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Upscaling of used Sari Cutting Machine for Handlooms Operated by Visually challenged Individuals By Dr. Suhas Joshi Professor, Department of Mechanical.

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Presentation on theme: "Upscaling of used Sari Cutting Machine for Handlooms Operated by Visually challenged Individuals By Dr. Suhas Joshi Professor, Department of Mechanical."— Presentation transcript:

1 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. Door Mats Floor Mats 2

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

4 Mat Making Process Weaving ProcessWeaving machines at GSP 4

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 5

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 1/3 rd 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. 6

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 7

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 8

9 Prototype 1: Single Layer Cutting 1.The stitched sari is wound on the roller 2.The sari is passed through the stretching rollers 3.The sari gets cut as it passes through the cutters 4. Ribbons formed gets wrapped around the bobbins 5. The bobbin shaft is rotated using the pedal mechanism 6. 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 9

10 Prototype 2: Multiple Layer Cutting 1. The stitched sari is wound on the roller 2. The roller is mounted on the machine and is rotated using the pedal mechanism 3. While the sari bundle is rotating the circular cutter is pressed on it 4. The cutter is pressed till the whole bundle is cut and then it is released 5. 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 10

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. 11

12 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 12

13 New Design: Multiple Layer Cutting 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 1.The circular blade mounted on a shaft and is rotated by motor 2.The shaft holders are stationary 3.The sari is wrapped on the bobbin rollers which is mounted on moving platform 13

14 New Design: Single Layer Cutting 3.The ribbons generated are wrapped around the bobbins 4.The bobbin shaft will be rotated by using a pedal mechanism 1.The sari passes through the stretching rollers 2.The sari is cut by the reciprocating motion of straight blades 14

15 Approach for manufacturing the machine 1.Design of the machine components in detail, involves selection of materials, designing of component sizes and tolerances. 2.Design of manufacturing processes for various components 3.Fabrication of the components 4.Assembly of the machine 5.Testing of the machine 15

16 Budget for the project Sr. No.ItemCost (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 year 1, 44, 000/- 5.Miscellaneous expense including travel25, 000/- Total2, 38, 000/- Budget bifurcation 16

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


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