Industrial project report
Abstract:
This is an industrial project report. The project is to improve any mechanism of our own
interest from any industry related to mechanics. In this project the bending machine is a
semiautomatic bending machine, in which the loading and unloading of the component
is done manually and the bending of the plate is done automatically. The
bending machine is one of the most important machine tool in sheet metal work shop. It
is primarily designed for bending. The bend has been made with the help of punch
which exerts large force on the work clamped on the die. The bending machine is
designed in such a way that, it works automatically. The automation strategy, when
implemented is believed to result in reduced cycle time, costs and improved product
quality. Other possible advantages are repeatability, increased productivity, reduced
labor and integration of business systems. Automation is achieved with the help of
Electropneumatic system.
Problem statement:
During manual rolling of metal sheets into cylinders, there are a lot of errors due to the
human power involved in rolling. The task is to overcome those errors.
Industry introduction:
From the wide range of industries in Pakistan, Industry chosen for our given assignment
is UNITECH Pvt. Ltd.
This industry is fundamentally a vendor of company HONDA which provides silencers
used in the assembly of automobile vehicles like Honda CD 70 and Honda 125.
This industry is no doubt giving excellent output to market and having a good image but
within this industry there are a lot of things to bother about, which can not only increase
the productivity but also save cost of labor involved.
Selected machine:
Plate Rolling Machine:
A plate rolling machine is a machine that will roll different kinds of metal sheet into a
round or conical shape. It can be also called a “roll bending machine”, “plate bending
machine” or “rolling machine”
In this machine there are two rollers, one of which can be tilted. The main purpose is to
bending sheets to a curved form. The Sheet Metal, which is to be formed in cylindrical
shape, is present atm the edge by hammering. To start the operation easily and to avoid
flats at the beginning and at the ends of the rolled form. In rolling cylindrical shapes a
gradual curve is to be put in the metal rather than sharp bends. Now the sheet metal is
introduced between the top and the bottom rolls, the gap between the top and bottom
rolls are adjusted as per the required diameter by regulating the screw rods
Current model:
Current flaws and effects:
The bending edge is nit straight and the size is unstable
There are cracks at bending angles.
The bending surface is thinner
The concave part is uneven at bottom.
The axis of holes on two sides are misaligned after bending.
New proposed design:
3rd Roller used to bend the sheets
A sliding bed used to insert the sheets automatically.
And an external link used to take off the rolled sheet from the roller.
Conclusion:
The manual machine is based on old technology and it has some severe errors. So,
there is a great need to improve that machine which will in turn improve the productivity.
The flaws in annual rolling of plates will be improved and the products will be more
satisfactory and labor will be reduced.
To conclude, this project is made keeping in mind that any manually operated machine
can be converted to automatic machines by using pneumatic, electrical and electronic
devices. For these purpose one should have the full know how of the devices which are
being used. By doing so the existing old machines can be modified and made automatic
by which the initial cost, to procure new automatic machines may be minimized. Thus
there is a lot of scope in this area(automation).
Comments:
It is possible to convert this manual machine to automated machine which will have
certain qualities and in this way we can get rid of many issues and errors.
References:
http://www.academia.edu/9325550/Researchpaper_Automation-of-Sheet-Bending-
Machine-Using-Electro-Pneumatic-Devices
https://www.wileymetal.com/2017/06/28/automated-bending-vs-manual-press-brake-
bending/
