Presentation on theme: "Student Investigators Indian Institute of Technology Bombay, India"— Presentation transcript:
1 Student Investigators Indian Institute of Technology Bombay, India Upscaling of used Sari Cutting Machine for Handlooms Operated by Visually challenged IndividualsByDr. Suhas JoshiProfessor, Department of Mechanical Engineering (PI)Dr. Bakul RaoAssociate Professor, CTARA (Co-PI)Student InvestigatorsVikalp Jambhulkar (Dual degree MTech) and Alap Kshirsagar (B. Tech.)Indian Institute of Technology Bombay, IndiaJanuary 2012
2 Preamble Grameen Shramik Pratishthan – An NGO Swadhar- Training cum production centerTrains visually challenged people for handloom weaving.Provide stable employment opportunityCurrently employs 65 visually challenged individuals.Floor MatsDoor Mats
3 Cutting of sari bundles Mat Making ProcessCutting of sari bundlesWrapping the ribbonsaround sticksStitching of Sari
4 Mat Making ProcessWeaving ProcessWeaving machines at GSP
5 Need for the Machine Earlier Method Ribbons are made by tearing the Sari2-3 hours for cutting 7-9 SarisConsumes 30% time of the weaversVariation in the size and loose fibersUsage of razor blades is dangerousCurrent MethodA machine is used for cutting folded Sarees for making ribbonsVariation in the size and entanglement of ribbons.Time consuming and productivity is very less
6 Objectives and ScopePrimary objective was to evolved an easy method of ribbon making and development of proto-type.Accordingly, Yogendra Meena (Dual Degree M.Tech.) student has worked on it last year to evolve two proto-types of scale 1/3rd scale.The objective of this proposal is to take one the prototypes (the second prototype) ahead for upscaling so as to develop a real life machine.
7 Design: Single Layer Cutting Design 1: Single layer cutting of sari with multiple cutters in seriesDesign 2: Single layer cutting of sari with multiple reciprocating cutters in series
8 Design: Multiple layer cutting Design 3: Simultaneous cutting of multiple layers of saris with multiple bladesDesign 4: Simultaneous cutting of multiple layers of saris with single blade
9 Prototype 1: Single Layer Cutting The stitched sari is wound on the rollerThe sari is passed through the stretching rollersThe sari gets cut as it passes through the cuttersRibbons formed gets wrapped around the bobbinsThe bobbin shaft is rotated using the pedal mechanismAfter the whole sari is cut, the bobbins are taken outand they are used in weavingPassing of sari through thestretching rollersThe sari gets cut between thecutters and gets collected in bobbins
10 Prototype 2: Multiple Layer Cutting The stitched sari is wound on the rollerThe roller is mounted on the machine and is rotated using the pedal mechanismWhile the sari bundle is rotating the circular cutter is pressed on itThe cutter is pressed till the whole bundle is cut and then it is releasedThe sari is cut into ribbons on the roller, the ribbons are taken out and can be used for weavingThe sari is wrapped aroundthe wooden rollerCutters are pressed on the rotating woodensari roll to get the ribbons
11 Problems Faced Single Layer Cutting Machine Initial cut has to be made.Attaching ribbons on the bobbins; around 25 bobbins.Both are very time consuming processes.
12 Force measurement using dynamometers Problem FacedMultiple Layer Cutting ProcessVery large force is needed to cut, experimental results show that the force get to as high as 50 N for single cutterThe cutter gets stuck while it is slightly inside the bundlePoor finish of the ribbons;loose fibers are formedRibbons are not cut on bobbinsForce measurement using dynamometers
13 New Design: Multiple Layer Cutting The circular blade mounted on a shaft and is rotated by motorThe shaft holders are stationaryThe sari is wrapped on the bobbin rollers which is mounted on moving platform4. When the cutters are moving, the sari bundle is pressed into the cutters by pushing the platform5. The ribbons are produced on the bobbins which can be taken out for weaving
14 New Design: Single Layer Cutting The sari passes through the stretching rollersThe sari is cut by the reciprocating motion of straight blades3. The ribbons generated are wrapped around the bobbins4. The bobbin shaft will be rotated by using a pedal mechanism
15 Approach for manufacturing the machine Design of the machine components in detail, involves selection of materials, designing of component sizes and tolerances.Design of manufacturing processes for various componentsFabrication of the componentsAssembly of the machineTesting of the machine
16 Budget for the project Budget bifurcation Sr. No. Item Cost (Rs.) 1. Raw materials, wood steel and aluminium25, 000/-2.Paddling arrangement4, 000/-3.Fabrication cost40, 000/-4.Research 12,000/- per month for 1 year1, 44, 000/-5.Miscellaneous expense including travelTotal2, 38, 000/-Budget bifurcation
17 Timeline for the project Duration of Project: One yearDeliverable: Sari cutting machine of real-life sizeActivityOctober – Dec. 2011January-March 2012April-June 2012July-Sept. 2012First PrototypeMachine DevelopmentMachine testingMachine transfer & installation
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