International Journal of Mechanical Handling and Automation vol 2 issue 1 by JournalsPub

Office No-4, 1 Floor, CSC, Pocket-E, 6 Mayur Vihar, Phase-2, New Delhi-110091, India 1 t E-mail: info@journalspub.com 0 2 mi icle b rt u S A Mechanical Engineering Applied Mechanics r International Journal of Electro Mechanics and International Journal of Thermal Energy and u Mechanical Behaviour Applications International Journal of Machine Design and International Journal of Production Engineering Yo «

« « «

¬ ¬ International Journal of Industrial Engineering

Manufacturing International Journal of Mechanical Dynamics and Analysis International Journal of Fracture and damage Mechanics International Journal of Structural Mechanics and Finite Elements

and Design ¬ International Journal of Manufacturing and

Materials Processing ¬ International Journal of Mechanical Handling and

Automation 5 more...

Electronics and Telecommunication « International Journal of Radio Frequency Design « International Journal of VLSI Design and Technology « International Journal of Embedded Systems and Emerging

Technologies « International Journal of Digital Electronics « International Journal of Digital Communication and Analog

Chemical Engineering « International Journal of Renewable Energy and its

Commercialization « International Journal of Environmental Chemistry « International Journal of Agrochemistry « International Journal of Prevention and Control of Industrial

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Signals

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« International Journal of Housing and Human Settlement

Planning « International Journal of Architecture and Infrastructure

Planning « International Journal of Rural and Regional Planning

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Development

International Journal of Water Resources Engineering International Journal of Concrete Technology International Journal of Structural Engineering and Analysis International Journal of Construction Engineering and Planning

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Computer Science and Engineering International Journal of Wireless Network Security International Journal of Algorithms Design and Analysis International Journal of Mobile Computing Devices International Journal of Software Computing and Testing International Journal of Data Structures and Algorithms 5 more...

International Journal of Analog Integrated Circuits International Journal of Automatic Control System International Journal of Electrical Machines & Drives International Journal of Electrical Communication Engineering « International Journal of Integrated Electronics Systems and 4 more... Circuits « « « «

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IJMHA

Material Sciences and Engineering

International Journal of Immunological Nursing International Journal of Cardiovascular Nursing International Journal of Neurological Nursing International Journal of Orthopedic Nursing International Journal of Oncological Nursing

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International Journal of Energetic Materials International Journal of Bionics and Bio-Materials International Journal of Ceramics and Ceramic Technology International Journal of Bio-Materials and Biomedical Engineering 4 more...

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International Journal of Photochemistry International Journal of Analytical and Applied Chemistry International Journal of Green Chemistry International Journal of Chemical and Molecular Engineering 3 more...

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Biotechnology « International Journal of Industrial Biotechnology and « « « «

Mechanical Handling & Automation

Civil Engineering

Architecture

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International Journal of

Pollution

Biomaterials International Journal of Plant Biotechnology International Journal of Molecular Biotechnology International Journal of Biochemistry and Biomolecules International Journal of Animal Biotechnology and 3 more... Applications

Nanotechnology « International Journal of Applied Nanotechnology « International Journal of Nanomaterials and Nanostructures « International Journals of Nanobiotechnology

Chemistry

Physics « International Journal of Solid State Materials « International Journal of Optical Sciences

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Jan – Jun 2016

International Journal of Mechanical Handling and Automation International Journals Publisher

JournalsPub is a multi-disciplinary international journal boosting innovative & eminence research work by Division of Dhruv Infosystems Pvt. Ltd. Launched in 2014 under the support and guidance by our Honorable Editorial Board Members from renowned institutes.

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International Journal of Mechanical Handling and Automation

International Journal of Mechanical Handling and Automation provides a forum for publishing original research articles, comprehensive or interdisciplinary reviews on the topics of utmost importance. The journal promotes the exchange of ideas and communicates significant findings of recent or immediate importance that interests the researcher and also contributes to the formative research that is capable of shaping the society. The journal ensures that the experimental and theoretical work under its scope is given equal importance.

Focus and Scope of the Journal !

Design of machine elements,

! Computer Integrated Manufacturing and Robotics ! Control panel design and build ! Control panel modification ! MCC Building ! Electrical Wiring Drawings using AutoCAD ! PLC Programming ! HMI design and programming ! Robot control programming ! Machine safety systems ! Mobile Elevated Work Platform ! Safe Loading And Lashing

International Journal of Mechanical Handling and Automation is published twice a year (bi-annual) by JournalsPub an imprint of Dhruv Infosystems Pvt. Ltd., India. The outlooks stated in the articles do not essentially reflect of the publisher. The publisher does not endorse the quality or value of the advertised/sponsored products described therein. Please consult full prescribing information before issuing a prescription for any products mentioned in this publication. No part of this publication may be reproduced, stored in retrieval or transmitted in any form without written permission to the publisher. To cite any of the material contained in this journal, in English or translation, please use the full English reference at the beginning of each article. To reuse any of the material, please contact JournalsPub (info@journalspub.com).

PUBLICATION MANAGEMENT TEAM

Chairman Mr. Puneet Mehrotra Managing Director, JournalsPub, New Delhi

INTERNAL MEMBERS

Associate Manager Hidam Renubala

Commissioning Editors Ankita Singh

Priyanka Garg

Akanksha Marwah

Chhavi Goel

Deepika Bhadauria

Shrawani Verma

EDITORIAL BOARD MEMBERS Dr. V. Sugumaran School of Mechanical Engineering and Building Sciences, VIT University, India

Dr. S. Ramabalan Department of Mechanical Engineering, E. G. S. Pillay Engineering College, Nagapattinum, (Tamil Nadu), India

Dr. Mark Ovinis Department of Mechanical Engineering Universiti Teknologi Petronas, Bandar Seri Iskandar, Perak, Malaysia

Dr. M. Syed Ali Department of Mathematics, Thiruvalluvar University Vellore, Tamil Nadu, India

Dr. Dinesh Singh G. Thakur Department of Mechanical Engineering, Defence Institute of Advanced Technology, DRDO, Ministry of Defence, Girinagar, Pune, India

Dr. Wilson Udo Udofia Department of Technical Education, State College of Education, Afaha Nsit, Akwa Ibom State, University of Uyo, Nigeria

From the Editor's Desk Dear Readers, We would like to present, with great pleasure, the inaugural volume of a new scholarly journal, International Journal of Mechanical Handling and Automation. This journal is part of the Engineering Sciences, and is devoted to the scope of present Mechanical Handling and Automation from theoretical aspects to application-dependent studies and the validation of emerging technologies. This new journal was planned and established to represent the growing needs of Mechanical Handling and Automation as an emerging and increasingly vital field, now widely recognized as an integral part of scientific and technical investigations. Its mission is to become a voice of the Engineering Science community, addressing researchers and practitioners in this area. The core vision of International Journal of Mechanical Handling and Automation in Journals Pub is to propagate novel awareness and know-how for the profit of mankind ranging from the academic and professional research societies to industry practitioners in a range of topics in Automation in general. Journals Pub acts as a pathfinder for the scientific community to published their papers at excellently, welltime & successfully. International Journal of Mechanical Handling and Automation focuses on original high-quality research in the realm of Design of machine elements, Computer integrated manufacturing and robotics, Control panel design and build, Control panel modification, Electrical wiring drawings using autocad, Robot control programming etc. The Journal is intended as a forum for practitioners and researchers to share the techniques of Mechanical Handling and Automation and solutions in the area. Many scientists and researchers have contributed to the creation and the success of the Mechanical Handling and Automation community. We are very thankful to everybody within that community who supported the idea of creating an innovative platform. We are certain that this issue will be followed by many others, reporting new developments in the field of Mechanical Handling and Automation. This issue would not have been possible without the great support of the Editorial Board members, and we would like to express our sincere thanks to all of them. We would also like to express our gratitude to the editorial staff of Journals Pub, who supported us at every stage of the project. It is our hope that this fine collection of articles will be a valuable resource for engineering readers and will stimulate further research into the vibrant area of Mechanical Handling and Automation. Puneet Mehrotra Managing Director

Contents 1. Enhancing Stiffness of Caliper Bracket on Four Wheeler Disc Brake R. Srisaanth, M. Balamurugan

2. Implementation of Machinery Failure Mode and Effect Analysis for CNC Machines in Valve Manufacturing Industry R.K. Salvi, C. Agarwal, B.P. Nandawana, M.A. Saloda

3. Review on the Use of PLCs in Control System Education S. Sharmila, T. Devi, P. Garg

4. Research Insight: Guidelines for Mechanical Handling Applications Himanshu Garg

5. Research Insight: Developments in Automation Priyanka Garg

International Journal of Mechanical Handling and Automation Vol. 2: Issue 1

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Enhancing Stiffness of Caliper Bracket on Four Wheeler Disc Brake R. Srisaanth, M. Balamurugan Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, Tamil Nadu, India

Abstract Brakes are most important component of any vehicle. The disc brakes are used in rear wheel brakes of four wheelers to provide better braking. These disc brakes contain brake caliper brackets to hold the pads of the brakes. These caliper bracket must withstand the forces generated during braking and also should withstand heavy load during emergency or sudden braking. These caliper brackets must possess high stiffness to resists deformation due to load applied which leads to crack development. Due to low stiff materials used in brackets leads to squeal which is another major concern. Hence in this paper the existing caliper bracket is analyzed for its static strengths using ANSYS depending upon the loading conditions and improvement is made on the bracket according to the results obtained. Keywords: deformation, stiffness, Young’s modulus

INTRODUCTION Disc brakes are most common in four wheelers to make braking precise and to gain good stopping force. One of the important parts in disc brake is brake caliper where caliper bracket is used. In brake caliper the hydraulic pressure pushes out one of the piston. This causes the outer portion of the caliper and the piston to squeeze the rotor between two brake pads. The frictional forces which are produced are conveyed at this pad interface. Fig. 1. Brake Caliper Bracket. A caliper bracket holds the pads and attaches the caliper to the spindle. Thus, the caliper bracket must withstand all the braking forces at the wheel under heavy braking. It should not over deflect while withstanding the forces. If the stiffness of the bracket reduces large deformations occurs and even a structural failure. After large deformation, cracks will begin to appear soon after fracture. Material with low stiffness will cause brake squeal. [1–3]

MODEL DEVELOPMENT The 3D model of the caliper bracket is developed in SolidWorks using the measurement taken. The model developed is shown in Figure 1. The material used for making the caliper bracket is Aluminum 7075.

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International Journal of Mechanical Handling and Automation Vol. 2: Issue 1

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Implementation of Machinery Failure Mode and Effect Analysis for CNC Machines in Valve Manufacturing Industry R.K. Salvi*, C. Agarwal, B.P. Nandawana, M.A. Saloda Department of Mechanical Engineering, College of Technology and Engineering, Maharana Pratap University of Agriculture and Technology, Udaipur, Rajasthan, India

Abstract Failure Mode and Effects Analysis (FMEA) is a pro-active quality tool for evaluating potential failure modes and their reasons. It helps to prioritization of the failure modes and to corrective measures for the avoidance of cataclysmic failures and improvement of the quality. In this paper, an attempt has been made to implement machinery FMEA in valves manufacturing unit of GG Valves, Udaipur, Rajasthan, India. The failure modes and their causes identifying for all CNC machines, the three key indices (Severity (S), Occurrence (O) and Detection (D)) we reassessed and the statistical analysis of failures was carried out with help of Machinery Failure Mode and Effects Analysis (MFMEA) worksheet. Finally, the necessary corrective actions were recommended. Keywords: CNC machine failures, MFMEA, RPN, severity, occurrence, detection

INTRODUCTION Failure data of CNC machine in GG Valves industry is the basis of this work, as a data source where the CNC machines are being used for the machining of the valves. This work aims to identify the problems in manufacturing and maintenance, especially in manufacturing stage takes corrective actions, so that the reliability of the machine can be maintained. The Failure Mode and Effect Analysis (FMEA) approach helps in identification of occasions of malfunction of equipments. FMEA shows the causes and effects of potential failure modes. It also helps to identify the occurrence of failures in CNC machines. This technique was firstly used by NASA in 1960s. The first applications in automotive industry were held by Ford Motor Company. This method enables the

manufacturing process to increase its efficiency. The FMEA identifies the corrective measures and possible failure modes by prioritization of possible failure modes with the help of a template. [1] There are many other advantages of FMEA as given below:  Identify and prevent safety hazards  Minimize loss of product performance or performance degradation  Improve test and verification plans  Improve process control plans  Consider changes to the product design or manufacturing process  Identify significant product or process characteristics  Develop preventive maintenance plans for in-service machinery and equipment  Develop online diagnostic techniques

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International Journal of Mechanical Handling and Automation Vol. 2: Issue 1

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Review on the Use of PLCs in Control System Education S. Sharmila*, T. Devi, P. Garg University of Madras, Tamil Nadu, India

Abstract The paper reviews the previous researches devoted to control system education. It shows how academic institutions are utilizing PLCs in education and how it can complement the traditional focus on continuous-based control. A key objective of this paper is to review the PLC use in mechanical engineering education, which traditionally takes place in a control systems engineering course. This paper will also address a proposal by the authors that implementing PLCs into a control systems course for mechanical engineering students can enable a natural integration of continuous and non-continuous control theory. Keywords: control system, automation, PLC, education, laboratory, controller

INTRODUCTION Automation plays great role in contemporary industries. Through the twentieth century it has been evolved from simple sequential control to the complicated electronics systems. Today it is hard to imagine a factory without robots, numerically controlled machines and programmable logic controllers (PLC). Traditional control systems engineering courses focus on the theory and mathematics of continuous-based control systems and rarely involve the use of PLCs, which provide an excellent platform to teach feedback control. Only a few programs have included a specific focus on non-continuous (on/off) control commonly used in industrial environments.

Engineering control problems can generally be categorized solely or as a combination of the following three ways: 1. Continuous Linear – these systems can be described by linear differential equations, and exact equations can be used to design controllers.

2. Continuous Non-linear – these systems can be described with differential equations that are nonlinear, and the controllers can be designed with some effort. In some systems differential equations are not available, forcing reliance on other methods, such as heuristic rules. 3. Non-continuous – these systems have discrete states and are characterized with on/off transitions of inputs and outputs. Logical decisions are required to control the system. Control Systems Engineering is traditionally seen as a “dry” course by students with a mechanical concentration. The popular textbooks on the subject are meant for a more general engineering student audience, cover the theory that is typically associated with the subject, and focus mainly on continuous linear controls. A few industrial, chemical, and electrical engineering as well as various technology programs have included some introduction to PLCs into their programs, where they are often presented as part of

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International Journal of Mechanical Handling and Automation Vol. 2: Issue 1

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Research Insight: Guidelines for Mechanical Handling Applications Himanshu Garg* IEET, Baddi, H. P. University, Shimla, India

INTRODUCTION Handling materials shouldn’t cause injuries or fatalities. Nor should it be a back-breaking job. Failing to protect workers from either mechanical or manual material handling injuries can be costly. Items being lifted or mechanically handled have the potential to cause serious injury. This has been seen in the last few years where a number of fatalities and serious accidents have occurred during lifting and mechanical handling operations. As a result of this, there is a strong desire within the oil and gas industry to improve the safety performance of such operations. To achieve this aim, a work group was established to produce these Lifting and Mechanical Handling Manual handling injuries are among the most commonly sustained by people at work, and mechanical handling aids are often used to help prevent such injuries. Numerous types of equipment are available to help with the task of handling goods, and whenever reasonably practicable, mechanical handling systems should be used in preference to manual handling by people. The main types of mechanical handling are: • conveyorised systems • elevators (escalators, lifts and moving walkways) • internal workplace transport • goods vehicles • other mechanical handling products

The guidelines define the responsibilities, training, competencies and assessment of those involved in lifting and mechanical handling operations, and set out a structured approach to ensure that such operations are systematically planned and carried out safely. They also provide examples of key documents such as lift plans and checklists which can be used where no similar document exists or to benchmark those that do. These guidelines are therefore aimed at all personnel involved in lifting and mechanical handling operations, particularly those who plan these operations and the supervisors of those personnel performing them. This Guide addresses the requirements for the safe use of conveying equipment and mobile handling equipment of various types, but does not address lifting equipment and operations. THE LAW RELATING TO MECHANICAL HANDLING The following legislation applies to mechanical handling operations: •

•

‘Health and safety at work etc act 1974’ – this deals with the general duties of employers and employees, and designers etc of equipment and installations. ‘Provision and use of work equipment regulations 1998’ – the main legislation relating to mechanical handling equipment.

Mechanical Handling Guidelines

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International Journal of Mechanical Handling and Automation Vol. 2: Issue 1

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Research Insight: Developments in Automation Priyanka Garg University of Madras, Tamil Nadu, India

BACKGROUND Automated systems are usually required to interact with humans in some way. For example, an automatic bank teller machine must receive instructions from customers and act accordingly. In some automated systems, a variety of different instructions from humans is possible, and the decisionmaking capability of the system must be quite sophisticated in order to deal with the array of possibilities. This article covers the fundamentals of automation, including its historical as well as modern development. Also, a brief description is presented on the development of robotics as a part of modern automation technology. The term automation was coined in the automobile industry about 1946 to describe the increased use of automatic devices and controls in mechanized production lines. The origin of the word is attributed to D.S. Harder, an engineering manager at the Ford Motor Company at the time. The term is used widely in a manufacturing context, but it is also applied outside manufacturing in connection with a variety of systems in which there is a significant substitution of mechanical, electrical, or computerized action for human effort and intelligence.

In general usage, automation can be defined as a technology concerned with performing a process by means of programmed commands combined with automatic feedback control to ensure proper execution of the instructions. The resulting system is capable of operating without human intervention. The

development of this technology has become increasingly dependent on the use of computers and computer-related technologies. Consequently, automated systems have become increasingly sophisticated and complex. Advanced systems represent a level of capability and performance that surpass in many ways the abilities of humans to accomplish the same activities. HISTORICAL DEVELOPMENT OF AUTOMATION The technology of automation has evolved from the related field of mechanization, which had its beginnings in the Industrial Revolution. Mechanization refers to the replacement of human (or animal) power with mechanical power of some form. The driving force behind mechanization has been humankind’s propensity to create tools and mechanical devices. Some of the important historical developments in mechanization and automation leading to modern automated systems are described here. Early Developments The first tools made of stone represented prehistoric man’s attempts to direct his own physical strength under the control of human intelligence. Thousands of years were undoubtedly required for the development of simple mechanical devices and machines such as the wheel, the lever, and the pulley, by which the power of human muscle could be magnified. The next extension was the development of powered machines that did not require human strength to operate. Examples of these machines include waterwheels,

Page 24

« « «

¬ ¬ International Journal of Industrial Engineering

Manufacturing International Journal of Mechanical Dynamics and Analysis International Journal of Fracture and damage Mechanics International Journal of Structural Mechanics and Finite Elements

and Design ¬ International Journal of Manufacturing and

Materials Processing ¬ International Journal of Mechanical Handling and

Automation 5 more...

Electronics and Telecommunication « International Journal of Radio Frequency Design « International Journal of VLSI Design and Technology « International Journal of Embedded Systems and Emerging

Technologies « International Journal of Digital Electronics « International Journal of Digital Communication and Analog

Chemical Engineering « International Journal of Renewable Energy and its

Commercialization « International Journal of Environmental Chemistry « International Journal of Agrochemistry « International Journal of Prevention and Control of Industrial

5 more...

Signals

1 more...

« International Journal of Housing and Human Settlement

Planning « International Journal of Architecture and Infrastructure

Planning « International Journal of Rural and Regional Planning

« « « «

Development

« International Journal of Town Planning and Management

2 more...

Electrical Engineering

Nursing « « « « «

IJMHA

Material Sciences and Engineering

« « « «

5 more...

Biotechnology « International Journal of Industrial Biotechnology and « « « «

Mechanical Handling & Automation

Civil Engineering

Architecture

« « « « «

International Journal of

Pollution

Nanotechnology « International Journal of Applied Nanotechnology « International Journal of Nanomaterials and Nanostructures « International Journals of Nanobiotechnology

Chemistry

Physics « International Journal of Solid State Materials « International Journal of Optical Sciences

www.journalspub.com

Jan – Jun 2016