CHAPTER 1 INTRODUCTION

 The designer should make the machine as reliable as reasonably possible to

minimize the maintenance requirement and allow for long intervals between

routine maintenance tasks. It is also important to design the machine and its

control system so that maintenance can be carried out safely.

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 For example, hold-to-run controls can be installed that allow a machine to be

run at a reduced speed, or removable tool holders can be used so that sharp

blades can be replaced on a workbench instead of in an difficult position

inside a machine. In addition, operators and maintenance technicians must

be discouraged from bypassing safety equipment.

 Safety components are often designed to interrupt processes in the event of a

fault and will have an impact on machine availability. In order to minimize

this effect - and the temptation to interfere with the safety circuits - high-

reliability safety components should be specified so as to keep the number of

nuisance faults at a minimum.

 Designing safety into a new machine is important, but it has to be

remembered that the vast majority of machines do not remain unaltered,

with unchanged operating procedures, for their entire lifetime.

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 CHAPTER - 2 PROBLEM DEFINITION

 PROBLEM SUMMARY

 NEED FOR SAFETY SYSTEM IN MACHINERY

 Modifications are almost inevitable and working practices can evolve or be

deliberately revised by managers in an attempt to improve throughput. Any

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 changes made to the machine or the way it is operated also changes the

original risk assessment. Research has shown that a significant number of

industrial accidents result from uncontrolled changes. It is usually via a

complex sequence of events that a change leads to an accident.

 Clearly it is necessary to ensure that machinery and operating procedures are

fully documented. Even if a machine and its associated safety systems are all

properly designed and documented, it is vital that the machine is monitored

during installation, commissioning and first-off production. Often it is

necessary to make small changes during any or all of these stages.

 It is imperative that any proposed change is first subjected to a rigorous risk

assessment, and any changes that are implemented must be fully

documented. After production has commenced, a further review should take

place to make certain that no further changes have been made. Note also that

"no further changes" also refers to the raw materials or components that are

being processed by the machine. Audits should be undertaken on a regular

basis to check that the machine and operating procedures are still in the

documented state.

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 Furthermore, functional audits should also be carried out on the machinery

safety systems. Often the components in a safety control system are only

used in the event of an emergency, which can make them very difficult to

test. Nonetheless these systems should be tested at regularly scheduled

intervals.

 Safety field buses such as AS-i Safety At Work (AsiSafe) and Profisafe can

support intelligent field devices able to perform self-monitoring functions

and transmit diagnostic data to a central controller that can alert the machine

operator prior to the failure becoming an unacceptable risk.

 Education and training is another aspect of the company-wide approach to

machinery safety. Increasingly complex modern machinery makes education

and training ever more important. There are new standards and regulations

with which companies must comply. On-the-job experience may have

sufficed in the past but this is unlikely to be acceptable in the future.

 Obviously training for machine operators and maintenance technicians is a

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 requirement, but there is also an important need for more general education

of the workforce and management in order to generate a safety-first

corporate culture.

CHAPTER - 3 LITERATURE REVIEW

1. DESIGN AND FABRICATION OF PAPER PUNCHING MACHINE

 Paper punching is one of the important processes in spiral binding industry.

The project selected is based on automation and this help to improve spiral

binding works. The motor is used for operating the punching head. Hence

human fatigue is reduced. So it can find application in all spiral binding

shops.

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 An eccentric cam mechanism is used for punching papers for spiral binding .

It can be used in all spiral binding shops.To operate the punching head an

electric motor is needed. If the motor is ON, the cam attached to the motor

with speed reduction mechanism will rotates. As it rotates the pull rod will

oscillates up and down.

 This reciprocating motion is transmitted to punching head and it punch the

papers when the punching head moves in downward direction.This machine

reduces human fatigue and reduces punching time than manually operated

machine. Due to this number of sets of paper can be punched in a very short

time. So this machine finds application in all spiral binding shops.

2. REVIEW ON PNEUMATIC PUNCHING MACHINE AND

MODIFICATION IN PUNCH TOOL TO REDUCE PUNCHING

FORCE REQUIREMENT

By p.goyal, g.srivastava, r.singh, n.singh ug students [mechanical], dept. Of

mechanical engineering, jss academy of technical education, noida,uttar

pradesh, india

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 This project work deals with the design of pneumatically controlled small

scale punching machine to carry out piercing operation on thin sheets (1-2

mm) of different material (aluminium and plastic). Reduction in punching

force requirement being the main aim of this project work is obtained by

modification in punch tool design i.e. by provision of shear on punch face.

Subsequently it results in reduction in amount of punching force

requirement. And further a CATIA model of the machine is developed on

the basis of calculations with respect to punching force requirement.

 A pneumatic punching machine is always a better choice than a hydraulic

punching machine for the production of similar products if it is suited for the

method. It is comparatively more economical for production of large

quantities of products as it uses compressed air rather than some hydraulic

fluid which is rather expensive. A pneumatic punching machine uses

compressed air to generate high pressure to be applied on the piston. A

solenoid valve controls the directional flow of air into and out of the

cylinder. Polyurethane tubes are used for pressure transmission from the

pneumatic cylinder to the punch assembly. The high pressure air fed to the

punch, forces it on the material and as the punch descends upon the sheet,

the pressure exerted by the punch first cause the plastic deformation of the

sheet.

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  Since the clearance between the punch and the die is very small, the plastic

deformation takes place in a localized area and the sheet material adjacent to

the cutting edges of the punch & die edges becomes highly stressed, which

causes the fracture to start on both sides of the sheet as the deformation

progresses.

CHAPTER - 4 METHODOLOGY

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 WORKING PRINCIPLE

 This project involves controlling accident or defecting due to machines.

Here one IR transmitter and IR receiver is fixed in machine where if

anybody gets close contact with the machine then the relay circuit will trip

off the machine. Fault out by pt which connected to ADC through precession

rectifier. This value is read out by controller and processed through that

according to solenoid value that returns. This machine operates

pneumatically.

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  AIM AND OBJECTIVES

 The aim of our project is to take a system wide approach to preventing the

machine accident. The system includes not just the machine and the

operator; but rather it includes everything from the initial design of the

machine to the training of every one that is responsible for any aspect of it,

to the documentation of all changes to regular safety audits and a finally a

corporate culture of safety first.

 Design is the part of a machine life where the greatest impact can be made in

relation to avoiding accidents. The designer should ensure that the machine

is safe to set up and operate, safe to install, safe to maintain, safe to repair

and safe to decommission.

 Although safe operation is usually at the forefront of a designer mind safe

maintenance and repair should also be a high priority. Around 50% of fatal

accidents involving industrial equipment are associated with maintenance

activities and design contributory factor in some 32% of these fatalities.

 This project involves controlling accident or defecting due to machines.

Here one IR transmitter and IR receiver is fixed in machine where if

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 anybody gets close contact with the machine then the relay circuit will trip

off the machine. In our project Accident Avoiding System For Punching

Machine the IR sensors are used to avoiding the accident. The system

automatically stops, when the IR sensor detecting the any parts of the

operator inside the machine.

CHAPTER - 5 DESIGN AND COMPONENTS

 DESIGN PROCEDURE:-

1. Material Selection:-

To prepare any machine part, the type of material should be properly selected

considering design and safety .The selection of material for engineering

application is given by the following factors:-

1) Availability of material

2) Suitability of the material for the application of the product.

3) Suitability of the material for the desired working conditions,

4) Cost of the materials.

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The machine is basically made up of mild steel. The reasons for the selection

are:

1. Mild steel is readily available in market,

2. It is economical to use,

3. It is available in standard sizes,

4. It has good mechanical properties i.e. it has good machinability.

5. It has moderate factor of safety, because high factor of safety results in

unnecessary wastage of material and heavy selection. Low factor of safety

results in unnecessary risk of failure,

6. It has high tensile strength,

7. Low coefficient of thermal expansion.

The materials of the sheets to be punched are taken as aluminium and plastic as

they are replacing many metals in the present scenario because of their

distinguished properties and features.

2. Force Calculation for existing punch design:-

Terms and formulae used:

Cutting force: - The force which has to act on the stock material in order to cut

the blank or slug.

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Stripping force: - The force developed due to the spring back (or resiliency) of

the punched material that grips the punch.

Cutting force = L x t x Tmax

Stripping force =10% -20% of cutting force

L= Length of periphery to be cut in mm

t= Sheet thickness in mm

Tmax= Shear strength in N/mm

 Accident Avoiding System For Punching Machine

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Fig. – 5.1 - Accident Avoiding System For Punching Machine

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Fig. - 5.2 - Sketch of Accident Avoiding System For Punching Machine with
components details

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 MAIN COMPONENTS AND ITS DESCRIPTION:

The major parts used in our project are

 Frame

 Electric motor

 Reduction gear box

 Eccentric cam mechanism

 Punching head

 Punching head mechanism.

 FRAME:

 It is the basic skeleton structure withstands all components such as electric

motor, gear box, pull rod and punching head and loads acting while

punching paper.

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  ELECTRIC MOTOR:

 It is mounted at bottom of the frame and its shaft is mounted by a pulley and

a “V” belt drive which drives the gear box. It converts electrical energy into

mechanical energy. A 1HP motor, single phase, with 1440 rpm is used for

our project.

 REDUCTION GEAR BOX:

 It is also mounted on the bottom of the frame. It has pulley at one end to

which motor drive is connected and another end (output shaft) is connected

to eccentric cam mechanism. It uses a speed reduction gear box with ratio of

40:1. Worm and worm wheel is used for speed reduction

 ECCENTRIC CAM MECHANISM:

 In this mechanism a flat plate is mounted to the gear box output shaft.

Another pin is fixed with an eccentric distance in the flat plate to perform

cam function. In the pin a bearing is mounted over which a bush is mounted.

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 The pull rod is attached to the bush. And the whole eccentric plate

mechanism is bolted to the gear box shaft.

 RAM HEAD:

 It is a flat plate to which pull rod is attached, and it slides with respect to

sliding mechanism as eccentric cam rotates. In sliding mechanism a bush

slides over a circular rod, which is mounted on the frame. The punching die

is attached to the bottom side of the flat plate. The follower of punching die

is attached to the frame in which punching pins reciprocate.

 CONSTRUCTION:

 This machine has a rigid frame made with L angles and it is welded rigidly.

The electric motor is connected to reduction gear box through “V” belt, here

first reduction of speed takes place. The reduction gear box has a warm and

warm wheel in which second speed reduction takes place.

 In reduction gear box a worm and worm wheel is used for speed reduction.

At the output of reduction gear box an eccentric cam plate is used to obtain

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 reciprocating mechanism.

 A follower (pull rod) which connects both eccentric cam and punching head.

The punching head is guided in a bushed shaft. The shaft is clamped to

frame by U clamp on both sides. The bottom side of punching head has

punching pins which actually make holes on papers. The bottom side of the

punching pins will slide in a guide plate which helps in good quality of

punching.

 If the electric switch is ON the motor will rotates, as it rotates it drives the

gear box shaft. As the diameter of gear box pulley is larger than the motor

pulley speed reduction takes place. In gear box worm and worm wheel is

used high speed reduction takes place in the order of 40:1 ratio.

 Then the output of gear box is connected to eccentric cam plate. Due to

speed reduction the will rotates at very slow speed. As the eccentric cam has

a follower over it makes the pull rod to reciprocate. The movement of

punching head depends upon the eccentricity of cam. The punching head has

a sliding mechanism in which the punching head is guided up and down.

The bottom of the punching head has a whole plate to guide the pins

accurately without bending. After switch ON the motor the paper is placed

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 between the head and base. The punching action takes place when the

punching head moves down wards. This process is repeated for as number of

times for punching number of sets of papers.

 In designing and fabricating this project, we gained invaluable technical

knowledge, regarding material solution, planning the project, group efforts

in achieving the target, cost estimation and also gained confidence in doing

works.

 However, in completing the project we felt that aims of the implementation

of project work in our courage is completely fulfilled.

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 CHAPTER - 6 GENERAL DETAILS

 APPLICATIONS

All Heavy Cutting Machine

All Ramming Machine

In all Foundries

In all Machine Shop

All the industries

 ADVANTAGES

This system is more safety to the operator

Simple type of automatic accident avoiding system

Quick in response

Simple in construction

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It is very useful in all industries

 DISADVANTAGES

The addition cost is required (sensor, Control Unit cost.

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CHAPTER - 7 CONCLUSION

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 CHAPTER - 8 REFERENCES

[1] R. Joshua, V. Vasu and P. Vincent “Solar Sprayer – An Agriculture

[2] R. D. Fox, R. C. Derksen, “Visual and image system measurement of spray

[3] M. A. Miller, B. L. Steward, M. L. Westphalen “Effects of multi−mode

[4] A. Taiwo K. Oje, “Development and testing of a swirl chamber nozzle”,

WEBSITES:-
1.http://ocw.metu.edu.tr/pluginfile.php/6885/mod_resource/ content/1/ch7/7-2.htm
2. http://en.wikipedia.org/wiki/Sprayer
3. http://en.wikipedia.org/wiki/Weeder
4.http://www.hindu.com/seta/2010/04/29/stories/20100429 50601500.html
5. http://www.skybirdagro.com/agriculture-sprayers.html

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 APPENDIX

 CANVAS

1. AEIOU CANVAS

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2. EMPATHY CANVAS

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3. IDEATION CANVAS

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4. PRODUCT DEVELOPMENT CANVAS

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PLAGIARISM REPORT

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PATENT SEARCH ANALYSIS REPORT (PSAR)

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PROJECT PROGRESS REVIEW (PPR)

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