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“Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center” This paper involves the use of automation solution to reduce operator fatigue and increase efficiency. Industries in the recent day concentrating on CNC machineries for mass production by replacing conventional lathes to improve productivity, But loading and unloading of job carried over by manual , However Present work, machine tool manufacturer are coming with solutions including automatic loading and unloading to reduce the fatigue of labor and reduce cycle time and increasing productivity. Productivity Improvement on a CNC DX-100 by Automatic Loading and Unloading of Cylindrical Component includes analysis and detailed study of manufacturing process including loading and unloading methods of components on a machine. Present work aims at improving the productivity of cylinder components on a CNC turning center. Here emphasis is placed upon improving the existing time consuming methods.
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IJSTE - International Journal of Science Technology & Engineering | Volume 1 | Issue 11 | May 2015 ISSN (online): 2349-784X
All rights reserved by www.ijste.org
359
Design and Development of Automation of
Loading and Unloading to DX-100 CNC Turning
Center
Shivbhadrasinh Jhala Apurva Indrodia
PG Scholar Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering
Marwadi Edu. Foundation Rajkot Marwadi Edu. Foundation Rajkot
R.L. Jhala
Principal Faculty of Technology
Department of Mechanical Engineering
Abstract
Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center This paper involves the use of automation solution to reduce operator fatigue and increase efficiency. Industries in the recent day concentrating on CNC
machineries for mass production by replacing conventional lathes to improve productivity, But loading and unloading of job
carried over by manual , However Present work, machine tool manufacturer are coming with solutions including automatic
loading and unloading to reduce the fatigue of labor and reduce cycle time and increasing productivity. Productivity
Improvement on a CNC DX-100 by Automatic Loading and Unloading of Cylindrical Component includes analysis and detailed
study of manufacturing process including loading and unloading methods of components on a machine. Present work aims at
improving the productivity of cylinder components on a CNC turning center. Here emphasis is placed upon improving the
existing time consuming methods.
Keywords: Autoloader, Loading-Unloading, Automation, CNC, DX-100
________________________________________________________________________________________________________
I. INTRODUCTION
Turning operation is one amongst the foremost basic machining processes. within the family of DX series DX100 is developed
for batch kind production in trade. Its incline rigid mono block structure permits high dynamic parameters that absorb torsion and
damps vibration therefore guarantee in highest preciseness, metal cutting capability and gear life. There area unit several
operations will done by DX100 like Facing, shaping (external shaping and face grooving), tapper turning , parting, boring,
drilling, threading. Automation is that the use or introduction of automatic instrumentation during a producing or alternative
method or facility.
II. PROBLEM DEFINITION
In DX 100 Machine loading and unloading Is done by Manually, and manual work manpower Target is to Automation in DX
100 machine,. So By using robotics we can load & unload the components, which in turn reduces the cycle time & also require
less labour work. So, we compare the job in less time at high accuracy. Hence we can achieve the goal to reduce the cycle time &
increase the productivity.
III. PROBLEM APPROACH
Existing Scenario: A.
In DX 100 Operator friendly operating controls with simple job loading and unloading facilities. Selecting easy and human
ergonomically position labour adjust the distance from the machine and make the manual job loading unloading.In DX 100
machine, for calculating manual loading and unloading time, there is referred a particular job with following dimensions:
A cylindrical part with length of 148mm and diameter 0f 20mm
To calculate average time of loading and unloading job in manual operations, there are performed some practical to record their
different time of loading-unloading. Table -1
Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center (IJSTE/ Volume 1 / Issue 11 / 062)
All rights reserved by www.ijste.org
360
Sr
No.
operation
Time (Approximate)
Required Operator
1 Open the door and unload the finished job from chuck 8 to 10 sec 1
2 Put the finished job on table and bring the new job for machining 5 sec 1
3 Load the job in the chuck and close the door and start machining 8 to 10 sec 1
21 to 25 sec by one operator
To calculate average time of loading and unloading job in manual operations, there are performed some practical to record
their different time of loading-unloading. Table 2
Practical
No.
Time for Loading and
Unloading(Approximate) 7 22 sec
1 22 sec 8 28 sec
2 24 sec 9 30 sec
3 21 sec 10 25 sec
4 24 sec Average Time for loading-unloading 24.4 sec 25 sec
5 23 sec
6 25 sec
So, approximately, total time of finished job = machining time + Loading-unloading time
= 1 min 52 sec + 25 sec
= 2 min 17 sec =137 sec
According to this time for a single job,
Number of finished job per hour =
= 26.27 26 jobs So, there are 26 jobs which are completed in one hour.
As working condition of machine, it performs for 22 hour per day in company.
So, total number of finished job per day = number of job per hour * total working hour per day
= 26 * 22
= 572 job per day
To calculate average time for loading-unloading per day,
= average time of loading-unloading for single job * number of finished job per day
= 25 sec * 572
= 14,300 sec
= 238 min 20 sec
= 3 hour 58 min 20 sec
So, average time for loading-unloading per day is 3 hour 58 min 20 sec.
Cycle on Each Component: B.
The Auto Loader is one of the equipment which design for DX 100 Turning Machine and it manipulates the human as it is an
automatic device. It loads the work pieces on the chuck from the plate and because of that the production rate of DX 100 turning
machine can be increased.
IV. DEVELOPMENT OF LOADING UNLOADING SYSTEM
Turning operation is one amongst the foremost basic machining processes. With in the family of DX series DX100 is developed
for batch kind production in trade. Its incline rigid mono block structure permits high dynamic parameters that absorb torsion and
damps vibration therefore guaranteeing highest preciseness, metal cutting capability and gear life. There area unit several
operations will done by DX100 like Facing, shaping (external shaping and face grooving), tapper turning ,parting, boring,
drilling, threading. Automation is that the use or introduction of automatic instrumentation during a producing or alternative
method or facility.
Concept of Automation: A.
For automation in DX 100 machine, considering a plate which is used to store number of job pieces which are going to perform
for machining. The capacity of plate is 9 to 10 jobs. This is depended on the dimensions of job.
Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center (IJSTE/ Volume 1 / Issue 11 / 062)
All rights reserved by www.ijste.org
361
Fig. 1: Job
Fig. 2: Plate
Design Possibility: Case I: Upper Side of the Chuck: B.
Fig. 3: Upper Side of the Chuck
Here, Plate is located at upper side of the chuck. A mechanism like gripper is used to hold job from the plate and to load in the
chuck. Dimension of gripper is approximately same as per job. The path of this mechanism is shown as line diagram in figure
4.3. The path of mechanism is denoted as 1-2-3-4-5. The unloading of the part is automatic, after the completion of machining
cycle, chuck will open and part will be dropped into the plate.
Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center (IJSTE/ Volume 1 / Issue 11 / 062)
All rights reserved by www.ijste.org
362
Design Possibility: Case Ii: Lower Side of the Chuck: C.
Fig. 4: Lower Side of the Chuck
Here, Plate is located at lower side of the chuck. A mechanism like gripper is used to hold job from the plate and to load in the
chuck. The path of this mechanism is shown as line diagram in figure 4.4. The path of mechanism is denoted as 1-2-3-4-5.
Design of Autoloader And Its Assembly Component: D.
Fig. 5: Assembly of Auto Loader
Fig. 6: Exploded View of Auto Loader
Production Time for New Design: E.
Table 3
Sr. No. Operation Time(Approximate) Required Operator
1 Open the door and unload the finished job from chuck 5 to 6 sec 0
2 Put the finished job on table and bring the new job for machining 2 sec 0
3 Load the job in the chuck and close the door and start machining 5 to 6 sec 0
Total Time( Approximate) 12 to 14 sec
To calculate average time of loading and unloading job in manual operations, there are performed some practical to record their
different time of loading-unloading.
Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center (IJSTE/ Volume 1 / Issue 11 / 062)
All rights reserved by www.ijste.org
363
Table 4 Average Loading Unloading Time for Job
Practical No. Time for Loading and Unloading(Approximate) 6 13
1 13 7 13
2 13 8 13
3 13 9 13
4 13 10 13
5 13 Average Time for loading-unloading 13
So, Average time for loading-unloading is 13 sec.
To calculate production of number of jobs per day, there is taking 1 min 52 sec as machining time for job. Here, machining
operation is considered as threading on the job.
So, approximately, total time of finished job = machining time + Loading-unloading time
= 1 min 52 sec + 13 sec
= 2 min 17 sec=125 sec
According to this time for a single job,
Number of finished job per hour =
= 28.8 29 jobs So, there are 29 jobs which are completed in one hour.
As working condition of machine, it performs for 22 hour per day in company.
So, total number of finished job per day = number of job per hour * total working hour per day
= 29 * 22
= 638 job per day
To calculate average time for loading-unloading per day, = average time of loading-unloading for single job by autoloader * number of finished job per day
= 13 sec * 638
= 8294 sec
= 137 min 14 sec
= 2 hour 17 min 14 sec
So, average time for loading-unloading per day is 2 hour 17 min 14 sec.
V. RESULT AND DISCUSSION
Table 5 Result and Discussion
Sr.
No. Operation Time(Approximate)
Required
Operator Time(Approximate)
Required
Operator
1 Open the door and unload the finished job from
chuck
with Auto loader Manually
- 0 8 to 10 sec 1
2 Put the finished job on table and bring the new
job for machining - 0 5 sec 1
3 Load the job in the chuck and close the door and
start machining - 0 8 to 10 sec 1
Total Time( Approximate) 12 to 14 sec by one operator 21 to 25 sec by one operator
Average Time for loading-unloading 13 sec 25
total time of finished job 125 sec 137 sec
Number of finished job per hour 29 jobs 26 jobs
finished job per day 638 job per day 572 job per day
average time for loading-unloading per day 2 hour 17 min 14 sec 3 hour 58 min 20sec
After experimental investigation we can conclude that implementation of Auto loader in cycle the DX100 CNC machines productivity increase.
Design and Development of Automation of Loading and Unloading to DX-100 CNC Turning Center (IJSTE/ Volume 1 / Issue 11 / 062)
All rights reserved by www.ijste.org
364
VI. CONCLUSION
Development of automatic loading and unloading arrangement in the in DX 100 reducing Labur cost and total cycle time is
minimized also increased productivity. Profit for industry is 638 job instead of 572 job per day using proposed Design of
autoloader in particularly DX 100 Machine
ACKNOWLEDGMENT
This Research work grateful to Department of Mechanical Engineering Faculty of PG Studies & Research, MEFGI and Mr
Yuvrajsinh Jadeja (Engineer- Customer Solution) &Jyoti CNC Ltd Rajkot for necessary Experimental facilities and all
testimonial provided for make successful Research.
REFERENCES
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