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In this section, various factors are studied such as human comfort, area availability, type of machine, distance between manipulator and machine required, placement of the manipulator and compressor and accordingly suggest the modifications. Modified Design Once the existing design is analyzed and various parameters are studied, design has to be modified according to the requirement. Test Run and Preparation of Maintenance Schedule Once the modified design is fabricated it has to be sent to the production line. In production line, the machine will be in under commissioning for few days. After the success of test run, the maintenance schedule and data will be prepared which will involve the predictive maintains and breakdown maintenance manual. Experiments Some of the experiments have been done for trial run of the existing design. Experiments for the modified design have to be conducted after completion of the machine fabricators.
8. PROJECT UNDERTAKEN
8.1 NAME OF THE PROJECT : DESIGN MODIFICATION IN MANIPULATOR FOR APPLICATION IN HEAVY AXLES LINE
Organization of Report
The report has been distribute systematically into different sections. The first chapter is the introduction of the project that is followed by geometric dimensioning and drafting. The geometric dimensioning and drafting is followed by pneumatic circuit which is followed by kinematics and mechanism of the links. After the complete study of structure, mechanism and the circuit, the design is analyzed. Analysis is followed by modified design which is followed by test run and preparation of maintenance schedule. Smoothly, combining different media forms and sources of knowledge in an easily accessible fashion. Fluid Sim united and intuitive circuit diagram editor with detailed description of all components, component photo, sectional view animation and video sequences.
Kinematics and Mechanism
The Kinematics and mechanism is studied while keeping in mind the distance between the manipulator, work piece and the machine. In this work piece handling mechanism is also studied. It involves the use of auto Desk Force Effect M.
* Introduction to Auto Desk Force Effect M
Autodesk, Inc is a leader in 3D design, engineering and software. Auto Desk Force Effect M is an application for developing and testing mechanical system with moving parts (scissor Lift, windshield wipers, automotive engine, robotics, etc.). It enables engineers and technical enthusiasts to easily evaluate their designs early in the design process, thereby empowering concept evaluation. Real-time solving capabilities provide immediate feedback on the system\'s performance, which users can then print, e-mail or view as a results report.
Analysis and Modifications
In this section, various factors are studied such as human comfort, area availability, type of machine, distance between manipulator and machine required, placement of the manipulator and compressor and accordingly suggest the modifications.
Modified Design
Once the existing design is analyzed and various parameters are studied, design has to be modified according to the requirement.
Test Run and Preparation of Maintenance Schedule
Once the modified design is fabricated it has to be sent to the production line. In production line, the machine will be in under commissioning for few days. After the success of test run, the maintenance schedule and data will be prepared which will involve the predictive maintains and breakdown maintenance manual.
Experiments
Some of the experiments have been done for trial run of the existing design. Experiments for the modified design have to be conducted after completion of the machine fabricators.
8.4 PNEUMATIC MANIPULATOR
A pneumatic manipulator is a manipulator that is driven by compressed air. The desired circuit helps to control and manipulate the machine property.
8.5 COMPONENTS OF MANIPULATOR
Following are the main components of the manipulator:
1. Base plate
2. Column
3. Links
4. Pneumatic Circuit
5. Material handling mechanism
6. Counter Weight.
Problem Definition
As per expansion program of GNA Axles Ltd. to introduce heavy axles manufacturing in the industry, there is requirement of heavy machinery and material handling equipments in order to machine and handle heavy axles that weigh above 1000 Kilograms. Hence, the requirements of the manipulator are necessary. Therefore, it is very essential to study and modify the design of the existing manipulator in order to bring them into action. The manipulators were bought from some other manufacturing industry and no technical data was provided with them.
Methodology
The project has been divided into sub-parts on the basis of various parts of mechanical engineering. Following methodology has been followed:
Geometric Dimensioning and Drafting
This section involves the dimensioning of the components of the manipulator in order to draft the model in the cad software. Also, geometric dimensioning is important in order to midify the design of the manipulator.
Pneumatic Circuit
The pneumatic manipulator is driven by compresses air with help of pneumatic cylinder and related components. In this the pneumatic circuit is studied so that modifications can be suggested. It involves the application of fluidsim.
Introduction to FluidSim
FluidSim is a comprehensive software for creation, simulation, instruction and study of electro pneumatic, electrohydraullic and digital circuits. All of the program functions interact smoothly. Combining different media forms and sources of knowledge in an easily accessible fashion. FluidSim united an intuitive circuit diagram editor with detailed descriptions of all components, components photos, sectional view animations and video sequences.
Kinematic and mechanism
The kinematic and mechanism is studied while keeping in mind the distance between the manipulator, work piece and the machine. In this, work handling mechanism is also studied.
8.6 GEOMETRIC DIMENSIONING AND DRAFTING
In this section, geometric is done of the manipulator. Kindly note that the components are studied by not disassembling the machine.
Rough Sketch of manipulator
Rough sketch of pneumatic circuit
8.7 BILL OF MATERIAL OF MANIPULATOR
Following is the Bill of Material for the Manipulator:
S.No
Part
Material
Qnty.
1
Arm
M.S.
1
2
Arm
M.S.
1
3
Arm
M.S.
1
4
Arm
M.S.
1
5
Clamp
M.S.
1
6
Arm
M.S.
2
7
Arm
M.S.
1
8
Nut/Bolts for Links
M.S.
7
9
Plate
M.S.
2
10
Pneumatic Cylinder
Steel
1
11
Main Box
M.S.
1
12
Cylinder Column
M.S.
1
13
Base Plate
M.S.
1
14
Column with Structure
M.S.
1
15
Controller Box
M.S.
1
16
Counter weight
M.S.
2
17
Bolts for Coupling
M.S.
4
18
Nuts for Coupling
M.S.
4
19
Nuts for Main Box
M.S.
1
20
Supports for Cylindrical Column
M.S.
4
21
Handle
Plastic
1
22
Bolts for Handle
M.S.
2
23
Nut/Bolt for Cylinder Base
M.S.
1
24
Studs for Cylinder
M.S.
4
25
Nuts for Studs
M.S.
12
26
Stud for Counter Weight
M.S.
1
27
Nut fo