Mattingly "AI & Prompt Design" - Introduction to Machine Learning"
Vimalreport
1. DESIGN AND FABRICATION OF FABRIC CUTTING
MACHINE
A PROJECT REPORT
Submitted By
G.SAMI DURAI
(08MER092)
B.SATHISH KUMAR
(08MER102)
R.VIMALANATHAN
(08MER119)
in partial fulfillment of the requirements
for the award of degree
of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
SCHOOL OF BUILDING AND MECHANICAL SCIENCES
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI, ERODE – 638 052
NOVEMBER 2011
2. DEPARTMENT OF MECHANICAL ENGINEERING
KONGU ENGINEERING COLLEGE
(Autonomous)
PERUNDURAI ERODE – 638052
NOVEMBER-2011
BONAFIDE CERTIFICATE
This is to certify that the Project report entitled “DESIGN AND FABRICATION OF
FABRIC CUTTING MACHINE” is the bonafide record of project work done by
G.SAMI DURAI
(08MER092)
B.SATHISH KUMAR
(08MER102)
R.VIMALANATHAN
(08MER119)
in partial fulfillment of the requirements for the award of the Degree of Bachelor of
Engineering in Mechanical Engineering in Anna University, Coimbatore during the
year 2011 - 2012.
SUPERVISOR
HEAD OF THE DEPARTMENT
Date:
Submitted for the end semester viva voce examination held on ___________
INTERNAL EXAMINER
EXTERNAL EXAMINER
3. iii
DECLARATION
We affirm that the Project Report titled “DESIGN AND FABRICATION OF
FABRIC CUTTING MACHINE” being submitted in partial fulfillment of the
requirements for the award of Bachelor of Engineering is the original work carried out
by us. It has not formed the part of any other project report or dissertation on the
basis of which a degree or award was conferred on an earlier occasion on this or any
other candidate.
Date:
G.SAMI DURAI
(08MER092)
B.SATHISH KUMAR (08MER102)
R.VIMALANATHAN (08MER119)
I certify that the declaration made by the above candidates is true to the best of my
knowledge
Date:
SUPERVISOR
4. iv
ACKNOWLEDGEMENT
We thank our beloved Correspondent Thiru. R.K.VISHWANATHAN and all
the members of Kongu Vellalar Institute of Technology Trust at this high time for
providing us with plethora of facilities to complete my project successfully.
We take privilege to express my profound thanks to our beloved Principal
Prof. S. KUPPUSWAMI who has been a bastion of moral strength and a source of
incessant encouragement to us.
We express our sincere thanks to Dr. K. KRISHNAMURTHY, Dean, School of
Building and Mechanical Sciences, for his valuable guidance and suggestions.
We express our sincere thanks to Dr. P. NAVANEETHAKRISHNAN, Head of
the Department Mechanical Engineering, for his valuable guidance and suggestion.
We take immense pleasure to express our heartfelt thanks to our beloved
project guide, Mr. M.VIJAY ANAND for his valuable suggestions, excellent guidance
and constant support provided all through the course of our project.
We thank our project coordinator Dr. V.HARIHARAN and review committee
members for their valuable suggestions for completion of the project successfully.
We also thank the teaching and non teaching staff members of Mechanical
Engineering Department and all our fellow students who stood with us to complete
our project successfully.
5. v
ABSTRACT
Nowadays, the textile industry is the fastest growing sector in India. For such a
sector, the productivity and the quality of the product should be enhanced. In this
project, we enhance the product quality of the textile industry. The fabrics cutting is
the major process carried out in textile industries. At present, the cutting process in
the textile industry is carried out manually by using cutting and tools, this result in
improper cutting of fabric materials. The main reason for the above problems is due to
fatigue nature of the employees and improper measuring and cutting. To overcome
these problems, an automated fabric cutting machine is designed and fabricated. In
this machine, the fabric material is fed between the rollers. The measurement of the
required length is fed in the microcontroller as an input. As soon as the desired length
is obtained, the roller will stop its rotation and the metal cuter which is placed
horizontally will cut the fabric material. The function of the cutter is attained with the
help of the pneumatic circuit. The machine is mainly designed and fabricated to avoid
the improper alignment of the fabric and increase the productivity and quality of the
product.
6. vi
TABLE OF CONTENTS
CHAPTER NO.
TITLE
PAGE NO.
ABSTRACT
v
LIST OF TABLES
LIST OF FIGURES
ix
LIST OF NOMENCLATURE
x
INTRODUCTION
01
1.1
COMPONENTS USED
02
1.1.1 Power Supply
02
1.1.2 Step down Transformer
02
1.1.3 Voltage Regulator
02
1.1.4 Capacitor
03
1.1.5
Resistor
03
1.1.6
Relay
03
1.1.7
1
viii
Microcontroller Interfacing with
Motor
03
1.1.8
Roller
04
1.1.9
DC Motor
04
1.1.10 Flow Control Valve
05
1.1.11 Five-Port / Two-Way
Directional Valve
1.1.12 Pneumatic Cylinder
05
05
2
LITERATURE REVIEW
07
3
PROBLEM DEFINITION
10
7. vii
4
DESIGN AND DEVELOPMENT
11
4.1
DESIGN PHASE
11
4.1.1
Design of Bearing
11
4.1.2
Cutting Mechanism
11
4.1.3
Clamping Mechanism
12
4.1.4
Design of Electrical Circuit
12
4.1.5
Design of Pnuematic Circuit
13
4.1.6
Design of Setup
15
4.2
16
4.3
5
OPERATIONAL FEASIBILITY
ECONOMIC FEASIBILITY
16
17
5.1
6
FABRICATION PROCESS
17
PROCESS DESCRIPTION
19
6.1
7
RESULT AND DISCUSSION
20
ADVANTAGES
CONCLUSION
21
APPENDIX
22
REFERENCES
23
9. ix
LIST OF FIGURES
FIGURE NO.
1.1
TITLE
BLOCK DIAGRAM OF A REGULATED
POWER SUPPLY SYSTEM
1.2
PAGE NO.
02
INTERFACING OF
MICROCONTROLLER
04
4.1
DIMENSION OF PNEUMATIC CYLINDER
11
4.2
BLOCK DIAGRAM OF ELECTRICAL
CIRCUIT
13
4.3
SEQUENCIAL CIRCUIT DESIGN
14
4.4
MODEL OF FABRIC CUTTING
MACHINE
5.1
15
PARTS AND DIMENSION OF BASE
SETUP
6.1
18
FABRICATION PROJECT
19
10. x
LIST OF NOMENCLATURE
SYMBOLS
NOTATIONS
A
Area, cm2
D
Diameter of the shaft,cm
d1
Bore diameter ,mm
d2
Piston rod diameter, mm
F
Force,N
L
Bearing length,cm
L1
Stroke Length of cylinder,mm
N
Speed of the shaft,rpm
P
Pressure,bar
DCV
Direction control valve
PS
Push Button
SOL
Solenoid
V
Voltage
11. 1
CHAPTER 1
INTRODUCTION
In this technological and sophisticated world, automation becomes an
important factor in every field. So in every industry, automation of machines is
promoted to increase the accuracy and quality of the products. Insufficient in human
resource also leads to automation of machines in the industry. Thus for every industry
automation is a necessary one which includes textile industry. As textile industry is
the fast growing industry in India which contributes about 14% to the country's
industrial output and about 17% to export earnings. But still there is less accuracy and
man power is more in one field that is none other than textile industries.
In textile industry, fabric material is the only raw material. The cutting operation
of fabric materials is done by high cost machine in large scale industries. But in small
scale industries, the cutting operation is performed by manually i.e., by using cutting
tools. In small scale industries, the cutting operation is done manually because the
industry cannot afford huge amount for the cutting machine. This process of cutting
requires skilled person for cutting the fabric materials. Sometimes accuracy of the cut
cannot be obtained by the above stated process. This leads to wastage of fabric
materials
The major problem in these industries are improper measuring and cutting of
fabric materials, this leads to wastage of materials and reduce the productivity which
intern increases the cost of the product. . If the above problems are rectified at the
low cost, then the productivity of the products can be increased. To overcome this
problem, an Automatic Fabric Cutting Machine is designed and fabricated, which is
used to cut the fabric material for the required length accurately.
The project proceeds with fabrication of cutting machine at low cost which is an
automated one. The components used in the projects are electrical components,
pneumatic components and mechanical components. They are described in the next
section.
12. 2
1.1
COMPONENTS USED
The components used in the project are described as follows.
1.1.1 Power Supply
A power supply is a device that supplies electrical energy to one or more
electric loads. The term is most commonly applied to devices that convert one form of
electrical energy to another, though it may also refer to devices that convert another
form of energy to electrical energy. A regulated power supply is one that controls the
output voltage or current to a specific value; the controlled value is held nearly
constant despite variations in either load current or the voltage supplied by the power
supply's energy source. The Figure 1.1 shows the block diagram of a regulated power
supply system.
Figure 1.1 Block Diagram of a Regulated Power Supply System
1.1.2 Step down Transformer
Step down transformers convert electrical voltage from one level or phase
configuration usually down to a lower level. The transformer takes in the high voltage
at a low current and puts out a low voltage at a high current. In this project 220 V AC
is converted to 5-12 V DC.
1.1.3 Voltage Regulator
A voltage regulator is an electrical regulator designed to automatically maintain
a constant voltage level. A simple voltage regulator can be made from a resistor in
series with a diode. The power supply of most PCs generates power at 5 volts but
most microprocessors require a voltage below 3.5 volts. The voltage regulator's job is
to reduce the 5 volt signal to the lower voltage required by the microprocessor.
Typically, voltage regulators are surrounded by heat sinks because they generate
significant heat.
13. 3
1.1.4
Capacitor
A capacitor is a passive two-terminal electrical component used to store
energy in an electric field. It is used in this circuit to help keep the voltage regulator’s
output voltage constant over time. The rate of change of the voltage across a
capacitor is proportional to the current flowing out of it divided by the capacitance.
Therefore, the larger the capacitor, the small changes in voltage at the output of the
regulator over time for a fixed current drain.
1.1.5
Resistor
A linear resistor is a linear, passive two-terminal electrical component that
implements electrical resistance as a circuit element. The current through a resistor is
in direct proportion to the voltage across the resistor's terminals. Thus, the ratio of the
voltage applied across a resistor's terminals to the intensity of current through the
circuit is called resistance.
1.1.6 Relay
A relay is an electrically operated switch. Many relays use an Electromagnet to
operate a switching mechanism mechanically, but other operating principles are also
used. Relays are used where it is necessary to control a circuit by a low-power signal,
or where several circuits must be controlled by one signal. The first relays were used
in long distance telegraph circuits, repeating the signal coming in from one circuit and
re-transmitting it to another. Relays were used extensively in telephone exchanges
and early computers to perform logical operations.
1.1.7 Microcontroller Interfacing With Motor
The AT89C51 is a low power, high performance C-MOS 8-bit microcomputer
with 4k bytes of flash programmable and erasable read only memory (PEROM). The
device is manufactured using Atmel’s high-density nonvolatile memory technology
and is compatible with the industry standard MCS-51 instruction set and pinout. The
on-chip flash allows the program memory to be reprogrammed in-system or by a
14. 4
conventional nonvolatile memory programmer. By combining a versatile 8-bit CPU
with flash on the monolithic chip, the AT89C51 is a powerful microcomputer, which
provides a flexible and cost-effective solution to many embedded control applications.
Figure 1.2 shows the microcontroller interfacing with motor.
Figure 1.2 Interfacing of Microcontroller
1.1.8 Roller
Roller is made up of sheet metal. In this sheet is rolled and wielded by using
electric arc wielding. The ends of rolled sheets are closed by using sheet plates
machined to proper dimensions and the shaft is provided at centre of roller. The
material of plate and shaft is MS steel. Thus desired roller is obtained. The
dimensions are specified below. The specifications of roller are as follows:
Outer diameter
Length of the roller = 305 mm
= 76 mm
1.1.9 DC Motor
A DC Motor is high quality low cost DC geared motor. It has steel gears and
pinions to ensure longer life and better wear and tear properties. Stall Torque is the
torque which is produced by a motor when the output rotational speed is zero, it may
also mean the torque load that causes the output rotational speed of a motor to
become zero - i.e. to cause stalling. The motor is used to rotate the roller at constant
speed.
15. 5
The specifications of the motor are described as follows
Input voltage
= 12 V
Type
= DC motor
Speed
= 30 RPM
Shaft Diameter
= 8 mm
Motor weight
= 1 ½ Kg
Load withstanding capacity
= 75 Kg
1.1.10 Flow Control Valve
Flow control valves, also known as volume control valves, are used to regulate
the volumetric flow of the compressed air to different parts of a pneumatic system. In
this project, two flow control valves are used for two pneumatic cylinders. By using
this, the flow can be controlled during the operation of ejecting, holding and cutting
operation.
1.1.11 Five-Port / Two-Way Directional Valve
Two-way valves are also available with five external ports, one pressure port,
two actuator ports, and two exhaust ports. Such valves provide the same basic
control of flow paths as the four-ported version, but have individual exhaust ports. In
the fluid power field this is referred to as a "five-ported, two-way valve." This type of
valve brings all flow paths to individual external ports. The pressure port is connected
to system pressure after a regulator. Actuator ports are connected to inlet and outlet
ports of a cylinder or motor. Each exhaust port serves an actuator port.
1.1.12 Pneumatic Cylinder
Pneumatic cylinders are the devices used for converting the pressure energy
of air (also called pneumatic energy) into linear mechanical force and motion to
perform useful work. Pneumatic cylinder mainly consists of a piston, a cylinder, and
valves or ports. Mainly pneumatic cylinder is classified into single acting and double
acting cylinder. Pneumatic cylinders employ a smooth-bore cylinder with a piston
16. 6
affixed to a piston rod, with several seals between the piston and cylinder. They most
often consist of metal components, although many composites are used for special
applications. They are available with a variety of end fittings and pneumatic piping
and tubing connections. In double-acting cylinders, air pressure can be applied to
either side of the piston, therefore producing pneumatic force in both directions. They
perform work in both directions of movement. These cylinders do not require a return
whenever the device is not powered. In this project, two double-acting cylinders are
used. The dimension of the pneumatic cylinders are specified below,
Cylinder diameter
= 140 mm
Bore diameter
= 100 mm
Stroke length
= 100 mm
Piston rod diameter
= 50 mm
17. 7
CHAPTER 2
LITERATURE REVIEW
Borelli et al (2002) convey about the hot cutting fabric by using infrared images
to cut. In the hot cutting of fabric, one of the variables of great importance in the
control of the process is the contact temperature between the tool and the fabric. This
work presents a technique for the measurement of the temperature based on the
processing of infrared images. The cutting mechanism used in this was thermal
degradation.
Thilagavathi et al (2010) about Fiber structures, yarn structures, and
mechanical properties of fibers namely tensile modulus, tenacity, and elongation, are
the key performance indicators of fabric cut resistance. P-aramid and UHDPE (Ultra
High Density Polyethylene) based high performance fibers are most commonly used
for protection against mechanical risks. Specially engineered composite yarns and
fabrics enhance cut resistance. This paper discusses the influence of textile structure
configuration on the performance of cut resistant textiles. A three tier laminate
composite was made using knitted Kevlar fabric, as the outer surface, polyurethane
foam in the middle and a knitted nylon fabric as the skin contact layer. This specially
engineered laminate showed a 20% increase in cut resistance when compared with
the Kevlar fabric used for lamination. The combination of breathable PU foam and
knitted fabric yielded high stretch with improved breathability and dexterity.
Kothari et al (2006) reports about the cutting behavior of textile fabrics have
been developed. It has been tried to identify the forces involved in cutting a material
with a reciprocating knife and also to derive an expression for the sliding distance,
which is a measure of the cut resistance of the material. The cut resistance increase
with the increase in inch of the fabric.
ASTM committee (2002) reports that the hydraulic bursting strength of textile
fabrics. This deal with the strength of the fabrics can be determined by pressure
applied on the fabrics. The various methods used to determine the strength clamping,
18. 8
hydraulic pressure system and gauges. The different types of fabrics material are
taken for the determination of strength.
Zheng et al (2008) report about a new creditable and effective multiaxial
circular tensile tester (MACTT) with 16 load sensors installed around a circumference
has been developed. The new tester could be used to measure tensile properties in
various directions with one sample simultaneously under the same initial conditions.
As a result, not only an error could be reduced, but also the experiment samples and
time could be saved. The experimental results showed good agreement with the
theoretical approximate values calculated based on Hooke’s Law. For general fabrics,
the anisotropic tensile properties could be measured easily with the new tester,
although it was difficult to understand their structures and mechanical characteristics
systematically. Therefore, the new tester showed more important results.
Hace et al (2002) convey about the working of water jet cutting machine that
has been built for cutting of leather or synthetic textile in shoe industry. The main
parts of the machine are the transport system, the XY system with the cutting head,
and the high-pressure (HP) pump. The transport system feeds material into the
cutting section and holds it during the cutting period. It consists of three sections. In
the input section the material is laid down on a transport table. The table then
transports material toward the cutting section. When cutting, the gripper holds down
the material and the transport system is stopped. Afterward, the cut pieces are
transported to the output section. Electrical motors and pneumatic cylinders power
the transport system.
Chiang, L.E (1994) describes the design and construction of a low power laser
cutting machine with three degrees of freedom for applications such as wood, textile
fabrics and the like. An available 10 Watt laser gun is used to provide the cutting
mechanism. The results show that such a machine is feasible at a reasonable cost for
applications where speed and repeatability are more important than high precision
and power.
CO2 laser cutting machine uses focus lens to make CO2 laser beam focus on
material surface to melt materials, at the same time uses compressed gas which is
19. 9
coaxial with the laser beam to blow melting materials, and laser beam and materials
are in relative motion along certain tracks, thus forming cutting slotting in a definite
shape. Since 1970s, with the unceasing development and perfection CO 2 laser and
numerical control technology, CO2 laser cutting machine has become an advanced
processing device for plates cutting in industry. In 1950s &1960s the main methods
for plates cutting are as follows: cutting medium thickness plate, adopting method is
oxyacetylene flame cutting method; for thin plate, forming by shearing mass complex
components by stamping, sheet by adopting the vibration shears. All cutting methods
have their flaws, but still have their applications in specific fields.
The hydraulic cutting machine is specifically designed to cut Emery Cloth,
Rubber and Leather with precision and speed. The salient features of the hydraulic
cutting machines are
The accuracy of the programme is 0.01 mm 0.001 inches. Conversion from mm
to inch fraction is also possible.
The worm gear drive has ground worm and needs less power than any other
conventional drive. The gears are running in oil bath.
It has a new drive mechanism for clamping. The special features of this
machine are double clamping pressure and gentle setting of the clamp on the
materials to be cut. The clamping pressure is adjustable with a knob positioned
under the table at a convenient place.
The knife can be changed easily by lift system and safely by a single operator.
A set of infra red light beams are projected in front of the cutting zone just
above the table to avoid an accident.
2.1
Summary
From the above study there are different types of cutting mechanism used in
fabric. In that cost of cutting in each machine is higher and manual work operation is
maximum in cutting a fabric. This project deals with the reduction in cost and to
reduce manual work. In this various kinds of fabric material are used for cutting with
required force mentioned in the above study tension of the fabric is determined.
20. 10
CHAPTER-3
PROBLEM DEFINITION
In textile shop all the fabric materials are measured and cut manually with the
help of cutting tools and measuring tools. In this process of cutting is not obtained
accurately and time taken for cutting is also quite high. If the measurement is not
accurate, wastage of materials will be more and then the quality will also be reduced.
Nowadays quality is the main aspect of customer. Mostly the length of the cutting will
vary according to the type of the fabric material.
In those machines, bulk orders of fabrics and same size of cutting is only
possible. The size cannot be changed immediately for cutting a fabric. It has large
procedure and that should be followed for changing the size.
This project deals with above the defined problems and rectifies them in order
to reduce manual work and also the continuous process of cutting is obtained.
Adjusting the size can be made easily in this machine. Cost is much less compared to
the large machine used in textile industries.
21. 11
CHAPTER 4
DESIGN AND DEVELOPMENT
The design and development section deals with the designing of various
components that are used in the project. The design can be carried out for various
components are bearing design, clamping and cutting mechanism, design of electrical
circuit, design of pneumatic circuit and design of model.
4.1
DESIGN PHASE
The designing of various parts of the model is described as below
4.1.1 Design of Bearing
Diameter of the shaft, D = 20mm
Speed of the shaft,
N = 42.8 rpm
Assumed allowable bearing pressure is 0.016 N per sq.mm
Area, A = L × D
Area, A = 20 × L sq.mm
Pressure,
P=
Load
Area
58.86
= 20×L
(20×L)×0.016 = 58.86
L = 183.93mm
For this bearing length and shaft diameter p204 bearing is selected.
4.1.2 Cutting Mechanism
Figure 4.1 shows the dimensions of the pneumatic cylinder.
Figure 4.1 Dimensions of Pneumatic Cylinder
22. 12
Bore diameter
d1= 100 mm
Piston rod diameter
d2= 50 mm
Stroke length
L = 100 mm
Pressure
p = 6 bar
Force needed for cutting fabrics is less compared to clamping force,
F=
F=
π
4
π
4
[p × (d12 - d22)]
× [6 × e5× (0.12 -0.052)]
F = 3.534 KN
4.1.3 Clamping Mechanism
Bore diameter
d1= 100 mm
Piston rod diameter
d2= 50 mm
Stroke length
L = 100 mm
Pressure
p = 8 bar
Force needed for cutting fabrics is less compared to clamping force,
F=
π
F=
4
π
4
[p × (d12 - d22)]
× [8 × e5× (0.12 -0.052)]
F = 4.71 KN
4.1.4 Design of Electrical Circuit
The entire circuit consists of three major blocks power supply unit, data
processing unit and controller unit. In this circuit, it requires 5V DC supply which is
step down from a 230V AC supply using 15-0-15 step down transformer. This 15V AC
supply is converted into 15V DC using rectifier circuit. The rectified DC supply is
filtered using 1000 µF capacitor and finally 5V DC supply is acquired using 7805
23. 13
regulator. This 5V DC supply is given to the DC motor, Variable Resistor and
Microcontroller.
The input to the Microcontroller is given in the form of Keypad which acts as a
controller unit. Based on the signal given, corresponding signal will be generated in
the Microcontroller unit. The generated signal is given to the DC Motor, which makes
the motor to run. The motor speed can be varied using a variable resistor through
which the motor runs at a desired speed. Figure 4.2 shows the circuit design of
electrical components.
Figure 4.2 Block Diagram of Electrical Circuit
4.1.5 Design of Pnuematic Circuit
The operating sequence of the cylinders is A+B+B-A-. The cylinder A is used
to clamp the fabrics and cylinder B is used to cut the fabrics. This operation is done
as follows. When PS A is in normally close condition ,the SOL A is actuated and the
cylinder A extracts.Then the clamping of fabrics occurs. When PS B is in normally
close condition ,the SOL B is actuated and the cylinder A extracts.Then the cutting of
fabrics occurs. Figure 4.3 shows the sequential circuit design of the pneumatic circuit.
24. 14
SOL A = Solenoid A
SOL B
PS A
PS B
= Push button A
= Solenoid B
= Push button B
Figure 4.3 Sequential Circuit Design
When PS B is in normally open condition ,the spring pulls the piston in 5/2
DCV. This forces air in opposite direction and the cylinder B retracts.Thus the knife
retracts. When PS A is in normally open condition ,the spring pulls the piston in 5/2
DCV. This forces air in opposite direction and the cylinder A retracts.Thus the
clamping of fabrics releases.
25. 15
4.1.6 Design of Setup
By using PRO-ENGINEER WILDFIRE 4.0, the first prototype is designed. This
model is assembled by different parts. The part diagram is designed with the help of
different icon in Pro/E. Some of the icons used to create this model are line,
rectangle, pattern, extrude, trim etc. The parts we designed by using PRO-E are
roller, cylinder, base table, knife and motor. After designing the various parts of the
model with the help of PRO-E, the assembly section of the model begins. To
assemble these parts we changed the module as assembly and then the base table is
opened by using open icon. The base table is fixed by choosing default in the
placement tab. After fixing the base table, the roller part is opened by using open
icon. Then the alignment of roller is done by using align and mate icon in the
placement tab. Thus the roller is fitted on the base table. Similarly same size of roller
is fitted on the other side of the base table. Figure 4.4 shows the assembly diagram of
the fabric cutting machine.
Figure 4.4 Model of Fabric Cutting Machine
A stand like arrangement is made to hold the cutting mechanism i.e., two
cylinders. Then the cylinder part is opened and fitted to the stand arrangement. This
26. 16
is done by using mate and fix icon. After fixing the cylinders, knife and clamp are
assembled at the end of piston rod of the cylinders.
The motor is fixed at the one end of the roller which is used to roll the fabrics.
The shaft in the roller is used to couple with the motor. Thus the complete assembly
of this model is done with the help of Pro/E WILDFIRE 4.0.
4.2
OPERATIONAL FEASIBILITY
The motor is operated by means of the microcontroller when input is given. Its
operation is fully based on the microcontroller. After the length is measured it moves
to second process automatically with the help of microcontroller. When the clamping
process is over it moves to the cutting automatically. Its operation is based on
microcontroller only thing is input should be entered after that all the process are
carried out. It does not require any skilled labor to operate the machine.
4.3 ECONOMIC FEASIBILITY
The cost of the pneumatic components is only higher but for accuracy and
automation we have to choose pneumatic components. Table 4.1 shows the cost of
the fabricated model and it is economical one.
Table 4.1 Cost Estimation
S.NO
1
2
3
4
5
6
7
8
9
10
11
List of Components
30rpm DC motor
Pneumatic cylinders
5/2 DCV
Flow control valve
Hoses
Distributors
Electrical circuit
Rollers
Electrical wire
Switches
Stand for rollers & cylinders
QUANTITY
1
2
2
2
5m
4
1
2
4m
2
Total
COST in
Rs.
800.00
1000.00
1600.00
400.00
150.00
150.00
1250.00
550.00
70.00
30.00
625.00
6625.00
27. 17
CHAPTER 5
FABRICATION PROCESS
In this chapter, the electrical and pneumatic circuits of the fabric cutting
machine are discussed. The working principle and the process description of the
fabric cutting machines are discussed below.
5.1
PROCESS DESCRIPTION
In this method, cutting and clamping of fabrics is done by automatically. Two
rollers are used for obtaining the desired length of the fabric. First, two rollers are
mounted on the roller stand. One is act as a driver and another one is driven. First
roller is driven by a 30 rpm DC motor and second roller is driven by first roller.
Normally, fabric is rolled on the first roller and another end of the fabric is attached to
the driven roller. The motor is operated by means of microcontroller when the input is
given. The operation is fully based on the microcontroller. The entire circuit consists
of three major blocks Power Supply unit, Data Processing unit and Controller unit. In
this circuit, it requires a 5V DC supply which is step down from a 230V AC supply
using 15-0-15 step down transformer. This 15V AC supply is converted into 15V DC
using rectifier circuit. The rectified DC supply is filtered using 1000 µF capacitor and
finally 5V DC supply is acquired by using 7805 regulator. This 5V DC supply is given
to the DC motor, Variable Resistor and Microcontroller.
The input to the Microcontroller is given through the Keypad which acts as a
controller unit. Based on the signal given, corresponding signal will be generated in
the Microcontroller unit. The generated signal is given to the DC Motor, which makes
the motor to run. The time required to rotate the rollers is fed to the microcontroller as
the input through the keypad. The power supplied to various electronic components
by using a variable resistor.
Based on the input given the corresponding signal will be sent to the
microcontroller, which controls the rotation of the roller by enabling the dc motor. So,
the desired length of the fabric is obtained by this electrical circuit. If the given input to
28. 18
the controller unit is 30 sec means, then the motor runs for 30 sec and the
corresponding length of the fabric is obtained. If the desired length is obtained then
the clamping and cutting operations are done by actuated the pneumatic cylinders.
These double acting pneumatic cylinders are actuated by using 5/2 direction
control valves controlled by the solenoid and flow control valves. The operating
cylinder sequence is A+B+B-A-. When the air supplied to the pneumatic circuits, the
power supply is also given to the solenoid A which operates direction control valve.
Thus the pneumatic cylinders extraction and retraction is done by pressing the push
buttons. When the pneumatic cylinder A extracts, then the clamping is carried out and
then the cylinder B extracts to carry out cutting operation. Then the fabric is cut by
using sharp knife and the cylinder B retracts so that the knife arrangement returns
back to original place. When the push button A is in off state, then the cylinder A
retracts releasing the clamp. Thus the required length of the fabric is obtained by
using electrical and pneumatic circuit. Figure 5.1 shows the working procedure of the
fabric cutting machine.
Figure 5.1 Parts and Dimensions of Base Setup
29. 19
CHAPTER 6
RESULT AND DISCUSSION
This project is fabricated with the help of electrical and pneumatic components.
The model is fabricated mainly to reduce the manual cutting of fabrics. The required
length of the fabric was obtained by using the micro controller. Then the clamping and
cutting operation is done by using pneumatic circuit design. Because of vertical
motion of the knife, the fabric is not cut in good manner. Thus the fabric is cut by
using electrical and pneumatic circuit.
Figure 6.1 Fabrication Project
Figure 6.1 shows the fabrication model of fabric cutting machine. This project
gives the accurate result in cutting a different kind of materials in fabric. Cutting force
is depends on the material which is used.
30. 20
6.1 ADVANTAGES
The advantages of the fabric cutting machines are,
In this machine, skilled labours are not required to operate.
This machine very compact in size compared to the existing machine.
Cost of cutting is minimum and cost of this machine is also minimum.
This machine is produced even for a textile shops
Accuracy of cutting is maximum
Manual operation is less in this machine
31. 21
CHAPTER 7
CONCLUSION
The fabric cutting machine is used to cut the fabrics for the desired length. This
project is mainly used to increase the productivity, efficiency of the industry and avoid
manual errors. This machine is very accurate and compact. The machine can be
purchased at affordable cost. Because of the vertical movement of the knife, the
cutting operation is not effective. So in the future we are going to use the shearing
motion of the knife. This shearing mechanism will cut the fabric more effectively and
the cost will be quite low.
33. 23
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