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and Design¬ International Journal of Manufacturing and

Materials Processing¬ International Journal of Mechanical Handling and

Automation

« 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

Signals

« International Journal of Housing and Human Settlement Planning

« International Journal of Architecture and InfrastructurePlanning

« International Journal of Rural and Regional PlanningDevelopment

« International Journal of Town Planning and Management

Applied Mechanics

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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

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

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

Physics

« International Journal of Renewable Energy and itsCommercialization

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

Pollution

Civil Engineering« 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

Electrical Engineering« 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

Circuits

Material Sciences and Engineering « 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

Chemistry « International Journal of Photochemistry« International Journal of Analytical and Applied Chemistry« International Journal of Green Chemistry« International Journal of Chemical and Molecular

Engineering

« International Journal of Electro Mechanics andMechanical Behaviour

« International Journal of Machine Design andManufacturing

« International Journal of Mechanical Dynamicsand Analysis

« International Journal of Fracture and damageMechanics

« International Journal of Structural Mechanicsand Finite Elements

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Biotechnology « International Journal of Industrial Biotechnology and

Biomaterials« International Journal of Plant Biotechnology« International Journal of Molecular Biotechnology« International Journal of Biochemistry and Biomolecules« International Journal of Animal Biotechnology and

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Dr. V. SugumaranSchool of Mechanical Engineering and Building

Sciences, VIT University, India

Dr. S. RamabalanDepartment of Mechanical Engineering,

E. G. S. Pillay Engineering College,Nagapattinum, (Tamil Nadu), India

Dr. Mark OvinisDepartment of Mechanical Engineering

Universiti Teknologi Petronas, Bandar Seri Iskandar, Perak, Malaysia

Dr. M. Syed AliDepartment of Mathematics, Thiruvalluvar

University Vellore, Tamil Nadu, India

Dr. Dinesh Singh G. ThakurDepartment of Mechanical Engineering,

Defence Institute of Advanced Technology, DRDO, Ministry of Defence, Girinagar,

Pune, India

Dr. Wilson Udo UdofiaDepartment 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.

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Automation as an emerging and increasingly vital field, now widely recognized as an integral part of

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community, addressing researchers and practitioners in this area.

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professional research societies to industry practitioners in a range of topics in Automation in general.

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time & 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.

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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.

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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

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

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 10

3. Review on the Use of PLCs in Control System EducationS. Sharmila, T. Devi, P. Garg 16

4. Research Insight: Guidelines for Mechanical Handling ApplicationsHimanshu Garg 19

5. Research Insight: Developments in AutomationPriyanka Garg 24

Contents

IJMHA (2016) 1–9 © JournalsPub 2016. All Rights Reserved Page 1

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

www.journalspub.com

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.

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]

Fig. 1. Brake Caliper Bracket.

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.

IJMHA (2016) 10–15 © JournalsPub 2016. All Rights Reserved Page 10

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

www.journalspub.com

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

IJMHA (2016) 16–18© JournalsPub 2016. All Rights Reserved Page 16

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

www.journalspub.com

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 non-

linear, 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

IJMHA (2016) 19–23© JournalsPub 2016. All Rights Reserved Page 19

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

www.journalspub.com

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

Mechanical Handling Guidelines

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.

IJMHA (2016) 24–28 © JournalsPub 2016. All Rights Reserved Page 24

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

www.journalspub.com

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 decision-

making 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,

International Journal of

Mechanical Handling & Automation

Mechanical Engineering

Electronics and Telecommunication Chemical Engineering

Architecture

Office No-4, 1 Floor, CSC, Pocket-E,Mayur Vihar, Phase-2, New Delhi-110091, India

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¬ International Journal of Thermal Energy andApplications

¬ International Journal of Production Engineering¬ International Journal of Industrial Engineering

and Design¬ International Journal of Manufacturing and

Materials Processing¬ International Journal of Mechanical Handling and

Automation

« 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

Signals

« International Journal of Housing and Human Settlement Planning

« International Journal of Architecture and InfrastructurePlanning

« International Journal of Rural and Regional PlanningDevelopment

« International Journal of Town Planning and Management

Applied Mechanics

5 more...

1 more...

2 more...2 more...

5 more...

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

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

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

Physics

« International Journal of Renewable Energy and itsCommercialization

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

Pollution

Civil Engineering« 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

Electrical Engineering« 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

Circuits

Material Sciences and Engineering « 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

Chemistry « International Journal of Photochemistry« International Journal of Analytical and Applied Chemistry« International Journal of Green Chemistry« International Journal of Chemical and Molecular

Engineering

« International Journal of Electro Mechanics andMechanical Behaviour

« International Journal of Machine Design andManufacturing

« International Journal of Mechanical Dynamicsand Analysis

« International Journal of Fracture and damageMechanics

« International Journal of Structural Mechanicsand Finite Elements

5 more...4 more...

3 more...

Biotechnology « International Journal of Industrial Biotechnology and

Biomaterials« International Journal of Plant Biotechnology« International Journal of Molecular Biotechnology« International Journal of Biochemistry and Biomolecules« International Journal of Animal Biotechnology and

Applications3 more...

Nursing « 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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