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skimming robot

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Information about skimming robot
Science-Technology

Published on January 21, 2009

Author: namazibasheer

Source: authorstream.com

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DESIGN OF A SKIMMING ROBOT FOR INDIAN ZINC INDUSTRY : DESIGN OF A SKIMMING ROBOT FOR INDIAN ZINC INDUSTRY B M NAMAZI Contents : Contents The need Objectives Details Conclusion The need : The need The skimming operation employed in the Indian Zinc industry is manual This causes undue concern to the operators The manual skimming increases the rejects The skimming operation is carried out at temperatures of 450 This creates more unsafe condition Manual skimming operation : Manual skimming operation Skimming refers to the removal of the top layer of oxidized molten zinc metal in moulds during the casting operation. Objectives : Objectives Identification of an alternative solution to the manual skimming Eliminating the unsafe conditions during the skimming process. Reducing the skimming metal wastes during the skimming operation. Implementing highly safe work atmosphere Expected contribution : Expected contribution Elimination of stress, strain and pain Reducing rejects. Better and safe operational procedure. Better environmental and operating conditions. Casting machine details : Casting machine details No of moulds :160 Ingots/mould :1 Ingot weight :25kg Chain Pitch :279.4mm Type of drive :Direct on head shaft Head shaft sprocket :24 teeth Tail shaft sprocket :16 teeth Drive motor/gear box :Motorised double reduction worm gear unit(4 kw) Skimming cycle time : Skimming cycle time Maximum capacity :9000kg/hour :9000/25 :360 ingots/hour :360/60 :6 ingots/minute :6/60 seconds 6 ingots should be skimmed in 60 seconds So the time taken for skimming 1 ingot is 10 seconds Skimming operation present system-manual : Skimming operation present system-manual Closing of the knives (to collect the skimmed metal) Lifting of the knives (to lift above the moulds) Rotation of the knives(to leave the area of the moulds) Opening of the knives(to dislodge the skimmed metal) Tapping of the knives(to clean the skimming blade) Reverse positioning of the knives(back to position) Opening of the knives( Proposed skimming action : Proposed skimming action Part 1(skimming action) Movement of the blades perpendicular to the mould conveyor to collect the skimmed metal Movement of the blades at the same speed along the direction of the mould conveyor Lifting of the collected skimmed metal vertically Opening of the blades Repeated movement of the blades to remove the metal stuck on the blades Proposed skimming action(contd) : Proposed skimming action(contd) Part 2 (non skimming action) Sensing the lifting of the blades Movement of the skimmed metal collection tray to the top of the conveyor Reverse movement of the tray Movement of the skim disposal blade and directing the skimmed metal to the box Design : Design Pneumatic Design of skimmed metal collection tray : Design of skimmed metal collection tray Area of plate( base area) :800X1000 :800000mm² Thickness of plate considered :6mm Weight of 6 mm plate/m² :47.1 kg Weight of base plate :37.68 kg Height(side cover)of tray :100mm Perimeter of side cover :2800mm Area of side cover :280000mm² Design of skimmed metal collection tray : Design of skimmed metal collection tray Weight of side cover :13.188kg Total weight of skim tray :50.868 kg Design considerations Dimensions of the mould Total size of three moulds considered Lift to be maintained is 300 mm Minimum gap between the tray and skimming blades is 200 mm Skimmed metal collection tray : Skimmed metal collection tray Design of skimmed metal disposal blade : Design of skimmed metal disposal blade . Length of blade :796 mm Height of blade :100mm Area of blade :69600mm² Thickness of blade :4 mm Weight of 4 mm plate /m² :31.4 kg Weight of blade :2.185 kg Design of skimmed metal disposal blade : Design of skimmed metal disposal blade BLADE HANDLE Length of blade handle :1000mm Diameter of handle rod :20mm Weight of 20mm rod/m :2.5 kg Weight of handle :2.5kg Total weight of disposal blade + blade handle+accessories :2.5+2.198+2 =6.698kg Skimmed metal disposal blade : Skimmed metal disposal blade Cylinder design for disposal tray : Cylinder design for disposal tray Design considerations Force required Pressure available Speed of movement Air consumption Requirements Weight to be moved : 50Kg Distance to be moved : 800mm Cylinder design for disposal tray : Cylinder design for disposal tray From the pressure force chart The parameters for a 50mm bore dia cylinder Thrust area :19.63cm² Retraction area :16.49cm² Pressure selected :7 bar Thrust force :137.41N Retraction force :115.43 N Thrust motion :1372mm Retraction motion :1155mm Cylinder design for disposal tray(contd) : Cylinder design for disposal tray(contd) Selection considerations Actual distance to be moved :800 mm Pressure of air available :7 bar Time required for the single motion :2 s From the mass- piston velocity graph Mass of 50 kg can be moved at a maximum speed of .7m/s Thus ensuring that the time for the single action is less than 2 s Cylinder design forskimmed metal disposal blade : Cylinder design forskimmed metal disposal blade Considering various related factors as in the case of the design of the cylinder for the disposal tray the same cylinder diameter of 50mm is selected. Skimmed metal disposal box : Skimmed metal disposal box The skimmed metal is collected in the disposal box before it is send to the furnace for rework Dimensions of the open box :1mx1mx0.4m Area of the box :2.6m² Thickness of plate :6mm Weight of the box :122.46 kg Skimmed metal disposal box : Skimmed metal disposal box Rack and pinion : Rack and pinion A rack and pinion is one of the least expensive methods of converting rotary motion to linear motion Design : Design Robotic Robot selection : Robot selection Rectangular-Coordinated Cylindrical-coordinated Spherical-coordinated Jointed Arm -coordinated SCARA(Selective Compliance Assembly Robot Arm) The movements : The movements X Axis Y Axis Z Axis X axis movements-parameters : X axis movements-parameters Distance to be moved : 280mm Time allowed : 2 seconds Velocity : 0.140m/s Mass to be moved : 150 kg Drive : servo motor Mechanical : Rack and pinion Controls : PLC Y axis movement-parameters : Y axis movement-parameters Distance to be moved :300mm Time allowed for the movement :2 seconds Mass to be moved :150 kgms Velocity : 0.15m/s Drive : servo motor Mechanical elements : Rack and Pinion Controls : PLC Z axis movements-parameters : Z axis movements-parameters Distance to be moved :225mm Time allowed :2 seconds Mass to be moved :25 kgms Velocity :0.1125m/s Drive :servo motor Mechanical systems :Two racks and one pinion design Controls :PLC Z axis rack and pinion : Z axis rack and pinion Minimum no of teeth on pinion to avoid interference in a rack and pinion system z :2K1/sin²a :18 (a =20 and K1=1 ) Taking the no of teeth to be 30(>18) Acceleration time : .5 seconds Acceleration due to gravity : 9.8m/s² Acceleration : 0.1125/0.5 : 0.225m/s² Z axis rack and pinion : Z axis rack and pinion Application force at rack (Fr):µMg+Ma+F 0.25X25X9.8+25X.225+2 :68.875N Application torque at pinion(Tp) :FrXd/2000 :68.875X60/2000 :2.2065 Nm Design torque(Td) :TpXS.F :2.2065X2 :4.413Nm Max rotational speed of pinion Np :VX19100/d :0.226X19100/60 :71.94 rpm Z axis rack and pinion : Z axis rack and pinion T-rating for d 60mm and z 30 is 44Nm(for soft rack) (T-rating>Td) Length of the rack : 250mm No of racks : 2 Position of the rack : On the sides of a flat positioned pinion Y axis rack and pinion : Y axis rack and pinion Minimum no of teeth on pinion to avoid interference in a rack and pinion system z :2K1/sin²a :18 (a =20 and K1=1 ) Taking the no of teeth to be 30(>18) Acceleration time : 0.5 seconds Acceleration due to gravity : 9.8m/s² Acceleration : 0.15/0.5 : 0.3m/s² Y axis rack and pinion : Y axis rack and pinion Application force at rack (Fr):Mg+Ma+F 150X9.8+150X.3+2 :1517N Application torque at pinion(Tp) :FrXd/2000 :1517X60/2000 :45.51 Nm Design torque(Td) :TpXS.F :45.51X2 :91.02Nm Max rotational speed of pinion Np :VX19100/d :0.150X19100/60 :47.75 rpm Y axis rack and pinion : Y axis rack and pinion T-rating for d 60mm and z 30 is 195Nm(for hardened and ground rack) (T-rating>Td) Length of the rack : 325mm No of racks : 1 X axis rack and pinion : X axis rack and pinion Minimum no of teeth on pinion to avoid intereference in a rack and pinion system z :2K1/sin²a :18 (a =20 and K1=1 ) Taking the no of teeth to be 30(>18) Acceleration time : 0.5 seconds Acceleration due to gravity : 9.8m/s² Acceleration : 0.140/0.5 : 0.28m/s² X axis rack and pinion : X axis rack and pinion Application force at rack (Fr):µMg+Ma+F 0.25X150X9.8+150X.28+2 :411.5N Application torque at pinion(Tp) :FrXd/2000 :411.5X60/2000 :12.35 Nm Design torque(Td) :TpXS.F :12.35X2 :22.674Nm Max rotational speed of pinion Np :VX19100/d :0.140X19100/60 :44.55 rpm X axis rack and pinion : X axis rack and pinion T-rating for d 60mm and z 30 is 44Nm(for soft rack) (T-rating>Td) Length of the rack : 320mm No of racks : 1 Gantry base : Gantry base Steel Channel 100X50X5 Length =1500mm Breadth =1500mm Height =1600mm Gantry base =97.9kg Skimming Blades : Skimming Blades Blade Handle =15mm ss rod Handle length =150mm Blade width =80mm Blade dimensions =240 X 205 mm Material =ss 304 Components : Components Carriage Vertical Base Cross slide Vertical guide Rollers Gantry base with carriage rollers : Gantry base with carriage rollers Gantry base with carriage : Gantry base with carriage Gantry base with carriage and vertical base : Gantry base with carriage and vertical base Gantry base with carriage, vertical base and cross slide : Gantry base with carriage, vertical base and cross slide Gantry assembly without blades : Gantry assembly without blades Cross slide and blade assembly : Cross slide and blade assembly Gantry assembly with blades : Gantry assembly with blades Gantry assembly with skim tray : Gantry assembly with skim tray Gantry assembly with skim tray and disposal blade : Gantry assembly with skim tray and disposal blade Gantry assembly with skim tray and disposal blade : Gantry assembly with skim tray and disposal blade Conclusion : Conclusion Gantry robot design for automatic skimming is done The implementation with proper controls would eliminate manual skimming in the Indian Zinc industry Benefits to the organization : Benefits to the organization The implementation of the skimming robot eliminates the toughest manual job in the Indian Zinc industry The commissioning of the skimming robot increases the over all efficiency by reducing the metal wastes Implementation of the skimming robot would result in the saving of Rs 10 lakhs per annum Improves the house keeping Scope for future work : Scope for future work Implementation of the skimming robot after fine tuning and plc programming Modification in the system to carry out skimming operation so that three moulds could be skimmed in one action References : References Mercury manufacturers hand book Andantex manufacturers hand book Gear design hand book-gitin mitra Thank you : Thank you B M Namazi

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