1. INTRODUCTION:-
1.1 Automatic paper cutting machine Paper-cutting arts have been around as long as paper. Different cultures have different names for it, and different styles of execution. In Northern Europe, it is called scherenschnitte. German for “scissor cuts,” it involves cutting symmetrical shapes or silhouettes out of paper and displaying them against lighter or darker color paper for contrast. Scherenschnitte is easier to do than it is to pronounce, so it can be an enjoyable craft for children and adult paper crafters who like to scrapbook and make cards and other paper creations. With practice, a skilled paper-cutting artist can make elaborate designs.
Although paper cutting can be traced back to ancient China, credit is given to German immigrants in Pennsylvania for turning it into a popular folk art. In the 1800s, paper cutting was referred to as "scherenschnitte", which means "scissor cutting" or "scissor snipping" in German. Paper cutting involves making small cuts into paper to create designs. Artists often create visually elaborate designs that incorporate landscapes, flowers, trees, animals and hearts. Some basic techniques will get you started on paper cutting.
The paper roll cutting machine the principal of paper cutting used in industrial application.Paper cut occurs when a piece of paper or other thin, sharp material. If we can use a loose paper sheet is usually too soft to cut , it can be very thin , being then able to exert high levels of pressure enough to cut.
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1.2 History of paper machine Before the invention of continuous paper making, paper was made in individual sheets by stirring a container of pulp slurry and pouring it into a fabric sieve called a sheet mold. While still on the fabric in the sheet mold the wet paper is pressed to remove excess water and then the sheet was lifted off to be hung over a rope or wooden rod to air dry. In 1799, Louis-Nicolas Robert of Essonnes, [1] France, was granted a patent for a continuous paper making machine. At the time Robert was working for Saint-Léger Didot, with whom he quarrelled over the ownership of the invention. Didot thought that England was a better place to develop the machine. But during the troubled times of the French Revolution, he could not go there himself, so he sent his brother in law, John Gamble, an Englishman living in Paris. Through a chain of acquaintances, Gamble was introduced to the brothers Sealy and Henry Fourdrinier, stationers of London, who agreed to finance the project. Gamble was granted British patent 2487 on 20 October 1801.
With the help particularly of Bryan Donkin, a skilled and ingenious mechanic, an improved version by of the Robert srcinal tFrogmore, Hertfordshire, in 1803, followed another in 1804. A was thirdinstalled machine awas installed at the Fourdriniers' own mill at Two Waters. The Fourdriniers also bought a mill at St Neots intending to install two machines there and the process and machines continued to develop.
In the USA the first recorded paper machine was Gilpin's at Brandywine Creek, Delaware in 1817. This machine was also developed in England, but it was a cylinder mould machine. The Fourdrinier machine was introduced into the USA in 1827.
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2. MECHANICAL DESIGN:2.1 Main Paper Roller
Figure 2.1 Paper roll
Meeting the paper roll industry’s need for damage free roll handling with maximum efficiency, Cascade offers a full line of paper roll clamps and roll clamp damage reduction options to handle paper rolls regardless of diameter, weight or type of paper. Cascade's rugged paper roll clamps handle paper rolls of every size for industries from stevedoring to printing .
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2.2 Tighting Rollers
Figure 2.2 Tighting rollers
General Purpose Self Tightening Eccentric Roller Grip for dumbbell and flat samples. The roller is self-tightening, and operates using basic cam jamming principle. It has a cross hatched, serrated finish and clamps tightly against a horizontally grooved back plate. 4 | Page
2.3 Gripping Rollers
Figure 2.3 Gripping Rollers
Particulars
Dimensions ( in mm)
Roller Diameter
45
Shaft Diameter
15
Table 2.1 Specification of Gripping Rollers 5 | Page
2.4 Clamps:-
2.4.1 for idlers
Figure 2.4 Clamp for middle idlers
Particulars
Dimensions ( in mm)
Material
Wood
Length
100.150
Thickness
15
Width
40
Table 2.2 Specification of clamp
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The 360° rotating paper roll clamp is suitable for lifting horizontal or vertical paper rolls in a large range of diameters. The thin profile contact pad arms prevent damage to the rolls and allow for compact stacking and retrieving. The clamp uses the proven rotator with its direct worm/ring gear drive and clutch brake system. The 360° rotation prevents roll edge damage when placing rolls down onto surfaces that are not level.
Paper roll clamps increase productivity in your roll handling operations. Our 360 degree rotating pivot arm design effectively handles rolls in either vertical or horizontal positions.
Right line clamps feature heavy-duty rotators; hardened pivot pins and bushings; large-diameter, single-piece cylinder rods; and hardened cast steel contact pads. Paper roll clamps are ruggedly constructed of high quality components that are designed to perform under the most demanding conditions
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2.4.2 For Gripping roller Clamp
Figure 2.5 Clamp for Gripping Roller
Particulars
Dimensions ( in mm)
Material
Wood
Length
300
Thickness
35
Width
60
Table 2.3 Specification of clamp
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They are designed to handle just about every type of paper including newsprint, kraft coated or tissue. Slim tapered contoured arms allow the operator to slide easily between adjacent rolls without causing paper damage during roll pick up. Large curved pads and smooth arm movement ensure positive clamping and excellent friction upon contact with the roll and during roll rotation.
Sharp edges and corners on Total Paper Roll Clamps have been eliminated from both the clamp body and arms to reduce paper damage when contact is made with the roll.
Smooth continuous rotation is achieved via a “patented” ring gear that outperforms all conventional ball or roller bearings.
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3. MECHANICAL MODEL IN PRO-E:-
Figure 3.1 Plant Design in Pro-e
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4. BEARING:-
Here deep groove ball bearing is used for axial load. The smaller shaft has outer diameter of 15 mm. Hence bearing with inner diameter 15mm is selected.
4.1 Deep groove ball bearing 6004-ZZ
Figure 4.1Bearing a) Side view b) Actual view
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4.2 Measurement of Bearing
Model: 6004-ZZ
Structure: Deep groove
Type: ball
Inside Diameter: 20mm
Outside Diameter: 42mm
Thickness: 11mm
Bore Size: 20mm
Material: steel GCR - 15
Seals Type: Zz
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5. Pneumatic Cylinder:Pneumatic cylinders (sometimes known as air cylinders) are mechanical
devices which use the power of compressed air to produce a force in a reciprocating linear motion. Like hydraulic cylinders, pneumatic cylinders use the stored potential energy of a fluid, in this case compressed air, and convert it into kinetic energy as the air expands in an attempt to reach atmospheric pressure. This air expansion forces a piston to move in the desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved Engineers prefer to use pneumatics sometime because they are quieter, cleaner, and do not require large amounts or space for fluid storage. Because the operating fluid is a gas, leakage from a pneumatic cylinder will not drip out and contaminate the surroundings, making pneumatics more desirable where cleanliness is a requirement.
Figure 5.1 Pneumatic Cylinders (3D)
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Figure 5.2 Actual Cylinder Use in Project 5.1 Rod stresses:-
Due to the forces acting on the cylinder, the piston rod is the most stressed component and has to be designed to withstand high amounts of bending, tensile and compressive forces. Depending on how long the piston rod is, Pneumatic cylinder 5stresses can be calculated differently. If the rods length is less than 10 times the diameter, then it may be treated as a rigid body which has compressive or tensile forces acting on it. In which case the relationship is: F=σ×Α
Where: F is the compressive or tensile force Α is the cross-sectional area of the piston rod σ is the stress.
However, if the length of the rod exceeds the 10 times the value of the diameter, than the rod needs to be treated as a column and buckling needs to be calculated as well. 14 | Page
5.2 In stroke and Outstroke:-
Although the diameter of the piston and the force exerted by a cylinder are related, they are not directly proportional to one another. Additionally, the typical mathematical relationship between the two assumes that the air supply does not become saturated. Due to the effective cross sectional area reduced by the area of the piston rod, the in stroke force is less than the outstroke force when both are powered pneumatically and by same supply of compressed gas. The relationship between the force, radius, and pressure can derived from simple distributed load equation: Fr = Αe × P
Where: Fr is the resultant force P is the pressure or distributed load on the surface Αe is the effective cross sectional area the load is acting on.
5.2.1 Outstroke:-
Using the distributed load equation provided the Α e can be replaced with area of the piston surface where the pressure is acting on. 2
Fr = (πr ) × P
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Where: Fr represents the resultant force r represents the radius of the piston Π is pi, approximately equal to 3.14159.
5.2.2 In stroke:-
On in stroke, the same relationship between force exerted, pressure and
effective cross sectional area applies as discussed above for outstroke. However, since the cross sectional area is less than the piston area the relationship between force, pressure and radius is different. The calculation isn't more complicated though, since the effective cross sectional area is merely that of the piston surface minus the cross sectional area of the piston rod. For in stroke, therefore, the relationship between force exerted, pressure, radius of the piston, and radius of the piston rod, is as follows: 2−
Fr = P×π (r1
2
r2 )
Where: Fr represents the resultant force r1 represents the radius of the piston r2 represents the radius of the piston rod π is pi, approximately equal to 3.14159.
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5.3 Pneumatic dcv:-
5.3.1 Solenoids:-
A solenoid is a coil with an iron plunger inside it. When current flows in the coil, the plunger becomes magnetized and tries to move out of the coil. If a spring is used to resist the movement, the distance moved is directly proportional to the current in the coil. Solenoids are used in relays where they operate an electric switch. They are also used in hydraulic and pneumatic valves to move the valve element.
Figure 5.3 Solenoid Coil 17 | Page
A direct acting solenoid valve would have the plunger pushing directly on the valve element as shown. This is more common in pneumatic valves.
Figure 5.4 5/2 Direction Control Valves
Figure 5.5 Actual 5/2 DCV Use in Project
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Often the valve may be manually operated by pushing the plunger with a screw driver or by turning a screw on the side. This is very useful when checking to see if the valve has stuck. Modern solenoid valves are really pilot valves. A second small electrically operated poppet valve is fitted at the end which lets oil/air through to the end of the piston and so pilot operates them. The valve shown is a pneumatic solenoid/poppet operated and spring return. When the solenoid is activated, the valve switches. When the solenoid is deactivated, the valve switches back; hence it is a two position valve.
Figure 5.6 5/2 Solenoid Operated Direction Control Valves
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If it is required for the valve to stay switched when the solenoid is deactivated, then another solenoid is needed at the other end to switch it back as shown.
Figure 5.7 5/2 Both Side Solenoid Operated Direction Control Valves
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6. DC MOTOR:-
Figure 6.1 Dc Motor
A DC motor is an electric motor that runs on direct current (DC) electricity. DC motors were used to run machinery, often eliminating the need for a local steam engine or internal combustion engine. DC motors can operate directly from rechargeable batteries, providing the motive power for the first electric vehicles. Today DC motors are still found in applications as small as toys and disk drives, or in large sizes to operate steel rolling mills and paper machines. Modern DC motors are nearly always operated in conjunction with power electronic devices. Here high torque is needed so only 10 RPM motor is used.
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7. PROXIMITY SENSOR:-
Figure 7.1 Proximity Sensor
A proximity sensor is a sensor able to detect the presence of nearby objects without any physical contact.
A proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal. The object being sensed is often referred to as the 22 | Page
proximity sensor's target. Different proximity sensor targets demand different sensors. For example, capacitive photoelectric sensor might be suitable for a plastic target; an inductive proximity sensor always requires a metal target.
The maximum distance that this sensor can detect is defined "nominal range". Some sensors have adjustments of the nominal range or means to report a graduated detection distance. Proximity sensors can have a high reliability and long functional life because of the absence of mechanical parts and lack of physical contact between sensor and the sensed object.
Proximity sensors are also used in machine vibration monitoring to measure the variation in distance between a shaft and its support bearing. This is common in large steam turbines, compressors, and motors that use sleeve-type bearings. International Electro technical Commission (IEC) 60947-5-2 defines the technical details of proximity sensors.
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Figure 7.2 Proximity Sensor
Proximity sensors are the most common and affordable solution for no-touch object detection. The most commonly-used proximity sensor is the inductive type, which generates an electromagnetic field to sense metal objects passing close to its face. This is usually the easiest sensing technology to apply in applications where the metal objects to be detected is within an inch or two of the sensor faces. Atonics offers 12 products of 6 different types of proximity sensors, inductive and capacitive, and maintains No. 1 market share in Korea for more than 10 years and still endeavoring to advance product quality and sensing reliability up to the top level of global marketplace. If you are looking for the most cost effective and reliable proximity sensors, Atonics is the answer.
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Proximity sensors detect the presence of objects without physical contact. Since 1983 Fargo Controls’ proximity sensors have been of the highest quality, durability & repeatability to meet today's tough industrial requirements. We provide a wide range of proximity sensors to meet all types of applications. Typical applications include the detection, position, inspection and counting on automated machines and manufacturing systems. They are also used in the following machinery: packaging, production, printing, plastic molding, metal working, food processing, etc
7.1 How Proximity Sensor works
A proximity sensor is a type of sensor which detects the presence of nearby objects called target without any physical contact. There are different types of proximity sensors such as inductive proximity sensor, capacitive proximity sensor, ultrasonic proximity sensor, photoelectric proximity sensor. Depending on the type of technology used proximity sensor emits an electromagnetic or electrostatic field, or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal when target comes closer to the face of sensor.
There are different kinds of proximity sensors. They are
Capacitive proximity sensor
Inductive proximity sensor
Photoelectric proximity sensor
Ultrasonic proximity sensor
The advantages of the non contact proximity sensors are:
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No physical contact required with the target to be detected, therefore, no moving parts so no friction and wear out.
Fast switching characteristics
Unlimited number of switching cycles since there is no mechanical contact
Can work in harsh conditions
Any type of target material can be detected
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8. MICROLOGIX 1200C CONTROL SYSTEM (ALLEN BRADLEY):-
Figure 8.1 Allen Bradley PLC
For a proven, small programmable logic controller solution, look to our MicroLogix™ family. The MicroLogix 1000 controller offers control capabilities in an affordable, compact package. The MicroLogix 1200 provides features and options to handle extensive range of applications. The expandable MicroLogix 1500 controller helps you achieve high-level control in a variety of applications. The MicroLogix 1100 and 1400 controllers increase the application coverage with enhanced network communications at an affordable price.
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8.1. Features
Contains isolated RS-232/RS-485 combo port for serial and networked communication
Provides four latching or pulse-catch inputs and four interrupt inputs Includes built-in independent 20 kHz high-speed counter Offers Programmable Limit Switch function Includes two built-in ¾-turn trim potentiometers with a digital output range of 0...250
Provides program data security
Supports floating point data files
Expands up to 136 I/O points
Compatible with1762 MicroLogix Expansion I/O modules (up to six modules per controller)
Five levels of control available, providing a wide variety of features to suit most applications Offers similar functionality as traditional SLCs and PLCs, only in a smaller, packaged form factor
Compatible with our PanelView™ Component graphic terminals
Shares common RSLogix™ 500 programming software and RSLogix Micro programming software, providing an instruction set that is common to the MicroLogix™ and SLC™ 500 controller families
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8.2. Software
RSLogix 500 programming software
The RSLogix™ family of IEC-1131-compliant ladder logic programming packages helps you maximize performance, save project development time, and improve productivity. This family of products has been developed to operate on Microsoft® Windows® operating systems. Supporting the Allen-Bradley SLC™ 500 and MicroLogix™ families of processors, RSLogix™ 500 was the first PLC® programming software to offer unbeatable productivity with an industry-leading user interface.
Flexible, easy-to-use editors
Common look-and-feel
Diagnostics and troubleshooting tools
Powerful, time-saving features and functionality
RSLogix programming packages are compatible with programs created with Rockwell Software’s DOS-based programming packages for the SLC 500 and MicroLogix families of processors, making program maintenance across hardware platforms convenient and easy. RSLogix 500 software is a 32-bit Windows ladder logic programming package for the SLC 500 and MicroLogix® processors. RSLogix 500 is compatible with SLC 500 and MicroLogix programs created with any of Rockwell Software’s programming packages.
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8.4. RSLogix 500 software includes:
A free-form ladder editor that lets you concentrate on the application logic instead of syntax as you write your program
A powerful project verifier that you use to build a list of errors you can navigate to make corrections at your convenience
Drag-and-drop editing to quickly move data table elements from one data file to another, rungs from one subroutine or project to another, or instructions from rung to rung within a project
An address wizard that makes entering addresses easier and reduces keying errors.
Search and replace too quickly change occurrences of a particular address or symbol
A point-and-click interface called a project tree that lets you access all the folders and files contained in your project
A customs data monitor to view separate data elements together and observe interactions Trending and histogram functionality for monitoring and displaying process data
SLC libraries form storing and retrieving portions of ladder logic for use across any of Rockwell Software's SLC programming software products.
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9. PROGRAMMING:9.1 Beginning Programming Using RSLogix500
1. Turn on the computer, and at the password prompt hit CANCEL.
2. On the desktop locate the Icon for RSLogix500 English (2 ), and open the application.
3. To begin select FILE and create NEW
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4. A
window will
open
prompting processor
name, type
and
driver
information. All you are concerned with is the processor type and name. Select processor 1747-L542B 5/04 CPU – 32K MEM OS401.
5. Naming the Processor. The PLC5 and SLC500 processors are all eventually going to be connected to a DH+ network and because of this no two processors can be given the same name or node. We can avoid networking problems later by using the same method of naming the processor and node #'s now:
a.
Determine you bench number or location.
b.
Determine the type of PLC you will be using. This should be a SLC504.
c.
Determine the appropriate Processor Name using the format: 50XBYY, where the X is the processor type (should be 4 from SLC504) and YY is the
d.
bench number (bench #2 would be 02). Enter the Processor Name in the above window.
Example: If you are using a SLC504 at bench 13, the Processor Name would be 504B13
After you have named the processor, click OK
After you have chosen the correct processor, your RSLogix window should look like the one below.
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Configuring Input/output. The first step in writing a program is to configure the I/O. This can be done automatically. You will need to look in the left window and find and click on I/O
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9.2 Configuration
When the I/O CONFIGURATION window is open, select READ I/O CONFIG. You will see the following window appear. The PLC must be connected to the computer and be turned on for this to work .
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At this window, you must have the PLC connected to the computer, and turned on! Once both of those requirements are met, simply click Read I/O Configuration.
You will now be back to the first I/O Configuration window. When the I/O module descriptions appear in the lower left, make sure they correspond to the slots they appear to be in. If this matches, you can exit the I/O Configuration window.
You are now ready to begin programming. Below is an example of some of the instructions you could put in a program. The symbols and abbreviations have
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not changed. Using the small arrows in the lower left, you can scroll through other tabs for more instructions.
To add instructions to the program, first highlight the rung as shown below.
Once the red box is covering the rung number, simply click on the desired instruction in the toolbar.
There are no changes in the addressing. Simply click on the item you wish to address, and when the black box is around the item, enter the address. 36 | Page
When you have finished your programming, select EDIT, then VERIFY PROJECT. This will check the program for errors. Any errors will be listed at
the bottom of the window, as shown below.
Once you have finished your debugging and are ready to download your program to the PLC, Locate the box shown below.
Use the arrow on the right side to view your other choices.
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Once you have downloaded your program you will be able to switch the processor to REMOTE RUN, and monitor your program on the screen as you work on the trainer.
9.3 Overview of RSLogix 500:-
The RSLogix™ family of IEC-1131-compliant ladder logic programming packages helps you maximize performance, save project development time, and improve productivity. This family of products has been developed to operate on Microsoft® Windows® operating systems. Supporting the AllenBradley SLC™ 500 and MicroLogix™ families of processors, RSLogix™ 500 was the first PLC® programming software to offer unbeatable productivity with an industry-leading user interface. These RSLogix products share:
Flexible, easy-to-use editors
Common look-and-feel
Diagnostics and troubleshooting tools
Powerful, time-saving features and functionality
9.4 Programming:38 | Page
Figure
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Figure 9.1 Ladder Diagram
10. PHOTOGRAPHY
10.1 Lay out (side view)
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10.2 Lay out (Top view)
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10.3 Lay out (side view)
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10.4 Pneumatic Cutter
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11. CONCLUSION:The automatic paper cutting machine has been successfully introduced instead of manual cutting process by design and wooden material joint the components of the machine. Only one operator is required for placing empty sacks at the paper roll. Increased productivity,Safe operation – Presence of paper length is sensed at sensor and paper cutting operation.
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12.
REFRANCES:-
[1] http://winshiprc.tripod.com/paper _cut_.htm
[2] http://en.wikipedia.org/wiki/Cutting_(paper)
[3] http://a.purposefulprocess.org/2012/02/16/milliken-tegris-tumi-tumi-tegralite-suitcases/ [4] http://www.build-on-prince.com/paper-cutting.html
[5] http://en.wikipedia.org/wiki/paper - Properties
[6] www.google.com/images
[7]file:///C:/Documents%20and%20Settings/dave/Desktop/majorpro/RAW/cu tting%20Paper.html
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