MADANAPALLE INSTITUTE OF TECHNOLOGY AND SCIENCE
(UGC – AUTONOMOUS)
Department of Mechanical Engineering
Project Phase 2
Fabrication of Metal and Non-Metal chip collector machine for manufacturing
industry application
Supervised by
Dr . S. Baskaran , Assoc. Professor
Department of Mechanical Engineering
Presented by
M. Sai kumar naik 18691A03B3
S. Sai vardhan 18691A03B6
KM. Sandeep 18691A03B7
U. Sandeep 18691A03B8
N. Sreenivasulu 18691A03D8
Overview of the presentation
Introduction
Literature Survey
Problem Identification
Objectives
Experimental work
Future Work
Conclusion
References
INTRODUCTION
Technology advances in today’s industrial world drive major research focused towards
safe working manufacture environment .
The metal chips produced during machining operation.
The methods employed currently in industries to collect the metal chips includes,
picking pieces by hand and manual sweeping, both methods are not been effective due
to consuming and expose the worker to injuries.
Safety being prime focus of modern machining industries has led to the development of
technology driven chip collector, which work with the scientific principles of magnet.
The applications of development of magnetic chip collector have major applications in
the distinguished areas like machine shops, workshops, factory road ways, scrap yards
and so on.
• The developed magnetic chip collector replace human labor for collecting the
ferrous metal parts, and can operate at faster rate by an unskilled labor irrespective
of age and technical qualification.
• The unique features of magnetic chip collector is to reduce human efforts and related
hazards, ease and quick collection of large amount of metal chips, low operating and
maintenance cost, and require very low capital investment.
LITERATURE SURVEY
Sirichai Watanasophon and Sarinee Ouitrakul were represented Aim of
this research is to design and make garbage collection robot on the
beach by using wireless communication. The robot is built on the
caterpillar wheels sizes 52x74x17 cm and the power is supplied from
12V 30Ah battery which is connected to 40W solar cells.
The user can control a robot via a program developed from Visual Basic
2005 application based on Window XP. The commands from user are
sent via Bluetooth to PIC18F4550 for processing. In addition, it is also
equipped with an IP camera with added pan/tilt capabilities which
relays feedback information to the human operator via Ad-hoc system.
Electromagnetic Metal Collecting AGV S. Pradeep et al. presented as Scrap is one
of the leading wastes generated in manufacturing industries. Collection of scrap is a
tedious work and requires more labor work and is also a time consuming one. Thus
this project emphasis the importance of scrap collection and an AGV is designed to
eliminate the manual scrap collection.
In our project we are eliminating the need of manually collecting the scrap in heavy
industries. For this purpose we are designing an automated electromagnetic scrap
collecting AGV controlled by an Arduino mega 2560 controller.
The available methods of scrap collection techniques, manpowered and fuel
powered vehicles are used. In the near future, the fuel deposits in the world will be
completely depleted.
To avoid this situation of problems and to reduce manpower
requirements we are in need of other type of technique called as
battery operated automated electromagnetic scrap collecting
AGV. The Arduino mega 2560 controller is used to control the
Vehicle path automatically.
The rechargeable battery is supplying power to the automatic
scrap collecting. The Vehicle is having the one electromagnetic
arm which is used to collect the scrap automatically
PROBLEM IDENTIFICATION
In the above project we noticed that the efficiency of scrap
collection is less due to limited size of magnets.
To overcome that problem we are using strong electromagnets by
increasing the electromagnetic intensity and also size of the
magnets.
OBJECTIVES OF THE PRESENT WORK
The specific objectives of the present work is as follows.
To develop the mechanically driven magnetic chip collector machine and does
not rely on electrical power.
To develop and fabricate the magnetic chip collector which are economically
feasible for both small- and large-scale industries.
To develop a device where safety is of primary concern that does not causes
serious threat to human health and equipment.
To reduce the metal loss through chip, which are unnoticed that collect the chips
beneath the soil.
EXPERIMENTAL WORK
The magnetic chip collector consists of set of permanent magnets arranged axially
utilizing a shaft.
The shaft has gears on both ends. These gears are meshed to other gears which are
arranged coaxially to another shaft.
These two shafts are attached to the frame using Plummer bearings.
The shaft carries simple rubber wheels with fitted bearings for ease of rotation.
Spur gears are utilized from one side of shafts to transmit the motion from the
wheels to magnetic drum or assembly.
The angle iron bar of required dimensions are cut and then welded to get the frame
on which magnetic assembly is rested.
The metal blocks are welded to the frame, which are supported to the bearings on
both sides of two shafts.
The rollers also have bearings for ease of rotation on which the belt moves and the
bearings are supported by metal blocks which in turn welded to frame.
The collector acts as storage parts the chips which are thrown by the belt on to it.
The collector is designed as rectangular in shape made up of aluminium metal sheet
that fit metal frame.
The collector is also designed which can be easily removed after filling and placed again,
when it is empty.
The cotton belt is used over magnetic assembly and roller arrangement for collecting the
chips from floor to collector.
The angle bar is provided which acts as a handle to move the machine.
Noteworthy that, handle is welded to the frame.
Three shafts are made up of cast iron material. In one shaft magnets coupled with
insulating material is mounted on the magnetic drum.
The 16 mm shaft diameter is used to support the wheels. Third shaft is the roller to support
the belt placed over the magnetic drum and the diameter of the shaft is 16 mm.
The methodology employed for design and fabrication of magnetic chip collector machine.
The following parts are used for the design and fabrication of magnetic chip
collector machine is as follows:
1. Gears
2. Shaft
3. Magnets
4. Belt
5. DC Motors
6. Wheels
7. Chip Collector Tray
8. Ultrasonic Sensor with servo motar
9. Arduino uno
10. Motor driver
11. TT Gear motor
12. Lithium ion battery(2)
13. Battery holder
14. Jumper wires
15. Acrylic sheet
16. DC power switch
PART DIAGRAMS
[Link] SHAFT
[Link] COLLECTOR
[Link] ROLLER
BELT
[Link] GEAR
CIRCUIT DIAGRAM
1. Arduino Uno
The Arduino Uno is an open-source microcontroller board
based on the Microchip ATmega328P microcontroller and
developed by Arduino
[Link] Sensor
Ultrasonic Distance Sensor provides very short (2CM) to
long-range (4M) detection and ranging. The sensor
provides precise and stable non-contact distance
measurements from about 2cm to 4 meters with very high
accuracy. It can be easily interfaced to any microcontroller.
3. TT Gear Motors
Plastic gearbox motors (also known as 'TT' motors) are an easy, low-cost way
to get your projects moving. This is a TT DC Gearbox Motor with a gear
ratio of 1:48, and it comes with 2 x 200mm wires with breadboard-friendly
0.1" male connectors. Perfect for plugging into a breadboard or terminal
blocks.
[Link] Driver
The L298N is a dual H-Bridge motor driver which allows speed and
direction control of two DC motors at the same time. The module can drive
DC motors that have voltages between 5 and 35V, with a peak current up to
2A. Let's take a closer look at the pinout of L298N module and explain how
it works.
DESIGN AND CONSTRUCTION
The wheels are fixed to the TT gear motor and these are stick to the acrylic
sheet by using glue.
TT gear motor ,ultrasonic sensor and battery holder is fixed to the positive and
GND terminals in motor driver by using jumper wires .
The motor driver is connected to the Arduino UNO.
The USB cable is connected to the laptop and USB port in Arduino UNO the
code is transferred.
FUTURE WORK
The chip collector fabricated here is used for collecting chips from the floor.
Magnetic chip collector for lathe can be accomplished using the same principle.
But the basic setup of the belt is where the magnet is raised to a particular length of
the lathe above the ground.
Instead of using wheels DC motors can be used. Therefore, there is no requirement
of gears.
Electromagnetic can be used instead of normal magnets. And here a device can be
setup that attracts particular metals or non-metals.
For example, aluminum chips are collected, then electromagnetic that attract
aluminum can be preferred.
The principle of magnetic chip collector can be used to extract a particular material
from bulk of different materials.
The electromagnetic are to be used here.
APPLICATIONS
Machine shop Workshops
Factory roadways Scrap yards
CONCLUSIONS
The following conclusions are drawn from the present work, The design
and fabrication of the magnetic chip collector is tested for practical
utility in the college machine shop.
The developed magnetic chip collector met the desired requirements
that could pick the chips, in turn transfer on to the belt and collector,
thus help to clean the floor area.
This led the developed magnetic chip collector can be employed for
safe manufacturing environments in industries.
Simple in construction, mechanically driven ease to handle and discharge off
chips, unskilled labor, low operating and maintenance cost are unique
features of the developed magnetic chip collector.
The efficiency of the developed magnetic chip collector can be improved by
increasing the size and incorporating powerful magnets.
REFERENCE
Prof. Rohidas Waykole et al, “Electromagnetic Scrap Collecting Machine with Vacuum
System‟‟. “International Research Journal of Engineering and Technology (IRJET)
[Link] et al,“Electromagnetic Metal Collecting AGV”International research Journal
of Advanced Engineering and Science ISSN(Online):2455-9024.
Rakshan C. Naik et al, “Design and Development of Magnetic Chip Collector
Machine‟‟. International Journal of Engineering Research in Mechanical and Civil
Engineering (IJERMCE) Vol 2, Issue 5, May 2017
