Digitization of Cycle Time in Riveting Machine
This document discusses a project to digitize cycle time monitoring for 42 assembly machines. Currently, daily output is lagging plan by about 50% on average due to issues like inaccurate manual counting and a lack of analysis on factors affecting cycle time. The project aims to monitor machines in real time using IR sensors and a network of microcontroller units connected to a central computer. This will provide statistical data on cycle times to identify issues, increase productivity, and reduce overhead costs through optimized manpower allocation and industrial automation integration. A prototype has been built and the document outlines the system design, components used, and a future proposal to fully implement the system across all 42 machines.
Digitization of Cycle Time in Riveting Machine
- 1. Digitization of Cycle Time
- 2. Digitization of Cycle Time INTRODUCTION Present Status:- Total Number of assembly machines =42. Yield output= Lag of Plan. The daily output as per plan is not fulfilled. The data shows that appx. 50% on average of the target is fullfilled. This directly effect the routing, indirectly overhead costs. There is manual procedure for counting, high possibility mistake. Issue:- The cycle time depends not only the machining but also many different factors. There need to be proper Analysis about machine cycle time, component placement, loading and unloading, rejection, breakdown & manpower. Need to be specific which factor is more effecting the cycle time, need statistical data like instantaneous time, average cycle time.
- 3. Objective-Project To monitor 42 machines and obtain real time data analysis. To make overhead costs reduction with increasing productivity by means of needfull manpower and using integrated industrial automation. It is necessary to find out where we are lagging. It is necessary to award/reward the more productive manpower for motivation.
- 4. System Block Diagram RE C Computer Control Unit S= IR Sensor. E= End Device:- Controller Atmega 8 R=Router C=Co-ordinator. S Machine Control Unit Master Control Unit(CPU)
- 5. Machine Control Unit DS-1307 Timer Module Sample Data 1-19030-12:50 2-1390-1:09 3-240-1:10 4-240-1:10 5-870-1:11 6-6150-1:17 7-770-1:18 8-430-1:18 9-3340-1:22 10-780-1:22
- 7. Master Control Unit It Consist of an 802.11.15a module (RF) acting as a co-ordinator connected to remote PC. The PC is installed with Matlab and Xctu software as a communication link. Computer Control Unit R/F Interfacin g module Xbee Co- ordinator Rx Tx Vcc Gnd USB Display Monitor WiFi- Internet
- 8. Detail Component List S. No. Product Name Quantity Cost(₹) 1 Atmega16L Development Board 1 250 2 ATmega16L 1 150 3 Xbee Board 2 2400 4 XBee / ZigBee Adapter board with USB interface 3 700 5 Female to Female Cable 20 100 6 AVR-USB-ASP Programmer 1 399
- 9. Detail Component List S. No. Product Name Quantity Cost(₹) 7 RTC DS1307 Module 1 120 8 LCD 16x2 Module 1 250 9 USB-TTL Module 1 270 10 IR Sensor Module 1 150 Project Equipment Cost(Appx) 4789
- 10. Detail Software Tool Eltima – USB Network Gate MS Excel- Macro Enable PLX- DAQ AVR Studio:-6Khazama A.V.R Programmer
- 11. Model- Prototype Receiver Module Transmitter Module Sensor Device
- 12. Production data proto 27/11/15- reveting M/c 0 50 100 150 200 250 300 350 1 28 55 82 109 136 163 190 217 244 271 298 Piece P…
- 13. Future Proposal • Implementation of IR sensor on all 42 machine. • Data to be connected and controlled with server. • LED for monitoring the data in real time. • Need to purchase licenced software • A dedicated system is required for this task.