. Can I Use 3d Printing In Education?
8. What Software Do I Need For 3d Printing?
9. What Is A 3d Printing Model?
10. What Are The Most Common 3d Printing File Formats?
11. What Is The Minimal Wall Thickness Of A 3d Printing Model?
12. How Can I Protect My 3d Printing Design From Being Stolen?
13. What Resolution Can A 3d Printer Print?
14. What Is The Best Way To 3d Print Fully Functional Parts?

THANK YOU
4 D Printing Technology
3e. Compare 4 D printing
technology
3.5.1
4-D printing Technology- Printing Techniques,

4D PRINTING
WHAT IS 4D PRINTING?
WHY IT IS REQUIRED?
Agenda
1.
4D Printing technology and Key takeaways
printing techniques
2. Materials • 4D Printing
3. Applications • Materials
• Liquid crystal elastomers
• Digital shape memory polymers
• Applications
RAJESH KALE

3.5.1 INTRODUCTION – “4D” PRINTING
4D printing is also known as 4D bio-printing or shape changing systems. .

(3D + 1D = 4D), It uses the same techniques of 3D printing (Adaptive Manufacturing) through computer-
programmed deposition of material in successive layers to create a three-dimensional object.
It’s a type of programmable matter, wherein after the fabrication process, the printed product reacts with
parameters within the environment (i.e. water, humidity, temperature, wind, etc.,) and changes its form accordingly.
4D printing is a relatively new advance in bio-fabrication technology, rapidly emerging as a new model in disciplines
such as materials science, bioengineering, chemistry, and computer sciences.
4D printing Techniques
Stereo lithography is a 3D-printing technique that uses photo polymerization to bind substrate that has been laid layer
upon layer, creating a polymeric network.
4D printing is fundamentally based in stereo lithography, where in most cases ultraviolet light is used to cure the
layered materials after the printing process has completed.
Anisotropy is vital in engineering the direction and magnitude of transformations under a given condition, by
arranging the micro materials in a way so that there is an embedded directionality to the finished print.
Pattern-driven 4D Printing.
(413) 4D Printing: Shapeshifting Architecture - YouTube

4D PRINTING TECHNIQUES
Stereo lithography is a 3D-printing technique that uses photo polymerization to bind substrate that has been laid layer
upon layer, creating a polymeric network. As opposed to fused-deposition modelling, where the extruded material
hardens immediately to form layers, 4D printing is fundamentally based in stereo lithography, where in most cases
ultraviolet light is used to cure the layered materials after the printing process has completed. Anisotropy is vital in
engineering the direction and magnitude of transformations under a given condition, by arranging the micro materials
in a way so that there is an embedded directionality to the finished print.
. Pattern-driven 4D Printing
4D printing helps to achieve rapid and accurate manufacturing methods for controlling spatial self- bending
actuation in custom-designed soft structures. Spatial and temporal transformations can be realized through
several actuation mechanisms such as liquid crystal gel phase transition, thermal expansion coefficient, thermal
conductivity discrepancies, and the different swelling and de- swelling ratios of bi-layer or composite beams. One
approach to model 4D printing is to control 3D-printing parameters, such as different spatial patterns of hinges
affecting the response time and bending angle of the 4D print products. A parametric model of physical
properties of shape memory polymer panes incorporating 3D printed patterns was developed to that end. The
proposed model predicts the final shape of the actuator with an excellent qualitative agreement with
experimental studies. These validated results can guide the design of functional pattern-driven 4D printings.

Smart Materials Used for 4D Printing
▪ Fibber architecture
▪ Most 4D printing systems utilize a network of fibres that vary in size and material properties. 4D printed
components can be designed on the macro scale as well as the micro scale. Micro scale design is achieved
through complex molecular/fibre simulations that approximate the aggregated material properties of all the
materials used in the sample. The size, shape, modulus, and connection pattern of these material building
blocks have a direct relationship to the deformation shape under stimulus activation.
(a) Before activation (b) After activation
(413) Carbon3D's Super Fast 3D Printer Printing an Eiffel Tower - YouTube

Digital Shape-Memory Polymers
▪ Shape-memory polymers (SMPs) are able to recover their original shape from a deformed shape under
certain circumstances, such as when exposed to a temperature for a period of time. Depending on the
polymer, there may be a variety of configurations that the material may take in a number of temperature
conditions. Digital SMPs utilize 3D-printing technology to precisely engineer the placement, geometry, and mixing
and curing ratios of SMPs with differing properties, such as glass transition or crystal-melt transition temperatures.
In this technique a series of digital SMP hinges that have differing prescribed thermo-mechanical and shape
memory behaviors, which are grafted onto rigid, non-active materials. Thus, develop a self-folding sample that
could fold without interfering with itself, and even interlock to create a more robust structure. One of the projects
include a self-folding box modeled after a USPS mailbox is shown in the figure.
Figure - An interlocking and self-folding SMP simulating the folding procedure of a USPS mailbox.

Liquid Crystalline Elastomers
▪ Liquid crystal elastomers (LCEs) are a class of soft-active materials which can achieve rapid and reversible
shape changes. This is in contrast to SMPs which typically require a programming step and thus the
actuation is generally one-time and non-reversible. Hydrogels, on the other hand, can yield large and
reversible volume change, however, their response speed is relatively slow. LCEs achieve their actuation
through a transition of the molecular chains between an ordered liquid crystal (nematic) state and a random
(isotropic) state in response to light, heat, electrical, or magnetic fields.
Above Figure - A time-lapse of an SMP gripper developed for grabbing & releasing an object

Multi-Material 4D Printing using LCEs
► The concept of utilizing multi-material 4D printing using LCE to create reversible actuation of complicated
structures. Here, a three layer hinge was created by placing prefabricated LCE on a 3D printed silver wire and
elastomer structure. Joule heating was then used to heat the LCE past its transition temperature (TNI). The
basic hinge design is entirely 3D printed and utilized to create structures that could achieve complex folding
and activation sequences. Among other demonstrations, a hand was 3D printed such that each finger could be
activated separately to produce letters from the American Sign Language alphabet.
Figure - Multi-material 4D printing using LCE-based actuation .

Current Applications of 4D printing
▪ Architecture
▪ Common adaptive frontages and opening roofs require complex mechanical systems to operate which are often
difficult to install and frequently malfunction. 4D printed frontages would offer simplicity of installation and direct
actuation caused by weather conditions, eliminating any need for a larger controlling system or input energy.
 Biomedical
► 4D-printable, photo-curable liquid resin is made of a renewable soybean-oil epoxidized acrylate compound
that is also biocompatible. This resin adds to the small group of 3D-printable resins and is one of the few that
are biocompatible. A laser 3D-printed sample of this resin was subjected to temperature fluctuations from -18
°C to 37 °C and exhibited full recovery of its original shape. Printed skeletons of this material proved to be
successful foundations for human bone marrow mesenchymal stem cell (hMSCs) growth. This material's
strong qualities of shape memory effect and biocompatibility lead researchers to believe that it will strongly
advance the development of biomedical frameworks. The use of plant oil polymers as
liquid resinsfor stereolithography production in biomedical applications.

Assessment
▪ What is the difference between 3D and 4D printing?

▪ How does 4D printing work?
▪ What is 4D printing used for?
▪ Who invented 4D printing?
▪ Kindly note: As it’s an emerging field so MCQ’s can be given by respected faculties teaching the subject
Respected faculties ca n refer.
▪ https://www.sciencedirect.com/science/article/pii/S1369702117302250.
▪ Video links are given below:-
1. 4D Printing Technology-8476.pdf (researchpublish.com)
2. (413) NASA's New Meteorite Resistant Space Fabric 4D Printed - YouTube
3. What is 4D Printing? – All You Need to Know | All3DP

THANK YOU
4D PRINTING
Prof. KALE R.D

4D PRINTING
WHAT IS 4D PRINTING?
WHY IT IS REQUIRED?
Agenda
1. Introduction Key takeaways

2. Automation -Types
3. Applications Understand concept of the following
Fixed
Programmable
Flexible
Hard and soft
RAJESH KALE

3.5.2 INTRODUCTION – “3D” SCANNING TECHNOLOGY
A 3D scanner is a device that analyzes a real-world object or environment to collect data on its shape and its
appearance (i.e. color). The collected data then can be used to construct high resolution, accurate, digital 3D models.
3D Scanning
3D scanning is a technique used to capture the shape of an object using a 3D scanner. The result is a 3D file of the
object which can be saved, edited, and even 3D printed. Many different 3D scanning technologies exist to 3D
scan objects, environments, and people. Each 3D scanning technology comes with its own limitations,
advantages, and costs.
Creaform Metra SCAN optically tracked 3D scanning and probing system

3D scanning working-
► There are two major categories of scanners based on the way they capture data:
 White-light and structured-light systems that take single snapshots/scans
 Scan arms and portable handheld scanners that capture multiple images continuously. Scanning results are
represented using free-form, unstructured three-dimensional data, usually inthe form of a point cloud or a
triangle mesh. Certain types of scanners also acquire colorinformation for applications where this is
important.
 3D scans are compatible with Computer Aided Design (CAD) software and also 3D printing, after alittle
preparation on the computer software. A 3D scan can give a lot of information about the design of an object,
in a process called reverse engineering.
 Triangulated mesh representation shown in figure --

 The purpose of 3D scanning is
 To collect data of a real-world object or environment
 To recreate design in the form a digital 3D model.
 It bridges a gap between Physical world and Digital world.
 This 3D model has many applications, ranging from industrial product design to production quality control and
movie productions. 3D scanners are powerful tools for professionals in several industries, such as automotive,
aeronautics, dental, jewelry making, as well as video gaming special effects, and animation movies.

Types of 3D Scanning Processes
1) Contact
2) Non-contact
a) Active
(i) Time-of-flight
(ii) Triangulation
(iii) Structured light
(iv) Industrial Computed Tomography (CT)
a) Passive
(v) Stereoscopic
(vi) Photometric
(vii) Silhouette
Fig .: Non contact type 3D Scanner

Contact type 3D Scanning
► 3D contact scanners, generally calibrated to operate on a fixed platform, often contain a probe located at the
end of an articulated mechanical arm. The arm may be robotically or manually manipulated over the part's
surface. As the probe contacts the object's surface the scanner records the X,Y,Z position of the probe by taking
positional measurements of the armature. The recorded positions form a point cloud, which can be used to
calculate a 3D mesh. Some highly accurate 3D scanners called Coordinate Measuring Machines (CMMs) are
often used by the manufacturing industry to inspect parts for early indications of assembly problems. This device
is used for measuring the physical geometrical characteristics of an object. Measurements are defined by a probe
attached to the third moving axis of this machine. Probes may be mechanical, optical, laser, or white light,
amongst others.
► Non-Contact Active type 3D Scanning
In Non-Contact Active Scanning processes, scanners emit some kind of radiation or light and detect its reflection
or radiation passing through object in order to review an object or environment. Possible types of emissions used
include light, ultrasound, or x-ray.

 Non-contact passive type 3D Scanning
 Passive 3D imaging solutions do not emit any kind of radiation themselves, but instead depend on detecting
reflected ambient radiation. Most solutions of this type detect visible light because it is a readily available ambient
radiation. Other types of radiation, such as infra-red could also be used. Passive methods can be very cheap, because
in most cases they do not need particular hardware but simple digital cameras.
► Applications of 3D Scanning
a. Education
► 3D scanning is starting to become predominant in classrooms all around the world. By using shaping clay or a
similar medium, students with very limited 3D CAD modelling skills are able to create and 3D print completely
unique models that would be near impossible to produce using software only.
a.Mechanical Engineering / Reverse engineering
► Another area with huge potential for 3D scanning is engineering. The ability to scan any object and then use
CAD for modification makes both reverse engineering and rapid prototyping an extremely streamlined process.
Detailed measurements can be performed and investigation in to mechanical properties is simplified.

Reverse Engineering
 Reverse engineering of a mechanical component requires a precise digital model of the objects to be reproduced.
Rather than a set of points a precise digital model can be represented by a polygon mesh, a set of flat or curved
NURBS surfaces, or ideally for mechanical components, a CAD solid model. A 3D scanner can be used to digitize
free-form or gradually changing shaped components as well as prismatic geometries whereas a coordinate measuring
machine is usually used only to determine simple dimensions of a highly prismatic model. These data points are then
processed to create a usable digital model, usually using specialized reverse engineering software.

Application
a. Quality assurance and industrial metrology
The digitalization of real-world objects is of vital importance in various application domains. This method is especially
applied in industrial quality assurance to measure the geometric dimension accuracy. Industrial processes such as assembly are
complex, highly automated and typically based on CAD (Computer Aided Design) data. The problem is that the same degree of
automation is also required for quality assurance. It is, for example, a very complex task to assemble a modern car, since it
consists of many parts that must fit together at the very end of the production line. The optimal performance of this process is
guaranteed by quality assurance systems. Especially the geometry of the metal parts must be checked in order to assure that
they have the correct dimensions, fit together and finally work reliably.
a. Law enforcement
► 3D laser scanning is used by the law implementation agencies around the world. 3D Models are used for on-site
documentation of:
 Crime scenes
 Bombings

Cont.
a. Design process
 Increasing accuracy of working with complex parts and shapes,
 Coordinating product design using parts from multiple sources,
 Updating old CD scans with those from more current technology,
 Replacing missing or older parts,
 Creating cost savings by allowing as-built design services, for example in automotivemanufacturing plants,
 "Bringing the plant to the engineers" with web shared scans, and
 Saving travel costs.
a. Law enforcement
► 3D laser scanning is used by the law implementation agencies around the world. 3D Models areused for on-
site documentation of:
 Crime scenes
 Bombings

Application
► Medical CAD/CAM
► 3D scanners are used to capture the 3D shape of a patient in orthotics and dentistry. It gradually
supplants tedious plaster cast. CAD/CAM software are then used to design and manufacture the
orthosis, prosthesis or dental implants. 3D scanning is also being used for detailed study of body parts,
for example prior to a surgical procedure. Thorough planning and preparation of the location gives
doctors and surgeons the opportunity for more informed decisions and improved rates of surgical
success.

Digital Shape-Memory Polymers
 Shape-memory polymers (SMPs) are able to recover their original shape from a deformed shape under
certain circumstances, such as when exposed to a temperature for a period of time. Depending on the
polymer, there may be a variety of configurations that the material may take in a number of temperature
conditions. Digital SMPs utilize 3D-printing technology to precisely engineer the placement, geometry, and mixing
and curing ratios of SMPs with differing properties, such as glass transition or crystal-melt transition temperatures.
In this technique a series of digital SMP hinges that have differing prescribed thermo-mechanical and shape
memory behaviors, which are grafted onto rigid, non-active materials. Thus, develop a self-folding sample that
could fold without interfering with itself, and even interlock to create a more robust structure. One of the projects
include a self-folding box modeled after a USPS mailbox is shown in the figure.
Figure - An interlocking and self-folding SMP simulating the folding procedure of a USPS mailbox.

Assessment – Questions
1. What Is 3d Printing?
2. How Does 3d Printing Work?
3. What Are The Limitations Of 3d Printing?
4. Is There A Difference Between 3d Printing And Additive Manufacturing?
5. What Is The Difference Between 3d Printing And 4d Printing?
6. Who Invented 3d Printing?
7. Can I Use 3d Printing In Education?
8. What Software Do I Need For 3d Printing?
9. What Is A 3d Printing Model?
10. What Are The Most Common 3d Printing File Formats?
11. What Is The Minimal Wall Thickness Of A 3d Printing Model?
12. How Can I Protect My 3d Printing Design From Being Stolen?
13. What Resolution Can A 3d Printer Print?
14. What Is The Best Way To 3d Print Fully Functional Parts?

THANK YOU
Rev eng
Prof. KALE R.D

Machines
► As (CAD) has become more popular, reverse engineering has become a viable method to create a 3D virtual model of
an existing physical part for use in 3D CAD, CAM, CAE, or other software. [10] The reverse-engineering process
involves measuring an object and then reconstructing it as a 3D model. The physical object can be measured using 3D
scanning technologies like CMMs, laser scanners, structured light digitizers, or industrial CT scanning (computed
tomography). The measured data alone, usually represented as a point cloud, lacks topological information and design
intent. The former may be recovered by converting the point cloud to a triangular-faced mesh. Reverse engineering
aims to go beyond producing such a mesh and to recover the design intent in terms of simple analytical surfaces
where appropriate (planes, cylinders, etc.) as well as possibly NURBS surfaces to produce a boundary-representation
CAD model. Recovery of such a model allows a design to be modified to meet new requirements, a manufacturing plan
to be generated, etc.
Hybrid modeling is a commonly used term when NURBS and parametric modeling are implemented together. Using
a combination of geometric and freeform surfaces can provide a powerful method of 3D modeling. Areas of freeform
data can be combined with exact geometric surfaces to create a hybrid model. A typical example of this would be the
reverse engineering of a cylinder head, which includes freeform cast features, such as water jackets and high-
tolerance machined areas.[11]

Software
There are two components in reverse engineering: redocumentation and design recovery. Redocumentation is the
creation of new representation of the computer code so that it is easier to understand. Meanwhile, design recovery is
the use of deduction or reasoning from general knowledge or personal experience of the product to understand the
product's functionality fully.[8] It can also be seen as "going backwards through the development cycle."[12] In this
model, the output of the implementation phase (in source code form) is reverse-engineered back to the analysis
phase, in an inversion of the traditional waterfall model. Another term for this technique is program
comprehension.[5] The Working Conference on Reverse Engineering (WCRE) has been held yearly to explore and
expand the techniques of reverse engineering.[1][13] Computer-aided software engineering (CASE) and automated
code generation have contributed greatly in the field of reverse engineering.[1]
Other purposes of reverse engineering include security auditing, removal of copy protection ("cracking"),
circumvention of access restrictions often present in consumer electronics, customization of embedded
systems (such as engine management systems), in-house repairs or retrofits, enabling of additional features on low-
cost "crippled" hardware (such as some graphics card chip-sets), or even mere satisfaction of curiosity.

Software
► Reverse engineering: Methods and techniques

► As already mentioned, no 3D scanner, however expensive and performing, can automatically generate a
CAD model as its output.
► In fact, a 3D scanning system outputs 3D models in the form of polygons or point clouds in STL, OBJ, PLY,
or other similar file formats.
► For this reason, to generate a parametric or non-parametric CAD file starting from 3D scanning data,
reverse engineering procedures must be implemented. There are various possible techniques,
depending on the type of component to be reconstructed, the aim and final use of the resulting CAD
model and the required quality of the result.
► These techniques can be classified into three macro categories defined as follows:
► 1. Auto-surfacing
► 2. Extraction of CAD entities
► 3. Total reverse engineering
►

Software
► Auto-surfacing
► The first technique to generate a CAD model starting from a mesh implies the use of software tools for
automatic recognition of complex surfaces, such as NURBS (Non-Uniform Rational Basis Splines), which
interpolate the triangular surfaces of the mesh. This operation is commonly called auto-surfacing and
this technique is certainly very popular for various applications because it can be performed
automatically or semi-automatically by the reverse engineering software.
► The advantage of this method is that a complete CAD model can be obtained by launching a single
command, after having performed simple mesh optimization operations.
This technique is effective only when the object geometry is freeform, such as for statues, friezes and moldings, while
its use is strongly discouraged for mechanical components for which it is often necessary to obtain a CAD model on the
basis of the original intent of the designer.

Software
► Extraction of CAD entities

► Another reverse engineering technique involves the extraction of mathematical entities from the mesh
in the form of regular surfaces such as cylinders, planes, cones, spheres, and even some NURBS
surfaces for freeform parts. In this case, the mesh resulting from the scanner must be selected by
regions and interpolated with the best-fit surfaces. These surfaces are normally reconstructed by the
reverse engineering software, but to recreate a CAD model consistent with the original project
conceived by the designer, it is necessary to evaluate if any deformations or wear in the scanned
component have occurred, so as to compensate them in the reverse engineering phase. For this reason,
auto-surfacing tools must be used extremely sparingly.
► Different degrees of interpolation precision can be selected, and all the mathematical entities created
by mesh interpolation can be subsequently exported to any CAD software, even devoid of reverse
engineering tools, to be processed.
► At this point, CAD modeling involves trimming the surfaces and making any changes using the common
tools and commands available in 3D CAD software in order to obtain the complete CAD model.

Software
► This technique is more effective and reliable than the auto-surfacing technique because the CAD model
can be reconstructed by carrying out a real redesign, retracing the initial design intent. Therefore, it is
clear that the quality of the result depends on the experience and skill of the operator and furthermore
this technique can be applied only to objects with simple geometries; this is the case of prefabricated
concrete objects or components or simple mechanical parts used in concrete production machinery.
► The result of this reverse engineering method can however be used for any purpose: from redesigning
components to 3D printing of parts, even directly concrete-made 3D printed parts.

Software
► Total reverse engineering

► The total reverse engineering technique is the most effective but involves the use of advanced tools
and software for reverse engineering. In this case, the reverse engineering software must integrate
both mesh editing tools and all the most advanced features (better if parametric) of a 3D CAD software.
In fact, the quality of the result will increase in line with the performance of the used software and the
number of tools made available by it.
► Using this software, the mesh can be optimized and then we can work directly on it by creating curves,
surfaces and solids that interpolate the result of the scan. Therefore, both surface and solid modeling
can be performed. In doing so, we can work on the component just like the original designer would do
because all the modeling tools are available.

THANK YOU
Emerging Trends in
Mechanical Engineering - 22652
(ME/PG/PT/AE)
Unit No - 4
Energy Audit & Management
(For MSBTE Diploma in Engineering students)
Ketan V. Karandikar
Lecturer in Mechanical Engineering Department,
MAEER’s MIT Polytechnic, Kothrud, Pune - 38
Course Outcome (CO) - d
Use different standards for
Energy Management and Audit of a given system
UO - 4.a
List different Bureau of Energy
Efficiency (BEE) standards
4.1 Standards and Labelling Standard (HVAC)
Written by
Ketan V. Karandikar
Agenda
Key takeaways
1. Introduction ➢ Main provisions of Energy Efficiency Act on S & L
2. Bureau of Energy Efficiency (BEE) ➢ Functions of Bureau of Energy Efficiency (BEE)
3. Standards & Labels (S & L) ➢ Concepts of S & L and types of labels with examples
4. BEE Star Labeling & Star Labelled Appliances ➢ Concept, need and importance of BEE Star Ratings with examples
5. Types of BEE Star Levels & Power Savings Guide ➢ Understanding Big Label & Small Label and Power Savings Guide
6. EER, SEER & ISEER ➢ Understanding concepts of EER, SEER & ISEER
Ketan V. Karandikar
Page 4 1 March 2021 Maharashtra State Board of Technical Education

Introduction
► HVAC appliances like domestic Refrigerators, Window Air Conditioners, Split Air-Conditioners need to
be energy efficient with features like minimum operational cost, reduced energy requirement and less
carbon footprint.
► According to the Energy Conservation Act, 2001 of Government of India, a very important activity for
energy efficiency improvement for HVAC systems is preparation of Standards and Labelling (S & L)
Prohibit Mandatory
Maximize energy Manufacture, labelling on
efficiency of Sale and Import equipment for
HVAC appliances of non- customer
conforming awareness
equipment
Main Provisions of
Energy Conservation Act on S & L
Bureau of Energy Efficiency (BEE)
► BEE is an agency from Government of India, operating under Ministry of Power.

► It was established on 1st March 2002 under the provisions of Energy Conversation Act, 2001.
Important functions of BEE
1. Create awareness about Energy usage and it’s Conservation
2. Impart training for Efficient use of Energy and Conservation
3. Plan and Organize Research and Development through expert agencies
4. Development of Testing and Certification Procedures along with promotion of Testing facilities
5. Promotion of use of Energy Efficient Technologies, Processes, Equipment and Systems
6. Finance planning of Energy Efficiency Projects
7. Implementation of Pilot Projects and International Co-operation programmes for Energy

Conservation
Standards & Labels (S & L)
► Standards – Set the limits of energy consumption of a manufactured product. They are set of well-
defined test protocols to achieve highest level of energy performance.
► Labels – They certify energy performance level of a manufactured product. This will be in the form of
specific energy consumption or efficiency or energy cost.
1. Comparative Labels 2. Endorsement Labels
They help customers to compare the energy
They create awareness about highly efficient
consumption of other similar products and take a
category through certification.
decision.

BEE Star Labeling
► According to BEE Standards and Labelling Program 2006, star rating has been provided for all major
appliances and they are labelled accordingly.
► The Star Rating range from 1 to 5 in the ascending order of energy efficiency of a product.
• Since there is a wide variation in energy consumption for the same product from different
manufacturers.
Why ? • Energy consumption information generally is not easily available for customers
• Chance of customers buying inefficient product / appliance
• Manufacturer – Creation of Energy Efficient Product
Value Addition • Customer – Selection of high Energy Performance Product with optimum investment
• Country – Minimum Energy Consumption and Reduced Carbon Foot Print
Example
Refrigerator 1 has Star Label with 5 Star Rating Refrigerator 2 has Star Label with 3 Star Rating
Conclusion:
Refrigerator 1 is more energy-efficient than Refrigerator 2 (More Star Ratings = More Energy Efficiency)
►
Hence, the consumer should purchase Refrigerator 1
BEE Star Labelled Appliances
► As discussed earlier, the main objective of BEE’s Star Labeling Program is to reduce the energy
consumption of an appliance, without compromising it’s operational performance.
► There are two types of schemes for Star Labelling of appliances, as below :
1. Mandatory Scheme 2. Voluntary Scheme
Star Label is compulsory for these appliances Star Label is optional for these appliances
1. Room A/C 9. Electric Geyser 1. Induction Motor 9. Diesel Engine Driven Mono-set Pumps
2. Frost-free Refrigerator 10. Distribution Transformer 2. Pumps 10. Solid State Inverter
3. Direct Cool Refrigerator 3. Ceiling Fan 11. DG Sets
4. Room A/C (Floor Standing) 4. LPG Stoves 12. Chillers
5. Variable Capacity Inverter A/C 5. Washing Machine 13. Microwave Oven
6. LED Lamps 6. Computer 14. Solar Water Heater
7. Tubular Fluorescent Lamp 7. Ballast 15. Light Commercial A/C
8. Colour TV 8. Office equipment 16. Deep Freezers
The estimated saving till date, from the labelling program is 12,000 MW (Since 2007).
Types of BEE Star Labels
Sr. No. Parameter 1. Big Label 2. Small Label

Appliances having a Appliances having an
1. Applicability
constant usage. intermittent usage.
Type of Energy Appliances having Appliances having
2.
consumption high electricity consumption low electricity consumption
Yearly energy consumption, brand Visual representation of only the
3. Information
name, product category, etc. Star Ratings
Helps customers in identifying
Helps customers to estimate
4. Value Addition energy efficiency level of a product
electricity bill
(Low/High)
Refrigerators, washing machines, Ceiling fans, tube lights,
5. List of Products
geysers, etc. computers/laptops, TV, etc.

Types of BEE Star Labels - Examples
1. BEE - Big Labels 2. BEE - Small Labels

Power Savings Guide - Example with Explanation
► BEE has made it mandatory for all the air conditioners

to have a label as shown in the figure alongside.
► More number of Stars = More Efficiency or EER
► EER is given by W / W (same as COP)

► EER in BTU/hr/W = 3.413 X EER in W/W
► EER in BTU/hr/W = 3.413 X COP

Star Rating Levels - Values for A/C
► BEE revises Star rating for A/C from

time to time.
► Hence, A/C with 5 Star rating can

become a 3 Star next year as
shown in the table below https://carriermideaindia.com/images/star-rating.png
https://www.bijlibachao.com/wp-content/uploads/2014/04/bee_rating.jpg
► One should check the validity of Star Ratings as

shown in the tables above.

EER, SEER & ISEER
1. EER
• The Energy Efficiency Ratio (EER) of an HVAC cooling device is the
ratio of output cooling energy (in BTU) to input electrical energy (in
Watts) at a given operating point.
• EER is normally calculated with a 95 °F outside temperature and an
inside (return air) temperature of 80 °F and 50% relative humidity. https://www.lghvacstory.com/wp-content/uploads/2017/06/SEER-
• 2. SEER Formula_1-740x428-1.png
• It is the Seasonal Energy Efficiency Ratio (SEER) rating of a unit looks

at an air conditioner a bit more granularly—calculating the cooling
capacity during a typical cooling-season (rather than all-time)
divided by the total electric input during the same period.
• 3. ISEER
• It is the Indian Seasonal Energy Efficiency Ratio.
• It is the ratio of the total amount of heat that the equipment can
remove from the indoor air when operated for cooling in active
mode to the total annual amount of energy consumed by the https://bestproduct.in/guides/bee-star-rating-in-ac
equipment during the same period.

ISEER - More Details & Example
• Grading system set up by the BEE.

• Since the temperatures across India vary and see extreme changes
through the seasons, the EER standards of calculating performance
were less than ideal.
• This is meant for home appliances such as air
conditioners, refrigerators and other electrical equipment.
• For ISEER, temperature range of 24°C to 43°C is considered.
• Annual operating hours are assumed to be 1600.
https://www.bijlibachao.com/wp-content/uploads/2016/03/Inverter_AC_schedule_final_pdf.png
Outdoor Temperatures - National Weather Data for India
https://mybestac.in/wpcontent/uploads/2020/04/ISE
ER-1024x809.jpg

Assessment - Multiple Choice Questions (MCQs)
Sr. No. Question A B C D

Bureau of Board of Bureau of Board of
1. BEE stands for _______ Energy Environmental Energy Energy
Effectiveness Efficiency Efficiency Efficiency
_______ are used for describing the energy Standards & None of
2. Standards Labels
performance of manufactured products Labels these
Appliance 1 = 3 Star Rating and
None of
3. Appliance 2 = 5 Star Rating. Appliance 1 Appliance 2 Both
these
_______ will save maximum energy
_______ is included in BEE’s Star Labelling Microwave Frost-free
4. LPG Stove Computer
Program Oven Refrigerator
Air Conditioner having 5 Star Rating in 2015
5. 1 2 3 4
will have _______Star Rating in 2016.
If the EER in BTU/hr/W for an A/C is 3.30, its
6. 1 6.20 11.2629 7.7587
C.O.P in W/W is _______

Thank You !!!
Emerging Trends in
(ME/PG/PT/AE)
Unit No - 4
Ketan V. Karandikar
UO - 4.b
Describe methods of Energy
Monitoring and Targeting
4.2.1 Data & Information Analysis
Written by
Ketan V. Karandikar
Agenda
Key takeaways
1. Introduction to Energy Monitoring & Targeting (M&T) ➢ Concept of Energy M&T
2. Scope of Energy Monitoring & Targeting (M&T) ➢ Applications for Energy M & T
3. Elements of Energy Monitoring & Targeting System ➢ Functions of essential elements and processes in Energy M & T
4. Data & Information Analysis ➢ Techniques of data & information analysis
5. Examples on Data Information & Analysis ➢ Pie Charts & Bar Charts
Ketan V. Karandikar

Introduction to Energy Monitoring & Targeting
Energy Monitoring & Targeting is a management technique that uses Energy Information as a basis is aimed at :
Reduce and Control Current Improve Existing

Eliminating Waste Energy Usage Operating Practices
► It follows the principle “You can’t manage, what you don’t measure”
► It combines the Principles of Energy Use and Statistics.
Energy Monitoring Aims at establishing the current or baseline Energy Performance
Energy Targeting Aims at identification of defined targeted energy consumption

Scope of Energy Monitoring & Targeting
Energy Monitoring & Targeting manages the following utilities in a plant and a building:-
1. Fuel 4. Compressed Air
2. Steam 5. Water & Effluent
3. Refrigeration and Air Conditioning 6. Electricity
► It involves a systematic and disciplined division of the facility into Energy Cost Centres.
► The utilities in each centre are closely monitored.
► The energy used is compared with production volume or any other suitable measure of operation.
► Targets are set once this information is available on a regular basis.
► The gaps identified, are interpreted and rectified by suitable remedial actions.
Energy Monitoring & Targeting programs have been very effective
Estimated Reduction in Annual Energy Cost for various Industrial Sectors = 5 to 20 %

Elements of Energy Monitoring & Targeting Systems
Essential Elements of Energy Monitoring & Targeting System

https://energypower2system.files.wordpress.com/2018/11/mt-system.jpg?w=647&h=554&crop=1

Elements of Energy Monitoring & Targeting Systems
Essential Elements of Energy Monitoring & Targeting System

Sr. No. Name of Element It’s Function
1. Recording Measurement and Recording of the data related to Energy Consumption
2. Analysing Co-relating Energy Consumption with measured output (e.g. Production)
3. Comparing Compare Energy Consumption with an appropriate Standard or Benchmark
4. Setting Targets Set the target to reduce or control Energy Consumption
5. Monitoring Compare the Energy Consumption with the Set target on a regular basis
6. Reporting Report the gaps w. r. t. the set target
7. Controlling Implement measures to control the variation and reduce the gaps
Essential Steps in Energy Monitoring & Targeting System

1. Checking the accuracy of energy invoices
2. Allocatingenergy costs to respective departments (Energy Cost Centres)
3. Determiningthe energy performance
4. Recording energy usage to check whether energy performance is line with the target
5. Highlightingthe issues related with equipment or system under performance

Data and Information Analysis
Relating Energy Consumption with Production

➢ It is very important to understand the various ways of Energy Consumption.
➢ Data collection related with Production, Operational hours, Weather forms a baseline data.
➢ The data is analysed to establish base line Energy Performance of a plant.
➢ After collection of data related with Energy Consumption, Energy Cost and Production, the next step is
to analyse it.
➢ Graphical tools are very effective for developing a relationship between Energy Consumption and
Production
Energy data can be analysed by using the following techniques
Pie Chart Bar Chart CUSUM Technique

Energy Data and Information Analysis - Pie Chart - Example - 1
► Step 1:
► Electricity and Fuel Bills are collected for a defined
period and are analysed using an Annual Energy
Cost Sheet as shown in the table alongside.
► This table shows a typical format for monitoring
plant level information.
► Step 2:
► After collecting the Annual Energy Cost of each
Fuel, a Pie Chart showing % share of each fuel has
been prepared, as shown in the figure alongside.

Energy Data and Information Analysis - Pie Chart - Example - 2
► Step 1:
► All Energy resources purchased by the plant are
converted into a common energy unit i.e. Kcal
► The table alongside provides guidelines for
arriving at Equivalent Energy Units for each Energy
Source.
► Step 2:
► A Pie Chart is prepared showing % usage of each
energy resource, as shown by figure alongside.

Energy Data and Information Analysis - Bar Chart
➢ It is difficult to arrive at system performance from the plain data collected in a form of spreadsheet,
hence the data is presented in a form of bar chart.
➢ First step - To collect and collate data of 24/12 months of energy bills.
Use of Bar Chart (Different Types)
Annual Total for Energy SEC with Production

and Production Monthly SEC
Monthly Consumption
data for the Current
and Previous year

Energy Data and Information Analysis - Bar Chart - Examples
1. Monthly Energy Consumption for Current & Previous year

► Most commonly used bar chart in energy management
however, it is not a perfect tool.
► Production data for the same 24/12 months is required.
2. Annual Total for Energy and Production

► Energy and Production are plotted in the same chart on
y-Axis on both the sides.
► Each Point corresponds to the sum of previous 12
months data
► Each point covers seasonal cycle and holidays etc.
► Minimises the timing error of various meter readings

Energy Data and Information Analysis - Bar Chart - Examples
3. Monthly SEC (Specific Energy Consumption)

► Energy Consumption is directly related with production.
► Specific Energy Consumption (SEC) is energy
consumption per unit of production.
► Quality of M & T System will depend on quality of data
4. SEC with production

► Magnitude of Production may affect Specific
Consumption
► Few more features can be explained by adding
Production data to the monthly SEC chart.
► SEC and Production are plotted on y-Axis on both sides
as shown in figure along side.
►

Energy Monitoring & Targeting helps in reducing
1. annual energy costs in various industrial sectors 1 % to 2 % 2 % to 10 % 4 % to 15 % 5 % to 20 %
by _____
_______ aims at identification of energy
Energy Energy
2. consumption level which is desirable for energy Recording Controlling
Monitoring Targeting
conservation.
______ is the best method for representing
CUSUM
3. individual consumption of a number of fuels in Pie Chart Bar Chart None of these
Technique
percentage.
Sustainable
Sustainable Specific Energy Specific
4. SEC stands for _______ Energy
Energy Council Consumption Energy Council
Consumption
Co-relating energy consumption to a measured
5. output like production quantity is the function of Recording Analysing Comparing Monitoring
_______
6. 2 kg of Furnace oil will generate ______ kcal 1000 10,200 2000 20,400

Thank You !!!
Emerging Trends in
(ME/PG/PT/AE)
Unit No - 4
Ketan V. Karandikar
UO - 4.b
Describe methods of Energy
Monitoring and Targeting
4.2.2 CUSUM Technique
Written by
Ketan V. Karandikar
Agenda
Key takeaways
1. Relationship between Energy and Production ➢ Method of establishing relationship between Energy and Production
2. Introduction to the CUSUM technique ➢ CUSUM technique - Concept and Importance
3. CUSUM technique - Example ➢ Key highlights of CUSUM technique
4. CUSUM technique - Case Study ➢ Case Study of Energy Saving using CUSUM technique
Ketan V. Karandikar

Relationship between Energy and Production
► It provides basis for performance assessment.

► Energy Vs Production graph establishes the relationship,
as shown in figure alongside.
► A trend-line is drawn for the data set on the chart.
► The chart shows a good fit with low degree of scatter.
► High degree of scatter indicates the scope for energy
saving.
Energy Consumption for a period = C + (M x Production for the same period)

Where:
C = Fixed Energy Consumption
(For Lighting, Heating/Cooling and General Purpose Services, irrespective of change in Production Levels)
M = Variable Energy Consumption
(Directly Related with Production )
Using this formula, the estimated or ‘’Standard” Energy Consumption can be evaluated,
for any level of production within the range of the data set
Introduction to CUSUM Technique
► Cumulative Sum (CUSUM) is a graphical technique.

► It represents the difference between the baseline (expected or standard energy consumption) and the
actual energy consumption points over the defined period of time.
► It helps in calculation of Saving/Loss for the data period and also indicates change in performance.
► A typical CUSUM graph follows a trend.
► It shows random fluctuations of energy consumption.
► It has to oscillate around zero, which is the expected or standard energy consumption.

CUSUM Technique - Example
► In the chart alongside, Months are

plotted on x-axis and Energy
Consumption is plotted on y-axis.
► Horizontal line is a base (zero line)
► Brown colour line is a trend line.
► If energy consumption is less than
the baseline, performance is better
and vice-versa.
► January to March - Performance is
good.
► April - Performance is bad
► May to July - Performance is good
► July to December - Performance is
declining and it becomes worst in
December 2000.
► The changes in direction of the
trend-line has relation to the
energy consumption pattern.

CUSUM Technique - Case Study
► Question …?
► Energy Consumption and Production data
were collected for a plant over a period of
18 months.
► During month 9, a heat recovery system was
installed. Using the plant monthly data,
estimate the savings by Installation of heat
recovery system.
► The plant data is as shown in the table
alongside.
http://leansixsigmaenvironment.org/wpcontent/uploads/2020/03/1_8_CUSUM_Monitoring_Targeting.pdf

1. Plot the Energy Vs Production graph for the first 9 months
2. Draw the best fit straight line
3. Derive the Equation of straight line
4. Calculate the expected energy consumption based on the derived equation
5. Calculate the difference between actual and calculated energy usage
6. Compute the Cumulative Sum (CUSUM)
7. Plot the CUSUM graph
8. Estimate the savings achieved by installation of Heat Recovery System

CUSUM Technique Case Study - Steps 1 to 3

CUSUM Technique Case Study - Steps 4 to 6

CUSUM Technique Case Study - Steps 7 & 8

Conclusions:
From the CUSUM graph, following are the observations :
► It oscillates around the zero line for 11 Months and then drops sharply after 11th Month.
► After month 13, Energy Saving is in a steady state.
► This indicates, the heat recovery system took 2 months to commission and reach in steady state conditions.
► Savings achieved after month 11 (Month 12 to 18 = 7 months) are as follows: -
Savings = 50 toe - 6 toe = 44 toe
• Total Saving = Summation of (Eact - Ecalc) (For months 12 to 18) = 44
• Actual energy consumption = Summation of Eact (for months 12 to 18) = 2352
► The percentage of total savings in energy consumption = (For months 12 to 18) = (44 / 2352) X 100
► The percentage of Saving in Energy Consumption = 1.87%
► The CUSUM technique is a simple, but remarkably powerful statistical tool.
► It highlights small differences in energy performance.
► Its regular use allows the Energy Manager to improve their plant performance.

Both, fixed
Energy consumed for a period = C + (M *
Fixed Energy Variable Energy and variable No energy
1. Production for the same period). M stands for
Consumption Consumption energy consumption
_______
consumption
In a CUSUM technique chart, if energy
Performance is Performance is Performance is Performance is
2. consumption is less than the baseline, it shows
good bad very poor zero
that the _______
CUSUM technique: Total savings = 65,
3. percentage savings = 3.7 %. Actual energy 240.5 17.567 1756.75 2405
consumption will be _______
4. CUSUM technique is _______ technique Analytical Graphical Exponential None of these
In the graph of Energy vs Production, a high There is a scope There is no scope The graph is
Energy savings
5. degree of scatter with respect to the trend-line for energy for energy wrongly
are highest
indicates that _______ savings savings plotted
Equation of trend line is Ecalc = 0.2 P + 150, E act
6. 300 380 490 520
= 400, Ecalc = 248, P = _______

Thank You !!!
Emerging Trends in
(ME/PG/PT/AE)
Unit No - 4
Ketan V. Karandikar
UO - 4.c
Identify steps for conducting
Energy Audit
4.3.1 Objectives, Need & Types of Energy Audit
Written by
Ketan V. Karandikar
Agenda
Key takeaways
1. Introduction ➢ Concept of Energy Audit
2. Objectives of Energy Audit ➢ Goal of Energy Audit
3. Need for Energy Audit ➢ Necessity of carrying out Energy Audit
4. Types of Energy Audit ➢ Brief explanation about different types of Energy Audits
5. Preliminary Energy Audit (PEA) - Methodology ➢ Steps involved in PEA
6. Detailed Energy Audit (DEA) - Methodology ➢ Steps involved in DEA
7. Detailed Energy Audit (DEA) - Scope for Work ➢ Equipment/Processes covered in DEA
8.
Ketan V. Karandikar

Introduction
► According to the Energy Conservation Act, 2001 of Government of India, Energy Audit means -
“The verification, monitoring and analysis of use of energy including submission of technical report
containing recommendations for improving energy efficiency with cost benefit analysis and an action
plan to reduce energy consumption.’
In simple words, Energy Audit is
Inspection Survey Analysis
Of….. ?
Energy Flows
For… ?
ENERGY CONSERVATION
Of a Building, Equipment, Process or System
To Reduce Input Energy Cost without compromising the Output
Objectives of Energy Audit
1. Identify • Quality and Costs of various Energy Inputs
2. Assess • Present pattern of energy consumption in different departments
Objectives of Energy Audit

3. Compare • Energy Inputs with Production Output
4. Identify • Potential areas of Thermal and Electrical Energy Saving
5. Highlight • Wastages in Major Areas
6. Propose • Energy Saving Targets for the Individual Departments
7. Implement • Measures of Energy Conservation
8. Sustain • Ensure sustenance of Energy Efficiency by constant monitoring

Need for Energy Audit
► Why an Energy Audit is needed in an Industry?

► Top 3 operating expenses in any industry are:
1. Energy (Electrical and/or Thermal)
2. Labour
3. Materials
► Amongst these 3, energy has the maximum potential for Savings.
► Hence, Energy Audit and Management is a very important initiative for cost reduction.
► Energy Audit takes into account variations in Energy Cost, Consistent Availability and Reliability of Energy Source,
Optimization of Energy Mix and identifies Energy Conservation measures.
► End Objective – Identify means to reduce Energy Consumption per Unit of Production or to lower the operating
costs.
► This will help in improved bottom line.
► Energy Audit establishes a reference point (bench-mark) around which the costs are managed in the organisation.
► It provides basis for planning the future use of energy more effectively and also help in planning the future
equipment purchases.

Types of Energy Audit
Choice of Energy Audit depends upon
Function and Type of industry Depth to which the data analysis required Cost Savings Targeted
Types of Energy Audit
1. Preliminary Energy Audit
2. Detailed Energy Audit (DEA) 3. Targeted Energy Audit (TEA)
(PEA)
• Simple analysis of energy use. • Detailed analysis of energy • Based on the outcome of
• Readily available data used use. preliminary energy audit.
• Quick, hence gives general • Data collected and analysed • Provides data and detailed
results for energy efficiency using on-site measurements. analysis about specified
improvement. • Time-consuming, hence gives target equipment/processes.
• Time required -Generally, 1 to specific results for energy • Results depend upon the
10 days efficiency improvement. competency and experience
• Time required - Generally, 1 of an auditor
to 10 weeks. • Low focus on other potential
saving areas

1. Preliminary Energy Audit (PEA) - Methodology
1. Establish Energy Consumption
2. Estimate scope for saving
3. Identify low cost and major saving areas simultaneously
4. Identify immediate/low-cost savings
5. Set a reference point
6. Identify areas for more detailed savings

2. Detailed Energy Audit (DEA) - Methodology

http://www.pcra.org/pages/display/180-Energy-Audit


2. Detailed Energy Audit (DEA) - Scope for Work

In an industry, _______ has the best potential
1. Energy Labour Materials All of these
for cost savings.
The inspection, survey and analysis of energy
Energy
2. flows for energy conservation in a building is Energy Efficiency Energy Audit Energy Output
Management
called as _______
If specific results for energy efficiency
3. improvement are required, ______ energy audit Preliminary Detailed Targeted All of these
will be the best choice.
Detailed Energy Audit generally requires
4. 1 to 10 weeks 1 to 3 days 1 to 3 weeks 1 to 10 days
_______
If readily available data is used, the energy audit
5. PEA DEA TEA All of these
performed is _______
A company has 10 machines. During energy
6. audit, only 3 machines are considered. It is Preliminary Detailed Targeted All of these
______ energy audit.

Thank You !!!
Emerging Trends in
(ME/PG/PT/AE)
Unit No - 4
Ketan V. Karandikar
UO - 4.c
Identify steps for conducting
Energy Audit
4.3.2 Energy Management, Energy Conservation &
Energy Audit Instruments
Written by
Ketan V. Karandikar
Agenda
Key takeaways
1. Introduction ➢ Concept of Energy Management
2. Objectives of Energy Management ➢ Goal of Energy Management
3. Process Flow steps in Energy Management ➢ Step-wise procedure of Energy Management with an example
4. Energy Conservation ➢ Concept, approaches and objectives of Energy Conservation
5. Energy Conservation Opportunities ➢ Major energy consuming assets and different ways to conserve energy
6. Energy Costs and Energy Performance ➢ Fuel costs & power costs, Calculations for Plant Energy Performance (PEP)
7. Fuel Substitution & Energy Substitution ➢ Concepts of Fuel Substitution and Energy Substitution with examples
8. Energy Audit Instruments ➢ Different types of Energy Audit Instruments with their applications
Ketan V. Karandikar

Introduction to Energy Management
► According to VDI-Guideline 4602, Energy Management is -

► “The proactive, organised and systematic coordination of procurement, conversion, distribution and
use of energy to meet the requirements, taking into account environmental and economic
objectives”.
In simple words, Energy Management is
Conserving & Optimizing
Energy use
for ?
1. Getting more production output 2. Saving money and making the processes
from the same or less energy more comfortable, healthy and safe

Objectives of Energy Management
1. Achieving & maintaining • Optimized Energy Procurement and Utilization
2. Minimizing • Energy Cost and Wastages without compromising Production and Quality
3. Minimizing • Environmental damage
4. Increasing • Energy Efficiency
5. Reducing • Carbon footprint
6. Finding • Superior energy alternatives
7. Implementing • Measures of energy conservation

Energy Management Cycle
➢ Steps in Energy Management :
1. Energy Data collection through smart

metering
2. Identifying energy-savingopportunities
3. Implementation of Identified Proposals.
4. Track and Sustain the Energy Performance
by follow-through audits
https://www.energyworxsa.com/

Detailed Process Flow Steps in Energy Management
➢ In this flow diagram of Penicilin-G

manufacturing, the process steps are
listed using existing drawings and
shop-floor walk through.
➢ Waste Stream (Myecelium) and
obvious Energy Wastages like
condensate drain and Steam leakages
have been identified.
➢ Energy audit focuses on following
areas:
➢ 1. Consumption of input resources
➢ 2. Energy efficiency potential
➢ 3. Energy consumption
➢ Major energy conservation areas are:
➢ Germinator, prefermentor, fermenter
and extraction.
http://knowledgeplatform.in/wp-content/uploads/2017/03/1.3-Energy-management-Audit.pdf
Bureau of Energy Efficiency
Energy Conservation
Energy Conservation is -
►
► “The focussed approach to reduce energy consumption using latest optimisation tools”
Approaches of Energy Conservation
1. Using energy more efficiently 2. Reducing the amount of energy used

Example: Example:
Using a car with a highly efficient engine, Driving less
having minimum energy losses or wastages (Using car as and when
necessary)
Objectives of Energy Conservation
► Reduce the dependency on foreign countries for resources
► Reduce energy requirement by demand-side management
► Rising energy demands owing to higher production
► Minimize the carbon footprint
► Protect the environment and conserve the natural resources

Major Energy Consuming Assets
Sr. No. Equipment/Asset Type of Energy

1. Boilers & Steam Utilisation Thermal
2. Furnaces, Thermal Oil Heaters Thermal
3. Compressed Air Generation and Electrical
Utilisation
4. HVAC and Air Conditioning Electrical
5. Pumps Electrical
6. Blowers & Fans Electrical
7. Electric Motors Electrical
8. Diesel Gensets (DG) Thermal
9. Lighting Electrical
10. Process Equipment Thermal / Electrical
11. Cooling Towers and Accessories Thermal & Electrical
► BEE has identified these energy consuming equipment/assets in Industrial processes.
► They have identified energy conservation opportunities and formulated set of guidelines to achieve the recommended savings
Energy Conservation Opportunities
Sr. No. Equipment / Asset Energy Conservation Opportunities & Methods (Main)
a) Preheating of air & feedwater - economiser & air preheater
b) Minimizing incomplete combustion by using uniform fuel size
c) Reducing excess air
1. Boiler
d) Reducing radiation & convection heat losses - proper insulation
e) Automatic blowdown control
f) Replacing boilers which are inefficient and in service for long
a) Reducing excess air with flow-rate controller
b) Proper heat distribution by adjusting the alignment of burners
2. Furnaces c) Minimizing heat losses - provision of proper insulation
d) Waste heat recovery from flue gases - preheaters and recuperators
e) Minimizing heat losses using proper insulation and thick walls
a) Locate suction duct outside compressor house in well ventilated area
b) Using air filters and dust separators for avoiding under performance
c) Avoiding the location of compressors at high altitudes
3. Compressed Air Systems
d) Using intercooling between stages to reduce the energy input
e) Fixing existing leakages and preventing new ones
f) Turning off compressors when not in use
a) Using water-cooled condensers instead of air-cooled condensers
b) Makeup Refrigerant level
c) Minimize leakages & heat energy losses
d) Building Automation System (BAS) and Energy Management System (EMS)
4. HVAC & Chillers
e) For chiller - Using the lowest temperature condenser water available
f) Using evaporative coolers in dry climates
g) Minimise Fan speed, Clean the Damper blades & fins, Maintain Filters
h) Sealing leaky HVAC ductwork
a) Ensuring adequate NPSH
b) Operating pumps near best efficiency point
c) Using variable speed drives
5. Pumping System
d) Using booster pumps for small loads and higher pressures
e) Maintenance of seals, pressure gauges, flow meters, etc.
f) Optimizing number of stages
a) Using a motor management plan
6. Electric Motors b) Conducting regular maintenance
c) Using energy-efficient motors and conducting motor rewinding
a) Ensuring cold and dust-free air intake.
b) Using air filters and air washers during hot and dry weather
c) Ensuring steady load conditions and avoiding fluctuations
7. Diesel Gensets (DGs)
d) Calibrating fuel pumps periodically y
e) Using efficient engine technologies like EGR, VGT & Micro-processors
f) Using emission control techniques like DOC, DPF & FTF, SCR, etc.
a) Using automatic sensors for turning-off lights
b) Replacing T-12 tubes with T-8 tubes
c) Replacing mercury lights with metal halide lights
8. Lighting
d) Replacing HID lights with High-intensity fluorescent (HIF) lights
e) Replacing magnetic ballasts with electronic ballasts
f) Replacing incandescent lighting with LED and CFL lighting
a) Optimizing fan blade angle and blade tip clearance according to load
b) Using FRP fan blades & square spray practically non-clogging nozzles
Cooling Towers and
9. c) Replacing slat-type drift eliminators with PVC cellular units
Accessories
d) Segregating cooling towers for sensitive applications like A/C plants
e) Optimize water flow - efficient pumps and cover hot water basins
Classification of Energy Conservation Measures
► Categories of Energy Saving Projects

Sr. No. Category of energy saving project Priority
1. Low cost - High return Highest
2. Medium cost - Medium return Medium
3. High cost - High return Lowest
► Project Priority Guidelines

Sr. No. Priority Economical Feasibility Technical Feasibility Risk / Feasibility
1. A - Good Well defined & attractive Existing technology adequate No risk / High feasibility
Well defined and only Existing technology may be Minor operating risk /
2. B - May be
marginally acceptable updated, lack of confirmation May be feasible
Poorly defined and Existing technology is
3. C - Held Doubtful
marginally unacceptable inadequate
4. D - No Clearly not attractive Need major breakthrough Not feasible

Energy Costs
► Understanding energy cost is very important for creating awareness& calculating savings.
► Many industries do not have meters to measure energy, they use fuel and electricity invoices
► Purposes of energy invoices: -
1. For providing record of annual energy purchased, for future reference
2. For indicating potential for savings when related to production
3. For quantifying energy and cost savings through energy conservation measures
1. Fuel Costs 2. Power Costs (Electricity)
Factors to be
Factors involved in deciding
Type of Fuel considered during
final cost of purchased electricity
procurement
1. Maximum demand 5. High tension and low
1. Fuel Oil -
• Price at source, charges (kVA) tension tariff
Low Sulphur Heavy Stock (LSHS)
transport 2. Energy Charges (kWh) 6. Slab rates variation
2. Light Diesel Oil (LDO) charges, type of
transport 3. ToD charges 7. Category-wise tariff
3. Liquefied Petroleum Gas
(LPG) • Quality of fuel 4. Power Factor (PF) charge 8. Tariff for developed /
• Calorific Value underdeveloped areas
4. Coal, Lignite, Wood, etc.
Energy Performance
Current Year’s Production

Production Factor =
Reference Year’s Production
► Reference Year Equivalent Energy Use or Reference Year Equivalent
► It is the reference year’s energy that would have been used to produce the current year’s production output
Reference Year Equivalent = Reference Year’s Energy Use X Production Factor
► Plant Energy Performance (PEP)

► It is the measure of whether a plant is now using more energy or less energy to manufacture the products than it
did in the past.
► It is the improvement or deterioration in energy performance from the reference year.
► It indicates how well the energy management programme is doing.
Reference Year Equivalent - Current Year’s Energy
Plant Energy Performance (PEP) = X 100
Reference Year Equivalent

Fuel & Energy Substitution
Fuel Substitution
►
► It is substituting an existing fossil fuel with
more efficient and less cost / less polluting fuel
such as natural gas, biogas and locally available
agro-residues. Energy Substitution
►
► It is implemented in all major sectors of the ► Energy is an important input in production.

Indian economy. ► 2 ways to reduce energy dependency are: -
► Examples: - ► Energy conservation and Energy substitution
Existing Fuels Substitute Fuels ► Energy substitution is substituting an existing
1. Soft Coke 1. Kerosene & LPG type of energy with a better alternative.
2. Coal 2. Coconut Shell, Rice husk, ► Examples: -
Biomass Briquette Existing Energy Substitute Energy
3. LDO 3. LSHS 1. Oil & Gas 1. Solar, Wind, Nuclear Energy
2. Electric heaters 2. Steam heaters
3. Steam hot water 3. Solar hot water

Energy Audit - Parameters measured
2. Non-electrical Parameters
1. Temperature
2. Radiation
1. Electrical Parameters
3. Air & gas flow
1. Voltage (V)
4. Liquid Flow
2. Current (I)
4. Speed (RPM)
3. Power Factor
5. Air velocity
4. Active Power (kW)
6. Noise & vibration
5. Apparent Power (kVA)
7. Dust concentration
6. Reactive Power (kVAr)
8. Total Dissolved Solids (TDS)
7. Energy consumption (kWh)
9. pH
8. Frequency (Hz)
10. Moisture content
11. Relative Humidity (RH)
12. Flue gas analysis
3. Wattmeter/Power Factor Meter.

To measure power consumption
and power factor of individual
motors and other inductive devices
1. Tape Measure
To check dimensions of walls,
ceilings, windows, etc.
2. Light Meter / Lux Meter
To measure illumination levels in
facilities as per the standards
4. Combustion Analyzer / Fyrite 5. Contact Thermometer 6. Infrared Thermometer

To measure concentration of O2, CO, NOx To measure temperature of flue Non-contact instrument for
and SOx in flue gases generated in gases, hot air and hot water by measure high temperatures from a
combustion direct insertion of probe long distance. Used in furnaces and
other hot surfaces
8.2 Doppler Effect

8.1 Transit time type
Ultrasonic Flow Meter
Ultrasonic Flow Meter
7. Pitot Tube & Differential Manometer 8. Ultrasonic Flow Meter

To measure air velocity and Non-contact-type instrument used to directly measure flow-rate of water and any other
air pressure in ducts fluids. High accuracy can be achieved in measurement.

9.3 Stroboscope 9.4 Anemometer

9.1 Tachometer 9.2 Laser Tachometer
Non-contact type To measure air speed
Contact type Non-contact type
9. Speed Measurement Instruments
To measure speeds of machine shafts, gearboxes, motors, rotors, fans, blowers, turbines, etc. These can be contact -type and non-
contact type instruments.

10. Ultrasonic Leak Detector 11. Digital Psychrometer 12. Digital Bourdon Tube Pressure Gauge
To remotely detect leaks of compressed air To measure DBT, WBT & RH of air To measure pressures of liquids and gases
and other gases not possible for humans
Conserving and optimizing energy use for

Energy Energy
1. getting more production output and saving Energy Conservation Energy Audit
Efficiency Management
money is called as _______
Using water-
Energy can be conserved in HVAC systems Using air-cooled Maximizing fan Maximizing heat
2. cooled
by _______ condensers speeds losses
condensers
Reducing Increasing
Using energy more Using energy
3. Use of a highly efficient machine is _______ amount of amount of
efficiently less efficiently
energy used energy used
To reduce pollution, soft coke should be
4. Petrol Kerosene & LPG Diesel LDO
replaced by _________
Energy performance Energy Audit of Production of Production of
Plant Energy Performance (PEP) compares
5. of current & current & current & current & future
_______
reference year reference year reference year years
If the temperature inside a furnace is to be
Contact type Laser Combustion Infrared
6. measured, ______ will be the most suitable
Thermometer Tachometer Analyzer Thermometer
instrument.

Thank You !!!
Engineering - 22652
UNIT V – Agriculture Equipment's and Post
Harvest Technology
(For MSBTE Diploma Engineering students.)
Prof. Naresh B. Chaudhari, Lecturer in Mechanical Engg. Dept.

MAEER’S MIT Polytechnic, Pune - 38
Course Outcome –
Select the recent
agricultural equipment for
pre and post harvesting
UO 1 –
Explain the working of Pre-
harvesting Equipment's
Written by
Naresh B. Chaudhari
Lecturer in Mechanical Engg. Dept.
Agriculture Activities
Cultivation of crops involve several activities undertaken by farmers over a period of time. These activities are similar
to those carried out by a gardener or even by you when you grow ornamental plants in your house.
These activities or tasks are referred as agricultural practices.

(i) Preparation of land
(ii) Sowing
(iii) Applying fertilisers and manure
Pre-harvesting Activities
(iv) Irrigation
(v) Intercultural operation (Weeding)
(vi) Plant Protection
(vii) Harvesting
(viii) Threshing Post-harvesting Activities
(ix) Storage
Page 4 27 February 2021 Presentation title

Tillage
Mechanical manipulation of soil to provide a favorable condition for crop production is called as tillage
OBJECTIVES OF TILLAGE
(i) Turn the soil & loosen it which allows roots to penetrate deeper.
(ii) Loose soil allows the roots to breathe easily even when they go deep.
(iii) Helps in the growth of earthworms and microbes present in the soil.
(iv) Buried the crop residues of previous crop into the soil for increasing decomposition rate as well as adding more
humus into the soil.
(V) Exchange the top layer of soil with bottom layer of soil, it brings the nutrient-rich soil to the top so that plants
can use these nutrients.
(VI) To increase water absorbing capacity of soil and reduce soil erosion.
(VII) To destroy the insect, pests etc.

Classification of Tillage
Primary Tillage: the operation performed to open any cultivatable land with view to prepare a seed bed for growing crops are
known as primary tillage operations. The primary tillage implements are:
1. M. B. Plough – used for :
(i) cutting the furrow slice (ii) lifting the soil (iii) Turning the furrow slice and (iv) pulverizing the soil.
2. Disc Plough- It is a plough, which cuts, turns and in some cases breaks furrow slices by means of separately mounted
large steel discs. A disc plough is designed with a view of reduce friction by making a rolling plough bottom
instead of sliding plough bottom.
It consists of steel disc of 60 to 90 cm diameter, set at a certain angle to the direction of travel.
3. Sub soiler- It is used to prepared drainage pipe below the soil. Also, it removes hard pan created inside the soil layer.
It is mostly used in the area where drainage is not proper. Its operating depth is grater than 75 cm.
4. Chisel Plough- It mostly used to remove the hard pan devolved in the soil. Its operating depth ranges from 30 cm to 75cm.
5. Rotary Plough - A rotavator is a primary tillage implement especially designed for seed bed preparation in a single pass. It
gives excellent pulverization of soil and mixes the trash, crop residues, weeds etc. into the soil
6. Indigenous Plough- Pulled by bullock and it opens the soil at depth less than 10 cm.
Page 6 27 February 2021
It consist of : Presentation
(i) handle title
(ii) Beam (iii) Body (iv) Share.
Primary Tillage Implements :
Indigenous Plough M. B. Plough

Disc Plough
Sub Soiler Chisel Plough Rotary Plough

Classification of Tillage
Secondary Tillage: The tillage operations following primary tillage which are performed to create proper soil tilth for
seeding and planting are known as secondary tillage operations. The secondary tillage implements are:
1. Disc harrow:
It used to reduces the size of clod and prepare fine tilt of soil. Mostly it preferred in trash and stony soil for the
operation.
2. Spike tooth harrow:

It having no of small spikes that placed on harrow body. It pulled by tractor and maintain operating depth in
between 10 to 15 cm.
3. Levelers:
Levelers are used to maintain uniform level of land. It benifical to improve water distribution efficiency, maintain
uniform crop height and prevent the water logging condition in the field.
4. Cultivators:
Cultivators are used to remove the weed present in the field and reopen the soil before sowing. It mostly preferred
when there is large gap between secondary tillage operation and sowing.
Secondary Tillage Implements :
Disc Harrow Spike tooth harrow Levelers
Cultivator Clod crusher

Cultivators:
One type refers to frames with teeth (shanks) that pierce

the soil as they are dragged through it linearly.
Another type refers to machines that use rotary motion

of disks or teeth to accomplish a similar result.
Cultivators stir and pulverize the soil, either before planting (to aerate the soil
and prepare a smooth, loose seedbed) or after the crop has begun growing
(to kill weeds—controlled disturbance of the topsoil close to the crop plants
kills the surrounding weeds by uprooting them, burying their leaves to disrupt
their photosynthesis, or a combination of both).
Sowing
Seeding or sowing is an art of placing seeds in the soil to have good germination in the field.
A perfect seeding gives:
➢ Correct amount of seed per unit area.
➢ Correct depth at which seed is placed in the soil.
➢ Correct spacing between row-to-row and plant-to-plant.
SOWING METHODS
(i) Broadcasting
(ii) Dibbling
(iii) Drilling
(iv) Seed dropping behind the plough
(v) Transplanting
(vi) Hill dropping
(vii) Check row planting.

Sowing Methods
Broadcasting Dibbling Drilling
Seed dropping behind the plough Transplanting

SEED CUM FERTILIZER DRILL
COMPONENTS
1. Frame
2. Seed box Fertilizer box
3. Seed metering mechanism Seed box

Seed
4. Fertilizer metering mechanism Frame
metering
5. Drive transmission system mechanism
6. Furrow openers
7. Covering device
Transmission
8. Clutch system
9. Hitch frame and
10. Transport wheels.
Furrow openers

Weed control
The main objectives of weed control are
• To remove unwanted plant.
• To Improve the soil conditions for healthier growth of plant.
• To reduce competitions to take nutrients from the soil.
Power weeder Wheel hoe

Power weeder is a rotary equipment used The wheel hoe is used cultivating the land
for secondary tillage and weeding between rows.
operation. It consists of a wheel, two handles and a tyne
to place the cutting tool on.
A man operates the hoe in standing position

by pushing through a short length each time.
In a working day, about 0.04 hectare can be

covered.

Plant protection
It has become necessary now to use pesticides and fungicides for controlling the pests and diseases. The chemicals are
applied on plants in the form of spray and dust.
Many types of sprayers and dusters are available in different sizes for plant protection work
Sprayer – It is a machine used to apply liquid chemicals on plants in the form of droplets to control pests and diseases. It
can be used to apply herbicides also to control weeds and to spray micro-nutrients for enhancing plant growth.
Functions of Sprayer
• The main function of a sprayer is to break the liquid into droplets of effective size and distribute them uniformly over
the surface or space to be protected.
• Another function is to regulate the amount of insecticide to avoid excessive application that might prove harmful or
wasteful.

Plant protection equipments
Knapsack Motorized Mist Blower Cum Duster
Knapsack Sprayer (Hand Operated) • It consists of a 1.2- 3.0 hp high speed petrol engine,
a blower, a 12 lit chemical tank.
• This sprayer is suitable for applying
chemicals to several field crops. • Sprayer can be converted in to a duster by changing
• The operator carries the sprayer on his back few parts.
and hence the name knapsack sprayer.
• It has a flat or bean-shaped tank of 10-15
litres capacity,
• The tank is made of either brass or PVC
material.
• The pressure developed in these sprayers
depends on the pump and varies from 3 to
12 kg/cm2
• The application rate is 500 lit/ha.
• The coverage is 0.5-1.0 ha/day.

Plant protection equipments
Power Sprayer
• It is a heavy duty and efficient sprayer.
• It consists of a triplex pump with stainless steel piston

with oil bath lubrication.
• It can Develops 250 to 350 pounds pressure and can

deliver the solution up to 15 m.
• It can be powered by a 3 HP engine or electric motor .
• It is convenient to spray with 4 to 6 spray lances at a

time using the sprayer.
• There are sprayers can be operated by tractor PTO as

well as by a power tiller

Summative Questions -
1. The purpose of ploughing is
A. To improve soil aeration B. To prevent soil erosion C. To add fertility to soil D. All are correct
2. The purpose of harrowing is to
A. Pulverize soil B. Destroy weeds C. Break clods D. All are correct
3. A vertical plate that is used to control depth and adjust line of pull in plough is ANSWERS
A. Vertical suction B. Vertical clevis C. Horizontal suctionD. Horizontal clevis 1-D 5-C
4. Two-way plough is advantageously working in
2-D 6-D
A. Levelled field B. Contour field C. Undulated field D. None of these
3-B 7-C
5. A plough that works effectively in hard, dry and sticky soil is
4-B 8-B
A. Mould board plough B. Harrow plough C. Disc plough D. Indigenous plough
6. Tillage system, which is suitable for dry land agriculture, is
A. Till plant system B. Zero tillage C. Minimum tillage D. All are correct
7. A tillage system in which the field is ploughed and followed by row crop planter directly is
A. Zero tillage system B. Rotary tillage system C. Plough plant D. Till plant system
8. Of the following, which are the primary tillage implements?
A. Chisel plough and disc harrow B. Chisel plough and subsoiler C. Disc plough and disc harrow D. Leveler and clod crusher
Engineering - 22652
Harvest Technology

Course Outcome –
Select the recent
post harvesting
UO 1 –
Explain the working of Post-
harvesting Equipment's
Written by
Naresh B. Chaudhari
Key takeaways
1. Harvesting
Students will able to know the different Post-harvesting
equipment's.
2. Threshing
3. Threshing Methods
4. Parts of Thresher
Naresh B. Chaudhari
5. Working of Thresher Lecturer in Mechanical Engg. Dept.
6. Drying of Grains
7. Cleaning of Grains
8. Storage of Grains

Overview of Post Harvest Technology
Post Harvesting Operation
1. Harvesting
2. Transportation
3. Threshing
4. Drying
5. Cleaning
6. Storage

Harvesting
It is the operation of cutting, picking, plucking and digging or a combination of

these operations for removing the crop from under the ground or above the
ground or removing the useful part or fruits from plants.
Harvesting action can be done by four ways:

1. Slicing action with a sharp tool.
2. Tearing action with a rough serrated edge
3. High velocity single element impact with sharp or dull edge.
4. Two elements scissors type action.
Harvesting can be done by:

(i) Manually operated tool
(ii) Animal drawn machine
(iii) Mechanically operated machine.

Manually operated tool
Manual harvesting involves slicing and tearing action. Sickle is the most widely used harvesting tool for various crops.
Sickle used may be plain or serrated edged and both types are found effective in cutting plants.
Fig. Different Types of Sickles

Animal drawn reaper
Animal-drawn reaper:
It consists of a cutter bar of 1.05 m length. The power to drive the knife bar is given from the ground wheel by means of
gear box, crank and connecting rod mechanism.
As the machine is pull forward by a pair of bullocks, a reciprocating motion is imparted to the knife bar with a peak
cutting velocity of about 100 m/min.
The crop is cut due to shearing action.
The effective field capacity of machine varies between 0.2-0.3 ha/h.

Combine Harvester
1. It is a machine designed for harvesting, threshing, separating,

cleaning and collecting grains while moving through standing
crops. Bagging arrangement may be provided with a pick up
attachment.
2. The main functions of a combine are:

(i) Cutting the standing crops
(ii) Feeding the cut crops to threshing unit
(iii) Threshing the crops
(iv) Cleaning the grains from straw (v) collecting the grains
in a container.
1. The whole machine is composed of the following

components: (1) Header (2) Reel (3) Cutter bar (4) Elevator
canvas (5) Feeder canvas (6) Feeding drum (7) Threshing drum
(8) Concave unit (9) Fan (10) Chauffer sieve (11) Grain sieve
(12) Grain auger (13) Tailing auger (14) Tail board (15) Straw
spreader (16) Return conveyor (17) Shaker (18) Grain elevator
(19) Grain container.
Mechanical operated reaper
Mechanical operated reaper having two types
1) Tractor front mounted reaper binder

It used for harvesting the crops are wheat, paddy and
soybean crops.
It can also be used for harvesting of and other similar crops.

Engine operated reaper can be operated with a 5-6 hp
engine, whereas, tractor operated reapers can be operated
with 25-35 hp tractor.
Width of cut is about 1.6 m in power tiller reaper, and about

2.05 m in tractor operated reapers.
Power tiller and tractor-front reaper windrower can cover

about 0.2 ha/h and 0.4 ha/h, respectively.

2) Self-propelled reaper binder
a) It is suitable for harvesting and making bundle of

wheat, paddy and other oilseeds and pulse crops.
b) It is operated by 9 kW diesel engines.
c) It is provided with four pneumatic wheels; two driving

wheels in the front having agricultural tread pattern
tyres and two steering wheels at the rear having
automotive tyres.

Threshing
 Threshing is a method used to separate grains from the

harvested crop and provide clean grain without much loss
and damage.
 During threshing, grain loss in terms of broken grain, un-

threshed grain, blown grain, spilled grain etc. should be
minimum.
 Bureau of Indian Standards has specified that the total grain

loss should not be more than 5 per cent, in which broken
grain should be less than 2 per cent.
 Clean un-bruised grain fetch good price in the market as well

as it has long storage life.

Traditional threshing methods
 Trampling of paddy under feet, beating shelves of

rice or wheat crop on hard slant surface, beating crop
with a flail, treading a layer of 15 to 20 cm thick
harvested crop by a team of animals are traditional
methods followed by farmers depending upon
capacity, lot size and situation.
 Tractor in many places is now used in place of

animals for treading.
 In all above methods the threshed materials are

subjected to winnowing either in natural wind flow
or blast from winnowing fan for separation of grain
from straw.
 Threshing wheat by traditional method involves

drudgery and takes more time to obtain required
quality of bhusa, due to these, mechanical threshers
are widely accepted by the farmers.

Thresher and Its Different Parts
A threshing machine or a thresher is a piece of farm

equipment that threshes grain, that is, it removes the seeds
from the stalks and husks. It does so by beating the plant to
make the seeds fall out.
A mechanical thresher consists of the following parts

i. Feeding device
(chute/tray/trough/hopper/conveyor)
ii. Threshing cylinder
(hammers/spikes/rasp-bars/wire-loops/syndicator)
iii. Concave
(woven-wire mesh/punched sheet/welded square bars)
iv. Blower/aspirator
v. Sieve- shaker/straw-walker. https://www.youtube.com/watch?v=cphF0TEZjrM
https://www.youtube.com/watch?v=eBFj2GtvhhA

Working principle of a thresher
• During operation, the crop material is slightly pushed into the threshing cylinder through the feeding chute, which
gets into the working slit created between the circumference of the revolving drum having attached spikes and the
upper casing.
• The speed of the spikes is greater than the plant mass due to which they strike the latter which results in part of the
grain being separated from straw.
• Simultaneously, the drum pulls the mass through the gap between the spikes and the upper casing with a varying
speed.
• The material layer is struck several times by the spikes against the ribs, causing threshing of the major amount of
grains and breaking stalks into pieces.
• As the material layer shifts towards the progressively converging slit of lower concave, its size reduces.
• The vibration amplitudes, therefore, decrease where as the speed of the layer increases. This causes mutual rubbing
of the ear stalks, as well as rubbing of the ears against the m is closed, the thicker stalk, which cannot be sieved
through the concave, again joins the fresh stalk and edges of the concave bars and causes breaking of stalks
depending on the concave clearance.
• This process is repeated until the stalk size is reduced to the extent that it can pass through the concave apertures.
Thus fine bruised straw is produced.

Drying
 After threshing, the moisture content of most grain is too

high for good conservation (13-14 percent).
 "Drying" is the phase of the post-harvest system during

which the product is rapidly dried until it reaches the "safe-
moisture" level.
 The aim of this dessication is to lower the moisture content in

order to guarantee conditions favorable for storage or for further
processing of the product.
 Drying permits a reduction of losses during storage from causes
such as: premature and unseasonable germination of the grain;
development of moulds; proliferation of insects.
Cleaning
 After threshing, the straw, chaff, immature grains, sand, stones, and
other substances are separated from the grain by sieving, winnowing
or hand picking.
 In traditional manual winnowing, a shallow basket containing grain is
held overhead, and the grain is tossed during periods of fast winds.
 Lighter weight broken grain, straw, and weed seed are carried by the
wind to one side, as the whole grain falls to the bottom of the
winnowing device.
https://www.youtube.com/watch?v=d6LP_cUpLWw
https://www.youtube.com/watch?v=hYWmaYsh61I

Storage
 "Storage" means the phase of the post-harvest system during

which the products are kept in such a way as to guarantee food
security other than during periods of agricultural production.
 The main objectives of storage can be summed up as follows:
1. At the food level, to permit deferred use (on an annual and

multi-annual basis) of the agricultural products harvested
2. At the agricultural level, to ensure availability of seeds for the
crop cycles to come
3. At the agro-industrial level, to guarantee regular and
continuous supplies of raw materials for processing industries;
4. At the marketing level, to balance the supply and demand of
agricultural products, thereby stabilizing market prices.
https://www.youtube.com/watch?v=WOJzlafGJQE
https://www.youtube.com/watch?v=6MKWJJbLa_s

1. A thresher causes more seed damage if:

A. Speed is increased B. Clearance increased C. Speed is decreased D. Feed rate is reduced
2. A type of cylinders used on power wheat threshers is:
A. Serrated disc and rasp bar B. Spike tooth and wire loop
C. Spike tooth and hammer mill D. Hammer mill and syndicate
3. In thresher, the percentage of healthy grain dropped from sieve with respect to healthy grain received from main outlet
is
A. Cylinder loss B. Blower loss C. Sieve loss D. Visible loss
4. An action involve in threshing of crops are: ANSWERS
A. Rubbing action B. Impact action C. Stripping action D. All are correct 1-A 5-B
5. The tripping method of threshing is used for 2-C 6-B
A. Wheat B. Paddy C. Gram D. Corn 3-C 7-A
6. The Olpad thresher is mostly used for threshing
4-D
A. Paddy B. Wheat C. Oil seeds D. All are correct
7. The material that is left by the harvesting machine in row is
A. Swath B. Stubble C. Straw D. All are correct
Engineering - 22652
Harvest Technology

Course Outcome –
Select the recent
UO – 2
Elements of Cold Chain
Written by
Naresh B. Chaudhari
Key takeaways
1. Post Harvest Technology Students will able to know the different types of food processing
industry and its importance.
2. Importance of Post Harvest Technology
3. Food Processing Industry

Naresh B. Chaudhari
4. Types of Food Processing
5. Food Processing Sector

Post harvest Technology
 Post harvest technology is inter-disciplinary "Science and Technique" applied to agricultural produce after harvest
for its protection, conservation, processing, packaging, distribution, marketing, and utilization to meet the food and
nutritional requirements of the people in relation to their needs.
 The process of developing of post harvest technology approach includes, scientific creativity, technological
innovations, commercial entrepreneurship.
 The total value of the agricultural produce can be increased by performing certain Post Harvest Processing
operations rather than selling it as such after harvest.

Losses due to lack of Post Harvest Technology
Huge post harvest losses
Huge postInharvest lossespulse, oil seeds - 10-14%
cereals,
Perishables
In - 20-30%
durable, semi-perishables: 10-14%
 Reasons Perishables fruits & vegetable: 30-40%
- Lack of post harvest handling storage and management
facilities
-Reasons
Careless
: attitude
- Poor
 Lack ofvalue addition
post harvest facilities
handling at farm
storage and level
management
facilities
 Lack of awareness
 Poor value addition facilities at farm level
 Poor Infrastructure

Importance of Post Harvest Technology
 Reduction in post harvest losses
 Increasing the availability of food
 Maintain quality & quantity
 Benefits to farmers and consumers
 Better nutrition preservation
 High employment generation
 Increase of export trade and foreign exchange
 Improvement in quality of life

Food Processing Industry (Sector)
Important sectors in agro processing industries are: fruit and vegetable processing, grain processing, fish processing,
milk processing, meat and poultry processing, packaged/ convenience foods, alcoholic beverages and soft drinks etc.
Types of Food Processing –

 Primary processing: Purification of raw materials by removing foreign matter, immature grain and then making the
raw material eligible for processing by grading in different lots or conversion of raw material into the form suitable
for secondary processing.
 2. Secondary processing: Processing of primary processed raw material into product which is suitable for food uses
or consumption after cooking, roasting, frying etc.
 3. Tertiary processing: Conversion of secondary processed material into ready to eat form.

1. Fruits and Vegetable Processing
 India is the world‘s second largest producer of fruits and vegetables.

 The total production of fruits and vegetable in year 2018- 2019 is 98.57 million
tonnes & 185.85 million tonnes respectively (http://nhb.gov.in/statistics)
Post harvest Operations

 Cleaning & sorting
 Washing & air drying
 Grading
 Pre cooling
 Packaging
 Ripening
 Storage
 Transportation
 Market distribution
Page 9 27 February 2021 Presentation title https://www.youtube.com/watch?v=lGTH3rwN4Ns

1. Fruits and Vegetable Products
 Cleaned, graded and packaged fruits for table purposes.

 Fruits and vegetable juices and drinks.
 Dried fruit (whole/ sliced) like mango, apricots and apples.
 Canned fruits like mango, litchi, and cherries.
 Dried vegetables for off season use.
 Fresh, cleaned, cut vegetables for kitchen.
 Jams, jellies, marmalades, morabba, and pickles.
 Dried fruit bars and cakes
 Cooked retort packed ready to eat vegetables.
 Fruits and vegetable powders for snacks and baby foods.
 Other products like chips from potato and flakes etc.
Page 10 27 February 2021 Presentation title https://www.youtube.com/watch?v=lGTH3rwN4Ns

2. Grain Processing
• India set a record 298.3 million tonne target for production of food grains for
the 2020-21.
• India‘s food grains include rice, jowar, bajra, maize, wheat, gram and pulses.
Post Harvest unit operations are

 Field drying
 Threshing
 Cleaning
 Grading
 Packaging
 Storage
 Transportation
 Market distribution

https://www.youtube.com/watch?v=RIZi9XTt9Lk
2 Grain Processing- a) Rice milling:
RICE BASED PRODUCTS

MilledRice Cattle feed (based
for cooking on rice bran Puffed rice with
Flaked rice Ready-to-eat retort Husk boards
jaggery packed rice
Puffed rice Rice starch Quick cooking rice Furfural Edible oil (rice bran
oil)
https://www.youtube.com/watch?v=RIZi9XTt9Lk
2 Grain Processing- b) Wheat milling:
WHEAT BASED PROJECTS

• Wheat flour milling
• Wheat based bakery products
• Wheat grits
• Wheat flakes as snack food
• Wheat starch for functional foods
• Fortified wheat flour
• Wheat bran for cattle feed
• Wheat Seed Processing
• Gluten extraction
Page 13 27 February 2021 Presentation title https://www.youtube.com/watch?v=QVvEue4gMLs

3 Grain Processing- c) Pulse milling:
 Pulses are the major sources for protein for the vegetarians in India.
 The pulses are made into dhal by dehusking and dehulling.
Water Treatment
PDKV Mini Dal Mill
Page 14 27 February 2021 Presentation title https://www.youtube.com/watch?v=QVvEue4gMLs

3 Grain Processing- d) Oil Extraction
Oil seeds production: 38.4 million tonnes

Oil seed based Projects
 Edible oil
 Meal as feed ingredient.
 Shells (fuel).
 Snacks from oilseeds
 Lecithin.
 Vegetable oil butter.
 Hydrogenated fats.
https://www.youtube.com/watch?v=2GwQtQT3yAA
3. Cash Crops Processing
 Sugarcane, Tobacco, Cotton, Turmeric and Tea are major

cash crops grown in India.
 India is the largest producer and exporter of cash crops.
 Sugar mill industry, cotton ginnning industry, Turmeric

processing & packing, tea processing industry
4. Spice Processing
Spice Projects
• Cleaned, graded and packaged whole spices.
• Powdered spices.
• Paste of spices.
• Spice oleoresin/ spice oil.
• Encapsulated spices.
• Sweetened/ salted condiments as mouth freshners.
5. Milk and Milk products
The total milk production in the country amounted to about Milk based Projects & Products
187 million metric tons.
1. Processed Milk Pouch
2. Milk Powder Plant
3. Butter , Butter milk & Butter oil Plant
4. Skim milk plant
5. Yoghurt Plant
6. Curd, Lassi Plant
7. Flavoured milk plant
8. Cheese Plant
9. Panner Plant
10. Basundi, Shrikhand, Amrakhand Plant
11. Khoa, Milk based sweets plant
12. Manufacture of casein and lactose

6. Meat Processing
Meat processing Meat based Products & Projects

unit operations
1. Slaughter houses of animals and fowl.
• Grinders.
2. Processing of the carcasses into cured,
• Mixers.
canned, and other meat products.
• Bowl cutters.
3. By-products such as lards and oils.
• Konti-Cutters.
• Emulsifiers.
• Breakers.
•Vacuum fillers.
https://youtu.be/isdKEo_qMqY
1. Which of the following is an advantage of food processing?
A. Removal of toxins and preserving food for longer B. Removal of toxins and preserving food for longer
C. Adds extra nutrients to some food items D. All of the above
2. The main purpose of agricultural processing is to minimize the ______ deterioration of the material after harvest.
A. Qualitative B. Quantitative C. Qualitative and Quantitative D. None of the above
3. Which among these is a factor for processed food in India?
A. Changing lifestyles B. Food habits C. Organized food retail D. All of the above
4. Which of the following is not related to Post Harvest losses?
ANSWERS
A. Post harvest losses can be reduced by adding value to products
B. Packaging, storage, transportation areas are where losses take place 1-D 4-C
C. Farmers don’t earn much after adding value to products 2-C 5-C
D. Value can be added to products by converting raw form into a more processed/refined form 3-D 6-B
5. Which of the following is a performance parameter for the food industry?
A. Hygiene B. Labour Used C. Hygiene & Labour Used D. None of the above
6. Food processing in India is concentrated in which sector, maximum?
A. Organized Sector B. Unorganized sector C. Small Scale D. Large scale

Engineering - 22652
Harvest Technology

Course Outcome –
Select the recent
UO – 2
Cold Chain Transportation &
benefits
Written by
Naresh B. Chaudhari
Key takeaways
1. Introduction to Cold Chain
Students will able to know the different Post-harvesting
equipment's.
2. Benefits of Cold Chain
3. Cold Chain Process Flow
4. Packing and Pre-Cooling

Naresh B. Chaudhari
5. Food Processing
6. Refrigerated Transportation
7. Cold Storage

1.Introduction of Cold Chain
 A cold chain for perishable foods is the uninterrupted handling of the product within
a low temperature environment during the postharvest steps of the value chain
including harvest, collection, packing, processing, storage, transport and
marketing until it reaches the final consumer.
 It is controlled chain of logistics activities, which conditions and maintains the
goods (produce or product) within a stipulated range of parameters that include
temperature, humidity, atmosphere, packaging etc.
 Cold-chain is all about end-to-end connectivity.
 The temporary extension in life, allows the product to remain in a consumable state
for a longer period.
 The degradation processes are highly dependent upon temperature and most of
these processes double their rate for each increase of 100C. In general, food
degradation processes increase two or even three-fold with every 100C increase in
temperature.

2. Benefits of Cold Chain
 Reduces transpiration: lessens water loss, less shriveling
 Reduces ethylene production: slows ripening
 Delays ripening and natural senescence
 Eliminate food safety risks.
 Maintain the food quality
 Maintain efficient logistic inter linkage between manufacturer, distributor and

supplier and consumer.
 Increase cold chain efficiency and productivity.
 Decreases activity of micro-organisms and extend product shelf life.
 Reduces browning and loss of texture, flavor and nutrients

3. Cold Chain Process Flow
The primary segments of an integrated cold chain, which include
1) Packing and cooling fresh food products
2) Food processing (i.e. freezing of certain processed foods)
3) Cold storage (short or long term warehousing of chilled or frozen foods)
4) Distribution (cold transport and temporary warehousing under temperature controlled

conditions)
5) Marketing (refrigerated or freezer storage and displays at wholesale markets, retail

markets and foodservice operations) can be simple or complex, low tech or high tech.
6) Consumer
https://www.youtube.com/watch?v=Y93DkkG_wsE
4. Packing & Pre-cooling:
 Pack-houses are facilities where established systems for sorting, grading,

washing, drying, weighing, packaging, pre-cooling and staging are present.
 A pack house allows special operations to be performed.
 Pre-cooling refers to reducing the field temperature of fresh horticultural produce

soon after harvest and the target temperature depends upon the type of produce.
 They are used to prepare and pre-condition the fresh farm produce for subsequent
logistics connectivity in the cold-chain. The activities at pack house depend on the
type of produce and market.

4. Packing & Pre-cooling:
There are three types of packaging:

1. Consumer units or prepackaging
2. Transport packaging
3. Unit load packaging or pallets
Fig. Consumer units or prepackaging
Fig. Transport packaging Fig. Unit load packaging or pallets

5. Food processing:
 Cold chain processing plays a significant role in increasing the shelf life and Ethylene Ripening Exposure
maintain the quality. concentrati temperature ° time to these
on (ppm) C conditions
(hr.)
 Food Processing can be done through ripening, chilling & freezing of the produce Avocado 10-100 15-18 12-48
having its own implications on the shelf life. Banana 100-150 15-18 24
Honeydew 100-150 20-25 18-24
melon
 Ripening Chambers are enclosures engineered to simulate ripening process without
altering the taste or freshness of fruits. Kiwifruit 10-100 0-20 12-24
Mango 100-150 20-22 12-24
Stone fruits 10-100 13-25 12-72
Tomato 100-150 20-25 24-48
A ripening chamber comprises of following components:

1. Air tight room with insulation
2. Temperature control for cooling and heating
3. Air circulation and ventilation system
4. Humidity control system
5. Electric control system
6. Ethylene gas injection system
6. Refrigerated transportation:
 Refrigerated transport plays a key role to maintain cold chain

 Transportation between farm to processing units and processing units to the retailer is very essential to maintain an unbroken cold chain.
 Vehicles equipped with active refrigeration designed for environment controlled carriage of products can be broadly classified a
1 Reefer Trucks:
2 Reefer Containers
3 Reefer Vessels/Ships: -
4 Refrigeration in Air Transport- Refrigerated air transport of some commodities can be justified on the basis
of saving in the time and preservation of quality.
 s:

Refrigerated transportation:
i) Reefer Trucks: Integrated diesel driven motors, independent of the main truck engine,
acting as cold rooms on wheels. Smaller vehicles cooling up is either engine driven or
battery operated.
Reefer Containers: Reefer containers are multi-modal containers with integrated

refrigeration equipment, used for rail-road-sea-air movements. It sources electric
power from a separate generator (power-pack) which is independent of the reefer
container.
Reefer Vessels/Ships: Cargo vessel specializing in

carriage of goods which are required to be
maintained at below ambient temperatures.

7. Cold Storage
 Cold Stores are buildings/chambers that achieve controlled environment

using appropriate thermal insulation and an efficient refrigeration
system.
 The conditions maintained inside the storage space depend on the

nature of the product stored.
 Its objective is to properly handle & store fresh produce under appropriate
temp. & humidity conditions for maintaining quality & extending shelf life.
 Fresh produce cold stores are designed to control respiration and prevent
discoloration, sprouting, dehydration and decay.
 Also, the storage life of produce depends on the storage temperature of the
product.

Cold Storage condition

Mechanical Technologies for Refrigeration/freezing to maintain cold chain

1 Thermophilic flat sour spoilage is due to _____

A. Storing conditions B. Temperature C. Equipment or ingredients D. All of the mentioned
2. Which of the following spore forming bacteria may lead to overcooked and degraded canned food?
A. Mesophiles B. Thermophiles C. Psychrophiles D. All of the mentioned
3. Which of the following falls in the low acidic group?
A. Plant and animal tissues B. Manufactured items C. Fruits D. Jams and jellies
4. _____ is added to fruits prior to freezing commercially to protect their quality.
A. Vitamin C B. Ascorbic acid C. Water D. None of the mentioned ANSWERS
5. Which of the following nutrients are lost in all steps of food engineering (including packaging and freezing)? 1-C 5-C
A. Minerals B. Fats C. Vitamins D. Proteins 2-B 6-D
6. Heat loss in the storage chamber of foods is in which of the following forms?
3-A 7-D
A. Heat loss from the walls of the chamber B. Heat loss due to opening and closing of the frozen food chamber
C. Heat loss due to the person in charge of the maintenance D. All of the mentioned 4-B
7. The heat required to bring down the temperature of the food is directly proportional to _____
A. Specific heat of the food B. Weight of the food C. Temperature difference D. All of the above

Engineering - 22652
Harvest Technology

Course Outcome –
Select the recent
UO – 3
List the features of NCAP
Written by
Naresh B. Chaudhari
Introduction to National Cooling Action Plan
 The Government of India has taken main steps to create a National Cooling Action
Plan (NCAP) – a vision document to meet the country‘s rapidly growing cooling needs
in a climate- friendly manner in 2018.
 Ministry of Environment, Forest and Climate Change (MoEFCC), Government of India,

is developing a National Cooling Action Plan (NCAP) that will provide a 20-year
outlook on how cooling demand in India will evolve and grow, and outline strategies
and actions that promote sustainable and smart .
 The NCAP aims to develop comprehensive, sustainable and smart cooling strategies.
 The objective to the NCAP is far-reaching and includes considerations ranging from
thermal comfort, building design, and standards and labeling for appliances, while
also considering energy poverty, energy access challenges and the impact of
emissions from increased cooling.

The Need for a National Cooling Action Plan
The Kigali Amendment to the Montreal

 India’s cooling energy demand is projected to grow Protocol has, for the first time, recognized
exponentially over the next few years. linkages between maintaining and/ or
improving energy efficiency of RAC
 The aggregated nationwide growth is expected to grow 2.2 equipment with refrigerant transition
under the Protocol.
to 3 times, just in the next decade, over the 2017 baseline.
 While this poses adverse environmental and societal

impacts – significant additional power generation capacity,
peak load impacts, and an enormous greenhouse gas
(GHG) footprint – there is also an increasing recognition
for the social and economic imperatives for access to
cooling as development priority in the country as well as
globally, especially amongst developing countries with
tropical climates in a warming world.

Development of the National Cooling Action Plan
 The development of the NCAP is envisioned as a multi-stakeholder effort. The stakeholders are cooling
industries, Ministry of Power, the Ministry of Transportation, the Ministry of Agriculture, the
Department of Science and Technology, and the Ministry of Housing and Urban Affairs, air-conditioning
and refrigeration industry partners.
 The collective engagement of all these stakeholders will be the key in the development of a Plan that is
readily actionable and easily deployed across the nation.
 Ministry of Environment, Forest and Climate Change (MoEFCC), Government of India, is developing a
National Cooling Action Plan.

India’s Cooling Growth Trajectory: Key Findings
 The following key findings and highlights emerge from the research and analysis undertaken:
A. Cooling Demand- The aggregated nationwide cooling requirement, in TR, is projected to grow around 8
times by 2037-38 as compared to the 2017-18 baseline.

B. Refrigerant Demand - The projected cooling growth leads to a 5 to 8 times increase in the aggregated refrigerant
demand by year 2037-38. The Intervention Scenario suggests that through proactive measures, this total refrigerant
demand can be reduced by 25%-30% by 2037-38.
C. Primary Energy Supply for Cooling –

The Total Primary Energy Supply (TPES) like coal, oil, gas, nuclear, hydro, solar, wind, and other renewable.
The TPES requirement for cooling is expected to grow nearly 4.5 times in 2037-38 Reference Scenario, over the
2017-18 baseline. Under Intervention Scenario this requirement can be reduced by up to 30% (Figure C).

4. Sector highlights:
The relative share of cooling energy demand for all sectors remains more or less the same in in the next two
decades. The sector-wise salient findings are given below.

Key areas of NCAP
NCAP will discuss the cooling growth scenarios and

the potential pathways under the following key
areas:
1. Space Cooling (or comfort cooling) in Buildings
2. Cooling for Transportation
3. Cold Chain & Refrigeration
4. Air Conditioning & Refrigeration Technologies

5. R&D and Production Sector (alternative
refrigerants and technologies)
6. Servicing Sector

Significance and Goal
Significance:
1. India is the first country in world to develop such a document (ICAP), which addresses cooling requirement across
sectors and lists out actions which can help reduce the cooling demand.
2. The overarching goal is to provide sustainable cooling and thermal comfort for all while securing environmental and
socio-economic benefits for the society.
Goals :
1. Reduction of cooling demand across sectors by 20% to 25 % by year 2037-38.
2. Reduction of refrigerant demand by 25% to 30% by year 2037-38.
3. Reduction of cooling energy requirements by 25% to 40% by year 2037-38.
4. Training and certification of 100,000 servicing sector technicians by the year 2022-23, in synergy with Skill India Mission.
5. Recognize “cooling and related areas” as a thrust area of research under the national S&T Programme.

Objectives of the India Cooling Action Plan
1. Assessment of cooling requirements across sectors in next 20 years and the associated refrigerant demand and
energy use.
2. Map the technologies available to cater the cooling requirement including passive interventions, refrigerant-
based technologies and alternative technologies such as not-in-kind technologies.
3. Suggest interventions in each sector to provide for sustainable cooling and thermal comfort for all.
4. Focus on skilling of RAC service technicians.
5. Develop an R&D innovation ecosystem for indigenous development of alternative technologies.

Priority Areas Identified by the India Cooling Action Plan
 Promote development and commercialization of technology pathways, especially low-energy cooling

technologies, which would reduce the energy footprint of active cooling.
 Accelerate (i) reduction of the cooling load of the building sector through fast-tracked implementation of
building energy codes, (ii) adoption of adaptive thermal comfort standards, (iii) ratcheting-up energy efficiency of
room air-conditioners and fans, and (iv) enhancing consumer awareness through eco-labelling of cooling
products.
 Public Procurement of (i) energy efficient cooling equipment and (ii) trained and certified RAC service technicians
for public buildings.
 Allocate government funding and support towards targeted programmes to enable cooling for the economically
weaker segment:
 Drive skill-building of the service sector through training and certification:
 Ensure harmonization of policies:
 Create an ecosystem for promoting robust and collaborative R&D:

Implementation Framework
The ICAP serves to underscore the urgency of proactively and collaboratively addressing India’s projected cooling
growth and lays out sector-wide priorities and pathways for interventions.
Given the cross-cutting nature of cooling demand, the ICAP implementation will be best served by active
collaboration among the relevant ministries as well as the private sector entities.
For effective implementation, the ICAP must be monitored and executed under the governance of a high level multi-
ministerial framework.

Benefits of NCAP
1. Thermal comfort for all – provision for cooling for EWS and LIG housing.
2. Sustainable cooling – low GHG emissions related to cooling.
3. Doubling Farmers Income – better cold chain infrastructure – better value of products to farmers, less wastage of
produce.
4. Skilled workforce for better livelihoods and environmental protection.
5. Make in India – domestic manufacturing of air-conditioning and related cooling equipment’s.
6. Robust R&D on alternative cooling technologies – to provide the push to innovation in a cooling sector.

1. Under the action plan, the government has planned to achieve at least ____ reductions in cooling energy
requirement by improving the energy efficiency
A. 30 % B. 50% C. 55% D. 60 %
2. MoEFCC means
A. Minister for Environment, Forest and Climate Change B. Minister for Energy, Finance and Capital Change
C. Minister for Environment, Finance and Capital Change D. None of the above
3. The NCAP aims to develop _________comprehensive, sustainable and smart cooling strategies.
A. Comprehensive B. comprehensive, sustainable and smart C. Sustainable D. Smart
4. Training and certification of _____ servicing sector technicians by the year 2022-23, in synergy with Skill
India Mission.
ANSWERS
A. 1,000 B. 10,000 C. 1,00,000 D. 2,00,000
1-A 4-C
5. Reduction of refrigerant demand by 25% to 30% by year 2037-38. is the goal of NCAP.
2-A 5-D
A. 10 to 15 % B. 15 to 25 % C. 20 to 30% D. 25% to 30%
6. Which of the following is the key area of NCAP. 3-B 6-D
A. Cooling for Transportation B. Cold Chain & Refrigeration C. Space Cooling in Buildings D. All of the above

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Recent Trends in Mechanical

Page 3 9 March 2021 Presentation title

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Manufacturing: “IoT Manufacturing”. Below Fig will explain .

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• Predictive and preventative maintenance

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Disadvantages of Artificial Intelligence:

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Disadvantages of Artificial Intelligence:

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Disadvantages of Artificial Intelligence:

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The USA Principle : USA stands for-

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► Improved quality or increased predictability of quality.

► Improved healthiness of processes or product.

► Reduced direct human labor costs and expenses.

► Can complete tasks where a high degree of accuracy is required.

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► Due to increased relative susceptibility for committing errors.

► Unpredictable or excessive development costs.

► Displaces workers due to job replacement.

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► Productivity – Automation enhances the productivity of Industry.

► Prevent Non-conforming Product from Shipment –

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process to reduce the difference between them.

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e difference between them.

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The USA Principle : USA stands for-

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► Improved quality or increased predictability of quality.

► Improved healthiness of processes or product.

► Reduced direct human labor costs and expenses.

► Can complete tasks where a high degree of accuracy is required.

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► Due to increased relative susceptibility for committing errors.

► Unpredictable or excessive development costs.

► Displaces workers due to job replacement.

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Automated production systems are classified into three basic types:

❑ Programmable automation, and

► Low production rates relative to fixed automation.

► Most suitable for batch production.

Fig. Home Automation an example

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Automated power production

► Business process automation