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 Hearth Furnace CEW PRT MOC SS 304 Fe C Cr Ni Mn Si P S PLC SMPS ISA LASER i.e. I/O CPU Unmanned Automatic operation of machines Brick lined oven used for heating Conveyors & Engg Works Pulse Ranging Technology Material of Construction Stainless Steel grade 304 Ferrous Carbon Chromium Nickel Manganese Silica Phosphorus Sulphur Programmable Logic Control Switched Mode Power Supply Indian Standard Angles Light amplified for Simulated Emission and Radiation that is input / output Central Processing Unit

List of Figures Fig.No 1 2 3 4 5 6 7 A 8 9 10 11 B 12 13 IX 14 15 Details Manufacturing Feeding conveyor The Tilting Arrangement The Central Moving Rack The Discharge Conveyor Total Assembly The Lifting arrangement The Hydraulic System The Lifting cylinder The Tilting cylinder Push / Pull cylinder Clamping cylinder The Powerpack Circuit of Hydraulic Connections Hydraulic Hose Connections The Sensors Inductive Proximity Sensor Distance Sensor The PLC Control 16 Programmable logic Page No 7 9 9 10 10 10 11 11 11 11 12 12 13 13 13 14 14 15 16 16

List of Figures Fig.No Details Page No

17 18 19 20 21 22

CPU Expansion Module Expansion Module Expansion Module HMI SMPS

17 17 17 18 18 19

List of Tables Table No 6.1 6.2 Details Sequence of Operation Cycle Time Page No 20 21

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TABLE OF CONTENTS Chapter No. a b c d e f 1 2 3 4 5 6 7 8 9 10 11 12. Certificate Abstract Acknowledgments Keywords Abbreviations & Acronyms List of Figures List of Tables Introduction Design Process Description & Operation Engineering (The debottlenecking) Manufacturing Components of System PLC Control Sequence of Operation & Cycle time Assembly and trial run Summary & Conclusion References Checklist 3 4 12 15 18 19 20 21 Description Page No. I II III IV V VI 1 2

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. 2. 3. 4. 5. A fair price Higher quality products and services Delivery Lead time Better presale and after sales service 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.

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 commissioned by the team of CEW developed manufactured, installed and

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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Functionality Strength / stress Distortion / deflection / stiffness Wear Corrosion Safety Reliability Manufacturability Utility Cost Friction Weight Life 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Noise Styling Shape Size Control Thermal Properties Surface Lubrication Marketability Maintenance Volume Liability 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.

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, <0.08% C, 17.5-20% Cr, 8-11% Ni, <2% Mn, <1% Si, <0.045% P, <0.03% S At maximum, 304 stainless can only withstand temperatures up to 1,650 degrees F (899 degrees C). Because of its high heat-resistance, 304 stainless steel is often used in welding projects. So this is the background for selecting SS304 as MOC for parts handling hot components 3. Sensors For the purpose of general sensing we have selected Proximity inductive sensors. We need to place sensors near the clamping cylinder which will hold the hot component. Proximity sensor will not work. Distance sensors are costly. What is the solution? Suddenly one thought came up of mirroring the sensing at the back of the clamping cylinder. But there came a problem of sensing hot components inside the furnace. Proximity sensors cant work near high temperatures. There was no solution other than Distance sensors which were costlier but no way, we opted for it 4. Hydraulic System We had a problem what would be the temperature requirement for Hydraulic seals. The component is above 500C but the seals can withstand only 180C. which the manufacturer of hydraulic system had and available in the market as well. Later searched and found a separate seal manufacturer to manufacture a special seal as per drawing to suit 500C. What about the oil in oil tank? Will it get heated? We opted for water cooling the tank with cooling coils provided 6

Chapter 5 - Manufacturing Special Purpose Machinery - Special Purpose Machinery is designed perform specific operations on one work piece or number of similar units to

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. 2. 3. 4. 5. Product Design and quality level Demand patterns and flexibility needed Capacity considerations Customer Involvement 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.

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

The Aluminum Slab

II. The Tilting Arrangement - Fig - 3

III. The Central Moving Rack Fig 4

IV. The Discharge Conveyor - Fig 5

V. TOTAL ASSEMBLY - Fig 6

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The Lifting arrangement Fig 7

VI. The Hydraulic System A. Cylinders A1.The Lifting cylinder - Fig 8

A2.The Tilting cylinder - Fig 9

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A3.Push / Pull cylinder - Fig 10

A4.Clamping cylinder - Fig 11

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The Powerpack B1.CIRCUIT OF HYDRAULIC CONNECTIONS Fig 12

B2. Fig 13. HYDRAULIC HOSE CONNECTIONS

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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)

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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

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Chapter 7 - PLC Control D.Programmable Logic Control Fig 16

PROGRAMMING SOFTWARE CH1 CH4

CH2

PROCESSOR

CH5

CH3 Input Module Channels

CH6 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.

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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 Humanmachine interaction. This term is system-oriented. it extends the computeroriented 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

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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

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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 2 3 4 conveyor 1 - start conveyor 1 - stop Tilting cylinder 1 - forward Clamping cylinder 3 - closing 5 6 7 Pushing Cylinder 2 - forward 1 Clamping cylinder 2 - closing Tilting cylinder 1 - reverse Pulling Cylinder 3 reverse 1 Pulling Cylinder 4 reverse 1 8 Pushing Cylinder 1 - forward 2 Pushing Cylinder 2 - forward 2 Clamping Cylinder 3 - Open Pulling Cylinder 3 reverse 2 Clamping cylinder 4 - closing Lifting cylinder - up Pulling Cylinder 3 forward Pulling Cylinder 4 forward

Clamping cylinder 1 - Open Clamping cylinder 2 - Open

conveyor 2 start Tilting cylinder 2 - reverse

10 11 12 13 14 15 16 17

Pushing Cylinder 1 - reverse Pushing Cylinder 2 - reverse Lifting cylinder - down conveyor 1 - start conveyor 1 - stop Tilting cylinder 1 - forward Pushing Cylinder 1 - forward 1 Clamping cylinder 1 - closing Tilting cylinder 1 - reverse Lifting cylinder - up Tilting cylinder 2 - forward Clamping Cylinder 4 - Open Pulling Cylinder 4 reverse 2 Tilting cylinder 2 - reverse conveyor 2 stop

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Cycle time - TABLE 6.2

Cycle Time 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Pushing Cylinder 1 - end Pushing Cylinder 2 - end Clamping cylinder 1 - Open Clamping cylinder 2 - Open Pushing Cylinder 1 - end Pushing Cylinder 2 - end Pulling Cylinder 3 home Tilting cylinder 1 - home Pushing Cylinder 1 - home Pushing Cylinder 2 - home Pulling Cylinder 3 reverse 1 Pulling Cylinder 4 reverse 1 Clamping Cylinder 3 - Open Pulling Cylinder 3 reverse 1 Tilting cylinder 1 - end Pushing Cylinder 2 - home Pushing Cylinder 2 - forward 1 Clamping cylinder 2 - closing Tilting cylinder 1 - end Lifting cylinder - home

Lifting cylinder - up conveyor 1 - start Pulling Cylinder 3 home Pulling Cylinder 4 home

conveyor 1 - stop Tilting cylinder 1 - home Pulling Cylinder 3 end Pulling Cylinder 4 end Clamping cylinder 3 - closing Clamping cylinder 4 - closing Pulling Cylinder 3 end Pulling Cylinder 4 end

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Cycle time - TABLE 6.2 Contd.

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Tilting cylinder 1 - home Lifting cylinder - home conveyor 2 - stop Tilting cylinder 1 - end Pushing Cylinder 1 - home Pushing Cylinder 1 - forward 1 Clamping cylinder 1 - closing Tilting cylinder 1 - end Tilting cylinder 2 - home Pulling Cylinder 4 home Tilting cylinder 2 - end conveyor 1 - stop Tilting cylinder 1 - home Tilting cylinder 2 - end Clamping Cylinder 4 - Open Pulling Cylinder 4 reverse 2 conveyor 1 - start Lifting cylinder - home Tilting cylinder 2 - home Pushing Cylinder 1 - home Pushing Cylinder 2 - home Lifting cylinder - end

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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.

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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

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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. 2. 3. 4. 5. 6. Use of technology in Design Various process of design and engineering Simultaneous Engineering Just in time technology Sub-contracting Use of technology in manufacturing

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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

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