Design and manufacture of automatic plastic valve welding machine

2021 ◽  
pp. 095440892098821
Author(s):  
Özgür Özdilli
Keyword(s):  
Welding Process ◽  
Production Costs ◽  
Automation System ◽  
Total Production ◽  
Welding Machine ◽  
Integrated Automation System ◽  
Speed Up ◽  
Traditional Manufacturing ◽  
Design And Manufacture ◽  
Plastic Welding

Plastic welding method is a widely used technology for the welding of pressure and vacuum bags using plastic valves. Conducting this process with traditional methods creates disadvantages in terms of production speed, product quality and economical aspects. Today, assembly costs make up the majority of total production costs, manufacturers pay more attention to assembly automation and work in this direction in order to reduce costs, speed up the production process and increase efficiency. In this study, it is aimed to design and manufacture a single Automatic Valve Welding Machine that can do all of these operations and integrated automation system instead of cutting, punching and plastic welding process that can be performed with multiple machines and workers. In this context, a new automated machine was designed in 3 D, and engineering analyzes were carried out to manufacture a prototype. In design, the machine has been made suitable for developing technology by using PLC (Programming Logic Controller) and pneumatic system. In addition, static analyzes of the machine were made. With the inclusion of a production-specific automatic controlled plastic welding machine, manufacturing can be done faster, with higher quality, lower costs and less wastage compared to the traditional manufacturing process.

scholarly journals PERANCANGAN MEJA PUTAR ROLL WELDING SEBAGAI ALAT BANTU PENGELASAN (STUDI KASUS : ART WELDING PT. MECO INOXPRIMA)

2019 ◽  
Vol 20 (1) ◽  
pp. 57
Author(s):  
Imam kholiq Imam Imam
Keyword(s):  
Welding Process ◽  
Zero Point ◽  
Setup Time ◽  
Travel Speed ◽  
Production Costs ◽  
Production Volume ◽  
Rotary Table ◽  
Starting Point ◽  
Welding Defects ◽  
Design And Manufacture

Welding that produces a quality connection and is very possible to connect metal by welding in various shapes and positions. Therefore the welding process must require a practical material supporting device and in accordance with the needs of all welding positions which will facilitate and provide welder comfort in welding. So that the results of maximum and quality welds (good hasis las visually) are produced in this study the type of connection used is angular joints with the aim of designing and making tools to get the results of welding joints and comparing the distortions that occur between using desk tools rotate and without using tools. In this study Gtaw welding was used with the brand DC ARC WELDER with type Bz-300F-3 and filler type ER 308L, Voltage 20-30 V, travel speed 60 mm / min and variations of Flow (A) namely 100 A, 125 A and 150 A. with a diameter of 2.4 mm as a filler. The study was limited to the design and manufacture of tools and measurements of distortion carried out 20 times. Distortion measurement uses a dial indicator with a starting point / zero point on the end of the test object and the end point in the weld joint area. The results show that the use of roll welding tools can reduce the occurrence of distortion. The smallest value of distortion is obtained using a roll welding rotary table tool which is equal to 0.33 degrees, while the smallest value of distortion without using roll welding is 1.33 degrees. And the use of roll welding rotary table aids can reduce welding defects reduce setup time and can increase production volume which results in a decrease in production costs, making it quite feasible and efficient in terms of the economy.

scholarly journals Performance of Dynamometer with Sensor Type Single Bar for Measuring Drive Power of Rotary Friction Welding Machine

2020 ◽  
Vol 64 (3) ◽  
pp. 73-80
Author(s):  
Yohanes Yohanes ◽  
◽  
Novri Andri ◽  
Keyword(s):  
Friction Welding ◽  
Welding Process ◽  
Performance Testing ◽  
Angular Speed ◽  
Drive Power ◽  
Welding Machine ◽  
Rotary Friction Welding ◽  
The University ◽  
Design And Manufacture ◽  
Measured Power

This study aims to determine the performance of the dynamometer design as a measure of mechanical power on a rotary friction welding machine. The design of the dynamometer includes the design, manufacture, calibration, and testing of the dynamometer. The design and manufacture of strain dynamometers is adjusted to the motor of the rotary friction welding machine at the University of Riau's Mechanical Engineering Production Technology Laboratory. The design of the strain dynamometer has a dimension of 175 mm × 3 mm × 50 mm and serves to determine the motor torque value with the help of a 120 ohm strain gauge sensor. The device designed is equipped with an electrical microcontroller device and an optocoupler sensor to measure the angular speed of the motor. Next, the dynamometer performance testing is performed on the rotary friction welding machine. The results of testing in the rotary welding process, the greater the pneumatic pressure exerted during welding, the greater the measured power. The largest measured power value is 2452.92 Watt in the forging process, and the smallest measured power value is 2050.24 Watt in the first time of the initial motor rotation. After doing the research, it can be concluded that the tools designed and built can work and have a fairly good performance.

scholarly journals Desain dan Pembuatan Cetakan Sistem Injeksi untuk Cetakan Plastik Adonan Donat

2016 ◽  
Vol 3 (2) ◽  
pp. 54
Author(s):  
Syamsul Hadi ◽  
Tandya Nanda Haswari Murti ◽  
Saifudin Kalih Sayekti ◽  
Agus Setiawan
Keyword(s):  
Plastic Material ◽  
Production Costs ◽  
Injection System ◽  
Cooling Systems ◽  
Domestic Industry ◽  
Plastic Molding ◽  
Speed Up ◽  
Design And Manufacture ◽  
Plastic Mold

The problem lies in the length of process, it is hard tomake, and a donut shape (circle-shaped cake and hollow in the middle) are not good made by the domestic industry that created manually (by hand). The purpose of the design and manufacture of plastic mold injection molding system for donuts is to speed up the processing of dough donut with easy and efficient way. Methods of design and manufacture of plastic molding dough donut capacity of 30 product/hour with injection system include: survey for dimensions of donuts on the market, determining the thermal expansion of the dough after frying for the determination of shrinkage in the dimensions of the mold, mold design on the top and bottom, the design of cooling systems, the design for ejection system for mold products, working drawings, machining components, assembly, testing, and the calculation of production costs. The results of the design and manufacture of plastic molding dough donut is a donut molds for parts of the top and bottom made of plastic material types of polypropylene (PP).

Immaterial Cost and Production: Maximum Production Cost Level Through Marginal Approach

2020 ◽  
Vol 8 (2) ◽  
pp. 128-149
Author(s):  
Dini Maulana Lestari
Keyword(s):  
Quantitative Study ◽  
Marginal Cost ◽  
Production Cost ◽  
Maximum Level ◽  
Production Costs ◽  
Total Production ◽  
Sugar Factory ◽  
Maximum Production ◽  
Cost Approach ◽  
South Sulawesi

This paper will discuss about the immaterial costs and production yields at one of the refined sugar factory companies in Makassar, South Sulawesi. The theory is based on the fact that Immaterial is a cost that is almsgiving, meaning costs that are outside of the basic costs of the company in producing production, so this research aims to find out: (1) what is the production cost needed to produce this production, (2) the maximum level of production at company from 2013 to 2017. This type of research is a quantitative study because it uses a questionnaire in the form of values ​​that are processed using the marginal cost approach formula. The results of the analysis show that (1) the maximum level of production costs occurred in 2016 amounting to 6,912 with an Immaterial cost of Rp. 2,481,796,800 and the total production produced is 359,077.3 tons (2) The required workforce with the total production produced is 359,077.3 tones of 180 people including the maximum production point which means that the lowest value is achieved (optimal).    

MINIMALISASI BIAYA SIMPAN DAN BIAYA SETUP PADA MULTIPLE PRODUK: SIMULASI DENGAN CAPACITATED LOT SIZING PROBLEM

2019 ◽  
Vol 4 (2) ◽  
pp. 205-214
Author(s):  
Erika Fatma
Keyword(s):  
Production Cost ◽  
Lot Sizing ◽  
Setup Time ◽  
Production Costs ◽  
Total Production ◽  
Product Cycle ◽  
Lot Size ◽  
Setup Costs ◽  
Lot Sizing Problem ◽  
Capacitated Lot Sizing

Lot sizing problem in production planning aims to optimize production costs (processing, setup and holding cost) by fulfilling demand and resources capacity costraint. The Capacitated Lot sizing Problem (CLSP) model aims to balance the setup costs and inventory costs to obtain optimal total costs. The object of this study was a plastic component manufacturing company. This study use CLSP model, considering process costs, holding costs and setup costs, by calculating product cycle and setup time. The constraint of this model is the production time capacity and the storage capacity of the finished product. CLSP can reduce the total production cost by 4.05% and can reduce setup time by 46.75%.  Keyword: Lot size, CLSP, Total production cost.

Capacity Planning for Cluster Tools of Wafer Fabrication Plant

2010 ◽  
Vol 450 ◽  
pp. 365-368
Author(s):  
James C. Chen ◽  
Chia Wen Chen ◽  
Kou Huang Chen ◽  
Chien Hsin Lin
Keyword(s):  
Capacity Planning ◽  
Production Costs ◽  
Wafer Fabrication ◽  
Total Production ◽  
Output Rate ◽  
Cluster Tools ◽  
And Performance ◽  
Using Data ◽  
Capital Intensive

Wafer fabrication is a capital intensive industry. A 12-inch wafer fabrication plant needs a typical investment of US$ 3 billion, and the equipment cost constitutes about two-thirds to three-quarters of the total production costs. Therefore, capacity planning is crucial to the investment and performance of wafer fabrication plants. Several formulae are presented to calculate the required number of machines with sequential, parallel, and batch processing characteristics, respectively. An AutoSched AP simulation model using data from real foundry fabrication plants is used in a case study to evaluate the performance of the proposed formulae. Simulation results indicate that the proposed formulae can quickly and accurately calculate the required number of cluster tools leading to the required monthly output rate.

Welding Procedure Establishment for Tubular Joints Welded by Single Station, Solid State Welding Machine

2010 ◽  
Author(s):  
Ganesan S. Marimuthu ◽  
Per Thomas Moe ◽  
Bjarne Salberg ◽  
Junyan Liu ◽  
Henry Valberg ◽  
...  
Keyword(s):  
Solid State ◽  
Oil And Gas ◽  
Welding Process ◽  
High Strength ◽  
Pipe Material ◽  
Tubular Joints ◽  
Welding Machine ◽  
Single Station ◽  
Welding Procedure ◽  
Treatment Procedures

Forge welding is an efficient welding method for tubular joints applicable in oil and gas industries due to its simplicity in carrying out the welding, absence of molten metal and filler metals, small heat-affected zone and high process flexibility. Prior to forging, the ends (bevels) of the joining tubes can be heated by torch or electromagnetic (EM) techniques, such as induction or high frequency resistance heating. The hot bevels are subsequently pressed together to establish the weld. The entire welding process can be completed within seconds and consistently produces superior quality joints of very high strength and adequate ductility. Industrial forge welding of tubes in the field is relatively expensive compared to laboratory testing. Moreover, at the initial stages of a new project sufficient quantities of pipe material may not be available for weldability testing. For these and several other reasons we have developed a highly efficient single station, solid state welding machine that carefully replicates the thermomechanical conditions of full-scale Shielded Active Gas Forge Welding Machines (SAG-FWM) for pipeline and casing applications. This representative laboratory machine can be used to weld tubular goods, perform material characterization and/or simulate welding and heat treatment procedures. The bevel shapes at mating ends of the tubes are optimized by ABAQUS® simulations to fine tune temperature distribution. The main aim of this paper is to establish a welding procedure for welding the tubular joints by the representative laboratory machine. The quality of the welded tubular joint was analyzed by macro/micro analyses, as well as hardness and bend tests. The challenges in optimizing the bevel shape and process parameters to weld high quality tubular joints are thoroughly discussed. Finally a welding procedure specification was established to weld the tubular joints in the representative laboratory machine.

Energy efficiency of multivariate cultivation techniques in pasture forage production

2021 ◽  
pp. 3-6
Author(s):  
К.Н. Привалова ◽  
Р.Р. Каримов
Keyword(s):  
Energy Efficiency ◽  
Production Process ◽  
Large Scale ◽  
Exchange Energy ◽  
Production Costs ◽  
Energy Yield ◽  
Total Production ◽  
Forage Production ◽  
Machinery Construction ◽  
Natural Factors

Исследования по определению энергетической эффективности пастбищных систем со злаковыми и бобово-злаковыми травостоями проведены в Федеральном научном центре кормопроизводства и агроэкологии им. В. Р. Вильямса. В статье приведены результаты агроэнергетической оценки многовариантных пастбищных систем со злаковыми травостоями, созданными в 1946 году. Даны количественные показатели по сбору обменной энергии, совокупным затратам на её производство, окупаемости затрат в зависимости от системы ведения пастбищ. Изучена эффективность совокупных затрат в виде овеществлённого труда (на семена, удобрения, сельскохозяйственные машины, средства огораживания загонов и прочее) и живого труда (работы трактористов, пастухов и строителей и др.). Обоснована высокая агроэнергетическая эффективность изучаемых пастбищных систем благодаря мобилизации в продукционный процесс природных факторов, долевое участие которых в структуре производства обменной энергии составило 69–84%. Природные факторы, участвующие в продукционном процессе луговых агроэкосистем, характеризуются большим разнообразием. Это не только использование солнечной энергии и азотфиксация бобовыми травами, но и долголетие травостоев, самовозобновление фитоценозов, дерновообразовательный процесс (повышение плодородия почвы), получение дешёвого корма и улучшение здоровья животных при летнем выпасе. Роль возобновляемых природных факторов выявлена на основе балансового метода, принятого в экономике (по разнице сбора обменной энергии и антропогенных затрат). Благодаря ведущей роли природных факторов в структуре произведённой продукции агроэнергетический коэффициент окупаемости совокупных затрат антропогенной энергии (АК) за счёт сбора обменной энергии достигал 3–6 раз в среднем за 45 лет. Разработанные в результате долголетних исследований многовариантные энергосберегающие пастбищные системы обосновывают возможность рекомендовать их производству с учётом применения различного уровня энергозатрат. Ключевые слова: культурные пастбища, системы ведения, долголетние травостои, сбор обменной энергии, совокупные антропогенные затраты, окупаемость затрат. The investigation was conducted at the Federal Williams Research Center of Fodder Production and Agroecology and was aimed at testing energy efficiency of gramineous and legume-gramineous swards. This article presents the results obtained on pasture ecosystems with gramineous planted in 1946. Exchange energy yield, total production costs and economic effectiveness were analyzed. Total production costs comprised costs for seeds, fertilizers, machinery, construction materials, labor, etc. Introduction of natural factors into the production process resulted in higher energy efficiency. Their share amounted to 69–84% in the final exchange energy yield. There are a lot of natural factors that affect grass productivity such as solar energy, nitrogen-fixation, sward longevity and regeneration, soil fertility, low-cost feed production, and livestock health. The value of natural factors was determined according to the balance method (by the difference between exchange energy yield and anthropogenic costs). Since environmental factors had a leading role in the production process, the return rate raised by 3–6 times for 45 years due to exchange energy increase. Therefore, pasture ecosystems developed can be recommended for a large-scale forage production.

scholarly journals Influence of bifurcation on thinning, productivity and harvester production costs of Pinus taeda L.

2020 ◽  
pp. 1259-1263
Author(s):  
Carlos Cézar Cavassin Diniz ◽  
Romano Timofeiczyk Junior ◽  
Renato Gonçalves Robert ◽  
Eduardo da Silva Lopes ◽  
João Carlos Garzel Leodoro da Silva ◽  
...  
Keyword(s):  
Pinus Taeda ◽  
Cycle Time ◽  
Production Costs ◽  
Total Production ◽  
Plantation Forest ◽  
Operating Cycle ◽  
Operational Cycle ◽  
Time And Motion ◽  
Motion Study ◽  
Pinus Taeda L

In this work, we present that how bifurcation in Pinus trees can influence productivity and harvester production costs. Our example draws from one harvesting machine that works in thinning operations in forest plantations of Pinus taeda L. in a small Brazilian forestry company. To get daily productivity, we use the machine’s system, which provides such daily information as total production. We also used a time and motion study to obtain the meantime to cut, delimb, and process the tree stem into logs. In this way, we separated the normal trees from the forked trees to get the operating cycle time of the machine and get the productivity to the two types of trees. The continuous timing method was used for this purpose. The results show an increase of up to 22.9% in the operational cycle time for cutting forked trees, resulting in reduction of productivity of 5.58 m³ for each hour worked. The production cost increased by 23.3% on operation of forked trees, as the machine took more time to perform the partial activities of the operational cycle. This study can help many companies and contractors to calculate the appropriate productivity and production harvest cost according to the type of tree stems from the plantation forest.

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