AKSHAY.S T.MEHANATHAN

N.C.SATHISH KUMAR R.SATISH KUMAR

Guided by: Mr. S. Prabhakaran Sr.Lecturer M.E

MODULAR PRESS (S1 LINE) DOWN TIME REDUCTION (PART IN FAULT & VACUUM CUP

FAULT REDUCTION)

The aim of the project is to observe and rectify the various factors responsible for downtime in the S1 line Press shop. The “Part in fault” and “Vacuum cup fault” stand out as the major sources. There by finding remedial measures for the proposed problems, reduction of downtime is our goal.

The Part in fault mainly arises because of several sub factors. The loosening of the proximity sensor placed on the die due to heavy vibrations during the processing is a major factor.

The Vacuum Cup fault mainly arises because wear and tear of the cup. The vacuum cup is mainly used in the robotic arm to lift up and place the sheets of metal from one die to another. The fault prevailed in them will lead to serious problems.

ABSTRACT

Hyundai Motors India Ltd  Hyundai is the sixth manufacturing unit outside the

parent country is also the largest groups overseas production base. Even as the project was being conceptualized, Hyundai Motors India Ltd. The Hyundai India plant located at Irungattukottai, 30Km from Chennai. The plant is self-sufficient manufacturing unit in India to be independently invested by an overseas automobile company, incorporated in may 1996, the ground breaking ceremony for the Chennai plant was held in December in the same year, and the first pilot santro was ready in a record breaking 17 months.

COMPANY PROFILE

Company Founded By: Chung Ju-Yung in 1967 Headquarters: Seoul, South Korea Present CEO: Mong-Koo Chung Industry: Automobile manufacturer Production Output: 2,943,529 units (2011) Revenue: US$ 97.408 billion (2011) Net income: US$ 4.707 billion (2011) Employees: 80,000 (2011) Parent: Hyundai Kia Automotive Group Website: Hyundai-Motor.com

PRESS SHOP

HMIL comprises of a computer controlled line that converts sheet metal to body panels with high dimensional accuracy and consistency.

Stamping includes a variety of sheet-metal forming manufacturing processes such as punching using a stamping press, blanking, embossing and bending. This could be a single stage operation where every stroke of the press produce the desired form on the sheet metal part, or could occur through a series of stages.

STAMPING

In the S1 Line blank enters into the sector through an input region where stacks of sheet metal are piled together, lifted using vacuum grippers and traversed by a conveyor which lead to the preliminary die. After having the primary stamping operations taken place, the sheet metal is picked up by the robotic arm (a pick and place assembly associated with 8 vacuum cups) and placed over an idle zone.

Similarly the blank traverses through a series of four dies and intermediate arms respectively and finally once the stamping operation is accomplished completely, the components exit out of the sector through a conveyor from where it is transported to the desired storage locations. The components exit the press shop and enter into the assembly shop for welding operations.

S1 LINE

S1 LINE LAYOUT

SOURCES OF PROBLEM

The traditional Cleat type of vacuum cups have a much accelerated wear and tear property which is mainly due to the heavy pressure acting over the walls of the cups. Wear and tear unnoticed may lead to problems such as dropping of sheet metal or even distorted outputs. Even the pressure exerted on the sheet metal component for lifting will be low.

VACUUM CUPS BEFORE REMEDY

By using bellowed type of vacuum cups, the lifespan of the cup can be maximized as the pressure acting on the walls of the cup is minimized while suction pressure between the walls and the sheet metal is enhanced.

By using this method the replacement time can be minimized as compared to the former method.

These bellows reduce uneven concentration of pressure on these cups which enhance life time.

VACUUM CUPS AFTER REMEDY

  Double Nut Remedy  The introduction of

double nuts which can revolve around the threaded contact in opposite directions can adjust the height of the sensor as well as keep it fixed that is to prevent it from further displacement. This technique is quite simple and allows perfection.

PART IN FAULT REMEDIAL MEASURE (I)

Internal Thread remedyIn the internal thread

remedy measure, the base plate is subjected to internal threads which mesh with the cylindrical sensory external threads. This will allow a supportive fixture to the sensor thereby preventing it from ever displacing due to vibrations. The internal thread will also permit adjustability of the sensor. The sensor can be slided up and down as per the recommended settings.

PART IN FAULT REMEDIAL MEASURE (II)

Spring remedy Our third proposed

remedial measure is “Spring Action Remedy”. This technique is quite simple. In this technique all that has to be done is to introduce a spring in between the nut and base plate which will favor adjustment as well as stationary support.

PART IN FAULT REMEDIAL MEASURE (III)

CABLE FAULT REMEDY:

PROJECT DESIGNS:

During the initial study of the press shop and S1 line we observed that there was a considerate amount of downtime arising out of various factors. After critically acclaimed examination we discovered that two major root causes were “The Part in Fault” and “Vacuum cup fault.” The part in cup fault arose mainly because of the problem of loosened or displaced proximity sensor on the die as a result of heavy vibrations during processing. So we had proposed three remedial measures for this problem. The first one was to have a double nut assembly which moves oppositely over the external thread of the sensor giving them adjustability and a firm grip of position. The second method was to have an internal thread on the base plate on which the sensor is mounted. The internal thread of the plate will mesh with the external thread of the proximity sensor. This would also provide adjustability and stability. The final proposed method is to introduce a spring in between the nut and base plate, which due to elasticity will provide stability of position and adjustability.

The Vacuum cup fault could also be rectified by a changed design of vacuum cup which we suggested. The new model cup consists of bellows. Our model of vacuum cup bellows compensate for uneven or inconsistent surfaces making them highly versatile with increased life and minimized replacements Towards the end, our suggested methods have been taken into account with a major view of reducing down time in production. The cable fault can also be rectified by enabling a proposed kind of opening jack.

Most importantly the OP10 die problems are mainly caused due to decentralization of sheet metals. The blanks can be arranged in an orderly pile by introducing a position sensor. The position sensor senses the uneven distribution of the pile and stacks them together using a mechanical stacking unit, thus eliminating the problem.

CONCLUSION:

The Stamping Journal, March/April edition, A Publication of the Fabricators & Manufacturer’s Association (FMA), U.S.A.

Mechanics of sheet metal forming, Edition 2002. Authors: Z. Marciniak, J. L. Duncan, Jack Hu. Butterworth-Heinemann Publications.

Websites: http://en.wikipedia.org/wiki/Stamping_(metalworking) http://www.efunda.com/processes/metal_processing/

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