of 38
8/9/2019 From Introduction
1/38
INTRODUCTION
1
8/9/2019 From Introduction
2/38
INTRODUCTION
This is a self assessment test on the part of the students to
assess his competency in creativity.
During the course of study, the student is put on a sound
theoretical foundation of various mechanical engineering subjects and of
course, to a satisfactory extent. Opportunities are made available to him to
work on different kinds of machines, so that he is exposed to various kinds
of manufacturing process.
As a students learn more and more his hold on production
technology becomes stronger. He attains a stage of perfection, when he
himself is able to design and fabricate a device.
This is the project work. That is the testimony for the strenuous
training, which the student had in the institute. This assures that he is no
more a student, he is an engineer.
This report discuses the necessity of the project and various
aspects of planning, design, selection of materials, fabrication, erection,
estimation and testing.
2
8/9/2019 From Introduction
3/38
SYNPOSIS
3
8/9/2019 From Introduction
4/38
4
8/9/2019 From Introduction
5/38
CONSTRUCTION
CONSTRUCTION:
5
8/9/2019 From Introduction
6/38
This unit consists of
1) DC Motor 12V DC
2) BATTERY 12V DC
3) CRANK MECHANISM
4) BLADE
5)M.S. fabricated work table
6) M.S. stand
6
8/9/2019 From Introduction
7/38
WORKING
PRINCIPLE
WORKING PRINCIPLE :
This unit consists of
7
8/9/2019 From Introduction
8/38
1) DC Motor 12V DC
2) BATTERY 12V DC
3) CRANK MECHANISM
4) BLADE
Initially the job is placed in the machine unit. Then press the start
switch. The DC Motor starts rotating . The rotary motion of the Motor shaft is
converted to reciprocating motion by the crank mechanism.
The plastic sheet cutting blade is connected to this reciprocating unit.
Hence the blade moves to and fro and thus cut the plastic sheet by feeding plastic sheet
with manual force.
8
8/9/2019 From Introduction
9/38
DRAWING
9
8/9/2019 From Introduction
10/38
10
8/9/2019 From Introduction
11/38
DETAILS OF
BATTERYCHARGING
ETAILS OF BATTERY CHARGING
A battery is something that supplies DC power through chemical reaction.
Batteries in different form have existed for over 150 years. The research work still
continues for better performance as the demand increases.
Battery was developed around 1800 by Alessandro Volta when he found
the generation of electrical current from chemical reactions between different metal of
11
8/9/2019 From Introduction
12/38
different properties. The battery now a days we use are divided into the following two
categories,
1. Primary / single use
2. Secondary / Rechargeable
PRIMARY BATTARY
Primary batteries are for single use as the chemical reactions that
produces the electric current in them are irreversible. These batteries are common
primary cells are the common Zinc Carbon battery, Zinc Manganese Alkaline battery
etc. These are used for domestic purpose like watches, tape recorders, torch etc.
SECONDARY BATTERY:
Secondary batteries are rechargeable batteries i.e they can be sued
multiple times, after using the charge stored in them, they can be recharged and reused.
These batteries are mainly; used in industries and automobiles where higher initial
current is required. Disadvantages of these batteries are they are costly and require
regular maintenance. Some of the common examples of secondary batteries are Nickel
Cadmium battery, Lead Acid battery etc,.
CELL COMPONENTS:
Let us now see the different components of a cell
1. The electrolyte
2. The positive electrode
12
8/9/2019 From Introduction
13/38
3. The negative electrode
4. The separator
Electrolyte:
The electrolytes may be acidic solution, which provide the positive ions,
or the alkaline solution which provides the negative ions. These ions are used to
conduct the charge flow from positive to negative electrode.
The Positive Electrode:
The positive electrode accepts the electrons from external circuit during
discharge and the negative electrodes supplies the electrode circuit when oxidized
during discharge.
The Negative Electrode:
In alkaline electrolyte the negative ions are created at positive electrodes
and absorbed at negative electrodes and in acidic electrolyte the positive ins are created
at negative electrode and are absorbed at positive.
The Separator:
In the cell a separator is used to electrically isolate the electrodes and save cell
from internal short circuit.
LEAD ACID CELL:
The Lead Acid cell consist of
1. Lead dioxide as positive electrode
13
8/9/2019 From Introduction
14/38
2. Sponge metallic lead as negative electrodes
3. Sulphuric acid as electrolyte
During discharge the active material of positive electrode react with
Sulphuric acid to form lead sulphate and active material of negative electrode react
with sulphuric acid to form water
When this cell is recharged, during recharge the lead sulphate converts
back to lead dioxide and metallic lead.
Battery Types:
Commonly the following four types of batteries are used with the inverter
system,
1. Automobile Batteries
2. Tubular / Industrial Lead acid batteries
3. Sealed Maintenance Free (SMF) Batteries
4. Nickel Cadmium Batteries
5. Automobile Batteries
These batteries are commonly used in the automobile, cars, truck etc.
Battery Rating:
The backup time provided by a Inverter depends very much on the rating
of the battery used with them.
14
8/9/2019 From Introduction
15/38
Commonly batteries are available in 6 and 12 and 24 Volts rating. Other
than the voltage rating, the ampere Hour rating is used to define the power
availability or capacity of the battery.
The backup time provided by a battery connected to Inverter depends on
the
DC bus voltage of the Inverter. This depends on their design. It could be
24V, 48V, 72V 120V and so on.
Normally more than one 6Volt or 12 V battery is used in series for higher
voltages requirements.
Charger Design:
The life of a battery used in inverter very much depends on the charging
methods used to charge the battery. These types of charging circuit are used in
Inverter to charge the battery
Constant voltage
Constant current
15
8/9/2019 From Introduction
16/38
Constant voltage constant current
Constant Voltage:
This type of charging method using series regulators is suitable in SMF
batteries, but they are not useful in automobile and industrial lead acid batteries.
Constant Current:
This charging method using shunt regulators is good for the automobile
and industrial lead acid batteries but it can damage the SMF batteries by overcharging
them.
Constant Voltage Constant Current:
This charging method is suitable for automobile and industrial lead acid
batteries and also for the SMF batteries.
16
8/9/2019 From Introduction
17/38
17
8/9/2019 From Introduction
18/38
PRINCIPLE OF DC
MOTOR
PRINCIPLE OF DC MOTOR
A DC motor is a dc machine working as a motor to convert dc electrical
energy into mechanical energy (dc) motor are very commonly used in cars, trucks,
aircrafts, etc. They are also used in large ratings, where wide range of speed control is
necessary.
When a conductor is carried a current and in lying in magnetic filed.
Force acting on the conductor. This is the principle of a Dc motor. The conductor is
18
8/9/2019 From Introduction
19/38
housed in armature slots and current is applied from the dc source through brushes and
commentator. The field poles provide the magnetic field.
The construction of dc motor and generator are similar. However their
external appearance may be somewhat different. A motor has a rather closed frame
because it is may be operating in dusty environment and unskilled workers may be
working in its vicinity.
19
8/9/2019 From Introduction
20/38
TYPES OF DC
MOTOR
TYPES OF DC MOTOR
DC Shunt Motor:
This motor has medium starting torque, a speed regulation of 5 10 %
and excellent adaptability to adjustable speed service. It can be used for constant
speed drives like pumps, fans blowers, etc,. However for all these applications, a 3
phase induction motor is preferable, because it ;is cheaper, more rugged and requires
lesser maintenance than dc motor. However a dc shunt motor is cheaper for low speed
drives. Moreover, whenever a wide range of speed control is required, dc shunt motor
20
8/9/2019 From Introduction
21/38
is used. The main application of dc shunt motor is in steel and aluminium, rolling
mills and ward Leonard speed control system.
Dc Series Motor:
This motor has a very high starting torque. Moreover it speed decreases
with increase in load torque. So that its power input remains more or less constant. It
is best suited for hoist cranes and traction. Speed control is generally obtained through
armature control. They are used for battery-powered vehicles.
Compound Motor:
A differential compound is rarely used. The characteristics of a
cumulative compounds motor depend on the relative strength of series and shunt fields.
It has good starting torque and dropping speed load characteristic. They can be used
for pulsating loads needing flywheel action, viz. shears, conveyors, crushers, hoists,
plunger pumps, etc., Whenever the supply voltage is likely to vary considerably, a
compound motor is preferred. Because its induction and contribution to back emf, the
series field helps in reducing the fluctuations of current drawn from mains.
21
8/9/2019 From Introduction
22/38
22
8/9/2019 From Introduction
23/38
ADVANTAGES
&DIS ADVANTAGES
ADVANTAGES
1. Single person is enough to operate this efficiently to cut the plastic sheet..
2. Easy and efficient handling of this unit without wastage or damage to the plastic
sheet, machine and to any other parts.
3. low maintenance cost and life of equipment also increased..
4. Least maintenance of the equipment.
5. Need not require any individual work place.
6. Can be worked in the work spot.
7. Suited for cutting plastic sheets of minimum thickness sheet..
23
8/9/2019 From Introduction
24/38
DISADVANTAGES
Manual power required to operate .
The time taken for loading and unloading the kit is more when Compared to
pneumatic controlled unit.
It cannot be used for more than 5mm thickness plastic sheet..
APPLICATION
24
8/9/2019 From Introduction
25/38
APPLICATIONS
By using this device many numbers of plastic sheets are cut and the cutting
operation can be performed very easily. It is very much useful in making name board
for advertisement This device is used to cut the various thickness ranging from 1mmto
5mm .
25
8/9/2019 From Introduction
26/38
PAINTING ANDFINISHING
26
8/9/2019 From Introduction
27/38
FINISHING AND PAINTING
JOB PREPARATION
Before welding, remove any bend in the L angle with the sludge hammer on the
anvil block. Then it is cut to the required length with the hacksaw blade and fabricated
to required dimensional shape with arc welding.
FINISHING OPERATION BEFORE PAINTING
After welding, any slag on the welded area is removed with the chipping
hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed with
the emery sheet.
Metalprimer is applied on the surfaces with the brush. After drying the metal
primer, the second coating is applied with the paint
27
8/9/2019 From Introduction
28/38
SAFTY,CARE AND
MAINTENANCE
28
8/9/2019 From Introduction
29/38
SAFTY,CARE AND MAINTENANCE
Before starting the machine, some of the points to be noted for safety purpose,
1. Before starting the operation, check the following items
(1) Check the mechanism for proper operation .
(2) Check the alignment of blade in the machine
(3) Dont insert the any material or object between the during operation
of machine
(4) Check the lifting alignment and handle in the machine
(5) Wear gloves and shoe for proper handling .
29
8/9/2019 From Introduction
30/38
FEATURES OF
THIS PROJECT
30
8/9/2019 From Introduction
31/38
FEATURES OF THIS PROJECT
It is compact in size
It can be move
Low electrical power consumption
It can be utilized at our work shop
It is simple in construction
Low cost
Less weight and easy to handle
It reduces the man power
It is simple in operation..
31
8/9/2019 From Introduction
32/38
COST
ESTIMATION
32
8/9/2019 From Introduction
33/38
COST ESTIMATION
S.NO ITEMS RUPEES
1. CUTTER AND HOLDING UNIT 500.00
2. MOTOR UNIT 3000.0
0
3. MECHANISM FOR OSCILLATION 600.00
4. M.S. FABRICTED HOUSING UNIT 600.00
5. BATTERY COST 300.00
6. TRANSPORT COST 700.00
7. REPORT 800.00
TOTAL 6500.
00
33
8/9/2019 From Introduction
34/38
CONCLUSION
34
8/9/2019 From Introduction
35/38
CONCLUSION
We make this project entirely different from other projects. Since concepts
involved in our project is entirely different that a single unit is used to various
purposes, which is not developed by any of other team members.
By doing this project we gained the knowledge of fabrication work and
how the welding is doing and material selection for particular components etc.,
It is concluded that any fabrication work can be done with the help of
welding.
We have successfully completed the project work on using welding work
at our Institute.
Once again we express our sincere thanks to our staff members.
35
8/9/2019 From Introduction
36/38
BIBLIOGRAPHY
BIBLIOGRAPHY
1. WORKSHOP TECHNOLOGY - HAJRA CHOWDRY
2. PRODUCTION TECHNOLOGY - R.S. KHURMI
3. MACHINE SHOP TECHNOLOGY - S.S.MANIAN
36
8/9/2019 From Introduction
37/38
4. JIG AND FIXTURE DESIGN - R.K.JAIN
5.FLUID POWER BY - E.SUNDRAMOORTHY
PHOTO VIEW
37
8/9/2019 From Introduction
38/38
PHOTO VIEW