A PROJECT SKILLS LAB REPORT / CREATIVITY AND INNOVATION LAB

ON

Design and Fabrication of 3-D Printing Prototype Machine

Submitted in partial fulfillment of the requirements for the award of the degree.

of

BACHELOR OF TECHNOLOGY
in

XXXXXXXXXXX ENGINEERING
Under the guidance of

Dr.XXXXXXXXXXXX, M.Tech, Ph.D.,

Professor / XXXXXXXXX Engineering

BY

A JAGADEESH 21751A0301
A SIVA REDDY 21751A0302
G AKHIL 21751A0303
M VENKATESH 21751A0304

SREENIVASA INSTITUTE OF TECHNOLOGY AND

MANAGEMENT STUDIES, CHITTOOR-517127, A.P.
(Autonomous)
(Approved by AICTE, New Delhi & Affiliated to JNTUA, Ananthapuramu)

DEPARTMENT OF XXXXXXXXXXXXX ENGINEERING

(2020-2024)
 SREENIVASA INSTITUTE OF TECHNOLOGY AND
MANAGEMENT STUDIES, CHITTOOR-517127, A.P.
(Autonomous)
(Approved by AICTE, New Delhi & Affiliated to JNTUA, Ananthapuramu)

This is to certify that the project work entitled “ENHANCING THE QUALITY
OF COMMUNICATION NETWORKS” is a genuine work of

A JAGADEESH 13751A0302
A SIVA REDDY 13751A0305
G AKHIL 13751A0321
M VENKATESH 13751A0350

Submitted to the department of Mechanical Engineering, in partial fulfillment of

the requirements for the award of the degree of BACHELOR OF TECHNOLOGY in
XXXXXXXXXXX ENGINEERING from Jawaharlal Nehru Technological University
Ananthapur, Ananthapuramu.

Signature of the Supervisor Signature of the Head of Department

XXXXXXXXXXXX, M.Tech, Ph.D., Dr.XXXXXXXXXXX, M.E., Ph.D.,
Professor, Professor & HOD,
Department of XXXXXX Engineering, Department of XXXXXX Engineering,
Sreenivasa Institute of Technology and Sreenivasa Institute of Technology and
Management Studies, Chittoor, A.P. Management Studies, Chittoor, A.P.

Submitted for University Examination (Viva-Voce) held on……………………

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

A Project of this magnitude would have not been possible without the guidance
and co-ordination of many people. I am fortune in having top quality people to help,
support and guide us in every step towards our goal.

Our team is very much grateful to the Chairman Sri K. Ranganadham, Garu for
his encouragement and stalwart support. We are also extremely indebted to the Secretary
Sri D.K. Badri Narayana, Garu for his constant support.

We express our sincere thanks to our Academic Advisor Dr. K.L. Narayana.,
M.Tech., Ph.D, further, we would like to express our profound gratitude to our principal
Dr.N.Venkatachalapathi, M.T.ech, Ph.D for providing all possible facilities throughout
the completion of our project work.

We express our sincere thanks to our Dean (Academics), Dr.M.Saravanan,

M.E., Ph.D., further we express our sincere thanks to our Head of the Department
XXXXXXXXXXXXXX., M.Tech, (Ph.D.)., for his co-operation and valuable
suggestions towards the completion of project work.

We express our sincere thanks to our guide XXXXXXXXXX., M.E., (Ph.D.).,

for offering us the opportunity to do this work under his guidance.

We express our sincere salutation to all other teaching and non-teaching staff of
our department for their direct and indirect support given during our project work. Last
but not the least, we dedicate this work to our parents and the Almighty who have been
with us throughout and helped us to overcome the hard times.

A JAGADEESH 21751A0301
A SIVA REDDY 21751A0302
G AKHIL 21751A0303
M VENKATESH 21751A0304
Course Outcomes for project work

On completion of project work we will be able to,

CO1. Demonstrate in-depth knowledge on the project topic.

CO2. Identify, analyze and formulate complex problem chosen for project work to
attain substantiated conclusions.

CO3. Design solutions to the chosen project problem.

CO4. Undertake investigation of project problem to provide valid conclusions.

CO5. Use the appropriate techniques, resources and modern engineering tools necessary
for project work.

CO6. Apply project results for sustainable development of the society.

CO7. Understand the impact of project results in the context of environmental

sustainability.

CO8. Understand professional and ethical responsibilities while executing the project
work.

CO9. Function effectively as individual and a member in the project team.

CO10. Develop communication skills, both oral and written for preparing and presenting
project report.

CO11. Demonstrate knowledge and understanding of cost and time analysis required for
carrying out the project.

CO12. Engage in lifelong learning to improve knowledge and competence in the chosen
area of the project.
 CO – PO MAPPING

CO\ PO PO PO PO PSO
PO1 PO3 PO5 PO7 PO8 PO10 PO11 PO12 PSO2
PO 2 4 6 9 1
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CO.2
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CO.4
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CO.5
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CO.9
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CO.10
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CO.12
3 3 3 3 3 3 3 3 3 3 3 3 3 3
CO
 ABSTRACT

The base concept of this project is to reduce difficulty occurred while assemble
the turbocharger core manually and to detect the error occurred during the process with
special control error proofing. The turbocharger core components are turbine wheel,
piston ring, heat shield, bearing housing, thrust ring, thrust plate, oil deflector, back plate,
socket head bolts, compressor wheel, and shaft nut. All the components are assembled as
a sequence of process in a single station to form the core which is the heart of
turbocharger. In existing system, the operator may fail to include some materials which
are necessary to assemble the core. To ensure that the programmable logic control detect
missing parts by receives signals from sensors and vision techniques at each stage of
process and indicates error, only by clearing the error, the controller will proceed to
further process. The turbocharger are widely used in many vehicles for Better power and
torque characteristics, Lower fuel consumption, Lower emission, Lower weight and a
smaller engine package, Lower engine noise, Reduced power loss at high altitude.
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT iv
LIST OF FIGURES x
LIST OF TABLES xi
LIST OF ABBREVIATIONS xii

1 INTRODUCTION 1
1.1 BACKGROUND AND MOTIVATION 1
1.2 TURBOCHARGER CORE ASSEMBLY 2
1.3 SCOPE OF PRESENT WORK 3
1.4 PROBLEM IDENTIFICATION 3
1.5 OBJECTIVE OF PRESENT WORK 5
1.6 METHODOLOGY 5

2 LITERATURE SURVEY 8
2.1 THE TURBOCHARGER FUNCTIONAL
ANALYSIS AND PROCESS STUDY 8
2.1.1 The structure principle of turbocharger
Assembly 8
2.2 CONTROLLING ASSEMBLY SYSTEM VIA
PLC 11
2.3 ASSEMBLY PART INSPECTION BY VISION
SYSTEM 16

CHAPTER NO TITLE PAGE NO

3 PROJECT DESCRIPTION 23
3.1 BLOCK DIAGRAM OF ENTIRE SYSTEM23
3.2 PROXIMITY SENSOR 23
3.2.1 Specification 24
3.2.2 Advantage 25
3.3 PROGRAMMABLE LOGIC CONTROL 25
3.3.1 PLC Hardware 26
3.3.2 CPU 27
3.3.3 Memory 27
3.3.4 Input and output modules 28
3.3.5 Power supply 29
3.3.6 Programming terminal 29
3.3.7 PLC Specification 29
3.3.8 Advantage 30

4 RESULTS AND DISCUSSION 34

4.1 PLC LADDER LOGIC SIMULATION 34
4.2 OMRON PLC BASIC OPERATING
PROCEDURE 34

5 CONCLUSION AND FUTURE WORK 40

5.1 CONCLUSION 40
5.2 FUTURE WORK 40

REFERENCES 41
APPENDIX 43

LIST OF FIGURES
 FIGURE NO TITLE PAGE NO

1.4 Manual Turbocharger Core Assembly 4

1.6(a) Flow diagram structure of Assembly process 6
1.6(b) Block Diagram of PLC 7
2.1(a) Impeller rotor assembly analyzed by Suying Xu 9
2.1(b) Design of robotic assembly made by S. S. Ngu 10
2.1(c) Block diagram of S. S. Ngu system 10

LIST OF TABLES
TABLE NO TITLE PAGE NO

1.1 Manual Turbocharger Core Assembly 6

LIST OF ABBREVIATIONS
PLC Programmable Logic Control
SPC Statistical Process Control
CCD Charge Coupled Device
 CHAPTER 1
INTRODUCTION

1.1 INTRODUCTION
In modern manufacturing, especially in light of increased globalisation, a primary
goal is to ensure high production efficiency. Optimal productivity is fundamental in
ensuring the competitiveness of a firm. While true for all organisations, it is particularly
important for manufacturing and related industries. Consequently, assembly line is often
evaluated in terms of their suitability for enhancements and the possible implementation
of continuous improvement initiatives.

Figure 1.1 Block Diagram of PLC

 CHAPTER 2

LITERATURE SURVEY

2.1 THE TURBOCHARGER FUNCTIONAL ANALYSIS

Turbo technical had become the most effective measures to improve engine
power and improve the economy since the first turbocharger patents - power-driven axial
turbocharger was applied by doctor Alfreed Buch in 1905, and it has become the
important development direction of the internal combustion engine. The power source of
driving turbocharger is completely the exhaust gas rather than other external drive. With
the widespread use of the turbocharger in the automotive and other industries, the
requirement of a new generation of turbochargers becomes increasingly strict on its
strengthening indicators, economic indicators and environmental indicators. The
processing and manufacturing processes to meet the technical requirements become one
of the key issues.

2.1.1 The structure principle of turbocharger assembly

The turbocharger core assembly space is mainly composed of turbine wheel(T/w),

piston ring, heat shield, bearing housing(B/hsg) sub-assembly, thrust ring, thrust plate, oil
deflector, back plate sub-assembly, socket head bolt, compressor wheel(C/w), and shaft
nut.

Figure 2.1(b) Design of robotic assembly made by S. S. Ngu

 CHAPTER 3

PROJECT DESCRIPTION

3.1 BLOCK DIAGRAM OF ENTIRE SYSTEM

Turbine
Push
wheel
Button
clamp

PLC
Leak check
for Bearing
Proximity Housing
Sensor
Nut Runner

Camera
Indicator

Presence of heat
shield, thrust ring,
oil deflector
Figure 3.1 Block diagram of turbocharger core assembly station

3.3.2 CPU
Like other computerized devices, there is a Central Processing Unit (CPU) in a
PLC. The CPU, which is the “brain” of a PLC, does the following operations:

 Updating inputs and outputs. This function allows a PLC to read the status
of its input terminals and energize or de-energize its output terminals.
 Performing logic and arithmetic operations. A CPU conducts all the
mathematic and logic operations involved in a PLC.
 CHAPTER 4

RESULTS AND DISCUSSION

4.1 PLC LADDER LOGIC SIMULATION

CX programmer software is a program editor of Omron CP1E series PLC for

WINDOWS computers. In addition to general PLC programming and WINDOWS
editing functions (e.g. Cut, paste, copy, multi-window display, etc.), CX programmer
software also provides various comment editing as well as other special functions (e.g.
register editing and settings, file accessing and saving, contacts monitoring and setting,
etc.).

Table No.4.1. Collection Hardware Details

1.
2.
3.
4.
5.
6.
 CHAPTER 5

CONCLUSION AND FUTURE WORK

5.1 CONCLUSION

In this project, PLC ladder logic was proposed in order to reduce the error, reduce
operator fatigue and increase the production rate. The programmable logic controller is
fast and has a good performance regarding accuracy and speed in detection of errors. Plc
based automation and vision techniques are used to develop core assembly station for
turbocharger assembly. Controls are established at each stage for ensuring zero defects.

5.2 FUTURE WORK

Future work involves the implementation of hardware system, which will be

interfaced using PLC. And in future some other classifier improvement may also be
applied like, SCADA system can be utilized, which increase efficiency, maximize
profitability and safety.
 REFERENCES

[1] Jia Yang, Turbocharger production organization and quality control, Advanced
Materials Research, Vol. 422, pp 420~423, 2012

[2] Rekiek, B., Dolgui, A., Delchambre, A. & Bratcu, A. 2002. State of art of
optimization methods for assembly line design, Annual Reviews in Control, 26(2002), pp
163-174

[3] T. G. Yip, Y. H. Chung, and V. Iyengar, “Challenges in Verifying and Integrated 3D

Design,” Design Automation & Test in Europe Conference & Exhibition (DATE), 2012,
pp. 167-168.

[4] J. Barata, L.M. Camarinha-Matos, M. Onori, A Multiagent Based Control Approach

for Evolvable Assembly Systems, INDIN'05 - 3rd IEEE International Conference on
Industrial Informatics 2005, pp. 478-483

[5] T. Borangiu, N. Ivanescu, S. Raileanu, A. Rosu, Vision-Guided Part Feeding in a

Holonic Manufacturing System with Networked Robots, RAAD 2008, Ancona, Italy

[6] www.nptel.ac.in
 Evaluation Rubrics for Project work:

Rubric (CO) Excellent (Wt = 3) Good (Wt = 2) Fair (Wt = 1)

Select a latest topic through Select a topic through partial Select a topic through
Selection of Topic (CO1) complete knowledge of facts knowledge of facts and improper knowledge of facts
and concepts. concepts. and concepts.

Thorough comprehension Reasonable comprehension Improper comprehension

Analysis and Synthesis (CO2)
through analysis/ synthesis. through analysis/ synthesis. through analysis/ synthesis.

Thorough comprehension Reasonable comprehension Improper comprehension

Problem Solving (CO3) about what is proposed in the about what is proposed in the about what is proposed in
literature papers. literature papers. the literature.

Incomplete literature survey

Extensive literature survey with Considerable literature survey
Literature Survey (CO4) with substandard
standard references. with standard references.
references.

Clearly identified and has Identified and has

Identified and has sufficient
Usage of Techniques & Tools complete knowledge of inadequate knowledge of
knowledge of techniques &
(CO5) techniques & tools used in the techniques & tools used in
tools used in the project work.
project work. project work.

Project work impact on Society Conclusion of project work has Conclusion of project work has Conclusion of project work
(CO6) strong impact on society. considerable impact on society. has feeble impact on society.

Conclusion of project work has Conclusion of project work

Project work impact on Conclusion of project work has
considerable impact on has feeble impact on
Environment (CO7) strong impact on Environment.
environment. environment.

Clearly understands ethical and Moderate understanding of Insufficient understanding of

Ethical attitude (CO8)
social practices. ethical and social practices. ethical and social practices.

Did literature survey and Did literature survey and

Selected a topic as
Independent Learning (CO9) selected topic with a little selected topic with
suggested by the supervisor
guidance considerable guidance

Presentation in logical
Presentation with
sequence with key points, clear Presentation with key points,
Oral Presentation (CO10) insufficient key points and
conclusion and excellent conclusion and good language
improper conclusion
language

Status report with clear and Status report with logical

Status report not properly
Report Writing (CO10) logical sequence of chapters sequence of chapters using
organized
using excellent language understandable language

Comprehensive time and cost Moderate time and cost Reasonable time and cost
Time and Cost Analysis (CO11)
analysis analysis analysis

Highly enthusiastic towards Interested in continuous Inadequate interest in

Continuous learning (CO12)
continuous learning learning continuous learning
 DESIGN OF HYDRAULIC POWER PACK FOR
Title of the Project :
VERTICAL TURNING LATHE MACHINE.
Name of the students:

Name of the Guide & Designation :

TABLE 1: OUTCOME ATTAINED AND ITS JUSTIFICATION

PO Justification

PO1 The knowledge hydraulic power pack was gained through this project work

PO2 Analyzed the problems of machines accuracy

PO3 Designed hydraulic power pack for vertical tuning machine.

PO4 We used research-based data to provide valid conclusions

We implemented our work with well appropriate techniques, good resources

PO5 modern engineering tools to uplift the project. Auto Cad is used to design
system

This solution increases the accuracy of the parts produced and Productivity for
PO6
sustainable development of the society.

This solution increases the accuracy of the parts produced. Hence reduction in
PO7
wastage of resources happens.

PO8 We followed the ethical principles.

PO9 We worked in this project function effectively as a member of the project team.

Oral and written communication skills are improved while planning,

PO10
implementing and executing the entire project and till submission of the report.

We demonstrated our knowledge and understanding of cost and time analysis

PO11
required for carrying out the project.

Facilitated ourselves in Lifelong learning to improve technical knowledge and

PO12
competence in the chosen area of the project.
 APPENDIX

HARDWARE DESCRIPTION

Any Related Photo