Annexure A

Automation of Loading & Unloading of Aluminium slabs for Two Tier Vertical Rotary Hearth Furnace

BITS ZC423T: Project Work

By

G.S.MAGESH

200918TS018

Project work carried out at

Conveyors & Engineering Works

Ambattur Chennai 600 098

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE PILANI (RAJASTHAN)

March 2012

Annexure B

Automation of Loading & Unloading of Aluminium slabs for

Two Tier Vertical Rotary Hearth Furnace

BITS ZC423T: Project Work

by

G. S. M A G E S H

BS ET ID No 2009 18 TS 018

Project Work carried out at

Conveyors & Engineering Works

Ambattur Chennai 600 098

Submitted in partial fulfillment of B.S. Engineering Technology degree programme

Under the Supervision of M.THIRUNAVUKKARASU

BE Automobile Conveyors & Engineering Works Ambattur Chennai 600 098

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE PILANI (RAJASTHAN)

March 2012

Key words & Abbreviations & Acronyms Automation - Unmanned Automatic operation of machines

Hearth Furnace - Brick lined oven used for heating

CEW - Conveyors & Engg Works

PRT - Pulse Ranging Technology

MOC Material of Construction SS 304 Stainless Steel grade 304

Fe - Ferrous

C - Carbon

Cr - Chromium

Ni - Nickel Mn - Manganese

Si - Silica

P - Phosphorus

S - Sulphur

PLC Programmable Logic Control

SMPS Switched Mode Power Supply ISA - Indian Standard Angles

LASER - Light amplified for Simulated Emission and Radiation

i.e. - that is

I/O - input / output

CPU - Central Processing Unit

??

???

?

List of Figures

Fig.No

Details

Page No 1

Manufacturing

7

2

Feeding conveyor

9

3

The Tilting Arrangement

9

4

The Central Moving Rack

10

5

The Discharge Conveyor

10 6

Total Assembly

10

7

The Lifting arrangement

11

A

The Hydraulic System

11

8

The Lifting cylinder

11

9

The Tilting cylinder

11

10 Push / Pull cylinder

12

11

Clamping cylinder

12

B

The Powerpack

13

12

Circuit of Hydraulic Connections

13

13

Hydraulic Hose Connections

13 IX

The Sensors

14

14

Inductive Proximity Sensor

14

15

Distance Sensor

15

The PLC Control

16

16

Programmable logic

16

V

List of Figures

Fig.No

Details

Page No

17

CPU

17

18

Expansion Module

17

19

Expansion Module

17 20

Expansion Module

18

21

HMI

18

22

SMPS

19

??

List of Tables

Table No

Details

Page No

6.1 Sequence of Operation

20

6.2

Cycle Time

21

VI

TABLE OF CONTENTS

Chapter No. Description Page No.

a

Certificate

I

b

Abstract

II

c

Acknowledgments

III

d

Keywords Abbreviations & Acronyms

IV

e

List of Figures

V

f

List of Tables

VI

1

Introduction

1

2

Design Process

2

3

Description & Operation

4

Engineering (The debottlenecking)

5

Manufacturing

3

6

Components of System

4

7

PLC Control

12

8

Sequence of Operation & Cycle time

15

9

Assembly and trial run

18

10

Summary & Conclusion

19

11 References

20

12.

Checklist

21

VI

Chapter 1 Introduction Industrial Customers and consumers worldwide have become more demanding and suppliers have responded by improving the range of products and characters they offer

1. A fair price

2. Higher quality products and services 3. Delivery Lead time 4. Better presale and after sales service

5. Product volume and flexibility

Positioning the firm

A firms positioning strategy defines how it will compete in the market, what unique value it will deliver to the customers. Competing on speed of delivery

Competing on Quality Competing on flexibility

In our firm our strategy is a combination of all the three and there lies the strong foundation.

Engineer to order

This means that the customers specifications require unique engineering design or significant customization. Usually the customer is highly involved in product

design. Inventory will not be procured until needed by manufacturing. Delivery lead time is usually longer but we had different circumstances which was not affected.

Automation is the use of control systems and information technologies to reduce

the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the

muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an

increasingly important role in the world economy and in daily experience.

We have started our company based on this idea to provide simple automation

where no one has ventured before and in a analysis during my tenure in Marketing I found such special services are not available in our industries.

If we look into industrial scenario we could see there are companies available either supplying or manufacturing industrial equipments or supply automation systems only. There are very few or no persons indulged in combining both

mechanical equipments equipped with electronic controls for Material Handling systems.

1

Industrial automation engineers carry a lot of responsibility in their profession. No other domain demands so much quality from so many perspectives of the function, yet with significant restrictions on the budget.

In our project we have done automatic loading of cold component aluminum

slabs of size 40 x 510 x 360mm simultaneously in two tiers and unloading of hot components, once it is circled through the furnace 360. Let us see in details all

its components and activities

This a report of new design developed manufactured, installed and

commissioned by the team of CEW

2

Chapter 2 - Design Process

Design Process for a product requires clear understanding of the functions and

the performance expected of that product, the product may be new or revision of an existing product

Design is an innovative and highly iterative process

Design Considerations

1. Functionality 14. Noise

2. Strength / stress 15. Styling 3. Distortion / deflection / stiffness 16. Shape 4. Wear 17. Size

5. Corrosion 18. Control 6. Safety 19. Thermal Properties

7. Reliability 20. Surface 8. Manufacturability 21. Lubrication 9. Utility 22. Marketability

10. Cost 23. Maintenance 11. Friction 24. Volume

12. Weight 25. Liability 13. Life 26. Recycling

Technology in Design

Modern Engineer has a great variety of tools and resources available to assist in the solution of the design problems. Inexpensive micro computers and software

packages provide tools of immense capability for design and analysis. In this part of area Computer Aided Design Tools like AutoCAD, ProE, Solidworks are most widely used. We have used Solid works for our Design

Selecting Materials

An ever increasing variety of Materials is now available each having its own characteristics, applications, advantages and limitations.

Properties

Mechanical Strength, Toughness, Ductility, Hardness, elasticity, fatigue, creep Physical - Hardness, specific heat, Thermal expansion, melting point,

electrical, magnetic properties

Chemical - Oxidation, Corrosion, Degradation, Toxicity, Flammability

Manufacturing Casting, Forming, Machining, Welding, heat treatment with relative ease

Standard size : The use of standard and available sizes is the first principle of cost reduction. An Engineer who selects ISA 55 for fabrication has added cost to

the product. He can easily select standard available ISA 50 or ISA65 for the same at reduced prices

3

Functional Design is concerned with how the product performs. It seeks to meet the performance specifications of fitness for use by the customer.

Three performance characteristics are considered during this phase of design 1. Reliability

2. Maintainability 3. Usability

Functional Specification can be described in the following ways 1. By brand

2. by specification of physical and chemical characteristics, material and method of manufacturing and performance 3. By Engineering Drawings

Quality

Since competition is aggressive, successful companies provide quality that not only meets high expectations but exceeds them.

Quality from Customers perspective

Quality should be aimed at the needs of the consumer present and future. From

this perspective product and service quality is determined by what the customer wants and is willing to pay for. Since customers have different product needs, they will have different Quality expectations.

This result is a commonly used definition for Quality i.e. fitness for use. How well does it, what the customer or the user thinks it is supposed to do and wants it to

do.

4

Chapter 3 - Description & Operation The system consists of the following items

I. Feeding conveyor

The feeding conveyor is a power roller conveyor of 2mtr length and 700mm width with rollers every 125mm pitch.

II. Forward Tilting arrangement on feeding conveyor This is a tilting arrangement placed in the end of feeding conveyor to move the

Aluminium slab forward when it reaches the end and stops, by means of a hydraulic cylinder placed at the bottom

III. Central rack which houses a. Pushing cylinder#1

b. Pushing cylinder#2 c. Clamping cylinder#1 d. Clamping cylinder#2

a. Pulling cylinder#1 b. Pulling cylinder#2

c. Clamping cylinder#3 d. Clamping cylinder#4

The Central rack is housed with cylinders for loading and unloading purpose. The rack moves up and down to place the slabs in top and bottom tiers.

The slab moves in the feeding conveyor gets tilted and stands vertical. A sensor at the bottom gives signal to the tilting cylinder to give forward motion to the

slab.as soon as it stands vertical another sensor gives signal to clamping / pushing cylinder assembly. Clamping cylinder along with pushing cylinder moves forward and holds the cold slab. As the slab holds, the rack is given signal to

move up till it reaches the top tier position. Immediately a sensor gives signal to the feed conveyor and it rolls and moves

next slab into the bottom rack. Similarly another sensor activates motion of clamping cylinder to hold the cold slab when it comes to vertical position. Now both the slabs in the top and bottom tiers are moved into the Furnace

simultaneously and placed while two other arms in the parallel side grabs and moves the hot slab into the rack. Once it reaches its position, a sensor activated

discharge conveyor and backward cylinder lowers the hot slab in the bottom position and moved in the conveyor and then the rack lowers to deliver the second slab into the discharge conveyor.

IV. Backward tilting on discharge conveyor

This is a tilting arrangement placed in the beginning of discharge conveyor to move the Aluminium slab backward and lowers it, by means of a hydraulic cylinder placed at the bottom, into the discharge conveyor

V. Discharge conveyor

Discharge conveyor is also of same size like feed conveyor and discharges hot components i.e. hot Aluminium slabs

5

Chapter 4 Engineering (The debottlenecking)

1. Conveyors: As emphasized earlier the main bottle neck in making this equipment capable of hot component having temperature not less than 500C.

For this we selected pipe having a wall thickness 5.4mm, so that the

temperature in the outer pipe shall pass onto bearings. Even if it is found, the

point contact at any given time is less; hence we have no fear of heat transfer to bearings. This wall thickness will not allow the pipe to deform when contacted

with hot component. If necessary we will provide air cooling during commissioning

2. Clamping the hot components

Since Stainless steel can withstand high temperatures we manufactured all the clamping, pushing and pulling components in SS304

Chemical Composition of SS 304

Fe,

Chapter 5 - Manufacturing

Special Purpose Machinery - Special Purpose Machinery is designed to perform specific operations on one work piece or number of similar units

Manufacturing in its broadest sense is the process of converting raw materials

into products

It encompasses Design of product, selection of raw materials, sequence of process thru which the product will be manufactured.

1. A product must fully meet the design requirements and product specifications and standards.

2. The product must be manufactured by most enviro friendly and economical methods

3. Quality must be built into the product at each stage of manufacturing

4. In a highly competitive environment production methods must be flexible

5. New developments in materials, Manufacturing methods and computer integration must be used

Market

Specification

Main Design Flow

Concept design

Detail design

Manufacture

S e l l

Fig 1 Manufacturing Methodology

LASER Beam Machining. Is a widely used method by us, which focuses optical energy on the surface of

the work piece. The highly focused high density energy melts and evaporates portions of in a controlled manner. This process is widely used for machining

metallic and non-metallic materials. There are many types of Lasers are used in manufacturing but we use CO2 Laser

7

Just in time production : The principle of JIT is that it supplies are delivered just in time t be used parts are produced just in time to made into subassemblies and assemblies and products are finished just in time to be

delivered to the customer. In this way inventory carrying costs are low, part defects are detected right away, productivity is increased, and high quality

products are made at low cost.

Sub-contracting As a pure strategy sub contracting always producing

minimum level and meeting additional demand thru sub-contracting. It can also mean buying extra demands. Major advantage is the cost. If we do in house, we

will not only need the develop the technology but also manufacture it, means lot of times and money

Designing the Process

5 basic factors 1. Product Design and quality level

2. Demand patterns and flexibility needed 3. Capacity considerations

4. Customer Involvement 5. Make or buy decision

Reasons to make in house

Can produce for less cost than supplier

To utilize existing equipment to fullest extent To keep confidential processes within the control of the firm

To maintain quality To maintain workforce

Reasons to buy out Requires less capital investment

Uses specialized expertise of suppliers Allows the form to concentrate on its own area of specialization Provide known and competitive prices

Simultaneous Engineering

To design a low cost manufacture requires close coordination between product design and process design which is called Simultaneous Engineering. If the two

groups can work together, they have a better chance of designing a product will

function well in the market and can be manufacture at low cost. This relationship

between a product design and process design can spell success of the product.

8

Chapter 6 Components of System I. Feeding conveyor - Fig - 2

The Aluminum Slab

II. The Tilting Arrangement - Fig - 3

9

III. The Central Moving Rack Fig 4

IV. The Discharge Conveyor - Fig 5

V. TOTAL ASSEMBLY - Fig 6

10

The Lifting arrangement Fig 7

VI. The Hydraulic System A. Cylinders

A1.The Lifting cylinder - Fig 8

A2.The Tilting cylinder - Fig 9

11

A3.Push / Pull cylinder - Fig 10

A4.Clamping cylinder - Fig 11

12

The Powerpack B1.CIRCUIT OF HYDRAULIC CONNECTIONS Fig 12

B2. Fig 13. HYDRAULIC HOSE

CONNECTIONS

13

Sensors

A sensor is a device which converts a physical phenomenon into an

electrical signal. As such sensors represent part of interface between the physical world and the world of electrical devices, such as computers. The other part of the interface is represented by actuators which converts

electrical signal into physical phenomena. Without sensors most electronic applications would not exist-they perform a vital function, namely

providing an interface to the real world. The importance of sensors is such that the world of automation means sensors. Today's smart sensors,

wireless sensors, and micro technologies are revolutionizing sensor design and applications. CI. Inductive Proximity Sensor - Fig 14

A proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact.

A proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in

the field or return signal. The object being sensed is often referred to as the proximity sensor's target. Different proximity sensor targets demand different

sensors. For example, a capacitive or photoelectric sensor might be suitable for

a plastic target; an inductive proximity sensor always requires a metal target. The maximum distance that this sensor can detect is defined "nominal range".

Some sensors have adjustments of the nominal range or means to report a graduated detection distance. Proximity sensors can have a high reliability and long functional life because of

the absence of mechanical parts and lack of physical contact between sensor and the sensed object. (Ref Sensor technology handbook, Volume 1 By Jon S. Wilson)

14

CII.VDM 28 The Universal Sensor for Measuring and Monitoring - Fig 15

Distance measurement sensor VDM28

The new, small VDM28 distance sensor uses Pulse Ranging Technology (PRT) to move it to the front of the market ahead of all comparable sensors from a

performance point of view. It is integrated into a compact housing from the standard series 28 sensor range. The universal VDM28 distance sensor can be used in a wide range of

industries and applications.

The smallest distance measurement sensor for use as a measuring sensor

with PRT (Pulse Ranging Technology)

Low-cost distance measurement sensor in standard photoelectric-sensor enclosure, Installation compatibility with common standard sensors

Measurement range of up to 50 m at repeatability of 5 mm Unique measuring result even at multiple targets in the measurement area

Measuring results independent on color of target Extremely fast (10 ms)

Red laser as the light emitter, Versions with Laser class 1 or 2 Versions with analogue output or IO-Link interface for servicing and process data

15

Chapter 7 - PLC Control

D.Programmable Logic Control - Fig 16

PROGRAMMING

SOFTWARE

CH1 CH4

CH2 PROCESSOR CH5

CH3 CH6

Input Module Channels Output Module Channels

PLC Operation is not simultaneous for the entire ladder diagram and is not

continuous as it is for relay sequences. Operation of PLC can be considered in 2

modes

1. I/O Scan Mode 2. Execution mode

I/O Scan Mode - During I/O scan mode the processor updates all outputs and inputs the state of all inputs one channel at a time. The time required for this

depends on the speed of the processor

Execution mode During this mode, the processor evaluates each rung of the ladder diagram program that is being executed sequentially, starting from the first rung and proceeding to the last rung. As a rung is evaluated the last known

state of each switch and relay contact in the rung is considered and if any true path to the output device is detected, then the output is indicated to be

energized that is set to ON. At the end of the ladder diagram, the I/O mode is entered again and all the O/P devices are provided with ON or OFF state determined from execution of the

ladder diagram program. All inputs are sampled and execution mode starts again.

Scan time: an important characteristic of PLC is how much times is required to complete one complete cycle of I/O scan and execution. Of course, this depends

on how many input and output channels are involved and on the length of the ladder diagram program. A typical maximum scan execution time is 5 to 20ms.

Programming is an external electronic package that is connected to the programmable controller when programming occurs. The unit usually allows

input of a program in ladder diagram symbols. The unit then transmits that program into the memory of the programmable controller.

16

D1. PLC CPU - Fig 17

Product description SIMATIC S7-1200, CPU 1214C, COMPACT CPU, DC/DC/DC, ONBOARD I/O: 14 DI

24V DC; 10 DO 24 V DC; 2 AI 0 - 10V DC, POWER SUPPLY: DC 20.4 - 28.8 V DC, PROGRAM/DATA MEMORY: 50 KB

D2. EXPANSION MODULE - Fig 18

Product description

SIMATIC S7-1200, DIGITAL I/O SM 1223, 16DI / 16DO, 16DI DC 24 V, SINK/SOURCE, 16DO, TRANSISTOR 0.5A

D3. EXPANSION MODULE - Fig 19

Product description

SIMATIC S7-1200, DIGITAL INPUT SM 1221, 16 DI, 24VDC, SINK/SOURCE INPUT

17

D4. EXTENSION MODULE - Fig 20

Product description SIMATIC S7-1200, DIGITAL OUTPUT SM 1222, 8 DO, 24V DC, TRANSISTOR 0.5A

D5.HMI HUMAN MACHINE INTERFACE FIG 21

Human-machine interface is the part of the machine that handles the Human-

machine interaction. This term is system-oriented. it extends the computer-

oriented term of user interface, referring also to system operators who are not

the machine users. The extension is useful for modelling complex systems, such

as in the process industry or in emergency control. For example, the users of

alarm system are the public, or people who happen to be at the risky place. The

interface to the audience may be by emergency lights or by loud-speakers. This

interface is different from that used for the operators, who generate the alarms.

Product description

SIMATIC HMI KTP600 BASIC COLOR PN, BASIC PANEL, KEY AND TOUCH OPERATION, 6" TFT DISPLAY, 256 COLORS, PROFINET INTERFACE,

CONFIGURATION FROM WINCC FLEXIBLE 2008 SP2 COMPACT/ WINCC BASIC V10.5/ STEP7 BASIC V10.5, CONTAINS OPEN SOURCE SW

18

D6. SMPS SWITCHED-MODE POWER SUPPLY FIG 22 A switched-mode power supply (switching-mode power supply, SMPS, or

simply switcher) is an electronic power supply that incorporates a switching regulator in order to be highly efficient in the conversion of electrical power. Like

other types of power supplies, an SMPS transfers power from a source like the electrical power grid to a load (such as a personal computer) while

converting voltage and current characteristics. An SMPS is usually employed to

efficiently provide a regulated output voltage, typically at a level different from the input voltage

Product description

SITOP PSA100E STABILIZED POWER SUPPLY 300 W INPUT: 230 V AC OUTPUT: 24 V DC/12 A

19

Chapter 8 - Sequence of Operation & Cycle Time

TABLE 6.1 - Sequence of Operation

Loading

conveyor 1 - start

conveyor 1 - stop

Tilting cylinder 1 - forward

Pushing Cylinder 1 - forward 1

Clamping cylinder 1 - closing

Tilting cylinder 1 - reverse

1 Lifting cylinder - up

2 conveyor 1 - start Pulling Cylinder 3 forward

3 conveyor 1 - stop Pulling Cylinder 4 forward

4 Tilting cylinder 1 - forward

Clamping cylinder 3 - closing

5 Pushing Cylinder 2 - forward 1 Clamping cylinder 4 - closing

6 Clamping cylinder 2 - closing

7 Tilting cylinder 1 - reverse Pulling Cylinder 3 reverse 1

Pulling Cylinder 4 reverse 1

8 Pushing Cylinder 1 - forward 2 Clamping Cylinder 3 - Open

Pushing Cylinder 2 - forward 2 Pulling Cylinder 3 reverse 2

9 Clamping cylinder 1 - Open conveyor 2 start

Clamping cylinder 2 - Open Tilting cylinder 2 - reverse

10 Pushing Cylinder 1 - reverse

Pushing Cylinder 2 - reverse

11 Lifting cylinder - down

12 conveyor 1 - start Tilting cylinder 2 - forward

13 conveyor 1 - stop Clamping Cylinder 4 - Open

14 Tilting cylinder 1 - forward Pulling Cylinder 4 reverse 2

15 Pushing Cylinder 1 - forward 1 Tilting cylinder 2 - reverse

16 Clamping cylinder 1 - closing conveyor 2 stop

17 Tilting cylinder 1 - reverse

Lifting cylinder - up

20

Cycle time - TABLE 6.2 Cycle Time

1 Lifting cylinder - home

2

3

4

5 Lifting cylinder - up

6 conveyor 1 - start Pulling Cylinder 3 home

7 Pulling Cylinder 4 home

8

9

10 conveyor 1 - stop

11 Tilting cylinder 1 - home

12 Pulling Cylinder 3 end

13 Pulling Cylinder 4 end

14 Tilting cylinder 1 - end Clamping cylinder 3 - closing

15 Pushing Cylinder 2 - home Clamping cylinder 4 - closing

16 Pushing Cylinder 2 - forward 1 Pulling Cylinder 3 end

17 Clamping cylinder 2 - closing Pulling Cylinder 4 end

18 Tilting cylinder 1 - end

19

20

21 Tilting cylinder 1 - home Pulling Cylinder 3 reverse 1

22 Pushing Cylinder 1 - home Pulling Cylinder 4 reverse 1

23 Pushing Cylinder 2 - home Clamping Cylinder 3 - Open

24 Pulling Cylinder 3 reverse 1

25

26 Pulling Cylinder 3 home

27

28 Pushing Cylinder 1 - end

29 Pushing Cylinder 2 - end

30 Clamping cylinder 1 - Open

31 Clamping cylinder 2 - Open

32 Pushing Cylinder 1 - end

33 Pushing Cylinder 2 - end

34

21

Cycle time - TABLE 6.2 Contd.

35

36

37

38

39

40 Pushing Cylinder 1 - home

41 Pushing Cylinder 2 - home

42 Lifting cylinder - end

43

44

45

46 Lifting cylinder - home

47 conveyor 1 - start Tilting cylinder 2 - home

48

49

50 Tilting cylinder 2 - end

51 Clamping Cylinder 4 - Open

52 conveyor 1 - stop Pulling Cylinder 4 reverse 2

53 Tilting cylinder 1 - home

54

55 Pulling Cylinder 4 home

56 Tilting cylinder 1 - end Tilting cylinder 2 - end

57 Pushing Cylinder 1 - home

58 Pushing Cylinder 1 - forward 1

59 Clamping cylinder 1 - closing Tilting cylinder 2 - home

60 Tilting cylinder 1 - end

61

62 Tilting cylinder 1 - home conveyor 2 - stop

63 Lifting cylinder - home

22

Chapter 9 Assembly and trial run

A layout is made in the factory in which the machines automation will work is made. Individual components like Feeding conveyor, central rack

and cylinders fitted, discharge conveyor and power pack are moved to its respective position. Interconnected with each other and leveling done.

One position of furnace position is made and erected in front of the rack to take trial.

All connections given to PLC control panel.

Hydraulic oil Hytrol 68 of Bharat Petroleum 120 liters procured and filled the Powerpac for trial run.

We took actual commissioning at our factory before moving the automation system to be synchronized with furnace. And arrived cycle time of 90 secs for single operation of loading and unloading of single set of components. In about 1.5 hrs the furnace will make one revolution and

60 sets will be completed

The Problems Faced In the Project

1. The problem of hot environment solved by proper selection of thickness of pipe for bearings. We have actually tested with a torch running over

the pipe at 900C.

2. The problem of proximity sensor at heat zone, eliminating a mirror probe at the rear of clamping cylinder.

3. The problem of lifting arrangement frame got eliminated by selecting ready available frame with bearings from Winkel Products which was not

only sturdy but suitable for the environment and long life 4. The problem of failure of hydraulic pressure switches not compatible with PLC panel. Discarded and put proximity sensors

5. The problem of movement of frequent travel of hydraulic hoses got housed inside drag chain made of engineering plastic.

6. During commissioning we found the clamps manufactured for holding Aluminium slab got slippery while holding it, made knurling over it for grip.

23

Results

1. The Customers need for an automatic system for handling aluminium slabs achieved

2. The customers demand of cycle time of 90 seconds per set achieved

3. The customers demand of operating twin tiers simultaneous has been

achieved

4. The customers demand of operating single tier only on demand is achieved by giving manual commands or manual mode of operation.

5. The customers demand of delivering the complete system in 4 months is achieved. 6. Since it is low cost high profile simple automation it was an instant

Order winner for us

24

Chapter 10 Summary and Conclusion

Summary

In humility I have proposed for automation as one among the three things we decided to manufacture / supply / offer services besides being

conveyors and special purpose machines when we started this company.

My Mentor is genius in designs and my good experience in engineering, project management and shop management, fabrication and purchase

took us to complete this project in limited time.

We use Solidworks for design and use laser beam machining, CNC folding

for conversion. CAD Software Solidworks actually saves time very much, almost 10 times lesser than AutoCAD. In which we make actual machine in 3rd dimension and convert it to 2nd dimension.

We used a separate vendor for Control Panel and Hydraulic system which were not in our scope of manufacturing, besides saving time for the

project.

Since we use latest technologies in conversion, we are able to achieve Quality, less space, less manpower, less time

Conclusion

We have given our customer the most wanted automatic loading unloading system for his furnace which is simple, cost effective, user friendly operation and easy to maintain. This kind of machine is new to

this Aluminium industry and we are proud of achieving it with limited resources.

We could learn the following things from this project by effective implementation which gave us immense experience and confidence

1. Use of technology in Design 2. Various process of design and engineering 3. Simultaneous Engineering

4. Just in time technology 5. Sub-contracting 6. Use of technology in manufacturing

25

References

Jon S. Wilson, Sensor technology handbook, Volume 1 by Jon S. Wilson, Elsevier Imprints,2004

Internet Russell, R.S. & Taylor, B.W., Operations Management, Wiley Student Edition, 6th Ed., 2009

Arnold, J.R. Tony & others, Introduction to Materials Management, Pearson Education, 6th Edition, 2007.

Serope Kalpakjian,Steven R.Sdhmid, Manufacturing Engineering and Technology, Pearson Education, 4th Edition, 2006 Joseph E.Shigley, Mechanical Engineering Design, Tata McGraw Hill, 8th

Edition 2008

Johnson, Curtis D., Process Control Instrumentation Technology, Prentice

Hall of India, 8th Ed., 2006.

S.Ramamurtham, Strength of Materials, Dhanpat Rai Publishing Company,15th Edition,2004

26