Project Summary
To Design and Develop Rubber Seals for Sealing the Idlers that are Used In Large Quantities in Belt Conveyors for Bulk Material Handling.
Key Words
Seals, Product Design, Process Design, Idlers, Belt Conveyors
Introduction
Idlers are Extensively Used In Belt Conveyors and Often Fail to give a Desent leave alone A Full Life Span before thay are Replaced. Many a Times The Reason for Replacement is Faulty Manufacture of the Seals that are Used 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 Idelrs Is A Matter of Concern to any Maintenance Department Head.
Problem Definition
To Develop a Fool Proof Design for An Idler Seal So that the Idlers do not Need any Testing for Water Penetration and Dust Penetration Tests on Special Testing Machines that are Mandatory at present as per Indian Standards.
Work plan
Designing Seals for Different Bearing Sizes.
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 | Designing Seals for 6204 Bearing | 2 |
| 2 | Choosing a suitable Rubber Material preferably Neoprene Rubber | 2 |
| 3 | Designing Molds for Rubber Molding of Seals | 2 |
| 4 | Testing of this for Batch Production. | 3 |
| 5 | Machines choosen must have Electronic controls for safety and Automation within permissible levels so that employment also is available and can be scaled. We can have an advanced mechanism for Automation that is disabled so that employment oppourtunity is generated in thickly populated areas and Automation in used if absolutely necessary. | 2 |
| 6 | Repeate the same for 6205 and 6206 Bearing Sizes | 4 |
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 |
