Low cost automation

CHAPTER. 1

INTRODUCTION

Automation is the creation and application of technology to monitor and control the
production and delivery of products and services. In today‟s world for any industry to
survive in the competitive market, must go for automation. Automation demands huge
capital investment which requires mass production for quick return on investment. Hence
Large Scale Industries can afforded and opt the option of automation, whereas medium and
small scale industries find it very difficult adopt automation. Low cost automation (LCA) is
one solution especially for medium and small scale industries. Automation demands
replacement of conventional machines by CNC, VMC, SPM‟s, etc, manual material
handling by conveyor‟s, AGV‟s and many more things. In the present paper a case study is
discussed which includes application of Low cost automation concept by replacing
conventional Radial Drilling Machine by Special Purpose Horizontal Multi Spindle
Drilling Machine. This SPM was in-house designed and developed by using the spare parts
of old machines which were declared as scrap by other industries. Due this there was a huge
saving in the manufacturing cost of this SPM. This newly developed SPM not only
increased the production rate by about 85% but also made it possible the machine operator
to operate another machine along with it with no compromise in quality requirements.

1.1. Automation

automation, application of machines to tasks once performed by human beings or,

increasingly, to tasks that would otherwise be impossible. Although the term mechanization
is often used to refer to the simple replacement of human labour by machines, automation
generally implies the integration of machines into a self-governing system. Automation has
revolutionized those areas in which it has been introduced, and there is scarcely an aspect of
modern life that has been unaffected by it.

The term automation was coined in the automobile industry about 1946 to describe
the increased use of automatic devices and controls in mechanized production lines. The

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origin of the word is attributed to D.S. Harder, an engineering manager at the Ford Motor
Company at the time. The term is used widely in a manufacturing context, but it is also
applied outside manufacturing in connection with a variety of systems in which there is a
significant substitution of mechanical, electrical, or computerized action for human effort
and intelligence.

In general usage, automation can be defined as a technology concerned with

performing a process by means of programmed commands combined with automatic
feedback control to ensure proper execution of the instructions. The resulting system is
capable of operating without human intervention. The development of this technology has
become increasingly dependent on the use of computers and computer-related technologies.
Consequently, automated systems have become increasingly sophisticated and complex.
Advanced systems represent a level of capability and performance that surpass in many
ways the abilities of humans to accomplish the same activities.

1.2. Historical Development Of Automation

The technology of automation has evolved from the related field of mechanization,
which had its beginnings in the Industrial Revolution. Mechanization refers to the
replacement of human (or animal) power with mechanical power of some form. The driving
force behind mechanization has been humankind‟s propensity to create tools and
mechanical devices. Some of the important historical developments in mechanization and
automation leading to modern automated systems are described here.

1.3. Early Development

The first tools made of stone represented prehistoric man‟s attempts to direct his own
physical strength under the control of human intelligence. Thousands of years were
undoubtedly required for the development of simple mechanical devices and machines such
as the wheel, the lever, and the pulley, by which the power of human muscle could be
magnified. The next extension was the development of powered machines that did not
require human strength to operate. Examples of these machines include waterwheels,

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windmills, and simple steam-driven devices. More than 2,000 years ago the Chinese
developed trip-hammers powered by flowing water and waterwheels. The early Greeks
experimented with simple reaction motors powered by steam. The mechanical clock,
representing a rather complex assembly with its own built-in power source (a weight), was
developed about 1335 in Europe. Windmills, with mechanisms for automatically turning
the sails, were developed during the Middle Ages in Europe and the Middle East. The steam
engine represented a major advance in the development of powered machines and marked
the beginning of the Industrial Revolution. During the two centuries since the introduction
of the Watt steam engine, powered engines and machines have been devised that obtain
their energy from steam, electricity, and chemical, mechanical, and nuclear sources.

1.4. Early Development In Automation

Each new development in the history of powered machines has brought with it an
increased requirement for control devices to harness the power of the machine. The earliest
steam engines required a person to open and close the valves, first to admit steam into the
piston chamber and then to exhaust it. Later a slide valve mechanism was devised to
automatically accomplish these functions. The only need of the human operator was then to
regulate the amount of steam that controlled the engine‟s speed and power. This
requirement for human attention in the operation of the steam engine was eliminated by the
flying-ball governor. Invented by James Watt in England, this device consisted of a
weighted ball on a hinged arm, mechanically coupled to the output shaft of the engine. As
the rotational speed of the shaft increased, centrifugal force caused the weighted ball to be
moved outward. This motion controlled a valve that reduced the steam being fed to the
engine, thus slowing the engine. The flying-ball governor remains an elegant early example
of a negative feedback control system, in which the increasing output of the system is used
to decrease the activity of the system. Negative feedback is widely used as a means of
automatic control to achieve a constant operating level for a system. A common example of
a feedback control system is the thermostat used in modern buildings to control room
temperature. In this device, a decrease in room temperature causes an electrical switch to
close, thus turning on the heating unit. As room temperature rises, the switch opens and the

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heat supply is turned off. The thermostat can be set to turn on the heating unit at any
particular set point.

fig. 1.4.1. automation line

1.5. Low Cost Automation

Automation is a very vast topic which can be briefly defined as „Automation is using set of
all measures aiming at replacing human work through machines and using technology for
this purposeThis includes automation in Storage Systems, Handling Systems, Assembly
Lines ,Production Lines, Production Cells, Machines, Computers, Controllers,
Software,etc.This requires huge capital investment. Only national and multinational
companies can afford to opt automation. These companies do have mass production which
balance the huge capital investment and provide quick return on investment. On the other
hand small & medium scale industries do not afford such huge capital investment and
generally avoid automation. But this leads to lower growth of such industries. Low Cost
Automation is a concept of developing new automated machines, mechanisms, systems, etc
by making use of parts, sub-assemblies, etc of old unutilized machines, mechanisms,
systems which are available free or at very lower cost.

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1. Design the machine, system, mechanism as per the requirement.

2. Decide upon the parts, sub-assemblies, sub-systems required.

3. Check for the above requirements from old unutilized machines, mechanisms,

systems, if they are available.

4. Inspect the parts, sub-assemblies, sub_systems available and see that they meet

the design requirements.

5. Use them for developing new machine, system, mechanism.

6. Due to use of parts of old unutilized machines, mechanisms, systems which are

available free or at very lower cost , there is no need to purchase new parts, systems

and hence ,the overall cost of development new machines, systems will be very low.

Thus automation is possible at lower cost.

1.5. Objective

1] To increase productivity with same quality standard.

2] To reduction in production line.

3] To reduction in cost of production.

4] Operateor (unskilled) can operate two more machines along with MOG SPM with
comfort and without helper

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CHAPTER.2

LITERATURE REVIEVE

[1] Low Cost Automation(LCA): A Case Study Sameer S. Gajmal1 , Prof. Sudhir.G
Bhatwadekar2 1Assistant Professor, Department of Mechanical Engineering, Gharda
Institute of Technology, Lavel 2Associate Professor, Department of Production
Engineering, K.I. T.‟s college of Engineering, Kolhapur. Email: 1
sameergajmal@git-india.edu.i - Interpretations of the results obtained, leads to know the
important achievement and performance of the developed multiple spindle drilling SPM
are: a) Increase in productivity with same quality standards. b) Reduction in production
time. c) Reduction in cost of production. d) Operator (unskilled) can operate two more
machines along with MOG SPM with Comfort and without Helper. e) Tremendous saving
in the operational time of machining, with the newly developed multi_spindle drilling
SPM.

[2] Agus and Hajinoor(2012) have addressedthe key relationships between lean production,
product qualityperformance and business performance within the Malaysian manufacturing
industry, whererelatively few studies are available. In addition, relationships between
constructs are analyzed throughstructural equation modeling (SEM) that measures not only
magnitude but also the causal direction of the relationships.Rajgor and Pitroda.

[3] explained the applications and activities of robotics and automation in construction
industry started in the early 90s aimingto optimize equipment operations, improve safety,
enhance perception of workspace and furthermore, ensure quality environment for
buildingoccupants. The main is to convince to incorporate robotic systems when
managingmodern buildings. Tommila et al.

[4] (2001) described that in an industrial plant, physicalprocess systems consist of

machinesand process equipment.They areindividual devices or largersubsystems of their
own which leadsto a wholes-parts hierarchy. Process systems canbe in different operational
states,such as „maintenance‟, „starting up‟ or„operating‟. In each state, theyprovide a set of

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capabilities that canbe combined to perform the variousstages of the process. In the
courseof control system design, controltasks identified in co-operation withusers and other
engineeringdisciplines are allocated to thecontrol system and human operators.The
automated parts should form astructured set of control activitiescorresponding to the
physicalequipment and processing tasks.

[5] Design and Analysis of Flat Belt Conveyor for Segregation of Defective Products Yash
Patil * , Shivraj Patil, Suhas Gawade, Vaishnav Shinde, Samidha Jawade Belt conveyor
system is mostly used in industries for transportation of raw materials and finished
products. This paper includes study of detailed design procedure and analysis of flat belt
conveyor components for light duty applications. Belt conveyors used for segregation of
defective products up to 2 kg maximum load whose conveyor capacity is 2 TPH and speed
of the conveyor will be 3.5 m/min. Our paper includes study of design calculation of
conveyor and FEA analysis of pulley, shaft and conveyor belt. 3D model is created using
solid work software. FEA is done on ANSYS and Inventor software with appropriate
loading condition, considering calculated tension. Stress analysis of shaft, pulley and belt is
done to find highest stressed area of belt conveyor. By following the design procedure for
flat belt conveyor system, all geometrical parameters obtained are within limits and design
of conveyor is safe. In FEA, contact status and contact pressure between belt and pulleys
are properly sticky and in contact. Max stress acting on belt is 58.85 MPa and deformation
will occur at 87.88 MPa. Stress on shaft comes out to be 13.17 MPa.

[6] Design and Analysis of Belt Conveyor System of Sugar Industry for Weight Reduction
1Mr. Memane Vijay S., 2Prof.N.S.Biradar - The aim of this paper is to study existing Belt
conveyor system and optimize the critical parts like Roller, Lchannels and support, to
minimize the overall weight of assembly. Paper also involves geometrical and finite
element modeling of existing design and optimized design. Geometrical modeling was
done using Catia V5R20 and finite modeling done in ANSYS14.0. Results of Linear static,
Modal and Transient analysis of existing design and optimized design are compared to
prove design is safe. In this paper we work on the roller design and optimization.

[7] Fundamentals of Automation Engineering: A hybrid project-based learning approach

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Devika Kataria1 , Gustavo Sanchez1 and Siddhartan Govindasamy2 - This paper describes
authors‟ experience with designing and teaching a new course on “Fundamentals of
Automation Engineering”, based on a hybrid Project-Based Learning approach. The
proposed challenge for students was to develop a low-cost Material Handling Machine,
equipped with basic control functions. The project was executed in three stages, with
different activities/tasks performed during each stage, which finally led to successful
completion of the challenge. Detailed course file containing syllabus, learning objectives,
assessment rubric, project goals, and deliverables was provided to students at first stage.
Handouts and assignments were also provided weekly to stu_dents, which required
extensive use of library resources (self-learning). Feedback survey was conducted
fortnightly and suggestions were considered for course improve_ment. In this paper,
authors discuss course organization, learning and assessment activ_ities, and perception of
students.

[8] Design and Manufacturing of Portable Drilling Machine Sanket Sonnad1 , Tejas Raut2 ,
Pratik Kesav3 , Prof. P.G.Rahate4 - Conventionally, we use a drilling machine to make
holes which is operated manually. But the height to which holes will be drilled is normal to
human height. And for higher levels we generally use ladders or cranes. This project
describes the design and fabrication of scissor lift which will be operated on DC motors for
drilling application. In the present market the fix drilling machine are available and in most
of the industries the drilling is done manually. It requires man power and more skilled
workers. For drilling at different position we need either a manual process or more drilling
machine. The former one consumes lot of time and is costlier. For portable drilling we need
to move the spindle in all three directions. Thus based on the functional and economical
aspects we have fabricated a unique machine.

[9] Fabrication and Automation of Drilling Machine by Using Arduino 1Mohammad Nasir
Khan, 1Mohd Shadman Ansari, 1Md Irfan Ansari, 1Saifuddin, 2Mohd Mukhtar Alam - For
precision workpiece manufacturing, the system should have good dimensional accuracy
and surface finish. In applications such as drilling, punching, marking, boring, tapping, etc.,
the workpiece is first positioned, and then the tool executes its action while the moving axis

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remains stationary. In the traditional method of such applications, manufacturers use very
expensive CNC machines to program the cycle and perform the same work. Large
manufacturers can afford such expensive machines, but for the small machinery
manufacturing industry, we must consider low-cost solutions that can provide high-quality
output. In this study, we tried to propose a low-cost design that can be used to achieve
functions similar to CNC. By applying this machine in industry, multiple generations can
be obtained in a short time. It is very difficult to estimate the drilling depth when manually
drilling with a traditional drilling machine, and the work will usually fail due to
over-drilling. In many cases, it is difficult to measure the depth after the drilling is
completed; especially the depth of the fine hole cannot be measured. Therefore, an
automatic drilling machine that performs the drilling function according to the generated
drilling depth and transmitted to the control circuit is indispensable; therefore, undertaking
the study, it exposed the technology of the dedicated drilling machine. The automatic
drilling machine designed here is very useful for the mechanical workshop. The machine is
built with power feed technology and is designed to drill the job to a certain specified depth.

[10] Development of a Belt Conveyor for Small Scale Industry Daniyan Ilesanmi A.1* ,
Daniyan O. Lanre2 , Mayungbe, O. Elijah3 and Oguntuase O. Bolaji4 - Most small scale
industries rely on human effort for transporting raw materials from one stage of processing
to another thereby reducing the overall system performance. The work discusses the
development of a belt conveyor system for small scale industry. The conveyor is of height
0.75 m at 0o angle of inclination, 35o troughing angle and a surcharge angle of 25o . It also
consists of a belt whose width is 410 mm, length 2.4 m and a basic length 4.54 m. The
conveyor has an average capacity of 43.75 tonnes/hr. The evaluation of the conveyor was
carried out by conveying 12 packs of bottled water of different weights across a distance of
2 m at a different speeds ranging from of 200-400 rpm. Results obtained indicated that the
time of conveying the materials increases with increase in weight of the bottled water. The
successful completion of this work provides a conveyor system which will aid the
movement of material from one place to another with little or no human intervention. This
will help the industry in reducing cost in acquiring labour that will be used in material
movement thereby reducing cost of production.

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CHAPTER. 3

CASE STUDY

One sample case is studied with all project member to understand the proper meaning of
Low Cost Automation. By studying this case we can generate new plan for LOW COST
AUTOMATION IN SMALL CASE INDUSTRY. The Case Study discussed is from a
Company named „Menon and Menon Pvt. Ltd.‟ Vikaramnagar, Kolhapur manufacturing
2, 3 & 4 cylinders Engine Block for SAME Tractors, Italy. The component under
consideration was 4 cylinders Engine Block for SAME Tractors, Italy. Actual demand for
this component from SAME was 600 blocks per month (i.e. @ 25 blocks per day). But the
supply was only about 264 blocks per month (i.e. @ 11 blocks per day). Therefore
increasing the rate of production of this particular block was the problem. Out of total 17
Nos. of operations one operation was MOG Hole Drilling Operation. The Details of MOG
drilling bare as follows:

Component under consideration

Table. no. 1

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Table. no. 2

The block was having one operation of Main Oil Gallery (MOG) Hole Drilling.

 (MOG) hole drilling (3 Nos.) which are through & 592 mm long.

 Machine used is Radial Drilling with Drilling Jig.

 For getting these holes produced half of the drilling length is achieved by drilling from
one (Rear) side & remaining by drilling from opposite (Front) side.

 Drills used are extra long (450 mm), H.S.S., taper shank, twist drills.

 Clamping of the job is done manually; &

location is by using dowel pins.

 Presently the number of jobs (4Cylinder) produced per shift is 11(very less).

Reason: drilling very long length holes (592mm) with wood pecking action in two

set-ups.

 Frequent problem of drill breakage As mentioned above by using radial drilling

machine the production rate was only11 Jobs/ shifts. Other problems which were frequently
observed

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were:

 High Tooling Cost: As the drills used were extra long drills, frequent breakage of

drills was resulting into high tooling cost.

 High Fatigue to the Operators: Due to frequent change of drills, drilling speeds,

spindle (drill) positions, loading unloading of jig plates the operator was feeling high
amount of fatigue. Also due to manual wood pecking action.

 Expected Production Rate: As per the demand from SAME TRACTORS, ITALY, the
production rate expected was 600 Jobs/ month i.e. about 25 Jobs/ day.

 Quality: As far as quality was concerned, the present set up was capable enough to
satisfy the quality requirements in the MOG drilling operation. As the holes being drilled
were used just to carry the lubricating oil (as per the name; Main Oil Gallery Hole) 1.5 mm
drill-shift was allowed and the present set-up was giving acceptable results (About 0-1%
rejection)

 5 - 10 % rework during the final inspection was one of the major problem being
observed.

Company‟s Requirement:

1. Increased Production Rate: As mentioned above company‟s requirement was to satisfy

the demand of 600 Jobs/Month i.e. about 25 Jobs/ day.

2. Consistent Quality: As far as quality was concerned the company‟s expectation was to
achieve the same quality level as that of the present set-up i.e. with radial drilling machine
with 0% rejection combined with 0% rework.

3. Low Cost Automation: To achieve the above two targets it was clear that the modified
new set-up was going to be very costly. Company‟s expectation was to Enhance Quality as
well as Production rate with low cost automation.Therefore increasing the rate of
production of this particular block was the Company‟s Requirement being identified.

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Total Time for MOG hole drilling on Radial drilling Machine = 42.83 Min. ≈ 43minutes
Similarly the time study was also conducted for 5 samples jobs by using newly developed
SPM. The sequence of operation is as follows:

i) Machine cleaning

ii) Component loading.

iii) Cycle starts i.e. locating + clamping + drilling from both LH & RH side simultaneously.

iv) Unloading the component.

The total time required in drilling the MOG holes by using Newly developed SPM is
tabulated as

follows:

It is seen that the total drilling time for MOG hole drilling operation with radial drilling
machine is 43 minutes, whereas the time required for MOG hole drilling operation with
newly developed SPM is equal to 5 minutes which is considerably lowered. Hence the %
saving in machining time is as follows: Saving in machining time = [(43 - 5)/ 43] x 100 =
88% Hence with the newly developed drilling SPM, the machining time can be saved as
much as by 88%. The next testing was for the accuracy of the holes drilled in the
component by using the newly developed SPM

Results

The important findings with the use of this newly developed multi-spindle drilling SPM
are:

 Productivity is increased by reducing the handling and machining (drilling) time as

all the three holes are drilled at a time. This reduction in production time leads to reduction
in the cost of production.

 As all the spindles are already fixed in position; the positional accuracy of these holes is

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ensured. This certainly reduces the inspection timing and percentages rejection, which leads
to better quality production.

 The length of the ф15 X 327 blind hole can be very well controlled by means of
adjustable adaptor

Conclusion

Interpretations of the results obtained, leads to know the important achievement and
performance of the developed multiple spindle drilling SPM are:

a) Increase in productivity with same quality standards.

b) Reduction in production time.

c) Reduction in cost of production.

d) Operator (unskilled) can operate two more machines along with MOG SPM with
Comfort and without Helper.

e) Tremendous saving in the operational time of machining, with the newly developed
multi_spindle drilling SPM.

f) Saving in unproductive time.

g) It can be seen that the loading and unloading time is also reduced.

h) Proper arrangements for loading the job, location of machine controls and ease of
operation reduces excessive strain on the operator and results into comfortable working
conditions.

i) Elimination of problems such as rejection, rework in MOG Hole Drilling operation

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CHAPTER.4

ACTUAL CASE STUDY

4.1. Introduction To Industry

IQON IQON SLIPPER MANUFACTURING PVT. LTD. The small scale industry
developed by young entrprenuier Mr. Mayur Madhukar Mankar in 2017 at Bharwaj located
in igatpuri sub district and nashik district.

4.1.1.About Product

They are manufacturing slippers for gents ladies and kids.

Following are some of their products.

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4.1.2. Processes Used In Industry

 Cutting Process
In this process foam sheet is cut in to the strips with proper size and then goes to the
press operation.

 Punching
Very important operation in slipper making is to cut the soles for slipper.
In this process materil is cut by press machine with the help of punching die.

Fig. 4.1. Punching

 Drilling
For the attachment of straps we required to drill the soles in required point.

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Fig.4.2. drilling
 Strap Attachment
In this process assembly of strap and sole is done.

Fig.4.3. strap fitting

 Finishing And Packing
In this process finishing with the help of polishing is done and further goes for the
packing with help of poly bags.

4.2. Problem Statement

 Actual industry production is 1 piece / minute but industry is not getting rated output
 More pieces get excess drill due to not accuracy in workers.
 Some workers got injured due to drill machine.

4.3. Solution

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Many solutions given to the industry as following.

 Increase number of machines
 Go for full automation
 Low cost automation ( semi automation)

4.4. Solution Confirmation

After giving all this solution and making discussion with owner of company LOW
COST AUTOMATION solution is finalized.

4.5. Terms And Condition

 Only one operation is provided for automation.

 Student should make the proper planning report
 After approval of report student will allowed for making prototype of model
 Amount required to making of prototype will be provided by industry.
 Student will get only certificate of completion after completion of project.
 Not any amount will be provide to student as a stipend.

4.6. Planning For Low Cost Automation

Fig. 4.4. low cost automation

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After study of various operations in present industry we all group members are observed
that bottlenecking is occurring at the drilling and the accidents are also occurring at same
station.

Machine 1 machine 2 machine 3

Production per hr = 60 pices Production per hr = 45 pices Production per hr =

60 pices
Defects per hr = 1 or 0 Defects per hr = 3/4 No defects as it is
packing process

As per guidelines of industry we all group members have decided to make a automation
system for drilling operation and submit report to the owner of industry.

4.7. Designing Of Automatic Drilling Machine

4.7.1. drilling machine

A Drilling Machine is another type of production machine in which works are to drill the
workpiece.

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Fig. 4.7.1. drilling mahine.

4.7.1.Types Of Automation Done In Drilling Machine

4.7.1.1. Hydraulic Automation

In hydraulic automation to achieve the movement of drill bit in up and down position we
need to attach a double actuated hydraulic linear actuator i.e. cylinder piston.

Fig.4.7.2. hydraucally operated drilling machine

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4.7.1.2. Pneumatic Automation

In pneumatic automation to achieve the movement of drill bit in up and down position we
need to attach a double actuated hypneumatic linear actuator i.e. cylinder piston.

Fig.4.7.3. pneumatically operated drilling machine

4.7.1.3. Mechanical Automation

In Mechanical automation to achieve the movement of drill bit in up and down position we
need to attach a rack and pinion gearbox attached with the motor.

Fig.4.7.4. mechanical drill

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To decide proper low cost automation system we are comparing all three automation types
on various basisis.

parameter Hydraulic Pneumatic Mechanical

Cost High Medium Low
Components Hydraulic circuit Pneumatic circuit. Rack and pinion
Maitainance High High No maitainance
Parts Resorvior Compressor Motor
Filter Filter Rack and pinion gear
Hydraulic lining pneumatic lining box
Pressure valves Pressure valves
Direction controll Direction controll
valves valves
Actuator Actuator
System Dirty system and Clean system but noise No any pollution
chances of fire hazard pollution occurs while smooth working
realising moisture system
Table.no. 4.7.1.comparision

With help of above chart we can conclude for low cost automation we can use the 3rd

System that is drill up and down motion automation will be done with motorise rack and
pinion system.i.e. Mechanical Automation.

4.7.1.3.1. Mechanically Automated Drill Machine

Drill machines are widely used to make the holes of required size and in this industry it is
used to enlarge the halp hole to perfect fitting of straps in the soal of slipper.

The problem in drilling is due to inproper working of worker whole hole get enlarged and
sole becomes scrap in lot of quantity.

Raw material for drilling is cut sole wich has previously 3 holes.

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Fig.4.7.5. Cut sole of slipper raw materil for drilling

Fig.4.7.6. Proper hole enlargement for strap fitting

Fig.4.7.7. wrong hole enlargement for strap fitting

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Fig.4.7.8. proper arrangement of sole with strap with proper hole enlargement

Fig.4.7.9. due to wrong whole strap can not fit into the sole

As per as above problem is concern we have to solve the problem of excess hole
enlargement.

To avoid excess hole enlargemrnt we make one precaution on drill bit.

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Fig.4.7.10. drill bit with washer arrangement

4.7.1.3.2. Design Of Automatic Drill Machine

This design of automatic drill machine is include with basic drill machine with special
arrangement of rack and pinion gear box to have vertical axis movement while required.

COMPONENTS

 Motor

Used to give power the drill bit for drilling wholes with help of electricity. Generally motor

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pulley and drill pully are connected with the help of belt and pully has arrangement of speed
lowering and increasing with variable diameter.

Fig.4.7.11. drill motor

 Rack and pinion gear box

Fig.4.7.12. drill motor with rack and pinion arrangement .

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Fig.4.7.13. actual drill machine used in automation

Drill motor

Pinion motor

Drill base and stand

Rack and pinion

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4.7.2. Objectives Of Automated Drill Machine

 To increase productivity
 To reduce scrap
 Reduced accidents

4.7.3. MATERIAL HANDELLING.

Material handling is the movement, protection, storage and control of materials and
products throughout manufacturing, warehousing, distribution, consumption and
disposal. Inventory management and control. Customer delivery. After-sales support
and service.

Fig.4.7.14. material handelling

Fig.4.7.15. conveyor belt

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4.7.3.1. Components

 Belt
 Motor
 Stand
 Rollers
 Electrical circuit

4.8. System Design

For the purpose of automation we need to make first material handelling system.

4.8.1 Design of conveyor belt

Design flat belt conveyor system for handelling of products having conveyor capacity of 2
tones/hr. and maximum weight to be carried is up to 2kg. Center distance between both
pulleys is 1000mm and height of conveyor is 518 mm. Other specification-

a. Material density: 1.5 tones/m³

b. Inclination angle: 0°

c. Angle of repose: 45°

d. Lump size: 120mm

e. Conveyor speed: 3.5 m/min

Belt Speed and Width Calculations:

Determine the width of conveyor speed using the relation,

B= 2*Amax+ 200 ...for solid material

B= Amax+ 200 ...for fine material

Where, Amax denotes lump size For solid material, the belt width comes out to be 440mm.
Selecting the standard belt width of 400 mm from PSG design data book

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Now, check for the belt speed,

Β = 1.11 [{ 𝒬 ρ∗𝒞∗𝒱 } 1 2 + 0.05] (1)

where,

B = Belt Width

Q = Conveyor Capacity = 2 tones/m³

𝜌 = Density of Material =1.5 tones/m³

C = Surface Factor for Type of Idler C = 240 (For flat belt)

V= Belt Speed (m/sec)

So, the value of belt speed is 0.0576 m/sec i.e. around 3.5m/min which is less than 1.5
m/sec, the allowable speed for 400 mm width belt. Therefore the belt width of 400 mm is
acceptable. The obtained values are compared with design data given in PSG design data
book.

Resistances of belt at top and bottom run:

Resistance of belt at top run [𝒲ο]:

𝒲𝜊 = ∁ ∗ 𝑓 ∗ 𝐿[(𝐺𝑔 + 𝐺𝑏) 𝑐𝑜𝑠 𝛿 + 𝐺𝑟𝑜] ± 𝐻(𝐺𝑔 + 𝐺𝑏) (2)

Where,

C= secondary resistance factor C= 9 (for conveyor length ≤ 3 m)

f = 0.02 (for standard conveyors)

L= length=1000m Gg=weight of conveyed material per meter length, k g f

m= 9.65 kg/m

Gb =weight of belt per meter length kgf/m = 5 kgf/m

𝛿 = inclination angle = 0°

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H= height of conveyor = 518.16 mm 𝛿∴

∴ 𝒲𝜊 = 10.227 kgf

Resistance of Belt at Bottom Run

[Wu]: 𝒲𝑢 = ∁ ∗ 𝑓 ∗ 𝐿[𝐺𝑏 ∗ 𝑐𝑜𝑠 𝛿] ± 𝐻 ∗ 𝐺𝑏 (3)

∴ Wu = 3.4908 kgf Power (P) can be determined as;

Power = Resistance of Belt at Top Run + Resistance of Belt at Bottom Run

P=𝒲𝜊 + 𝒲𝑢 (4) P= 13.7178 kgf

Belt Tension Calculations:

Effective force on belt is given by;

𝛲 = � 〵1 − 𝛵2 (5) Also,

𝛵1 𝛵2 = ℯ 𝜇𝜃 (6)

Where,

𝜇 = coefficient of friction between belt and pulley

𝜇 = 0.3 𝜃 = angle of lap

Considering angle of lap over load pulley as 200° ˃ 165° to avoid slip of belt during running
conditions

𝛵1 𝛵2 = ℯ 0.3∗200∗ 𝜋 180 ∴ Τ1 = 2.8496 Τ2 ∴ Τ2=7.416*10³N

Τ1 = 2.8496∗ 7.416 ∗ 10³ ∴ Τ1 = 21.132 *10³ N

Maximum belt tension on carrying side is 21.132*10³ N and minimum slack side tension is
7.416*10³ N.

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Selection of Driving Unit:

Power, P = Force ×Velocity Transmission (8)

∴ P = (𝑇1−𝑇2)∗𝑉 𝜂𝒻

Where,

𝜂𝒻 = transmission efficiency

𝜂𝒻 = considering efficiency as 95%

P = 13.716∗103×0.0576 0.95

∴ P = 831.6227 W

∴ P = 0.8316 KW

Therefore, from PSG design data book a Flange Mounted Motor of 1.1 kW ratings and
1000RPM is selected. [6]

The motor will be connected to the gear box to reduce and maintain the rpm of driving
pulley shaft.

Conveyor Pulley:

As the conveyor is flat belt conveyor system both the pulleys are of same diameter having
same length and material as well. [6]

For the belt width selected of 400 mm, from PSG design data book selected the standard
diameter of conveyor pulley drum, D, to be 110mm and have standard face width of 450
mm and edge clearance of about 25 mm is considered on both ends of pulley.[7]

. Belt length and thickness:

Center distance between pulleys is 1000mm checking for the minimum center distance
required for conveyor using the relation,

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C˃2 (d1+d2) (9)

C ˃ 2(100+100)

C ˃ 400 mm

Therefore center distance greater than 400 mm will be accepted as per requirement.
Therefore taking center distance between pulleys as 1000 mm as given. For open belt drive
system length of shaft can be determined as;

𝐿 = 𝜋/ 2 [(𝐷𝑙 + 𝐷𝑠) + 2𝐶 + 1/ 4𝐶 (𝐷𝑙 − 𝐷𝑠) 2 ] (10)

Where, C is center distance

Dl = diameter of large pulley and

Ds = diameter of small pulley

∴ L = 2314.1595 mm

But taking into considerations, initial tension, the belt length should be shortened by 1%

L = 2291.018 ≅ 2290 mm

For rubber belt coefficient of frictions is taken as

𝜇 = 0.4

Design power(Pdes)=service factor*required power (11)

Design power (Pdes) = 0.997 KW

Design stress for rubber belt material can be taken as 1.5 MPa &

Density of rubber belt is 1140kg/m³.

Design stress in belt can be calculated as, 𝜍 ′ = 𝜍𝑚𝑎𝑥 ∗ 𝐶𝑠𝑝𝑑 ∗ 𝐶𝑤 (12) 𝑃𝑑𝑒𝑠 = 𝑏𝑡(𝜍 ′ − 𝜌𝑣 2
) (1 − 1 𝑒𝜇𝛼) ∗ 𝑣 (13)

where�α=�angle�of�lap=200°�

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α=�3.49�rad�

bt =11509.80 mm²

So, selecting standard Rubber Belt as;

Length of belt =2290 mm

Width of belt = 450 mm

Thickness of belt = 3 mm

Pulley Shaft Calculations:

Length of shaft considering the belt

width of 400 mm

and clearance of 50 mm

and width of bearings on both ends of shaft, [8]

L = B + 100 + 50 (14) L = 550 mm

Max bending force on pulley,

Mmax= 𝑊 2 X l 2 = 3.925 x 106 N*mm (15)

Twisting�moment�on�shaft,�Mt=�P�X�60�2πN�(16)�

To find N,

Velocity�of�belt�(V),�V=�π�D�N�60�(17)�N�=�11�RPM�

Mt�=�p�x�60�2�π�N�Mt�=�721.921�x�103�N*mm�

Equivalent torque on shaft; Meq=√𝑀𝑚𝑎𝑥2 + 𝑀𝑏2

= √(3.925 x 106)² + (721.92 x 103)²

Meq = 3.990 X 106 N-mm Selecting the carbon steel material of grade C45 from PSG design
data book having properties,

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σy�=�360�N/mm2�

FOS = 4 (𝜏) = 45 N/mm2

Considering torsional failure of shaft;

Mteq = (𝜋 /16) ∗ 𝜏 ∗ 𝑑𝑠3 (19)

ds = 50 mm Selecting standard shaft of 50 mm diameter and 550 mm length of C45 grade

material for both pulleys from PSG design data book.

Selection of Bearing:

Bearings are machine elements which supports other moving machines elements. [8]

Bearings permit the relative motion between the contact surfaces of the members,

while carrying the load. [9]

Deep Groove Ball Bearings are selected for both the pulley shafts having

d = Internal diameter = 50 mm

D = Outer diameter = 80 mm and

w = width of bearing = 16 mm

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CHAPTER.5

ADVANTAGES

 Lower operating costs.

 Improved worker safety.

 Reduced factory lead times.

 Faster ROI. Ability to be more competitive.

 Increased production output.

 Consistent and improved part production and quality.

 Smaller environmental footprint.

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CHAPTER.6

CONCLUSION

Interpretations of the results obtained, leads to know the important achievement and
performance of the developed multiple spindle drilling SPM are:

a) Increase in productivity with same quality standards.

b) Reduction in production time.

c) Reduction in cost of production.

d) Operator (unskilled) can operate two more machines along with MOG SPM with
Comfort and without Helper.

e) Tremendous saving in the operational time of machining, with the newly developed
multispindle drilling SPM.

f) Saving in unproductive time.

g) It can be seen that the loading and unloading time is also reduced.

h) Proper arrangements for loading the job, location of machine controls and ease of
operation reduces excessive strain on the operator and results into comfortable working
conditions.

i) Elimination of problems such as rejection, rework in MOG Hole Drilling operation

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CHAPTER.7

REFERENCES

[1] P. K. V. Konakalla Naga Sri Ananth, Vaitla Rakesh, “Design and Selecting the Proper
Conveyor-Belt,” International Journal of Advanced Engineering Technology E, vol. IV, no.
II, pp. 43–49, 2013.

[2] L. Zhao, Y. Lin, “Typical failure analysis and processing of belt conveyor,” Procedia
Engineering, vol. 26, pp. 942–946, 2011,
doi:https://doi.org/10.1016/j.proeng.2011.11.2260.

[3] M. R. Sayali Todkar, “Design of Belt Conveyor System,” International Journal of

Science, Engineering and Technology Research, vol. 7, no. 7, pp. 458–462, 2018.

[4] Z. B. R. gunasegaran Madasamy, “Automated Mechanical SOrting Device for Mixed

Household Wastes,” LAP Lambert Academic Publishing, no. February 2013, pp. 50, 2013.

[5] P. Elamurugan et al., “Automatic material segregation using PLC,” International

Journal of Engineering and Technology(UAE), vol. 7, no. 2, pp. 376–380, 2018,
doi:https://doi.org/10.14419/ijet.v7i2.24.12088.

[6] PSG college of engineering, 307Design_Data_Data_Book_Of_Engineers_By_PSG

(Coimbatore, India: Kalaikathir Achchagam).

[7] K. S.J. Ojolo, J.I. Orisaleye, Adelaja, A.O., “Design and Development of Waste Sorting
Machine,” Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS),
vol. 2, no. 4, pp. 576–580, 2011.

[8] Bhandari V. B., Design of Machine Elements - V. B. Bhandari - Google Books (1994).
[9] P. K. Shanjenbam Brojendro Singh, Abu Salah Muslaha Uddin Laskar, Biltu Roy,
Aminul Hoque Choudhury, Zahidul Islam, Jakir Hussain Mollah, Shadeed Masood Ul
Hoque, Mohsin Ali, “Design of Municipal Dry Waste Segregating Machine Using
Conveyor,” International Journal of Innovative Research in Science, Engineering and
Technology (An ISO, vol. 5, no. 5, pp. 7156–7162, 2016.

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[9] P.M. Singru & Anish Alias, “Computer Aided Design of Machine(CADOM)”,
Proceeding of International Conference on : “Intelligent Flexible Autonomous
Manufacturing Systems” , IFAMS-2000, Institute of Technology, Coimbatore, 10
Jan.2000,PP 164-171.

[10] V.B. Bhandari, “ Design of Machine Elements” Tata McGraw- Hill Publishing Co.
Ltd. New Delhi, 25th Reprint, PP 234-246.

[11] N.K. Metha, “ Machine Tool Design and Numerical Control”, Tata McGraw- Hill
Publishing Co. Ltd. New Delhi, Second Edition, PP 179-219.

[12] Tsung-Ming Lo and Jieh-Shian Young, “Improvements of Productivity for PCB

Drilling by Laser Driller Machine”, International Journal of Precision Engineering and
Manufacturing vol. 15, no. 8, August 2014, pp. 1575-1581.

[13] Biman Das & Uday Venkatadri & Pankajkumar Pandey, “Applying lean
manufacturing system to improving productivity of air-conditioning coil manufacturing”,
International Journal of Advanced Manufacturing Technology, 24 November 2013,PP-
307–323.

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