Design and Implementation of a Fully Automated Central Lathe Machine

The world is steadily moving towards autonomous processes to minimize human errors; however, Pakistan lags behind in this aspect. Therefore, aim of the current proposed project is to reduce this lag through automation of manually operated machines. Current project plans to automate an existing manua

Project Title

Design and Implementation of a Fully Automated Central Lathe Machine

Project Area of Specialization

Robotics

Project Summary

The world is steadily moving towards autonomous processes to minimize human errors; however, Pakistan lags behind in this aspect. Therefore, aim of the current proposed project is to reduce this lag through automation of manually operated machines. Current project plans to automate an existing manually operated Lathe Machine on a professional level. Lathe machine is used for machining a variety of materials into required parts manually. This is done by various operations such as sanding, knurling and drilling using different tools while the work piece rotates. Currently automatic lathe machines are very expensive. Proposed project intends to use several motors being controlled by a microcontroller to achieve goal. Successful completion of this project will provide a strong background to industries through which autonomous lathe machines can be provided at a much lower cost. In addition to lower cost it will also provide a way to automate many other manually operated machines and fill the gap in Pakistan's automation industry.

Project Objectives

The objective of our project is to provide a path through which the metal working industry can compete on an international scale. For this purpose, we intent to automate a manual machine such that it requires the minimum possible changes to the machine itself. We will also have to make sure that it is financially viable and doesn’t interrupt the current industry when shifting to the automated machine.

In the long run we intend to make our project into a product that we can transform into a business and introduce it into the market.

As a by-product of this project we can show off the skills we have acquired throughout our engineering program.

Project Implementation Method

The first step was to do some research in order to find the best possible solution. First online research was done to find the possibilities of solutions, next some market search was done to find what components were available in the local market. After finding out what was available a design was developed and discussed with our project advisor. Once the design was finalized we started testing the small components of the circuit required. At the same time, we got the mechanical fittings for the motors and encoders built on the machine and then the next step was to integrate this all on the machine. Lastly we started working on the program for the machine which would interpret the G codes and run routines accordingly to control the motors and in turn the machine carriage to perform the job, and our final task is the user interface through which the user will interact with the machine.

Benefits of the Project

Unusable lathe machines can be brought back into working condition reducing wastage.

The factor of human error can be eliminated improving the quality and precision of the final product.

Manually operated industry can be transformed to autonomous industry significantly lowering costs compared to installing new CNC machines.

Pakistan’s metal works industry can use the provided platform to step up their performance and be able to provide better quality products.

Technical Details of Final Deliverable

Initially, the user would provide a CAD design to the microprocessor through the user interface. Stepper motor will be driven on command of microprocessor through the driver circuit according to the routine interpreted from the G codes of the CAD design. A rotary encoder is measuring the step angle at every instant of stepper motor. Stepper motor moves the carriage on the lathe as required to form the part. Proximity sensors would check if the machine is getting too close to the limit of the machine and would stop the motors if it is.

The software part includes the interpretation of the CAD design taken from the user into G codes and interfacing of all components with the microcontroller. The microprocessor takes input from the quadrature rotary encoder and the limit switches to determine where the carriage is and if it is safe to move it or not. The microprocessor then moves the motors by giving commands to the stepper motor drivers according to the G code interpretations. The microprocessor also runs the user interface for the user to interact with the machine in a simple and user friendly manner.

Final Deliverable of the Project

HW/SW integrated system

Type of Industry

Manufacturing

Technologies

Robotics, Others

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure

Required Resources

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