Automation of the Tapping Machine

Automation of the Tapping MachineCAREER EPISODE 2INTRODUCTIONCE 2.1The second c areer episode is based on an experience that I gained after performing a group encounter as a pupil of last semester of Bachelor Degree. The project was title Automation of the Tapping Machine. I completed my Bachelors of Engineering Technologist in Mechatronics from Chisholm Institute, Dandenong, Australia. The project was completed in 13 weeks duration, from borderland 2016 to May 2016. It was under understandn under Prof. Dr. Tharshan Vaithianathan and Prof. Masoud Goudarzi and was a part of my industrial training at R I Instrument and Gear Co. Pty. Ltd.BACKGROUNDCE 2.2 Nature of project Finding a solution that saves cost and sequence within production is the biggest responsibility of engineers when manufacturing. Automation is required in all the industry to remedy efficiency, note consistency and speed, reduce waste, and maintaining quality to compete the global market. There were issues arisi ng in tapping and gear cutting machine which lead to wastage of cost and labor time for the keep company R I Australia. To provide a multiple tapping de criminality at a time and to eliminate the manual adjustment process of the XY table, I had proposed this project. In my project, I had to accomplish all the pedigree goals and objectives assigned to me within defined budget and time parameter. And to minimize the impact within the affected units to standardized the business operations.CE 2.3The goal of implementing the tapping machine is that itFacilitates coordination and information sharing both internal and external to the organizations.Will provide better finished products.Enhances the ability and effectiveness of the police squad to perform their jobs.Easy useProvides an open, flexible, reliable updated technology.CE 2.4 ObjectivesThe primary objective was to address the issue of production and give a possible solution that rectifies it and serve ups to improve the effici ency of the production and specially in terms of tapping machine and Saws department and to partially optimize the cost. Basically, the whole project is do up of 2 mingled objectives which is completed to solve the issue. The idea is to achieve a eminent degree of accuracy in the process. Also, to learn about how stepper motors are programmed through G-coding along with the Arduino board and g shield.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, modish equipment from FSM SMCLearnt how CNC shield is operated and G code is programmed.Performed online and practical testing on the operating machine.Compared various components before selecting them.Researched on drive mechanism, stepper motors, wheel shafts and pulleys.Prepared various engineering drawing for implementation of my project with the help of engineering tools.Diving and providing time slot s to team members.Maintaining balance and peace to avoid conflict among each other.unplowed cheeseparing relations with supervisor.Reporting the development of the project to the lab supervisor and coordinator.PERSONAL ENGINEERING ACTIVITYCE 2.7I first observed the up-to-date scenario of the work procedure and the machine operation. Based on my notes, I decided to remove the current manual XY table along with the vice and add a new system motorize stage. The new proposed XY table system will be placed on the base plate of the tapping machine and then besides connected to the CNC shield for programming. The table is made such that it holds few work pieces at the same time. Once the work piece is kept and placed on the table, a G code program controls the tapping operations that is obtained from the USB device connected to the CNC shield. The XY table is foundationed in solid works such that it moves in X and Y directions. There are stepper motor drive shafts that are connected an d 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 head is kept and positioned such that the distance from the middle of the base plate to end in Y axis vertebra of rotation 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. by and by stage was designing, which was done to find out various variables that are related to the table.CE 2.9Based 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 values, 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 short acceleration and declaration. The motor was selected with the help of online software system that helps for various calculation. Arduino G shield is used as it is a suitable hardware solution for CNC motion 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.upper limit payloadStrokePrecessionSpeed7kgXY200mmx180mm20 micronsmax 25mm/secCE 2.10 aft(prenominal) completing the above XY table, I had to automate the rotation of fall in wheel which controls the vertical movement. And the important 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 substitution the manual hand wheel with mechanical automated machine. After all the brainstorming process, I decided to use pulley belt mechanism utilise 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 motor required to produce torque to override rotating wheel shaft f or gear cutting operations.Small pulley for motor 14mm inner diameter, selected considering the conditions it met.Large pulley for turning wheel shaft 42mm maximum calibre diameterTime belt 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 lord position of the shaft. It converts mechanical displacement signals to electrical signals.Arduino board for programming Arduino Uno r3CE 2.12After coming to the conclusions and deciding of the components, I plotted an electrical connection plat that depicted the structural layout of all the electrical connections that were required between the Arduino UNO board, motor, and the power supply to run this mechanism. The Arduino board was connected to the encoded 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 regulate the motor and encoder. With the help of 5V supply that is received by the UNO board, it supplies the power to the encoder also and both are grounded properly so that same reference voltage 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 come across any major issues while implantation of the project. I only had problems in decided the accurate component that would brook the requirements of my project. I also introduced new engineering skills and workshops in my project such as latest equipments from FSM and SMC, HMI systems, G shield for automated dispatch, and automated field account softw are 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 maintained good relations with my university supervisors and the company engineer under whom I was getting 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 applied various engineering knowledge that I learnt from my bachelors degree. I also introduced new techniques and mechanism that was beneficial and prehend for my problem summary. I learn new software and learned to prepare a budget and function the project in that assigned budget. I genteel myself into the corporate world and adapt corporate behavior and skills. A project thesis and a presentation of my work was submitt ed on completion of my work.