Design And Fabrication Of A Motorized Chain Hacksaw With Infrared Sensor

ABSTRACT

The objective of this work is to automate the conventional power hacksaw machine in order to achieve high productivity of work-pieces than the power hacksaw machine using Microcontroller. The automated machine acquires two inputs from the user namely the number of pieces to be cut and the length of each piece that is required to be cut. The inputs are given by the user with the help of a keypad and an LCD display, which will help the user to verify the data given by him. The operator need not measure the length of the work-piece that is to be cut and to load and unload the work-piece from the chuck each time after a piece has been cut. After acquiring the two inputs from the user, the machine automatically feeds the given length of work-piece in to a chuck and starts to cut till the given number of work-pieces has been cut. The machine feeds the work-piece with the help of a conveyor, which is driven by a DC motor and an IR sensor ensures that the feeding stops when the specified length has been reached. A pneumatic cylinder is used for holding the work-piece when cutting operation is done. An AC motor is used to bring about the reciprocating motion required for cutting the work-pieces. There is a self-weight attached with the reciprocating mechanism to provide the necessary downward force required for penetration of hacksaw blade in to the work-piece. When a single piece has been cut, a limit switch will get triggered by the self-weight mechanism, which is sensed by the microcontroller to start the cyclic operation again provided if the specified number of work-pieces has not been cut.

TABLE OF CONTENTS

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

TABLE OF CONTENT

CHAPTER ONE

1.0      INTRODUCTION

1.1      BACKGROUND OF THE PROJECT

1.2      OBJECTIVE OF THE PROJECT

1.3      SCOPE OF THE PROJECT

1.4     SIGNIFICANCE OF THE PROJECT

1.5      SCOPE OF THE PROJECT

1.6      PROBLEM IDENTIFICATION

1.7      JUSTIFICATION AND RELEVANCE

CHAPTER TWO

2.0     LITERATURE REVIEW

2.1      REVIEW OF THE STUDY

2.2         REVIEW OF THE RELATED WORK

2.3      TYPES OF HACKSAWING

2.4      FEATURES OF MODERN HACKSAW

2.5      DESCRIPTION OF HACKSAW

2.6      HISTORICAL BACKGROUND OF THE STUDY

CHAPTER THREE

3.0     METHODOLOGY

3.1      PROPOSED METHODOLOGY

3.2      COMPONENTS USED AND CALCULATIONS

3.3      DESCRIPTION OF THE HACKSAW MACHINE

• DESCRIPTION OF THE PROJECT SETUP

3.5      WORKING OF THE PROJECT

1. Acquiring data from the user
2. Sequence of operation

3.6      COST OF PRODUCTION

CHAPTER FOUR

RESULT ANALYSIS

4.0      CONSTRUCTION PROCEDURE AND TESTING

4.1      CASING AND PACKAGING

4.2      ASSEMBLING OF SECTIONS

4.3      MOUNTING PROCEDURE

4.4      TESTING OF SYSTEM OPERATION

CHAPTER FIVE

5.0      CONCLUSION, FUTURE SCOPE, AND REFERENCES

5.1      CONCLUSION AND FUTURE SCOPE

5.2      REFERENCES

 CHAPTER ONE

1.1                                                      INTRODUCTION

Power hacksaws are used to cut large sections of metal or plastic shafts and rods. Cutting of solid shafts or rods of diameters more than fifteen millimeters is a very hard work with a normal hand held hacksaw. Therefore power hacksaw machine was invented during 1920s in the United States to carry out the difficult and time consuming work. This motorized chain power hacksaw machine is considered as an automatic machine because the operator need not be there to provide the reciprocating motion and downward force on the work-piece in order to cut it. Once the operator has fed the work-piece till the required length in to the machine and starts the machine, then the machine will cut until the work-piece has been completely cut in to two pieces.

The fact that the operator has to feed the work-piece to the required length in to the vice is one aspect that motivated us to automate the feeding of work-piece automatically. Another one aspect is that after a shaft has been cut for one time, the operator has to unload the work-piece and advance the rest of the work-piece to the required length again and again till the end of the work-piece is reached. The Power hacksaw machine though being able to cut the shaft or rod without requiring any human effort to cut, it does require a human intervention to feed the work-piece many times with measurements being taken each time before feeding. Therein, arose a need to completely automate the process of cutting, and here we are with a proposal which will aid in eliminate the effort of the people associated with it.

In this particular project, a motorized chain hacksaw machine was designed. In this machine, the conveyor motor will get stopped by the microcontroller when the IR sensor has sent the necessary number of pulses to the microcontroller in relation to the user specified length of the work-piece. When the teeth of the rotating disc attached to the conveyor roller pass before the IR sensor, the IR sensor provides a pulse to the controller. The rotation of disc from one tooth to the next teeth means that the corresponding linear movement is one centimeter.

1.2                                       BACKGROUND OF THE PROJECT

General A hacksaw is a handheld tool used to cut through materials like plastic tubing and metal pipes. Its cutting mechanism is provided by removable blades which feature sharp teeth along their outer edge. In most cases, a hacksaw consists of a metal frame that resembles a downward- facing. A handle of plastic, wood, or metal is typically affixed to one end of the frame. The frame’s ends feature adjustable pegs that can be tightened to secure a blade in place, and loosened to remove it. Hacksaw blades are long, thin strips of hardened steel that feature a row of teeth along their cutting edge. Each end of the blade is punched with a small hole that fits onto the saw frame’s pegs. Most blades range in length from ten to 12inches (25.4 to 30.48 cm), although six-inch (15.24 cm) blades can be purchased to fit smaller hacksaw models.

1.3                                           OBJECTIVE OF THE PROJECT

The objective of this work is:

1. To cater to the issue of competition in mechanical industry the need for automation is assess by all the industry.
2. To identify the key policy avenues considered to be appropriate to meet the challenge of sustainable manufacturing and packaging industry for the future.
3. To provide alternative for industries aiming toward reducing human effort and improvement in material handling system by implementing automation.
4. Sustainable and practical automation solutions for the future industrial environment.

1.4                                         SIGNIFICANCE OF THE PROJECT

A device that applies force, changes the direction of a force, or changes the strength of a force, in order to perform a task, generally involving work done on a load. This machine is often designed to yield a high mechanical advantage to reduce the effort needed to do that work. A simple machines a wheel, a lever or an inclined plane. All other machines can be built using combinations of these simple machines.

• The machine can solve the problem of time consumption.
• Waste of resources in face of labor cost is reduced.
• The machine can be used in the industry where it is manufactured, at the packaging sector.
• And it is used as hardware in large quantity like in fabrication of machine
• It provide alternative for industries aiming toward reducing human effort
• It generates sustainable and practical automation solutions for the future industrial development.

1.5                                                 SCOPE OF THE PROJECT

This machine was built around an AT89C51 microcontroller, IR sensor, LCD, motor conveyor, etc. The conveyor motor will get stopped by the microcontroller when the IR sensor has sent the necessary number of pulses to the microcontroller in relation to the user specified length of the work-piece. When the teeth of the rotating disc attached to the conveyor roller pass before the IR sensor, the IR sensor provides a pulse to the controller. The rotation of disc from one tooth to the next teeth means that the corresponding linear movement is one centimetre.

1.6                                             PROBLEM IDENTIFICATION

The motorized chain power hacksaw machines, which are operated by human operators as aforementioned, have the demerit of unloading and loading the work-piece many times. In industries manufacturing pumps, these machines are used to cut the motor shafts to the required lengths. It will be difficult for the operator if he has been assigned to cut a huge quantity of motor shafts and he has to measure the lengths each time for cutting. Since humans are not as versatile as machines, there is a possibility that there may be inaccuracies. Besides, if there is a slight time delay in between every cycle of cutting a piece, the cumulative delay in time will be found to have a considerable magnitude, which might  have been utilized properly if the proposed machine were in use there.

1.7                                         JUSTIFICATION & RELEVANCE

We have found a power motorized chain power hacksaw machines to be the most useful for general shop work. Modern heavy- duty hacksaw machines provide an economical and efficient means of sawing a wide range of materials and stock sizes. motorized chain power hacksaw machines are getting rarer all the time but they do a good job within their capacity. If you can get one that takes standard hacksaw blades then you’ll have a tremendous range of blades to choose from and will be able to cut most anything. Hacksaws are more tolerant to tensioning maladjustment and run off. A major advantage of power hacksawing is the relatively low capital investment required. Tooling and maintenance costs are low. Accuracy and finishes produced, range from fair to good depending on the material being sawed. Time saving as compared to simple hacksaw. Comfortable then ordinary hacksaw