Design and Development of Automation of
Loading and Unloading to DX-100 CNC Turning
Center
Shivbhadrasinh Jhala Apurva Indrodia
PG Scholar Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering Marwadi Edu. Foundation Rajkot Marwadi Edu. Foundation Rajkot
R.L. Jhala
Principal Faculty of Technology Department of Mechanical Engineering
Abstract
“Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center” This paper involves the use of automation solution to reduce operator fatigue and increase efficiency. Industries in the recent day concentrating on CNC machineries for mass production by replacing conventional lathes to improve productivity, But loading and unloading of job carried over by manual , However Present work, machine tool manufacturer are coming with solutions including automatic loading and unloading to reduce the fatigue of labor and reduce cycle time and increasing productivity. Productivity Improvement on a CNC DX-100 by Automatic Loading and Unloading of Cylindrical Component includes analysis and detailed study of manufacturing process including loading and unloading methods of components on a machine. Present work aims at improving the productivity of cylinder components on a CNC turning center. Here emphasis is placed upon improving the existing time consuming methods.
Keywords: Autoloader, Loading-Unloading, Automation, CNC, DX-100
________________________________________________________________________________________________________
I.
INTRODUCTION
Turning operation is one amongst the foremost basic machining processes. within the family of DX series DX100 is developed for batch kind production in trade. Its incline rigid mono block structure permits high dynamic parameters that absorb torsion and damps vibration therefore guarantee in highest preciseness, metal cutting capability and gear life. There area unit several operations will done by DX100 like Facing, shaping (external shaping and face grooving), tapper turning , parting, boring, drilling, threading. Automation is that the use or introduction of automatic instrumentation during a producing or alternative method or facility.
II.
PROBLEM DEFINITION
In DX 100 Machine loading and unloading Is done by Manually, and manual work manpower Target is to Automation in DX 100 machine,. So By using robotics we can load & unload the components, which in turn reduces the cycle time & also require less labour work. So, we compare the job in less time at high accuracy. Hence we can achieve the goal to reduce the cycle time & increase the productivity.
III.
PROBLEM APPROACH
Existing Scenario: A.
In DX 100 Operator friendly operating controls with simple job loading and unloading facilities. Selecting easy and human ergonomically position labour adjust the distance from the machine and make the manual job loading unloading.In DX 100 machine, for calculating manual loading and unloading time, there is referred a particular job with following dimensions: A cylindrical part with length of 148mm and diameter 0f 20mm
To calculate average time of loading and unloading job in manual operations, there are performed some practical to record their different time of loading-unloading.
Sr
No. operation Time (Approximate) Required Operator
1 Open the door and unload the finished job from chuck 8 to 10 sec 1 2 Put the finished job on table and bring the new job for machining 5 sec 1 3 Load the job in the chuck and close the door and start machining 8 to 10 sec 1
21 to 25 sec by one operator
To calculate average time of loading and unloading job in manual operations, there are performed some practical to record their different time of loading-unloading.
Table – 2
Practical No.
Time for Loading and
Unloading(Approximate) 7 22 sec
1 22 sec 8 28 sec
2 24 sec 9 30 sec
3 21 sec 10 25 sec
4 24 sec Average Time for loading-unloading 24.4 sec ≈ 25 sec
5 23 sec
6 25 sec
So, approximately, total time of finished job = machining time + Loading-unloading time = 1 min 52 sec + 25 sec
= 2 min 17 sec =137 sec According to this time for a single job, Number of finished job per hour = = 26.27 ≈ 26 jobs
So, there are 26 jobs which are completed in one hour.
As working condition of machine, it performs for 22 hour per day in company.
So, total number of finished job per day = number of job per hour * total working hour per day = 26 * 22
= 572 job per day
To calculate average time for loading-unloading per day,
= average time of loading-unloading for single job * number of finished job per day = 25 sec * 572
= 14,300 sec = 238 min 20 sec = 3 hour 58 min 20 sec
So, average time for loading-unloading per day is 3 hour 58 min 20 sec.
Cycle on Each Component: B.
The Auto Loader is one of the equipment which design for DX 100 Turning Machine and it manipulates the human as it is an automatic device. It loads the work pieces on the chuck from the plate and because of that the production rate of DX 100 turning machine can be increased.
IV.
DEVELOPMENT OF LOADING UNLOADING SYSTEM
Turning operation is one amongst the foremost basic machining processes. With in the family of DX series DX100 is developed for batch kind production in trade. Its incline rigid mono block structure permits high dynamic parameters that absorb torsion and damps vibration therefore guaranteeing highest preciseness, metal cutting capability and gear life. There area unit several operations will done by DX100 like Facing, shaping (external shaping and face grooving), tapper turning ,parting, boring, drilling, threading. Automation is that the use or introduction of automatic instrumentation during a producing or alternative method or facility.
Concept of Automation: A.
Fig. 1: Job
Fig. 2: Plate
Design Possibility: Case I: Upper Side of the Chuck: B.
Fig. 3: Upper Side of the Chuck
Design Possibility: Case Ii: Lower Side of the Chuck: C.
Fig. 4: Lower Side of the Chuck
Here, Plate is located at lower side of the chuck. A mechanism like gripper is used to hold job from the plate and to load in the chuck. The path of this mechanism is shown as line diagram in figure 4.4. The path of mechanism is denoted as 1-2-3-4-5.
Design of Autoloader And It’s Assembly Component: D.
Fig. 5: Assembly of Auto Loader
Fig. 6: Exploded View of Auto Loader
Production Time for New Design: E.
Table – 3
Sr. No. Operation Time(Approximate) Required Operator 1 Open the door and unload the finished job from chuck 5 to 6 sec 0 2 Put the finished job on table and bring the new job for machining 2 sec 0 3 Load the job in the chuck and close the door and start machining 5 to 6 sec 0
Total Time( Approximate) 12 to 14 sec
Table – 4
Average Loading Unloading Time for Job
Practical No. Time for Loading and Unloading(Approximate) 6 13
1 13 7 13
2 13 8 13
3 13 9 13
4 13 10 13
5 13 Average Time for loading-unloading 13
So, Average time for loading-unloading is 13 sec.
To calculate production of number of jobs per day, there is taking 1 min 52 sec as machining time for job. Here, machining operation is considered as threading on the job.
So, approximately, total time of finished job = machining time + Loading-unloading time = 1 min 52 sec + 13 sec
= 2 min 17 sec=125 sec According to this time for a single job, Number of finished job per hour =
= 28.8 ≈ 29 jobs
So, there are 29 jobs which are completed in one hour.
As working condition of machine, it performs for 22 hour per day in company.
So, total number of finished job per day = number of job per hour * total working hour per day = 29 * 22
= 638 job per day
To calculate average time for loading-unloading per day,
= average time of loading-unloading for single job by autoloader * number of finished job per day = 13 sec * 638
= 8294 sec = 137 min 14 sec = 2 hour 17 min 14 sec
So, average time for loading-unloading per day is 2 hour 17 min 14 sec.
V.
RESULT AND DISCUSSION
Table – 5 Result and Discussion Sr.
No. Operation Time(Approximate)
Required
Operator Time(Approximate)
Required Operator
1 Open the door and unload the finished job from chuck
with Auto loader Manually
- 0 8 to 10 sec 1
2 Put the finished job on table and bring the new
job for machining - 0 5 sec 1
3 Load the job in the chuck and close the door and
start machining - 0 8 to 10 sec 1
Total Time( Approximate) 12 to 14 sec by one operator 21 to 25 sec by one operator
Average Time for loading-unloading 13 sec 25
total time of finished job 125 sec 137 sec
Number of finished job per hour 29 jobs 26 jobs
finished job per day 638 job per day 572 job per day
average time for loading-unloading per day 2 hour 17 min 14 sec 3 hour 58 min 20sec
VI.
CONCLUSION
Development of automatic loading and unloading arrangement in the in DX 100 reducing Labur cost and total cycle time is minimized also increased productivity. Profit for industry is 638 job instead of 572 job per day using proposed Design of autoloader in particularly DX 100 Machine
ACKNOWLEDGMENT
This Research work grateful to Department of Mechanical Engineering Faculty of PG Studies & Research, MEFGI and Mr Yuvrajsinh Jadeja (Engineer- Customer Solution) &Jyoti CNC Ltd Rajkot for necessary Experimental facilities and all testimonial provided for make successful Research.
REFERENCES
[1] Arun S, Sree Rajendra and Vijayavithal Bongale, “Automatic Punching Machine: A Low Cost Approach”, in International Journal of Advanced Mechanical Engineering 2014.
[2] Karan Sharma, Naik Nitesh, Arun Prabhu and George Verghese, “Setup Time Reduction for CNC Hobbing machine Implementing SMED snd Design of Split Fixture”, in 6th SARC-IRF International Conference, 2014.
[3] Sandeep Soni & Ravindra Mane, “Design & Modelling for Fixture for cylinder liner Honing operation by Automatic Loading & Unloading Device”, in 2013.
[4] Sandeep S and K. R. Prakash, “Automation of Loading and Unloading to CNC Turning Centre”, in International Journal on Mechanical Engineering and Robotics 2013.
[5] Prof. P.R. Sawant, Mr. R. A.Barawade, “Design and Development of SPM-A Case Study In Multi Drilling and Tapping Machine”, in International Journal of Advanced Engineering Research and Studies, 2012.
[6] Patel C H, Mohan Kumar G C, “Low Cost Automation for CNC Machining Center”, in International Journal Of Mechanical Engineering And Technology 2012.
[7] Rohan Kulkarni, Mr. S. Shivkumar & Roopa K. Rao, “Productivity Improvement on a CNC Lathe by Automatic Loading and Unloading of Throttle Valve Component”, in December 2011.
