Project Summary
To Design and Develop A CNC Welding Machine for Frames that are Used In Large Quantities in Belt Conveyors for Bulk Material Handling.
Key Words
Product Design, CNC, CNC Welding Machine, Idlers, Belt Conveyors
Introduction
Idler Frames are Extensively Used In Belt Conveyors and Fail at Times to give a Desent leave alone A Full Life Span before thay are Replaced. Many a Times The Reason for Replacement is Faulty Welds on Frames Although they are Manufactured as per the Standards Especially in India.
Origin Of Proposal
A large Amount of Resources are Spent in Keeping the Belt Conveyors in Running Condition In Process Oriented Industries and Failure of Frames Is A Matter of Concern to any Maintenance Department Head.
Problem Definition
To Develop a Fool Proof Design for A Idler Frame So that the Frames do not Need Extensive Testing that are Mandatory at present as per Indian Standards.
Work plan
Designing CNC Welding Machine.
Project Information
Review and Status of Research and Development in the Subject
Sample Drawings
Sample Drawings
Time Schedule of Work Plan
| Sl No | Broad Work Element | Time Estimates In Months |
| 1 | Concept Designing of 3-Axis CNC Welding Machine with Ball Screws with Stepper Motors | 2 |
| 2 | Design & Drawings for Mechanical Parts | 2 |
| 3 | Electrcal & Electronic Circuit Design | 2 |
| 4 | Swan Neck Design and Motor Assembly for Welding Torch Movement | 3 |
| 5 | Home Position Location Assembly | 1 |
| 6 | Emergency Stop Electrical Means | 1 |
| 7 | Emergency Stop Electronic Means | 1 |
| 8 | Emergency Stop Mechanical Means | 1 |
Suggested plan of action for utilization of Research Outcome Expected from the project
We are planning to Tie Up with Ramakrishna Mission Vivekananda Educational and Research Institute http://rkmvu.ac.in/ so that they can maintain the Entire Design, Source Code and Related Documentation necessary for it to Survive and Grow or Tie up with Microsoft Corporation / Microsoft Foundation so that A Team can be formed to Ensure that these Services and Upgrades are available to All Organisations in India freely to Develop and Enhance but not to Voilate the Set Statuatory and Predefined Standards.
Budget Estimates: Summary
| Item | BUDGET | (in Rupees) | |||
| 1st Year | 2nd Year | 3rd Year | Total | ||
| A. | Recurring | ||||
| Salary Expenses | 10860000 | 11946000 | 13140600 | 35946600 | |
| Printing and Stationery | 300000 | 330000 | 363000 | 993000 | |
| Travelling Expenses | 1200000 | 1320000 | 1452000 | 3972000 | |
| Others | 30000000 | 33000000 | 36300000 | 99300000 | |
| B. | Equipment To be Built If Applicable | 50000000 | 25000000 | 20000000 | 95000000 |
| Grand Total (A+B) | 92360000 | 71596000 | 71255600 | 235211600 |
Budget for Salaries/Wages
| Position Description | No Of Posts | Monthly Emoluments | BUDGET | (in Rupees) | ||
| 1st Year | 2nd Year | 3rd Year | Total | |||
| Design Engineer Mechanical | 1 | 125000 | 1500000 | 1650000 | 1815000 | 4965000 |
| Accountants | 1 | 125000 | 1500000 | 1650000 | 1815000 | 4965000 |
| Purchase Officer | 1 | 125000 | 1500000 | 1650000 | 1815000 | 4965000 |
| Staff Assistant | 2 | 40000 | 960000 | 1056000 | 1161600 | 3177600 |
| Marketing Managers | 2 | 100000 | 2400000 | 2640000 | 2904000 | 7944000 |
| Internal Project Manager | 1 | 250000 | 3000000 | 3300000 | 3630000 | 9930000 |
| Totals | 10860000 | 11946000 | 13140600 | 35946600 |
Budget for Consumable Materials
| Item | BUDGET | (in Rupees) | ||
| 1st Year | 2nd Year | 3rd Year | Total | |
| Printing and Stationery | 300000 | 330000 | 363000 | 993000 |
Budget for Travelling Expences
| Item | BUDGET | (in Rupees) | ||
| 1st Year | 2nd Year | 3rd Year | Total | |
| Travelling Expenses | 1200000 | 1320000 | 1815000 | 4335000 |
Budget for Other Expenditures
| Item | BUDGET | (in Rupees) | ||
| 1st Year | 2nd Year | 3rd Year | Total | |
| Others | 30000000 | 33000000 | 36300000 | 99300000 |
Budget for Equipment If Applicable
| Item | BUDGET | (in Rupees) | ||
| 1st Year | 2nd Year | 3rd Year | Total | |
| Equipment To be Built If Applicable | 50000000 | 25000000 | 20000000 | 95000000 |
Infrastructural Facilities
| SrNo | Infrastructural Facility | Status |
| 1 | Workshop Facility | Yes – Sharing basis |
| 2 | Water & Electricity | Yes - Sharing basis |
| 3 | Laboratory Space/ Furniture | Yes - Sharing basis |
| 4 | Power Generator | No |
| 5 | AC Room or AC | No |
| 6 | Air Cooler If Tempratures are too High | Yes |
| 7 | Telecommunication including e-mail & fax | Yes |
| 8 | Transportation | Yes |
| 9 | Administrative/ Secretarial support | Yes – Sharing Basis |
| 10 | Information facilities like Internet/ Library | Yes – Sharing Basis |
| 11 | Computational facilities | Yes – Sharing Basis |
| 12 | Animal/ Glass House | No |
| 13 | Any other special facility being provided | Not Required |
Equipment available with the Institute/ Group/ Department/ Other Institutes for the project
| Sl No | Equipment Available | Generic Name Of Equipment | Qty Available | Model Make And Year Of Purchase | Remarks Including Accessories Available And Current Usage Of Equipment |
| 1 | With Group | Laptops | 1 | 2016-2016 | 60% capacity utilisation |
| 2 | With Group | Laptops | 1 | 2016-2016 | 60% capacity utilisation |
| 3 | With Group | Laptops | 1 | 2016-2016 | 60% capacity utilisation |
| 4 | With Group | Major CNC Turning Center | 1 | Major 1000 - 2014 | 40% capacity utilisation |
| 5 | With Group | MIG welding equipment | 1 | Mogora – 2018 | 60% capacity utilisation |
| 6 | With Group | Drilling Machine | 1 | Local – 1996 | 20% capacity utilisation |
| 7 | With Group | Cutting Machine | 1 | Local – 2000 | 25% capacity utilisation |
