Smart Manufacturing for Gear Hobbing Process

Smart manufacturing has been defined as the fully-integrated, collaborative manufacturing systems that respond in real time to meet changing demands and conditions in the smart factory, in the supply network, and in customer needs. Smart industry is a synonym for Industry 4.0 or industrial transform

Project Title

Smart Manufacturing for Gear Hobbing Process

Project Area of Specialization

Mechatronics Engineering

Project Summary

Smart manufacturing has been defined as the fully-integrated, collaborative manufacturing systems that respond in real time to meet changing demands and conditions in the smart factory, in the supply network, and in customer needs. Smart industry is a synonym for Industry 4.0 or industrial transformation in the fourth industrial revolution within which smart manufacturing de facto fits. Smart Industrial Manufactured Processes are often regarded as processes of Smart Industry.

Industry, the manufacturing business, manufacturing companies and even manufacturing processes are in full transformation around the globe. This is mainly due to increasing automation, digital transformation, the bridging of digital and physical environments (as enabled by IoT or the Internet of Things), evolving industrial and manufacturing technologies (such as additive manufacturing), the intensive usage of data/analytics (with cloud and a shift of intelligence to the edge), industry and manufacturing challenges, human, economic and societal evolutions and demands and the integration of information technology and operational technology (IT and OT). Major problems a manufacturing machine faces are tool wear and due to it tool breakage. This slows down the process which affects the production rate as well as cost.

Therefore, aim of the project is to introduce and implement Smart industry on a manufacturing process (using Gear Hobbing machine) of an industry in Pakistan. Tool health prognosis, machine monitoring and improvements in production rate are the major objectives along with Tool life prediction. Different algorithms and techniques are to be implemented for prediction and pre-processing purposes. Optimized and optimal conditions are to be evaluated and implemented on the machine. This will not only enable improvised production processes of the machine but will also give economical benefit to the industry.

Project Objectives

1. Condition Monitoring of Gear Hobbing machine: Condition monitoring (or, colloquially, CM) is the process of monitoring a parameter of condition in machinery (vibration, temperature etc.), in order to identify a significant change which is indicative of a developing fault. It is a major component of predictive maintenance. The Project Aims to perform condition monitoring in Gear Hobbing machine.
2. Implementation of Sensors on Gear Hobbing Machine: Sensors play an important role in the transference of Data. The Project Aims to implement different sensors on our Gear Hobbing machine for our desired parameters to be measured.
3. Tool Health Monitoring: Tool health monitoring or the prediction of tool failure of our Gear Hobbing machine. The Project Aims to perform Tool health monitoring in order to predict our tool’s life span.
4. Machine Lifespan: The Project Aims to predict our Gear Hobbing Machine lifespan. Lifespan refers to the life of a machine.
5. Downtime: Downtime is basically defined as Period during which an equipment or machine is not functional or cannot work. The Project Aims to evaluate downtime of our machine and will try to overcome it accordingly.
6. Surface Roughness: The Parts that are manufactured will be used to calculate optimum surface roughness for the machine with the conditions that we will extract from the data collected.
7. Shop floor scheduling : The Project Aims to perform /maintain Shop floor scheduling. Shop floor control comprises the methods and systems used to prioritize, track, and report against production orders and schedules.
8. Minimize Takt time: The Project Aims to minimize the takt time. Takt time is the average time between the start of production of one unit and the start of production of the next unit.

Project Implementation Method

Project is to be implemented under the following method:

1. Sensors of the parameters are to implemented on a machine. Parameters are Current, Voltage, RPM, vibration and temperature.
2. IoT Server is to be established.
3. Data is to be collected.
4. Data is to be processed by using pre-processing techniques.
5. Filtered data undergoes Algorithmic process for the computation of optimal controllable parameters as well as prediction of tool life.
6. Parameters are to be implemented on the machine.

Benefits of the Project

Pakistan is a country which is based on ample amount of natural resources as well as enormous amount of talent. As a Pakistani, we all want to see Pakistan progressing in every field. Progression in industries and manufacturing, will not only result in economical production but also will improve the economy of the State by the help of import export and other factors. We all should take a plunge to start from industry to industry, sector to sector and within it, machine to machine. This gave us the motivation to pick Gear Hobbing machine and to enable it smartly for the use. Applying condition monitoring as well as the algorithm for the desired factors will not only improve the production but will also enable us to keep a check on health of our machine. completion of our Project might help the industries and might give them an option to adapt this. Progression of Pakistan is our motivation.

Following are the benefits:                  

1. Production rate will increase.
2. Tool life will be predicted therefore this will allow the industry to get to know about the changing of the tool at an appropriate time.
3. Optimal Controllable parameters will be implemented on machine which will allow the machine to work under optimal conditions and parameters. This will help the production process to be cost and time efficient.
4. Power consumption will be efficient which will lessen the electricity consumption and thus power expenditure will decrease.

Technical Details of Final Deliverable

Parameters whose data are to be collected are vibration, temperature, current, voltage and temperature. Therefore, sensors are used for the data collection process through IoT. Following are the final deliverables:

1. Power consumption: With the help of current and voltage sensors, power will be calculated and electricity cost will be estimated. Now, upon completion of the project, optimized and optimal parameters and conditions will be evaluated and implemented. This will not only make process efficient but will also consume less power than before. 
2. Tool health prognosis: As tool wear is the major problem which every industry faces during the production. Data collected from the sensors will undergo the processes and, in the end, optimal and optimized parameters and conditions will be evaluated and implemented on the machine. This will not only help to reduce tool wear but will also predict tool life as well as real time tool health result.
3. Downtime estimation: Downtime is the time during which the machine is nonoperational. Therefore, by the data collection process, this time will be evaluated. Upon completion of the project, downtime will be reduced.
4. Minimize Takt Time: Takt time is the production time of the process. Upon completion of the project, the parameters will be implemented and eventually takt time will reduce as now machine will run under its optimal conditions.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Core Technology

Internet of Things (IoT)

Other Technologies

Artificial Intelligence(AI)

Sustainable Development Goals

Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com