Project Summary
To Design and Develop A CNC / Laser Pipe Cutting Machine for Idler Pipes that are Used In Large Quantities in Belt Conveyors for Bulk Material Handling.
Key Words
Pipe Cutting, Laser Cutting, Product Design, CNC, CNC Pipe Cutting Machine, Idlers, Belt Conveyors
Introduction
Idlers are Extensively Used In Belt Conveyors and Fail many a Times to give a Desent leave alone A Full Life Span before thay are Replaced. Many a Times The Reason for Replacement is Faulty Cutting Practices on Pipes 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 Idlers Is A Matter of Concern to any Maintenance Department Head.
Problem Definition
To Develop a Fool Proof Design for Cutting Pipes So that the they Need not be Measured Frequently During the Manufacturing Process.
Work plan
Designing and Supervising of Manufacturing of CNC / Laser Pipe Cutting 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 CNC / Laser Pipe Cutting Machine with Ball Screws with Stepper Motors | 2 |
| 2 | Cutting of Pipes by LASER Technology preferably | 1 |
| 3 | Conveyor for moving the pipe automatically | 2 |
| 4 | Head Design and Motor Assembly for Tool Holding and 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 |
