Conversion of Manual into automatic Transmission of Micro Texturing machine
Texturing is a phenomenon used to enhance the tribological properties of the material. For this different texturing machines are available. We have texturing machine which was operates by buttons. And there are a lot of chances to get errors. For this purpose the machine was converted automatic by p
2025-06-28 16:30:57 - Adil Khan
Conversion of Manual into automatic Transmission of Micro Texturing machine
Project Area of Specialization Mechanical EngineeringProject SummaryTexturing is a phenomenon used to enhance the tribological properties of the material. For this different texturing machines are available. We have texturing machine which was operates by buttons. And there are a lot of chances to get errors. For this purpose the machine was converted automatic by placing 3 npn sensors to control the displacement in all 3 directions. Stepper driver is installed for input and there is load cell amplifier which is used to tell how much is load applied while texturing. Actuator gears were made up of plastic previously which were now changed by metallic actuatic gera so that it must bear more and more load and inhance the efficiency of the machine. A web cam placed in order to do monitoring the texturing process. We use a chuk nut to keep our job in vertical direction. And to end up play in our machine we use we do mechanical alignment analysis in all direction .
By this we can end up up errors and our texturing process will be controlled precisely.
The basic aim of this project was purely to convert our machine from manual to automatic and to end the previously present play in it. So that we must have our textures with precise measurement. we convert it into automatic by placing 3 measurement sensors NPN by installing a camera and stepper driver. By this, our measurement will precise and accurate. And the chance of errors will be ruled out. the textures we get will be accurate and errors free.
Project Implementation MethodIn this project first, we installed 3 NPN sensors to control the movement of the job and to get the job at the right place and at the right dimension. We change the placement of the load cell. At first, our load cell did not give us the value of our load but when we shift the load cell at the front side, above the arm then it gave the accurate value of the load. Then we add different drivers and by coding. we placed a camera as well so that the texturing process must be controlled and monitored well. We change the actuator gears and replace the plastic gears with metallic ones and now it will exert more and more load and can bear .by this we will get our desired results.
Benefits of the ProjectThe major benefit of this project is to get control over our texturing process and the precise dimension of our textures. We get an exact measurement of our own choice. The length, width, and area density of our grooves are accurate and well-controlled. Due to the camera, we have a clear vision of our process.
Due to the manual process, we got a lot of errors in the dimensions of our textures. Now by automatic and by using sensors our texturing process is well defined. And by having exact dimension we can get more and more benefits from texturing process. it will enhance the tribological properties of our material in a better way and will give us results that will be much fruitful.
Technical Details of Final DeliverableThe final product will be completely automatic. It will be completely working by using the software. The dimensions of the textures and area density and the movement of the job will be also done automatically, by using digital plate form. This texturing can be later used in piston rings, mechanical seals and bearings for gripping purposes and lower the coefficient friction and wear debris.
Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology Artificial Intelligence(AI)Other Technologies Robotics, OthersSustainable Development Goals Industry, Innovation and Infrastructure, Reduced InequalityRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 79510 | |||
| Stepper driver x,y & z | Equipment | 3 | 2500 | 7500 |
| Load cell amplifier | Equipment | 1 | 850 | 850 |
| Pic18f452 | Equipment | 1 | 1500 | 1500 |
| Atmega328 | Equipment | 1 | 680 | 680 |
| Relay 12v | Equipment | 2 | 35 | 70 |
| Usb to serial converter | Equipment | 1 | 280 | 280 |
| Contractors | Equipment | 1 | 1350 | 1350 |
| Wires flexible for connections | Miscellaneous | 1 | 350 | 350 |
| Soldring wire | Equipment | 1 | 750 | 750 |
| Soldring iron | Equipment | 1 | 480 | 480 |
| Power supply 24v for motors | Equipment | 1 | 3250 | 3250 |
| Pcb Designing | Equipment | 1 | 5000 | 5000 |
| Pcb etching on fiber | Equipment | 1 | 1500 | 1500 |
| Web cam | Equipment | 1 | 3500 | 3500 |
| Sensors (NPN) xyz | Equipment | 3 | 750 | 2250 |
| Actuator metal gear | Equipment | 1 | 5500 | 5500 |
| Nut bolts mix | Equipment | 1 | 2100 | 2100 |
| welding | Equipment | 1 | 4000 | 4000 |
| Bush motor | Equipment | 1 | 500 | 500 |
| Mechanical Alignment xyz axis on software | Equipment | 1 | 5000 | 5000 |
| Mechanical Fitting & Changing & chuck nut fitting | Equipment | 25 | 600 | 15000 |
| Chuck System | Equipment | 1 | 8500 | 8500 |
| machine pick and drop | Miscellaneous | 2 | 3200 | 6400 |
| vehicle expenditure formaterial purchasing | Miscellaneous | 2 | 1600 | 3200 |