0. Gathering pertinent information - P-division-2020-2021-even/Repo-08 GitHub Wiki
Gathering Pertinent information
1. The kind of information sources we searched are
- Youtube videos
- Internet
- Online sites
2. The Existing solution to the problem
- Expensive coil winding machines.
- Low cost and not durable thread winding machines.
- Bobbin winding machine.
- Silk winding machine are expensive.
- Solenoid winding machine.
- Armature winding machine for bigger DC motors
3. Some of the websites for information about winding machine
- motorcoilwindingmachine.com
- windingmachineindia.in
- coilwindingmachines.eu
- whitelegg.com
- Youtube
- instructables.com
- engineersgarage.com
4. Components & sub-components
| Sl.no | Components or Parts used | Mechanism/Working Principle identified | links |
|---|---|---|---|
| Electrical/Mechanical | |||
| 1 | Arduino | Motor current sensing, motor direction, motor speed setting, angle setting...etc | store.arduino.cc |
| 2 | Servo motor | Movement with a proper angle | realpars.com |
| 3 | on/off Switch | Indication | |
| 4 | DC Motor | rotation | allaboutcircuits.com |
| 5 | Sensors | For rotation count | |
| 6 | Bluetooth | To control the machine with software or app |
5. The Cost Estimation
| Sl.no | Components or Parts used | Cost |
|---|---|---|
| 1 | Arduino | Rs 999 |
| 2 | Servo motor | Rs 210 |
| 3 | on/off Switch | Rs 80 |
| 4 | DC Motor | Rs 411 |
| 5 | Sensors | Rs 450 |
| 6 | Bluetooth | Rs 499 |
| TOTAL | Rs 2,649 |
6. Existing or Direct solution for the need statement
Wool Winding Machine
Video: https://youtu.be/tsxu_KMYnTs
INTRODUCTION :-
A Winding Machine is a machine for wrapping string, thread , ribbon , coil , wool , cord etc. Winders have a center coil (a belt-winding shell)on which the material is wound up. Often there are metal bars that travel through the center of the roll, and are shaped according to their intended purpose. A circular bar facilitates greater speed, while a square bar provides a greater potential for torque. Edge sensor are used to sense how full the center roll is. They are mounted on adjustable slides to accommodate many different widths, as the width increases as the center roll is filled. The sensitivity of the sensor depends on the required speed of operation. The benefits of this winding is that it significantly increased the productivity, greater quality control and reduced waste.
Objectives of the project:-
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To reduce winding process time.
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To increase the precision of winding process.
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To reduce overall cost of process.
Three zones of winding:-
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Unwinding zone-In this zone wool gets unwounded from hank.
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Tension zone-In this zone proper thread tension is maintained for respective type of wool thread.
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Winding zone-in this zone wool gets wounded on bobbin.
Design Methodology:-
Design consists of application of scientific principles, technical information and imagination for development of new or improvised machine or mechanism to perform a specific function with maximum economy & efficiency.Hence a careful design approach has to be adopted.
The total design work has been split up into two parts;
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System design.
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Mechanical Design.
System design mainly concerns the various physical constraints and ergonomics, space requirements, arrangement of various components on main frame at system, man + machine interactions, No. of controls, position of controls, working environment of machine, chances of failure, safety measures to be provided, servicing aids, ease of maintenance, scope of improvement, weight of machine from ground level, total weight of machine and a lot more.
BENEFITS OF PROJECT:-
Easy To Operate: Machine is very simple in the operation unlike other machines; this machine does not include any complicated electronic devices or controls. This makes the machine quite easy to operate.
Reduction in process time: As the electric motor is used for the operation, speed of motor drive is higher and therefore the speed of winding is significantly high. In comparison to this the speed of manual winding is much less. This leads in saving lot much process time.
Less maintenance: As only few components are rotating in the machine, there is no need of regular maintenance. Moreover, most of the components used have large working life span, which reduces the maintenance of the machine.
Increases Human Comfort: Manual winding is quite tedious job to do and it depends completely on the skills of worker .But the machine can be used by any other person without much knowledge of the winding techniques. Human intervention is needed only at the time of thread breakage. Thus increases human comfort.
Inexpensive to Operate: Simple payback period of the machine is very less. Also the operating cost of the machine is reasonably low as compared to the cost to be paid to the skilled worker.