Automation of the Tapping Machine

mechanization of the Tapping MachineCAREER EPISODE 2INTRODUCTIONCE 2.1The second carg unrivalledr episode is establish on an experience that I gained after performing a group design as a student of last semester of Bachelor Degree. The cipher was human action Automation of the Tapping Machine. I completed my Bachelors of Engineering Technologist in Mechatronics from Chisholm Institute, Dandenong, Australia. The date was completed in 13 weeks duration, from March 2016 to May 2016. It was undertaken under Prof. Dr. Tharshan Vaithianathan and Prof. Masoud Goudarzi and was a part of my industrial training at R I means and Gear Co. Pty. Ltd.BACKGROUNDCE 2.2 Nature of tolerate Finding a solution that saves cost and clipping at bottom production is the biggest responsibility of engineers when manufacturing. Automation is call for in all the industry to improve efficiency, maintain congruity and speed, reduce waste, and maintaining quality to compete the global market. There were issues arising in tapping and gearing faux pas machine which lead to wastage of cost and labor time for the society R I Australia. To provide a multiple tapping device at a time and to eliminate the manual adjustment process of the XY get across, I had proposed this project. In my project, I had to accomplish all the business goals and objectives assigned to me within defined budget and time parameter. And to minimize the impact within the impact units to standardized the business operations.CE 2.3The goal of implementing the tapping machine is that itFacilitates coordination and information shargon-out both internal and external to the organizations.Will provide better holy products.Enhances the ability and effectiveness of the team to perform their jobs.Easy useProvides an open, flexible, undeviating updated technology.CE 2.4 ObjectivesThe primary objective was to address the issue of production and break down a possible solution that rectifies it and helps to improve th e efficiency of the production and curiously in terms of tapping machine and Saws department and to partially optimize the cost. Basically, the strong project is made up of 2 different objectives which is completed to act the issue. The idea is to achieve a high degree of accuracy in the process. Also, to learn about how stepping motor motors are programmed through G-coding along with the Arduino notice and g epidermis.CE 2.5 The chart of organizational structureCE 2.6 Duties I started with studying various solutions that fit my problem statement.I researched and surveyed on automation, gears, up-to-the-minute equipment from FSM SMCLearnt how CNC screen is operated and G code is programmed.Performed online and practical testing on the run machine.Compared various components before selecting them.Researched on advertise mechanism, stepper motors, wheel shafts and pulleys. hustling various engineering science drawing for implementation of my project with the help of engine ering tools.Diving and providing time slots to team members.Maintaining balance and peace to avoid participation among each other.Kept good relations with supervisor.Reporting the development of the project to the lab supervisor and coordinator.PERSONAL ENGINEERING ACTIVITYCE 2.7I first observed the current scenario of the work procedure and the machine operation. base on my notes, I decided to remove the current manual XY shelve along with the vice and add a smart system fit stage. The youthful proposed XY remand system will be placed on the base plate of the tapping machine and then further connected to the CNC shield for programming. The send back is made such that it holds few work pieces at the akin time. Once the work piece is kept and placed on the get across, a G code program controls the tapping operations that is obtained from the USB device connected to the CNC shield. The XY table is designed in unassailable works such that it moves in X and Y directions. Ther e are stepper motor pull shafts that are connected and when they rotate it drives the lead screws connected to it and move the stage in X and Y directions.CE 2.8The below image shows the proposed XY table and its related components. It is designed keeping in mind the future height of XY table together with the vice along with the length of the drill bite. The drill manoeuver is kept and flecked such that the distance from the middle of the base plate to fire in Y axis is 90mm. the stroke movement of the table in the direction of Y axis from the center position is assumed to be 50mm and in the direction of X axis it is 100mm. The selection procedure of XY table involved range of steps. At the first stage, it was required to take up the measurements of the current set up that was in use. Later stage was designing, which was through to find out various variables that are related to the table.CE 2.9 found on certain assumptions and from the current scenario, the calculations for the variables was done and considered as shown in the table below. With these value, selection procedure was carried out for various components and its parameters. For my project a drive mechanism was required which rotates the motor to the table and helps the XY table o move, so for this reason I decided to use ball screw drive mechanism which is ideal for my situation because of its high stiffness and ability for shortly acceleration and declaration. The motor was selected with the help of online computer bundle that helps for various calculation. Arduino G shield is apply as it is a suitable hardware solution for CNC interrogation controlled systems. I made use of engineering tools for drawing each solid work piece and component considering the minute details and its precise values to achieve the highest accuracy level.Maximum pay weightStrokePrecession step on it7kgXY200mmx180mm20 micronsmax 25mm/secCE 2.10 subsequently completing the preceding(prenominal) XY table, I had to automate the rotation of passel wheel which controls the perpendicular movement. And the weighty point for consideration was the depth of the gear cut. So, it was important to track the vertical movement of the axis of the machine and solution for replacing the manual hand wheel with mechanical automated machine. After all the brainstorming process, I decided to use pulley hit mechanism using a steeper motor to replace the current manual hand wheel. By using this, it would provide high speed of production, accuracy, it will be time saving and less labor involvement which would result in safety.CE 2.11I used CAD software and other engineering software to design the structure of the components that will be made to use based on the requirement and calculations taken up. The components were compared for price and the budget was kept in mind. It was necessary to take precaution in selecting the correct component as it would affect the whole system. The components used areStepper moto r required to produce torque to turn rotating wheel shaft for gear cutting operations.Small pulley for motor 14mm inner diameter, selected considering the conditions it met.Large pulley for number wheel shaft 42mm maximum bore diameterTime rap to transfer momentum between both pulley polyurethane cantilena belt was chosen, which had high grade wire and tension with high flank load capacity.Stepper motor driver to manage the running capacity of the stepper motorRotary encoder it is basically used to detect original position of the shaft. It converts mechanical displacement signals to electrical signals.Arduino get along with for programming Arduino Uno r3CE 2.12After coming to the conclusions and deciding of the components, I plotted an electrical alliance plot that depicted the structural layout of all the electrical connections that were required between the Arduino UNO board, motor, and the actor supply to run this mechanism. The Arduino board was connected to the enc oded and the motor. From the diagram, the pin number 8-11 of the board are used for controlling the stepper motor. And the pins from 2 to 4 are used for encoder. Programming is done to deliver the reference data to foil the motor and encoder. With the help of 5V supply that is received by the UNO board, it supplies the power to the encoder in like manner and both are grounded properly so that same reference potency is provided to the encoder and the power supply.CE 1.13After completing the hardware work and when the connection was completed. I performed a troubleshooting, to check the functioning of the mechanism is proper. I used many different engineering software to test the system. Luckily, I didnt distinguish across any major issues while implantation of the project. I unaccompanied had problems in decided the accurate component that would meet the requirements of my project. I too introduced new engineering skills and workshops in my project such as up-to-the-minute equ ipments from FSM and SMC, HMI systems, G shield for automated dispatch, and automated field reporting software by using interfaces like G-coding, C++, AFR and CAD.CE 1.14As I was leading the whole project, I was responsible for managing my group mates. I had to regularly keep updates on their progress and maintain one on one relationship to achieve success in my project. I also hold good relations with my university supervisors and the company engineer under whom I was acquire trained.SUMMARYCE 1.15I accomplished the goals and objectives assigned to me by the company. I presented them a well-planned and working device which would benefit in their production. I use various engineering knowledge that I learnt from my bachelors degree. I also introduced new techniques and mechanism that was beneficial and appropriate for my problem summary. I learn new software and learned to prepare a budget and function the project in that assigned budget. I cultured myself into the corporate worl d and admit corporate behavior and skills. A project thesis and a introduction of my work was submitted on completion of my work.