AUTOMATION OF SURFACE TREATMENT PROCESSES

Surface Treatment Facility finds its application in various industrial manufacturing processes. The facility operates the chemical tanks with Electroplating or Anodizing setups. These tanks are installed with electric or steam heaters, anodes and cathodes, fumes suction ducts and agitation system. P

Project Title

AUTOMATION OF SURFACE TREATMENT PROCESSES

Project Area of Specialization

Robotics

Project Summary

Surface Treatment Facility finds its application in various industrial manufacturing processes. The facility operates the chemical tanks with Electroplating or Anodizing setups. These tanks are installed with electric or steam heaters, anodes and cathodes, fumes suction ducts and agitation system. Parts/jobs to be chemically treated are placed inside tanks with the help of fixtures or mechanical system which are operated automatically or manually depending upon the operational system of the plant.

Our Project "AUTOMATION OF SURFACE TREATMENT PROCESSES" is categorized into two phases : first consisiting of Mechanical domain i.e Design and development of Material Handling System (Structural Part) and second towards Automation of the proposed system by applying the integration of Electromechanical system by developing the Mastercontroller.

An automated prototype is being developed in this project which will serve as the preferable complete solution for the manufacturing industrial sector specially for the Govenment,  including the Defence industries to perform the desired chemical operations well in time by increasing the productivity and bringing up the innovation by utilizing the advanced techniques. 

Prototype of surface treatment plant is capable of controlling the required essential parameters and setting up the quality assurance as provided by the industries.

Project Objectives

Due to technological advancement in industrial sector, the manufacturing industries are moving towards the automation of plant processes to overcome the manual operations and reducing workforce to increase production up to maximum, where time is of major concern. Likewise, our objective is to automate the surface treatment plant for electroplating and anodizing facility. Furthermore the setup requirement includes the design and development of the mechanical system (Prototype) that is well suited for the surface treatment processes operation, chemical tanks, transportation system between treatment lines and a master controller for controlling the specified parameters of the chemical processes using the PLC (Programmable Logic Controller).

Control Parameter includes:

1) Time (Material Handling System) and complete operation

2) Voltage

3) Current

4) Temperature

All of the above parameters are esssential to perform the desired task of chemical deposition and surface treatment.

After the automation phase, final objective is to control and monitor the whole operation for that it's necessary to built up the SCADA (Supervisory control and Data Acuusition System) for the pictorial representation of whole plant in the control rooom for the real time data update.

Project Implementation Method

Project implementaton method is devised to comprehensively monitor the progress of the project accomplisment by categorizing it into two phases

PHASE-1

Design and development of Material Handling equipment in view of it's  industrial problem as provided by the company. Implementing the engineering knowledge of solid mechanics and Manufacturing courses led towards the selection and numerical approach of the problem

PHASE-2

Automation of Surface Treatment plant by the integration of Electromechanical system using the industrial automation technique of controlling device i.e through  PLC (Programmable Logic Control). After the complete development of automated system, next implementation is of the integrating the control data with the synchronization of SCADA (Supervisory Control and Data Acquisition System) providing the control and representation of Real time data for the complete plant operation.

Control parameters include the implementation of different programing languages i.e PYTHON, LINUX and Ladder logic for the PLC's and Raspberry Pi.

Benefits of the Project

"Automation of Surface Treatment Processes" is a complete industrial application solution which provides the essential benefit to the Manufacturing companies by adopting the automation solution to improve their production at a rapid pace and sustainable development towards the major impact on the growing market. Our solution can be adopted by any company who wants to automate their complete production line by reducing the manpower and improving the efficiency and error free production..

Core benefits include:

* Extensive manual operation by the labours is directly replaced by the Automated machine which performs the same task in less time and no fatigue.

* Industrial work can be done with great procision and accuracy without any chance of error.

* Saving time and money.

* Mass product manufacturing.

* Reliable control and monitoring of the operation.

* Safety hazards are minimized.

Technical Details of Final Deliverable

Automation of Material Hnadling system and complete process of surface treatment facility protytpe is processed by the network of PLC's (Programable Logic Cotrollers), instruments and sensors that implements the desired logic to perform the necessary operation.

Development of Material handling system involves the numerical and analytical calculations in view of engineering knowledge to validate the design and developing a relation among them.

FEM (Finite Element Method) technique is also implemented to cross check the results for the mechnical structure and it's mathematical modeling.

Automation phase includes the PLC's which works on the  basis of the Ladder logic program that executes the operation according to the feed program as per the desired requirement.

A master controller is going to be developed which will monitor the control of :

1) Temperature

2) Voltage

3) Current

4) Time

To cover the software aspects of the final deliverables, a SCADA (Supervisory control and Data Acqusition System) system is developd using a Python and Linux languages to integrate the operations data with the visual representation of the entire processing plant.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Core Technology

Robotics

Other Technologies

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com