Special-purpose Machines Research Articles

Implementation and Evaluation of a Smart Machine Monitoring System under Industry 4.0 Concept

Production planning and control is essential in industrial manufacturing, ensuring efficient resource allocation and process management. Industry 4.0 introduces advanced technologies like cyber physical systems (CPS), artificial intelligence (AI), and internet of things (IoT) to effectively manage and monitor manufacturing operations. However, integrating these technologies into existing machinery, particularly for small and medium-sized enterprises (SMEs), poses challenges due to complexity and cost. The present study addresses this gap by designing and implementing a Smart Machine Monitoring System (SMMS) compatible with existing machinery such as computer numerical control and special purpose machines. The SMMS integrates IoT-based systems with AI algorithms to enhance machine tool utilization through effective planning, scheduling, and real-time monitoring. Through a nine-month case study in the shackle bolt manufacturing section, it was tested and compared to an Enterprise Resource Planning (ERP)-based system to assess its performance. Results showed significant improvements in production output, machine utilization rates, labor efficiency, and overall manufacturing costs. In conclusion, this study contributes to the body of knowledge on practical Industry 4.0 implementations for SMEs, offering insights into cost-effective solutions for enhancing operational efficiency and resource utilization in manufacturing environments.

Roxana ontology: a standard-based knowledge model for the formalisation of adaptive human-based processes in the manufacturing industry

In most European member states, employees stay with a company for over ten years. During this time, people gain valuable experience and build up expertise that is lost to production companies when employees leave. Despite increasing digitalisation, there will still be processes, especially in individual production, that require experts. Ontologies are an established method for formalising knowledge. Standards are needed to ensure interoperability. However, not all reference models are based on the standardised basic formal ontology. To the best of our knowledge, there are also no references for modelling human-bound production steps. We have developed the freely accessible ROXANA ontology based on actual use cases from special-purpose machines. This ontology is based on the basic formal ontology and uses references from the common core ontologies and the industrial ontology foundry. The difficulty with expert-bound process steps in production is individuality and complexity. The design of special-purpose machines is individual, as are the machine-specific documents and the associated workflows. This paper presents the ontology, explains it using practical examples, and shows its implementation in a real software-based expert system.

Simulation of passenger movement dynamics in a vehicle

A feature of the braking dynamics of a road train is the occurrence of shock loads between its links, which under certain conditions can significantly impair its stability. At the same time, there is a significant increase in dynamic loads on the support-coupling device, the destruction of which can lead to an emergency situation. It is suggested to use computer modeling in addition to bench tests to diagnose the condition of traction and coupling devices. It makes it possible not only to duplicate field tests, but also to reduce their costs, to apply methods of theoretical forecasting and determination of the strength of units of traction and coupling devices of trailers and towed vehicles. In the case of a semi-trailer, the impact of the tractor is modeled taking into account the initial lateral stiffness of the pivot pin, which indicates the elasticity of the suspension, tires, chassis and support-coupling device of the tractor-trailer on the level of the ground surface. The load on the finger of the hinged-coupling device during computer modeling was estimated by the amount of stress concentration on the surface of the finger. The greatest local stresses were observed in the area of the finger's phalanx, and the maximum deformation of the finger did not exceed 0.061 mm. Bench tests with the same tensile test force as in the calculation method showed that the difference in the values obtained by these two methods was 10-3 mm, which is included in the permissible measurement error (± 1.6•10-3 mm). The combination of bench tests and computer modeling is also relevant at the design and testing stages of agricultural, forestry and special purpose vehicles and machines.

Analyzing the effect of Process Parameters on Amaranth Popping and Puffing in the Lahi Machine using the Taguchi Method

Purpose - Amaranth grains are popped by various methods of heating like Oven puffing, Gun puffing, Extrusion puffing, Oil puffing, Pan Popping, etc. Popping of amaranth grains in an oven, gun, extrusion, oil, pan, etc. are having the limitation due to its size, puffing quality, low volume expansion ratio, etc. In this research work the Special Purpose Machine (SPM) with a heating plate was used to pop/puff the amaranth grains. This machine was designed to overcome all the above limitations mentioned earlier. The quality of amaranth grains are depending on temperature, angle, hole size of the nozzle, the material of the heating plate, etc. The impact of these process parameters is analyzed on the Popping Yield (PY), Ratio of Volume Expansion (VER), and Sensory Score (SS) of amaranth grains. The Popping Yield (PY), Ratio of Volume Expansion (VER), and Sensory Score (SS) are major quality parameters of amaranth grains. Therefore these parameters are finalized to carry out further research. The intent of this study is to analyze the more significant process parameters which are impacting PY, VER, and SC. Methodology – The Taguchi approach was adopted for analyzing the impact of process parameters on the quality of Amaranth grains. The Minitab 17 software was used to detect the significant factors. Findings – To identify the significant process parameters the design of the experiment (DOE) has been done. L16 Orthogonal Array (OA) has been obtained to carry out the experimental investigation. It was observed that temperature and material of the heating plate are the more significant parameters on PY, VER, and SS. Through investigation of the S/N ratio and ANOVA, it was detected that the temperature and Material are significant parameters and contributed 29.93%, 44.34%, 49.06%, and 44.58%, 28.73%, 29.33% respectively on Popping Yield, Ratio of Volume Expansion and Sensory Score.

Design and Development of an SPM for Bearing Cage Assembly

Bearing is one of the most critical machine element in every rotating equipment. Its performance is crucial for proper functioning of the equipment. The performance of the bearing is dependent on its components, its manufacturing precision and the proper assembly of the bearing components. In bearing assembly process the assembly of the retainer/cage and the rolling elements plays a vital role with regards to the functioning of the rolling elements to carry the load evenly. This work is focused on the assembly of brass cage of Cylindrical roller bearing. The proper locking or riveting of the cage of a Cylindrical Roller Bearing is important otherwise it will lead to bearing failure. In this work a special purpose machine is design and developed to ensure correct locking/ riveting of the brass cage. The concept orbital riveting is used in the machine which ensures sufficient flaring of the material of the brass cage resulting in strong locking of the bearing cage. The machine developed are giving positive results in terms of the productivity and the quality of the cage locking process. Keywords: Orbital Riveting, Design, Development, Cost TRIZ, SPM, Productivity

Component-based transfer path analysis on agricultural tractor

Agricultural tractors are special purpose machines that perform agricultural operation in harsh environments such as unpaved roads and farmlands, and generate high levels of noise and vibration. Eco-friendly tractors using electric drivetrains and hydrogen fuel cells are being developed to reduce exhaust gas in accordance with global environmental regulations. Unlike traditional tractor structures, these electrified tractors are being developed as modular and shared platforms. Therefore, it is changing into a system that is easy to apply component-based transfer path analysis (C-TPA) to reduce noise and vibration of tractors. In this paper, the noise and vibration contributions of an agricultural tractor were analyzed using C-TPA, and the blocked force usable as the excitation force of the virtual model was derived. The accuracy of transfer path analysis was improved by applying transfer functions including the rotational directions using virtual point transformation technique. The prediction result of developed experimental model were similar to the vibration response of the actual tractor, and the contribution of structure-borne noise could be quantitatively evaluated.

ОБЕСПЕЧЕННОСТЬ РЫНКА СПЕЦИАЛИЗИРОВАННОЙ ТЕХНИКИ ГИДРАВЛИЧЕСКИМИ РАСПРЕДЕЛИТЕЛЯМИ РОССИЙСКОГО ПРОИЗВОДСТВА

Currently, a relevant task for self-propelled machinery manufacturers is to replace hydraulic system components of the leading global manufacturers with hydraulic system components of alternative Russian manufacturers. The price share of a hydraulic system within the production cost of complete machinery is estimated by experts to be 5% to 25%. At the same time in the Russian Federation, hydraulic system components are produced in insignificant volumes. The components produced in the territory of the Russian Federation often fail to meet state-of-the-art requirements; therefore, it is the foreign components that are mainly used. The task of organizing production of state-of-the-art components for hydraulic systems is a very important one and is aimed at provision of production of modern equipment for various purposes in the Russian Federation. This work was carried out in order to assess the possibility of consolidated inquiry arrangement, qualitative development of the existing production of hydraulic equipment and creation of new production facilities. In the work, a list of typical hydraulic distribution equipment used in the modern special-purpose machinery design was compiled, and a dimensional range of hydraulic distribution equipment parameters was justified. Based on the results of analysis of the special-purpose machinery market, forecast market demand for hydraulic distribution equipment by segments until 2030 was determined. In order to assess the hydraulic distribution equipment market for types of machines not included in this study, based on expert opinions, we assume that their market is 50% of the considered types of machines. The analysis showed that when producing special-purpose machinery, hydraulic distribution equipment from various manufacturers is used, and hydraulic distribution equipment is one of the expensive components taking up to 20% of the total cost of a hydraulic system of special-purpose machines. The hydraulic distribution equipment potential market capacity in the Russian Federation in 2030 perspective will amount to 1.34 million pcs for a total of 56.9 billion rubles.

An Integrated Fuzzy MCDM Method for the Evaluation of R&D Projects

Research and development (R&D) activities are essential to guarantee continuity of firms, meet customer requirements and keep ahead in competition. R&D project selection constitutes a significant part of project management in order to achieve the desired results and outputs. In this study, an integrated fuzzy multi-criteria group decision making approach is developed for R&D project selection. The problem includes a hierarchical structure of the criteria, uncertainty in evaluating the relative importance of criteria/sub-criteria and rating of candidate projects. The method employs the ordered weighted average (OWA) operator as the aggregation operator, which helps to fully reflect the real behavior of the decision makers in group decision making problems. Fuzzy integral method, which does not require the assumption of the mutual independence of criteria, is used to rank the alternatives. The case study is conducted in a small-sized company in Turkey, which designs and produces special purpose machines. A R&D project selection model is developed to maximize the desired outputs. The results of the analysis show that technological, environmental, marketing, organizational, national and financial issues should be considered simultaneously in the evaluation process. The proposed method is shown to be efficient, generalizable and practical and it has several significant merits compared to the other methods.

Quantum computing in pharma: A multilayer embedding approach for near future applications.

Quantum computers are special purpose machines that are expected to be particularly useful in simulating strongly correlated chemical systems. The quantum computer excels at treating a moderate number of orbitals within an active space in a fully quantum mechanical manner. We present a quantum phase estimation calculation on F2 in a (2,2) active space on Rigetti's Aspen-11 QPU. While this is a promising start, it also underlines the need for carefully selecting the orbital spaces treated by the quantum computer. In this work, a scheme for selecting such an active space automatically is described and simulated results obtained using both the quantum phase estimation (QPE) and variational quantum eigensolver (VQE) algorithms are presented and combined with a subtractive method to enable accurate description of the environment. The active occupied space is selected from orbitals localized on the chemically relevant fragment of the molecule, while the corresponding virtual space is chosen based on the magnitude of interactions with the occupied space calculated from perturbation theory. This protocol is then applied to two chemical systems of pharmaceutical relevance: the enzyme [Fe] hydrogenase and the photosenzitizer temoporfin. While the sizes of the active spaces currently amenable to a quantum computational treatment are not enough to demonstrate quantum advantage, the procedure outlined here is applicable to any active space size, including those that are outside the reach of classical computation.

Design and fabrication of multi cutting hack saw machine

The growth of Indian manufacturing sector depends largely on its productivity & quality. Productivity depends up on many factors one of the major factors being manufacturing efficiency with which the operation/activities are carried out in the organization. productivity can be improved by reducing the total machining time, combinating the operations etc. In the case of mass production where variety of jobs is less and quantity to be produced is huge, it is very essential to produce the job faster rate. This is not possible if we carry out the production by using general purpose machines. The best way to improve the production rate (productivity) along with quality is by the use of special purpose machine. Usefulness and performance of the existing radial cutter machine will be increased by designing and manufacturing of multi cutter head attachment. This paper details with design and development of multi cutter head for cycle time optimization of the component.

DIRECTORS OF THE KHARKIV TRACTOR PLANT AND THEIR CONTRIBUTION TO THE DEVELOPMENT OF THE ENTERPRISE

The life's journey and contribution of the Kharkiv Tractor Plant directors to the enterprise's activities, including the production of examples of the new technique, were studied in the work. The practices analysis of each of the plant's seniors shows that these are people who are dedicated to their work and, no matter how the economic and political situation in the state develops, the directors tried to do everything for improving the enterprise's activities and modernising of the products. For the entire period of work (90 years), the Kharkiv Tractor Plant has produced more than three million tractors and other heavy-duty special-purpose machines. How the fate of the plant and its products is intertwined with the fate of the directors was shown

Thermal analysis on Ti-6AL-4V tool architecture using Johnson–Cook material model

Precision machine accuracy is harmed by a variety of error sources, including vibration, self-weight deformation, and measurement error. Thermal deformation of the machine structure is a major source of error that reduces the accuracy of precision machines. Thermo-elastic deformations of machine tools are caused by both internal and external heat sources, resulting in geometric inaccuracies in the work piece. Thermal effects can account for up to 75% of the total inaccuracy. Precision machines must meet higher precision and productivity standards. As a result, the Johnson-Cook dynamic failure model is used in this work to reduce. The Johnson–Cook material constitutive equation, which is employed in this work, takes into account the effects of strain, strain rate, and temperature on material properties. The results obtained from the present methodology are validated with the results available from the Literature. From the present study the thermal error could be kept within 16µm. Further the same methodology can be extended to HMC's and VMC's for special purpose machines in order to control the thermal deformations.

Development of Imitation Model of an Electromechanical Energy Converter with a Solid Rotor in ANSYS RMxprt, Maxwell and Twin Builder

This paper presents the development of a platform for coupling modeling (cosimulation) of an electromechanical energy converter using Ansys Maxwell and Ansys Twin Builder. The researched electromechanical energy converter is based on the operation principle of an induction motor with an external hollow solid rotor. The paper reveals the specifics of modeling this type of special electric machine. In the work, step-by-step modeling of the machine in Ansys RMxprt, export of the model in Ansys Maxwell 2D and 3D with further co-simulation in Twin Builder was performed. It shows how to set up the project to import an object calculated by the finite element method from Ansys Maxwell into the Twin Builder sheet. Coupling simulation of an electromechanical energy converter with a stable three-phase power source was performed. The simulation model considers the presence of a step mechanical load during the run-up to the rated speed. Such structure of a coupling project gives better simulation results compared to the use of simulation models with concentrated parameters, based on the implementation of differential equations of electromagnetic transients using functional blocks. The obtained characteristics showed a high coincidence of the expected results according to the indicators of phase currents of the stator winding, moving torque and rotation speed. This paper will be useful for coupling modeling special-purpose electrical machines that are not available in the Ansys Twin Builder library as ready-made blocks.

Development and Implementation of Autonomous Quality Management System (AQMS) in an Automotive Manufacturing using Quality 4.0 Concept– A Case Study

PurposeThe goal of this research is to use the Quality 4.0 (Q4.0) concept to digitalize the traditional Quality Management System (QMS) and demonstrate the efficiency of the Autonomous Quality Management System (AQMS) in the case organization. Design/Methodology/ApproachThe Internet of Things (IoT) concept was used to develop AQMS. The Q4.0 technique was used to digitalize the developed system. Gage repeatability and reproducibility (gage R&R) of traditional and autonomous QMS systems have been evaluated. Both the QMS systems were examined using six-sigma quality indicators, as well as machining and inspection cost analysis. FindingsIn traditional and autonomous QMS, the gage R&R was found to be 91.60 percent and 0.67 percent, respectively. The special purpose machine (SPM), computer numerical control (CNC), and hydraulic machine production rates were increased by 44.42 percent, 65.60 percent, and 65.76 percent, respectively. The effective deployment of AQMS has reduced the production and inspection costs by 52.16 percent and 78.35 percent. The AQMS process yield has increased from 86.80 percent to 99.99 percent, and the component rejection rate has decreased by 93.70 percent. Overall machining process improved significantly as the sigma level increased from 1.5 to 5.5. Research Limitation/ImplicationThe current study's findings are limited to hub bolt products only. In future investigations, the application of AQMS to other types of products will be considered. Originality/ValuesThis study was carried out practically to reflect the effectiveness of the implemented Q4.0 concept in the actual industry scenario.

Modeling and Analysis of Twin Spindle Twin Turret Machine

In the industrial industry, Special Purpose Machines (SPM) play a critical role in increasing productivity. Drilling and riveting activities are done on different machines in the majority of industrial processes, resulting in inefficient productivity. Drilling and riveting had hitherto been thought of as two separate procedures. To increase production, this study attempts to integrate two spindles and two turrets on a single machine. Work components are drilled on a drilling spindle and subsequently cut on a turret in this special purpose machine. Because the spindle shaft, ball screw, and slider base employed in this machine are crucial elements, static and modal analysis is performed using the Finite Element Analysis tool to determine stress distribution and natural frequency.

Shear strength of ultra high-performance concrete

Tests were conducted to determine the shear strength of a non-proprietary Ultra High-Performance Concrete (UHPC) mix, designed by the University of Oklahoma. Results for both material properties and shear strength are reported here. The shear strength was determined using a special-purpose panel testing machine, which can subject a 2-D panel to any desired combination of in-plane stresses. Only pure shear was used here. It was found that the local sourcing had no perceptible effect on the material properties, that the fiber content had only a small effect on the compression strength, and that considerable scatter exists in the tension strength results, although those obtained from the flexural beam tests showed less scatter than those from the direct tension test. The shear strength lay in the range 7.5– 10 MPa, and correlates more closely with tension strength than with traditional measures, such as fc'.

Design and Implementation of PLC Based Special Purpose Machine for Surface Coating

To improve the quality and efficiency of surface coating with the GTAW method a semi-automatic welding machine was designed based on PLC control. The control program using ladder logic can accomplish system management and control functions. This system could control welding travel speed up to 560 mm/min, measure and saves the current status of the surface temperature at the welding zone via infrared thermometer up to 1600 °C in real-time, has complete automatic fault diagnosis, modify the welding travel speed and save the inputted welding parameters. To evaluate the performance of the designed welding machine, several experiments have been conducted. An average of 377.5 HV0.2 microhardness was obtained from the surface of SAE (AISI) 1040 materials used in the experiments to a depth of 1 mm via the coating powders containing 64 wt% FeCrC + 16 wt% FeTi and 20 wt% Ni. The results from the experiments have shown that the designed PLC-based semi-automatic welding machine could be effective in determining the optimum conditions for surface coating and different welding processes.

Incorporating tool identification system in normal machining centre using radio frequency identification

The emerging trends in the field of flexible manufacturing system has made the role of automation are very important. To achieve complete automation in the production line identification of components, tools and palettes are necessary. The idea of radio frequency identification system has drastically developed only recently. Even this drastic development is limited to special purpose machines only. There are many number of ways to identify any part or product. But all of them have their own advantages and disadvantages. They are bar code, mechanical coding, magnetic cards, radio frequency system and microwave system. Out of all these Bar code and mechanical coding systems are either producing consumption of materials continuously or leaving a permanent mark. The microwave system is controlled directly by the satellite and it is used in vehicle tracking system. The cost incurred for the microwave system is too high and the operational cost is also very high. The only system which is having cost advantage in long run and has more advantage comparing all other system is radio frequency system. Also the interfacing links between these identification systems and the machine contains complicated techniques. In this project we identify the tools in the machining area so that the number of tools in the machining area is increased. Also ways to eliminate these communication obstacles has been determined.

HISTORY OF DEVELOPMENT AND MANUFACTURE OF TRACTORS AND PRIME-MOVERS BY THE STATE ENTERPRISE «KHARKIV DESIGN BUREAU OF ENGINEERING NAMED AFTER A. A. MOROZOV» AND STATE ENTERPRISE «MALYSHEV PLANT» (REVIEW ARTICLE)

The review article systematizes information and studies the history of designing tractors and prime-movers at the State Enterprise «Kharkiv Design Bureau for Mechanical Engineering named after A. A. Morozov» and their manufacture by the State Enterprise «Malyshev Plant » from the origin of such production in Kharkiv to the present time. The role of Kharkiv in providing the country with special equipment is revealed. Detailed biographical information about chief designers of this technique (B. N. Voronkov, N. G. Zubarev, M. N. Shchukin, A. I. Avtomonov, M. D. Borisyuk, A. D. Motrich, M. P. Kalugin, P. I. Sagir, B. I. Kalchenko) provided, their role in the development and improvement of designs of special-purpose machines is indicated. The main technical characteristics of basic models of tractors and prime-movers are presented. The main problems in the production of these types of equipment are mentioned. The article contains information about various modifications of AT-T, their main differences and purposes are indicated. Keywords: tractor, prime-mover, SE «Kharkiv Design Bureau of Engineering Named after A. A. Morozov», SE «Malyshev Plant», National Technical University «Kharkiv Polytechnic Institute»

A REVIEW PAPER ON WORK HOLDING DEVICES FOR DRILLING OPERATIONS

One of the important tool to improve productivity is to reduce set up cost on the shop floor. The research review presented here deals with the productivity improvement with the help of new types of work holding devices particularly for drilling operation. Various research works has been examined dealing with jigs and fixture design, ranging from optimization methods used to design, Efficacy of the Software tools used for design, Special purpose machine design etc. The review will not only helpful for the current research work but also will be instrumental for further researches in the field.