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Automation of the Tapping Machine

CAREER Instance 2

INTRODUCTION

CE 2. 1

The second profession episode is based on an experience i gained after accomplishing a group project as students of last semester of Bachelor Level. The job was title "Automation of the Tapping Machine". I completed my Bachelors of Executive Technologist in Mechatronics from Chisholm Institute, Dandenong, Australia. The job was completed in 13 weeks' duration, from March 2016 to May 2016. It had been performed under Prof. Dr. Tharshan Vaithianathan and Prof. Masoud Goudarzi and was a part of my industrial training at R & I Tool and Equipment Co. Pty. Ltd.

BACKGROUND

CE 2. 2 Characteristics of project

Finding a solution that helps you to save cost and time within production is the biggest responsibility of technicians when creation. Automation is necessary in all the industry to boost efficiency, maintain uniformity and rate, reduce misuse, and keeping quality to compete the global market. There were issues arising in tapping and equipment cutting machine which lead to wastage of cost and labor time for the business R & I Australia. To supply a multiple tapping device at a time and to eliminate the manual adjustment procedure for the XY table, I had suggested this project. In my own project, I had developed to perform all the business enterprise goals and objectives assigned if you ask me within defined budget and time parameter. And to lessen the impact within the influenced items to standardized the business operations.

CE 2. 3

The goal of employing the tapping machine is that it:

  • Facilitates coordination and information sharing both internal and exterior to the organizations.
  • Will provide better done products.
  • Enhances the ability and performance of the team to execute their jobs.
  • Easy use
  • Provides an open up, adaptable, reliable updated technology.

CE 2. 4 Objectives

The primary target was to handle the issue of production and present a possible solution that rectifies it and helps to increase the efficiency of the development and specially in conditions of tapping machine and Saws department and to partly optimize the cost. Basically, the whole project is made up of 2 different aims which is completed to resolve the issue. The theory is to attain a high amount of accuracy along the way. Also, to learn about how stepper motors are programmed through G-coding along with the Arduino panel and g shield.

CE 2. 5 The chart of organizational structure

CE 2. 6 Obligations

  • I began with studying various alternatives that fit my problem assertion.
  • I explored and surveyed on automation, gears, latest equipment from FSM & SMC
  • Learnt how CNC shield is controlled and G code is designed.
  • Performed online and practical screening on the operating machine.
  • Compared various components before selecting them.
  • Researched on drive mechanism, stepper motors, wheel shafts and pulleys.
  • Prepared various executive drawing for implementation of my task by making use of engineering tools.
  • Diving and providing time slot machine games to associates.
  • Maintaining balance and peace to avoid discord among each other.
  • Kept good relations with supervisor.
  • Reporting the development of the task to the lab supervisor and coordinator.

PERSONAL ENGINEERING ACTIVITY

CE 2. 7

I first discovered the current situation of the work procedure and the machine operation. Based on my notes, I decided to remove the current manual XY stand along with the vice and put in a new system motorize level. The brand new proposed XY table system will be placed on the base plate of the tapping machine and then further linked to the CNC shield for programming. The table is made so that it keeps few work portions at the same time. After the work piece is held and placed on the table, a G code program controls the tapping operations that is from the USB device linked to the CNC shield. The XY table is designed in sound works such that it goes in X and Y directions. You will discover stepper electric motor drive shafts that are connected and when they rotate it drives the business lead screws connected to it and move the level in X and Y directions.

CE 2. 8

The below image shows the suggested XY table and its own related components. It really is designed keeping in mind the future level of XY desk together with the vice along with the amount of the drill bite. The drill mind is retained and positioned such that the length from the center of the base plate to end in Y axis is 90mm. the stroke movements of the stand in direction of Y axis from the center position is assumed to be 50mm and in direction of X axis it is 100mm. The selection process of XY stand involved selection of steps. In the first level, it was required to take up the measurements of the current create that was used. Later level was designing, that was done to discover various factors that are related to the table.

CE 2. 9

Based on certain assumptions and from the existing scenario, the computations for the factors was done and considered as shown in the stand below. With these prices, selection treatment was completed for various components and its own guidelines. For my job a drive system was required which rotates the electric motor to the stand and helps the XY desk o move, so for this reason I made a decision to use ball screw drive mechanism which is ideal for my situation because of its high stiffness and capacity for brief acceleration and declaration. The motor unit was selected with the help of online software that helps for various calculation. Arduino G shield can be used as it is a suitable hardware solution for CNC movement managed systems. I used anatomist tools for drawing each sturdy work piece and component taking into consideration the minute details and its precise values to attain the highest exactness level.

Maximum payload

Stroke

Precession

Speed

7kg

XY:200mmx180mm

20 microns

max: 25mm/sec

CE 2. 10

After completing these XY table, I needed to automate the rotation of side wheel which manages the vertical movement. And the important point for consideration was the depth of the apparatus cut. So, it was important to keep tabs on the vertical activity of the axis of the machine and solution for updating the manual palm wheel with mechanical automated machine. After all of the brainstorming process, I decided to use pulley belt device utilizing a steeper motor to displace the existing manual hand steering wheel. Employing this, it could provide broadband of production, reliability, it will be time keeping and less labor involvement which would bring about safety.

CE 2. 11

I used CAD software and other executive software to design the composition of the components that will be designed to use predicated on the necessity and calculations adopted. The components were compared for price and the budget was considered. It was necessary to take precaution in selecting the correct component as it could affect the complete system. The components used are:

  • Stepper motor - necessary to produce torque to turn rotating wheel shaft for equipment cutting functions.
  • Small pulley for electric motor - 14mm internal diameter, selected considering the conditions it satisfied.
  • Large pulley for turning steering wheel shaft - 42mm maximum bore diameter
  • Time belt to copy momentum between both pulley - polyurethane cantilena belt was chosen, which got high grade wire and stress with high flank fill capacity.
  • Stepper motor driver - to manage the running capacity of the stepper motor
  • Rotary encoder - it is actually used to find original position of the shaft. It converts mechanical displacement signs to electrical indicators.
  • Arduino plank for programming - Arduino Uno r3

CE 2. 12

After arriving to the conclusions and deciding of the components, I plotted an electrical connection diagram that depicted the structural design of all electrical connections which were required between the Arduino UNO plank, motor, and the power supply to perform this mechanism. The Arduino mother board was linked to the encoded and the motor unit. From your diagram, the pin quantity 8-11 of the mother board are being used for handling the stepper engine. As well as the pins from 2 to 4 are used for encoder. Programming is done to deliver the research data to regulate the motor and encoder. With the help of 5V resource that is received by the UNO table, it supplies the power to the encoder also and both are grounded properly so that same reference point voltage is provided to the encoder and the energy supply.

CE 1. 13

After doing the hardware work and when the bond was completed. I performed a troubleshooting, to check on the functioning of the system is proper. I used a number of engineering software to check the system. Thankfully, I didn't come across any major problems while implantation of the task. I only possessed problems in determined the accurate element that would meet up with the requirements of my project. I also presented new engineering skills and workshops in my own task such as latest equipment's from FSM and SMC, HMI systems, G shield for automatic dispatch, and robotic field reporting software by using interfaces like G-coding, C++, AFR and CAD.

CE 1. 14

As I had been leading the whole project, I was responsible for taking care of my group mates. I needed to regularly keep revisions on their progress and maintain one on one relationship to have success in my task. I also looked after good relationships with my university supervisors and the company engineer under whom I used to be getting trained.

SUMMARY

CE 1. 15

I achieved the goals and targets assigned to me by the company. I provided them a well-planned and working device which would advantage in their production. I applied various anatomist knowledge that I learned from my bachelor's level. I also presented new techniques and device that was beneficial and appropriate for my problem brief summary. I learn new software and learned to prepare a budget and function the project in that assigned budget. I cultured myself in to the corporate and business world and modify corporate patterns and skills. A job thesis and a demonstration of might work was published on conclusion of my work.

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