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Student Investigators Indian Institute of Technology Bombay, India

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1 Student Investigators Indian Institute of Technology Bombay, India
Upscaling of used Sari Cutting Machine for Handlooms Operated by Visually challenged Individuals By Dr. Suhas Joshi Professor, Department of Mechanical Engineering (PI) Dr. Bakul Rao Associate Professor, CTARA (Co-PI) Student Investigators Vikalp Jambhulkar (Dual degree MTech) and Alap Kshirsagar (B. Tech.) Indian Institute of Technology Bombay, India January 2012

2 Preamble Grameen Shramik Pratishthan – An NGO
Swadhar- Training cum production center Trains visually challenged people for handloom weaving. Provide stable employment opportunity Currently employs 65 visually challenged individuals. Floor Mats Door Mats

3 Cutting of sari bundles
Mat Making Process Cutting of sari bundles Wrapping the ribbons around sticks Stitching of Sari

4 Mat Making Process Weaving Process Weaving machines at GSP

5 Need for the Machine Earlier Method
Ribbons are made by tearing the Sari 2-3 hours for cutting 7-9 Saris Consumes 30% time of the weavers Variation in the size and loose fibers Usage of razor blades is dangerous Current Method A machine is used for cutting folded Sarees for making ribbons Variation in the size and entanglement of ribbons. Time consuming and productivity is very less

6 Objectives and Scope Primary 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 series Design 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 blades Design 4: Simultaneous cutting of multiple layers of saris with single blade

9 Prototype 1: Single Layer Cutting
The stitched sari is wound on the roller The sari is passed through the stretching rollers The sari gets cut as it passes through the cutters Ribbons formed gets wrapped around the bobbins The bobbin shaft is rotated using the pedal mechanism After the whole sari is cut, the bobbins are taken out and they are used in weaving Passing of sari through the stretching rollers The sari gets cut between the cutters and gets collected in bobbins

10 Prototype 2: Multiple Layer Cutting
The stitched sari is wound on the roller The roller is mounted on the machine and is rotated using the pedal mechanism While the sari bundle is rotating the circular cutter is pressed on it The cutter is pressed till the whole bundle is cut and then it is released The sari is cut into ribbons on the roller, the ribbons are taken out and can be used for weaving The sari is wrapped around the wooden roller Cutters are pressed on the rotating wooden sari 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 Faced Multiple Layer Cutting Process Very large force is needed to cut, experimental results show that the force get to as high as 50 N for single cutter The cutter gets stuck while it is slightly inside the bundle Poor finish of the ribbons; loose fibers are formed Ribbons are not cut on bobbins Force measurement using dynamometers

13 New Design: Multiple Layer Cutting
The circular blade mounted on a shaft and is rotated by motor The shaft holders are stationary The sari is wrapped on the bobbin rollers which is mounted on moving platform 4. When the cutters are moving, the sari bundle is pressed into the cutters by pushing the platform 5. 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 rollers The sari is cut by the reciprocating motion of straight blades 3. The ribbons generated are wrapped around the bobbins 4. 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 components Fabrication of the components Assembly of the machine Testing of the machine

16 Budget for the project Budget bifurcation Sr. No. Item Cost (Rs.) 1.
Raw materials, wood steel and aluminium 25, 000/- 2. Paddling arrangement 4, 000/- 3. Fabrication cost 40, 000/- 4. Research 12,000/- per month for 1 year 1, 44, 000/- 5. Miscellaneous expense including travel Total 2, 38, 000/- Budget bifurcation

17 Timeline for the project
Duration of Project: One year Deliverable: Sari cutting machine of real-life size Activity October – Dec. 2011 January-March 2012 April-June 2012 July-Sept. 2012 First Prototype Machine Development Machine testing Machine transfer & installation


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