Posted tagged ‘industry’

Vibratory conveyor / Oscillating Conveyor

September 8, 2011


01-vibrating conveyor- vibrating conveyor systems-vibrating conveyor parts-shaker conveyor-inertia conveyor-reciprocating conveyor-oscillating conveyor

A vibratory conveyor essentially consists of an open or closed trough or pipe, generally horizontal but not always so, and which is elastically supported on a base structure or suspended from an overhead structure by springs. The trough or pipe is caused to oscillate at high frequency and small amplitude by an appropriate drive mechanism. Vibratory conveyors are commonly employed in industry to carry a wide variety of particulate and granular types of bulk materials. The fundamental action of the vibrating troughs on the bulk material loaded on it is to throw the particles upward in the forward direction so that the material performs series of short hopping movement and propagates at a certain speed.

Oscillating conveyors are utilized to convey sand or other granular particles at a desired rate. The conveyor is generally placed under a vibrating shakeout or a grid to eliminate direct handling of hot sand by the belt conveyor. In the process of reciprocation, the oscillating conveyor cools the hot sand to some extent which increases the life of the return sand conveyor belt.

An important characteristic of vibratory conveyor is the ease with which the flow rate of the conveyed material can be controlled by adjusting the amplitude and or frequency of the vibration. This particular aspects of such conveyor has led to the wide spread application of vibrating trough as feeders employed to supply material in controlled amount to various machines. When the trough is replaced by a screen, the vibratory conveyor may serve as vibrating screen, which has wide application in various industries. A distinction must be made between feeders and conveyors. A feeder is used as a discharge device under a storage hopper or bin and is subjected to varying head loads. A conveyor requires regulated feed rate and must not operate under varying head load conditions.

Construction details of Oscillating Conveyor:

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ADVANCE BATTERY STORAGE

August 26, 2011

01-EESTOR-Barium titanate Batteries-advanced battery storing technology-Ultra capacitor technology

For decades, battery storage technology has been a heavy weight on the back of scientific innovation. From cell phones to electric vehicles, our technological capabilities always seem to be several steps ahead of our ability to power them. Several promising new technologies are currently under development to help power the 21st century, but one small start-up looks especially well positioned to transform the way we think about energy storage.

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Texas-based EEStor, Inc. is not exactly proposing a new battery, since no chemicals are used in its design. The technology is based on the idea of a solid state ultra capacitor, but cannot be accurately described in these terms either. Ultra capacitors have an advantage over electrochemical batteries (i.e. lithium-ion technology) in that they can absorb and release a charge virtually instantaneously while undergoing virtually no deterioration. Batteries trump ultra capacitors in their ability to store much larger amounts of energy at a given time.

EEStor’s take on the ultra capacitor — called the Electrical Energy Storage Unit, or EESU — combines the best of both worlds. The advance is based on a barium-titanate insulator claimed to increase the specific energy of the unit far beyond that achievable with today’s ultra capacitor technology. It is claimed that this new advance allows for a specific energy of about 280 watts per kilogram — more than double that of the most advanced lithium-ion technology and a whopping ten times that of lead-acid batteries. This could translate into an electric vehicle capable of traveling up to 500 miles on a five minute charge, compared with current battery technology which offers an average 50-100 mile range on an overnight charge. As if that weren’t enough, the company claims they will be able to mass-produce the units at a fraction the cost of traditional batteries.

“It’s a paradigm shift,” said Ian Clifford of ZENN Motor Co., an early investor and exclusive rights-holder for use of the technology in electric cars. “The Achilles’ heel to the electric car industry has been energy storage. By all rights, this would make internal combustion engines unnecessary.”

But this small electric car company isn’t the only organization banking on the new technology. Lockheed-Martin, the world’s largest defense contractor, has also signed on with EEStor for use of the technology in military applications. Kleiner Perkins Caufield & Byers, a venture capital investment firm who counts Google and Amazon among their early-stage successes, has also invested heavily in the company.

Some posts need no Title-2

August 23, 2011

I comforted myself at the back of 50 seater with my crew…!!

All took their ID cards out and got ready with complete formals except few guys like me …
I took Rajeev’s shirt..
for the fact i dint picked even a single formal dress for the tour…!!
It took almost 40 odd minutes to reach the CMTI from the rail station..
those 40 odd minutes had given us little glimpse of bustling metro life..!
The wallposters of kannadaWOOD(Don’t know what to call!!)
I don’t know why they got my attention…
those actresses are the people who tried their luck at tollywood and failed…!!
I saw My childhood Fav star Nikhita in “GUN” wall poster..!!
And the most amazing thing is there are some people Called HEROES looked like the fellows who were denied admission in Mysore ZOO..!!
There i saw “5 Idiots”
Something that looked like” Kalamanja”(I really dont know how to pronounce Kannada words…!!)
I felt so sorry for the audience of mighty Bengaluru Metro People..!!
When compared to those stars even OM (Okka Ma…..) is lil better…!!
Suddenly the bus stopped at a junction huge traffic…!!
A huge construction under progress….
We don’t know that it was a part of B’lore Metro..!!
There is a huge iron pillar..
something like huge plate was attached to it…
We had a heated argument about whether the plate is riveted or bolted…!!
Then came a guy known for his photography with his brand new canon Mr.Mahendra Pedapati photographed that thing and zoomed that picture and showed that it was riveted..!!
i own my stake of Rs.10/- with Kesh..!!
Few minutes later we reached CMTI @ CVRamanNagar..
The lunch was already arranged there for us…
I expected lot from the kannada people…
But i just had to adjust myslef with Chapathi, 2 cups rice….
Sambar and the curd (Sour..!!)….
all for just Rs.50/-
Started into industry …!!
They just don’t allow Cameras or phones into industry…!!
Immediately after security check we were all allowed into that esteemed ,serene campus..!!
We were divided into 2 groups and set sailed for the next 3 hours..!!
The group which consisted me rushed into Rapid prototyping block ,Where a guy called Vinod waiting for us ..!!
He explained What prototyping is
and why it is being used and alll…..
It is the only process where we can produce a sphere inside another sphere freely rotating and without seam that in single step…!!
The process is supported by A slicing software and a machine which manufactures…
Somebody told us to note down the specifications of that machine….
I wonder what we do with them…??!!

FAILURE ANALYSIS

August 23, 2011

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• Why ?

As the standards of our industry rise due to increasing globalization and competition, there is an ever growing need for consistency and reliability. Breakdown of any unit, system or equipment is an avoidable and costly occurrence and must be prevented or minimized. Analysis of such failures becomes a resourceful and affordable tool in addressing such unwanted occurrences.

To establish whether the cause of component failure lay on:

a) Service conditions
b) Design considerations
c) Material and its specification
d) Improper processing and assembly procedures or
e)  Combinations of these.

01-RootCause-root cause analysis cycle-problem solving steps-avoidance of recurring problems

Only the real “Root cause” can ensure the effectiveness of corrective and preventive actions and avoid recurrence of failure.

01-CauseEffect-analysis-bottom up predictive-ishikawa - fishbone diagram-prediction analysis

• Stages Of Failure Analysis

1. Understanding and assimilation of background data and selection of samples.
2. Examination and documentation of the failed part by the following

1. Visual examination of parts, location (if necessary) and relevant photographs as well.

01-visual examination-metallographic examination-appearance of the parts-calibrated metallurgical microscope equipment-image analysis-microstructure

2.  Non destructive testing by means of Radiography, Dye      penetrant, Magnetic particle testing etc.

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3. Mechanical Testing for various physical properties.

3. Vital specimens are selected, classified, and subjected to:

  1. Macroscopic examination and analysis. This involves examining the fracture surfaces, secondary cracks, deposits and other such elements
  2. Microscopic examination and analysis of fracture surface (by Scanning Electron Microscopy, if required).

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4. Chemical analysis of material for conformation to specifications.

5. Chemical analysis of corrosion products, deposits, contaminants etc.

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6. The actual state of the failed part and the failure mode are established.

7.  Fracture mechanics study if found necessary.

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8. A simulation of the identical working environment to determine if any external      factors have contributed to the failure

9. Conclusions are determined after compiling all evidences and analysis and       then the report is generated.
10. Follow-up recommendations are also provided.

BLOW MOULDING PROCESS

August 23, 2011

Today, when walking in your supermarket, it is increasingly difficult to find items packed in glass and jars.  Packaging for soft drinks, healthcare and beauty products, household chemicals and medicines, among other products, have switched from glass or metal to plastics.  Today the Blow Molding industry has expanded from simple plastic containers to plastic drums, gas tanks, automobile parts and toys in all shapes and sizes.

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Blow Molding (BM) process makes it possible to manufacture molded products economically, in unlimited quantities, with virtually no finishing required.  The basic process of blow molding involves a softened thermoplastic hollow form which is inflated against the cooled surface of a closed mold.  The expanded plastic form solidifies  into a hollow product.

Blow molded components are now seen all over the markets and industries for traditional materials, particularly in liquid packaging applications.  The last few decades saw the introduction of  Poly Ethylene (PE) squeeze bottles for washing liquids, Poly Vinyl Chloride (PVC) for cooking oil and fruits squash bottles, and Poly Ethylene Terephthalate (PET) for carbonated beverage bottles.  Nowadays, it is also used for the production of toys, automobile parts, accessories and many engineering components.

There are basically four types of blow moulding used in the production of plastic bottles, jugs and jars. These four types are:

  1. Extrusion blow molding,
  2. Injection blow molding,
  3. Stretch blow molding and
  4. Reheat and blow molding.

Extrusion blow molding is perhaps the simplest type of blow molding, whereby a hot tube of plastic material is dropped from an extruder and captured in a water cooled mold. Once the molds are closed, air is injected through the top or the neck of the container; just as if one were blowing up a balloon. When the hot plastic material is blown up and touches the walls of the mold the material “freezes” and the container now maintains its rigid shape. There are various types of shuttle, reciprocating and wheel style machines for the production of extrusion blown bottles. Shuttle or reciprocating type machines can be used for small, medium and high volume production with wheel machines being the most efficient for huge volume production of certain resins.


01-petblow-plastic products manufacturing-PET Preform-PET bottles-stretch blow molding

A typical apparatus consists of following major components i.e. blow pin, plunger, accumulator and lastly a mold.

Actually the process utilizes air pressure to inflate softened thermoplastic tube which is sealed at one end (also called as parision). This parision is constantly inflated and extruded. Then later on it is cut according to required dimensions. The temperature in Accumulator is maintained around 400 degree Celsius or so.

Stretch_blow_mold-dies-PET Pre form mold-household appliance mold

The mold consists of two split parts which have a semi-circular cross-section. Usually the air pressure which is applied in low pressure molding is about 50 to 250 psi. Various forms of blow molding used in industry today on a wide scale are Injection Blow Molding.

Injection Blow Molding though not used in industry, has very limited and specific applications like making small medicine plastic bottles etc. Extrusion blow molding is the simplest form of blow molding. A tube of plastic material which is generally maintained hot, is dropped from an extruder only to be captured in a water cooled mold. Once the molds are closed, air is injected through the top or the neck of the container and the tube is inflated just like a balloon. When the hot plastic material is blown up and touches the walls of the mold the material is cooled and the container now maintains a solid, rigid shape.

Now Stretch blow molding, this process requires the raw material to be formed in a pre-form using injection molding and later on stretch blow molding process can be applied.

The product range varies from various cylindrical components like bottles, cans, floats heater ducts in automobile parts and various small pipe fittings and hollow cylindrical parts can be produced in mass production.

The advantages are many like the tooling costs are very less as compared to injection molding, the part performance is excellent under pressure. Then the products have excellent environmental stress crack resistance. The products also perform excellently in high speed impact strength than even the metal components the process can be automated and used in mass production.

The disadvantages mainly raise environmental concerns. It depends on petroleum industry as any plastic industry depends. Also the cylindrical shapes are delicate so if the dimensions are not accurate then they result in scrap.

DISI ENGINE

August 23, 2011

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In developing the DISI engine, we aimed to cool the interior of the cylinder as much as possible by promoting fuel vaporization and uniform mixing of atomized fuel and air. This produces a high charging efficiency of the air-fuel mixture and a high compression ratio, which results in significant improvements in both torque and fuel efficiency.


Characteristics of the direct injection engine:

  • Fuel is injected from a tiny nozzle into a relatively large cylinder, so it has a high latent heat of vaporization, which efficiently cools the air within (in-cylinder cooling effect).

  • The air temperature in the cylinder decreases, which means:

  • (1) more air may be charged into the combustion chamber, which produces increased torque.

  • (2) the engine is less prone to knocking. This contributes to increased torque, and enables a higher compression ratio that also contributes to good fuel efficiency.


In a direct injection engine, however, the fuel skips the waiting period it would have to endure inside a standard engine and instead proceeds straight to the combustion chamber. This allows the fuel to burn more evenly and thoroughly. For the driver, that can translate to better mileage and greater power to the wheels.

In the past, direct injection posed too many technical hurdles to make it worthwhile for mass market gasoline automobiles. But with advances in technology and greater pressure to make cars run more cleanly and efficiently, it looks as if gasoline direct injection — or GDI as it’s referred to in industry lingo — is here to stay. In fact, most of the major car manufacturers make or plan to soon introduce gasoline cars that take advantage of this fuel saving and performance enhancing system.