Abstract

In the context of machining, a cutting tool (or cutter) is any tool that is used to
remove material from the work piece by means of shear deformation. Cutting may be
accomplished by single-point or multipoint tools. Single-point tools are used in turning,
shaping, planning and similar operations, and remove material by means of one cutting
edge. Milling and drilling tools are often multipoint tools. Grinding tools are also
multipoint tools.

Even though the advantage of the CNC machines playing a major role in
industrial platforms, as these CNC type machines produces safer and the faster rate in
producing the products. But in some cases the requirements are not stationary they
change in size and order numbers are also variable. So in these cases a regular “manual
saw rotary cutting wheel” is a right option , since CNC setting is time consuming job
when the requirements size are not stationary.

In many industries still the “manual saw cutting tool machines are used”, since it
can increase the production rate then CNC in variable size of the product to be made.
CHAPTER-1
 CHAPTER-1

Problem Statement
To Design and development of SMART Saw rotary cutting tool machine. A
structure which is designed for safety cutting operation in Industries.

Problem Identification

The manual machine are not safe instruments, it responses to the fault operation
operates by the operator. But many industries having the safety policy, almost every
industry having the “Safety Man Power Hours” where these hours are calculated at the
end of the year and safety awards are given for the best among the industries with higher
“Safety Man power hour count”. So the particular industries have a high company rating
among the industries. As the company outsources customer’s order are placed based on
the company rating, so the industry profit indirectly lay on safety policy of the company.

As the Safety Integrity System (SIS) became the necessity criteria for the
industrial machine.
OBJECTIVE OF THE STUDY

 Many industries having the safety policy, by having the “Safety Man
Power Hours” where these hours are calculated at the end of the year and
safety awards are given for the best among the industries with higher
“Safety Man power hour count”.

 So the particular industries have a high company rating among the industries.

 As the company outsources customer’s order are placed based on the company
rating, the industry profit indirectly lay on safety policy of the company.

 As the Safety Integrity System (SIS) became the necessity criteria for the
industrial machine, in our system a novel design approach is made for the
manual cutting tool machine with safety critical operations.

SCOPE OF THE STUDY

 To avoid the accident in the industry

 To produce 0% of accident in the industries

 To achieve great result in the safety management.

WORKING:

 In our system a novel design approach is made for the manual cutting tool
machine with safety critical operations.

 With use of Photo electric sensor a detecting sensor which trace a human body
presence near the critical area, when it sense it triggered the relay card , which in
turn activates the “Pneumatic Piston” .

 This Pneumatic Piston pulls a “CAM operator” lever with high tension spring.

 Spring pulls the rotary cutting tool inside the table with fraction of “0.30 ms”,
and the blade retrains its position after the reset button is pressed.
INTRODUCTION:

 In the context of machining, a cutting tool (or cutter) is any tool that is used to
remove material from the work piece by means of shear deformation.

• Even though the advantage of the CNC machines playing a major role in
industrial platforms, as these CNC type machines produces safer and the faster
rate in producing the products.

• But in some cases the requirements are not stationary they change in size and
order numbers are also variable.

• So in these cases “manual saw cutting tool machines are used”, since it can
increase the production rate then CNC in variable size of the product to be made.
BLOCK DIAGRAM

PHOTO ELECTRIC
SENSOR

PNEUMATIC
SENSOR
Chapter-2
 Chapter-2
Mechanism of Machine

Whitworth quick return mechanism

Objective:

The objective of the experiment is to investigate the performance of a whit worth quick
turn motion and to verify that the motion does have a quick down stroke.

WHITWORTH QUICK THEORY:

Definition of Mechanism

This mechanism is made of a driving crank

and of a driven slider crank. In the considered
configuration, the fixed pivot of the driven crank is
located on the outside of the circle on which the end
of the driving crank moves. This leads to an
alternated motion of the slider crank. The
configuration where this pivot is located inside the
circle on which the end of the driving crank moves
is considered

The angular speed of the driven crank is variable. The duration of the motion for its part
corresponding to the blue arc is shorter than the one related to the red arc. This is why
this device is named quick return mechanism, which was used in crank shapers, with the
slow part or the stroke being used for the working time of the tool and the quick part for
the non-productive time. The menu bar includes a zoom (Animation detail) focusing on
the driving and driven cranks.

The Whitworth quick return mechanism converts rotary motion into reciprocating
motion, but unlike the crank and slider, the forward reciprocating motion is at a different
rate than the backward stroke. At the bottom of the drive arm, the peg only has to move
through a few degrees to sweep the arm from left to right, but it takes the remainder of
the revolution to bring the arm back. This mechanism is most commonly seen as the
drive for a shaping machine.
CHAPTER-3
 Chapter-3

DESIGN OF MODEL
ACTUAL DESIGN:
COMPONENT OF MACHINE:

1. Frame
2. Bearing (Ball)
3. Whitworth mechanism
4. Motor
5. CAM operator
6. Single cutting Blade
7. Pneumatic piston
8. Table
9. Nut and Bold
10. Photo Electric sensor
11. Relay board unit
12. Battery
13.Other component.
14.Clamping Unit
CALCULATION OF CUTTING OPERATION:

 A milling cut is to be taken with a 6.00 inch (HSS) side milling cutter on a
piece of 1045 steel with a brinnel hardness of 300. Calculate the RPM
setting to perform this cut.

Cutting Speed = 55 (fpm)

Diameter of Cutter = 6.00

 A 1-inch (HSS) drill is used on a piece of 1010 steel with a brinnel

hardness of 100. Calculate the RPM setting to perform this drilling
operation.

Cutting Speed = 140 (fpm)

Diameter of Cutter = 1.00

 A milling cut is to be taken with a 3.00 inch carbide face milling cutter
using coated inserts on a piece of 4140 alloy steel with a brinnel hardness
of 200. Calculate the RPM setting to perform this cut.
 Cutting Speed = 400 (avg. fpm)
Diameter of Cutter = 3.00
ADVANTAGE:

 Multi operations are performed at one time.

 Our machine is designed for safety operation mechanism

 The operation of blade is performed only by motor

 Size is compact therefore it requires less space

 Sensor is used for safety operation

 No accident occur

 Less man power

 Low manufacturing and maintenance cost.

OPERATION PERFORMED BY MACHINE

 Cutting
 Grinding

CUTTING OPERATION:

Cutting is the separation of a physical object, or a portion of a physical object,

into two or more portions, through the application of an acutely directed force.
Implements commonly used for cutting is saw, or in medicine and science
the scalpel and microtome. However, any sufficiently sharp object is capable of cutting
if it has a hardness sufficiently larger than the object being cut, and if it is applied with
sufficient force. Even liquids can be used to cut things when applied with sufficient
force (see water jet cutter).

Cutting is a compressive and shearing phenomenon, and occurs only when the
total stress generated by the cutting implement exceeds the ultimate strength of the
material of the object being cut. The simplest applicable equation is stress = force/area:
The stress generated by a cutting implement is directly proportional to the force with
which it is applied, and inversely proportional to the area of contact. Hence, the smaller
the area (i.e., the sharper the cutting implement), the less force is needed to cut
something.
GRINDING OPERATION:

A grinding machine, often shortened to grinder, is a machine tool used

for grinding, which is a type of machining using an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel's surface cuts a small chip from the work piece via
shear deformation.

Grinding is used to finish workpieces that must show high surface quality (e.g.,
low surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is on the order of 0.000025 mm, in most applications it tends to
be a finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm
depth. However, there are some roughing applications in which grinding removes high
volumes of metal quite rapidly. Thus, grinding is a diverse field.

TYPES OF GRINDING:

This machine include the:

 Belt grinder, which is usually used as a machining method to process metals and
other materials, with the aid of coated abrasives. Sanding is the machining of wood;
grinding is the common name for machining metals. Belt grinding is a versatile
process suitable for all kind of applications like finishing, deburring, and stock
removal.
 Bench grinder, which usually has two wheels of different grain sizes for roughing
and finishing operations and is secured to a workbench or floor stand. Its uses
include shaping tool bits or various tools that need to be made or repaired. Bench
grinders are manually operated.
 Cylindrical grinder, which includes both the types that use centers and the center
less types. A cylindrical grinder may have multiple grinding wheels. The work piece
is rotated and fed past the wheel(s) to form a cylinder. It is used to make precision
rods, tubes, bearing races, bushings, and many other parts.
 Surface grinder which includes the wash grinder. A surface grinder has a "head"
which is lowered, and the work piece is moved back and forth past the grinding
wheel on a table that has a permanent magnet for use with magnetic stock. Surface
grinders can be manually operated or have CNC controls.
 Tool and cutter grinder and the D-bit grinder. These usually can perform the minor
function of the drill bit grinder, or other specialist tool room grinding operations.
 Jig grinder, which as the name implies, has a variety of uses when finishing jigs,
dies, and fixtures. Its primary function is in the realm of grinding holes and pins. It
can also be used for complex surface grinding to finish work started on a mill.
 Gear grinder, which is usually employed as the final machining process when
manufacturing a high-precision gear. The primary function of these machines is to
remove the remaining few thousandths of an inch of material left by other
manufacturing methods (such as gashing or hobbing).
CHAPTER-4
 CHAPTER-4

COMPONENTS OF SMART CUTTING MACHINE:

 BEARING

A bearing is a machine element that constrains relative motion and reduces friction
between moving parts to only the desired motion. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free rotation around
a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that
bear on the moving parts. Many bearings also facilitate the desired motion as much as
possible, such as by minimizing friction. Bearings are classified broadly according to
the type of operation, the motions allowed, or to the directions of the loads (forces)
applied to the parts.

The term "bearing" is derived from the verb "to bear";[1] a bearing being a
machine element that allows one part to bear (i.e., to support) another. The simplest
bearings are bearing surfaces, cut or formed into a part, with varying degrees of control
over the form, size, roughness and location of the surface. Other bearings are separate
devices installed into a machine or machine part. The most sophisticated bearings for
the most demanding applications are very precise devices; their manufacture requires
some of the highest standards of current technology.
  WHITWORTH MECHANISM

The Whitworth quick return mechanism converts rotary motion into reciprocating
motion, but unlike the crank and slider, the forward reciprocating motion is at a different
rate than the backward stroke. At the bottom of the drive arm, the peg only has to move
through a few degrees to sweep the arm from left to right, but it takes the remainder of
the revolution to bring the arm back. This mechanism is most commonly seen as the
drive for a shaping machine.
  MOTOR

A brushed DC motor is an internally commutated electric motor designed to be

run from a direct current power source with a RPM of 1000. Brushed motors were the
first commercially important application of electric power to driving mechanical loads,
and DC distribution systems were used for more than 100 years to operate motors in
commercial and industrial buildings. Brushed DC motors can be varied in speed by
changing the operating voltage or the strength of the magnetic field. Depending on the
connections of the field to the power supply, the speed and torque characteristics of a
brushed motor can be altered to provide steady speed or speed inversely proportional to
the mechanical load. Brushed motors continue to be used for electrical propulsion,
cranes, paper machines and steel rolling mills. Since the brushes wear down and require
replacement, brushless motors using power electronic devices have displaced brushed
motors from many applications.
  CUTTING BLADE

A blade is that portion of a tool, weapon, or machine with an edge that is

designed to cut and/or puncture, stab, slash, chop, slice, thrust, or scrape surfaces or
materials. A blade may be made from a flaking stone, such as flint, metal
(usually steel), ceramic, or other material.

The ability of a blade to cut arises from the concentration of the force applied to
the blade onto a very small area, resulting in a high pressure on the matter to be
penetrated.

A serrated blade (a blade which has many small "teeth") takes this further as each
individual tooth concentrates the force on a smaller area which helps cut through denser
materials. A jagged knife can cut through objects solely with a sliding motion with little
pushing force; this is useful, for example, in bread knives. Some bladed weapons or
tools have curved blades.
 As a rule the blade must be made of a substance which is harder than (or
as hard as) the material it is intended to cut. If this is not the case the blade will either be
unable to cut (as it absorbs all the energy and is damaged) or will wear away very
quickly (if it is hard enough to transfer enough of the energy to damage the material).
The material must also be tough enough to last (e.g. glass is very hard but
it shatters easily and thus is not very effective as a material for a blade).
 PNEUMATIC PISTON

Pneumatic cylinder(s) (sometimes known as air cylinders) are mechanical

devices which use the power of compressed gas to produce a force in a reciprocating
linear motion.

Like hydraulic cylinders, something 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 sometimes prefer to use pneumatics because they are quieter,
cleaner, and do not require large amounts of 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.

Some of the earliest forms of actuation can be found as far back as Archimedes,
who lived approximately between the years 287 B.C., and 212 B.C. What became
known as Archimedes' screw was one of the first linear actuators used to haul water
from boats.
 Other early actuation methods included mechanisms with wooden screws
designed to crush grapes into wine and olives into oil.

An electric actuator is powered by a motor that converts electrical energy to

mechanical torque. The electrical energy is used to actuate equipment such as multi-turn
valves. It is one of the cleanest and most readily available forms of actuator because it
does not involve oil.

 CAM OPERATOR

CAM operator is used for pull down operation of the Cutting blade which coupled
with motor. The total size of the CAM operator is around 8 inch, top end is 4.5 inch and
the bottom end is 3.5 inch. The Top end of the CAM operator is connected with the
Cutting blade and the bottom end of CAM is connected to the actuator. Bearing is fixed
with the CAM operator for the freewheeling operation.
 PHOTO ELECTRIC SENSOR:

A photoelectric sensor, or photo eye, is an equipment used to discover the

distance, absence, or presence of an object by using a light transmitter, often infrared,
and a photoelectric receiver. They are largely used in industrial manufacturing. There
are three different useful types: opposed (through beam), retro-reflective, and proximity-
sensing

 OPERATING PRINCIPLE

A Photoelectric Sensor consists primarily of an Emitter for emitting light and a

Receiver for receiving light. When emitted light is interrupted or reflected by
the sensing object, it changes the amount of light that arrives at the Receiver. The
Receiver detects this change and converts it to an electrical output.
A photoelectric sensor emits a light beam (visible or infrared) from its light-emitting
element. A reflective-type photoelectric sensor is used to detect the light beam reflected
from the target.A thrubeam type sensor is used to measure the change in light quantity
caused by the target crossing the optical axis.

 IR SENSOR

 Introduction

An infrared sensor is an electronic instrument that is used to sense certain characteristics

of its surroundings by either emitting and/or detecting infrared radiation. It is also
capable of measuring heat of an object and detecting motion. Infrared waves are not
visible to the human eye.

In the electromagnetic spectrum, infrared radiation is the region having wavelengths

longer than visible light wavelengths, but shorter than microwaves. The infrared region
is approximately demarcated from 0.75 to 1000µm. The wavelength region from 0.75 to
3µm is termed as near infrared, the region from 3 to 6µm is termed mid-infrared, and the
region higher than 6µm is termed as far infrared.

Infrared technology is found in many of our everyday products. For example, TV has an
IR detector for interpreting the signal from the remote control. Key benefits of infrared
sensors include low power requirements, simple circuitry, and their portable feature.
Types of Infra-Red Sensors

Infra-red sensors are broadly classified into two types:

 Thermal infrared sensors – These use infrared energy as heat. Their photo
sensitivity is independent of wavelength. Thermal detectors do not require cooling;
however, they have slow response times and low detection capability.
 Quantum infrared sensors – These provide higher detection performance and
faster response speed. Their photo sensitivity is dependent on wavelength. Quantum
detectors have to be cooled so as to obtain accurate measurements. The only
exception is for detectors that are used in the near infrared region.

Working Principle

A typical system for detecting infrared radiation using infrared sensors includes
the infrared source such as blackbody radiators, tungsten lamps, and silicon carbide. In
case of active IR sensors, the sources are infrared lasers and LEDs of specific IR
wavelengths. Next is the transmission medium used for infrared transmission, which
includes vacuum, the atmosphere, and optical fiber.

Thirdly, optical components such as optical lenses made from quartz, CaF 2, Ge
and Si, polyethylene Fresnel lenses, and Al or Au mirrors, are used to converge or focus
infrared radiation. Likewise, to limit spectral response, band-pass filters are ideal.
 Finally, the infrared detector completes the system for detecting infrared
radiation. The output from the detector is usually very small, and hence pre-amplifiers
coupled with circuitry are added to further process the received signals.

Applications

The following are the key application areas of infrared sensors:

 Tracking and art history

 Climatology, meteorology, and astronomy
 Thermography, communications, and alcohol testing
 Heating, hyperspectral imaging, and night vision
 Biological systems, photobiomodulation, and plant health
 Gas detectors/gas leak detection
 Water and steel analysis, flame detection
 Anesthesiology testing and spectroscopy
 Petroleum exploration and underground solution
 Rail safety.
Operation
What is definitely detected is the broken field for a “normal” temperature. The
sensor detects the change in the infrared radiation and triggers an alarm if the gradient of
the change is higher than a predefined value. The field does not have to be broken by an
object with a different temperature in order to register change, as highly sensitive
sensors will activate from the movement alone.

PIRs come in many configurations for a wide variety of applications. The most
common models have numerous Fresnel lenses or mirror segments, an effective range of
about ten meters (thirty feet), and a field of view less than 180 degrees. Models with
wider fields of view, including 360 degrees, are available—typically designed to mount
on a ceiling. Some larger PIRs are made with single segment mirrors and can sense
changes in infrared energy over one hundred feet away from the PIR. There are also
PIRs designed with reversible orientation mirrors which allow either broad coverage
(110° wide) or very narrow "curtain" coverage, or with individually selectable segments
to "shape" the coverage.

RELAY UNIT

A relay is an electrically operated switch. Many relays use an electromagnet to

mechanically operate a switch, but other operating principles are also used, such
as solid-state relays. Relays are used where it is necessary to control a circuit by a low-
power signal (with complete electrical isolation between control and controlled circuits),
or where several circuits must be controlled by one signal. The first relays were used in
long distance telegraph circuits as amplifiers: they repeated the signal coming in from
one circuit and re-transmitted it on another circuit. Relays were used extensively in
telephone exchanges and early computers to perform logical operations.
 A type of relay that can handle the high power required to directly control an
electric motor or other loads is called a contactor. Solid-state relays control power
circuits with no moving parts, instead using a semiconductor device to perform
switching. Relays with calibrated operating characteristics and sometimes multiple
operating coils are used to protect electrical circuits from overload or faults; in modern
electric power systems these functions are performed by digital instruments still called
"protective relays".
Basic design and operation

A simple electromagnetic relay consists of a coil of wire wrapped around a soft iron
core, an iron yoke which provides a low reluctance path for magnetic flux, a movable
iron armature, and one or more sets of contacts (there are two in the relay pictured). The
armature is hinged to the yoke and mechanically linked to one or more sets of moving
contacts. It is held in place by a spring so that when the relay is de-energized there is an
air gap in the magnetic circuit. In this condition, one of the two sets of contacts in the
relay pictured is closed, and the other set is open. Other relays may have more or fewer
sets of contacts depending on their function. The relay in the picture also has a wire
connecting the armature to the yoke. This ensures continuity of the circuit between the
moving contacts on the armature, and the circuit track on the printed circuit board (PCB)
via the yoke, which is soldered to the PCB.

When an electric current is passed through the coil it generates a magnetic field that
activates the armature, and the consequent movement of the movable contact(s) either
makes or breaks (depending upon construction) a connection with a fixed contact. If the
set of contacts was closed when the relay was de-energized, then the movement opens
the contacts and breaks the connection, and vice versa if the contacts were open. When
the current to the coil is switched off, the armature is returned by a force, approximately
half as strong as the magnetic force, to its relaxed position. Usually this force is
provided by a spring, but gravity is also used commonly in industrial motor starters.
Most relays are manufactured to operate quickly. In a low-voltage application this
reduces noise; in a high voltage or current application it reduces arcing.

When the coil is energized with direct current, a diode is often placed across the
coil to dissipate the energy from the collapsing magnetic field at deactivation, which
would otherwise generate a voltage spike dangerous to semiconductor circuit
components. Some automotive relays include a diode inside the relay case.
Alternatively, a contact protection network consisting of a capacitor and resistor in
series (snubber circuit) may absorb the surge. If the coil is designed to be energized
with alternating current (AC), a small copper "shading ring" can be crimped to the end
of the solenoid, creating a small out-of-phase current which increases the minimum pull
on the armature during the AC cycle.[1]

A solid-state relay uses a thyristor or other solid-state switching device, activated

by the control signal, to switch the controlled load, instead of a solenoid.
An optocoupler (a light-emitting diode (LED) coupled with a photo transistor) can be
used to isolate control and controlled circuits.

Types

Latching relay

A latching relay has two relaxed states (bi-stable). These are also called "impulse",
"keep", or "stay" relays. When the current is switched off, the relay remains in its last
state. This is achieved with a solenoid operating a ratchet and cam mechanism, or by
having two opposing coils with an over-center spring or permanent magnet to hold the
armature and contacts in position while the coil is relaxed, or with a remanent core. In
the ratchet and cam example, the first pulse to the coil turns the relay on and the second
pulse turns it off. In the two coil example, a pulse to one coil turns the relay on and a
pulse to the opposite coil turns the relay off. This type of relay has the advantage that
one coil consumes power only for an instant, while it is being switched, and the relay
contacts retain this setting across a power outage. A remanent core latching relay
requires a current pulse of opposite polarity to make it change state.

A stepping relay is a specialized kind of multi-way latching relay designed for

early automatic exchanges. An earth leakage circuit breaker includes a specialized
latching relay. Very early computers often stored bits in a magnetically latching relay,
such as ferreed or the later memreed in the 1ESS switch.

Some early computers used ordinary relays as a kind of latch—they store bits in
ordinary wire spring relays or reed relays by feeding an output wire back as an input,
resulting in a feedback loop or sequential circuit. Such an electrically-latching relay
requires continuous power to maintain state, unlike magnetically latching relays or
mechanically ratcheting relays.

In computer memories, latching relays and other relays were replaced by delay
line memory, which in turn was replaced by a series of ever-faster and ever-smaller
memory technologies.

Reed relay
A reed relay is a reed switch enclosed in a solenoid. The switch has a set of
contacts inside an evacuated or inert gas-filled glass tube which protects the contacts
against atmospheric corrosion; the contacts are made of magnetic material that makes
them move under the influence of the field of the enclosing solenoid or an external
magnet.

Reed relays can switch faster than larger relays and require very little power from the
control circuit. However, they have relatively low switching current and voltage ratings.
Though rare, the reeds can become magnetized over time, which makes them stick 'on'
even when no current is present; changing the orientation of the reeds with respect to the
solenoid's magnetic field can resolve this problem.

Sealed contacts with mercury-wetted contacts have longer operating lives and less
contact chatter than any other kind of relay
Mercury-wetted relay
A mercury-wetted reed relay is a form of reed relay in which the contacts are
wetted with mercury. Such relays are used to switch low-voltage signals (one volt or
less) where the mercury reduces the contact resistance and associated voltage drop, for
low-current signals where surface contamination may make for a poor contact or for
high-speed applications where the mercury eliminates contact bounce. Mercury wetted
relays are position-sensitive and must be mounted vertically to work properly. Because
of the toxicity and expense of liquid mercury, these relays are now rarely used.

Mercury relay
A mercury relay is a relay that uses mercury as the switching element. They are
used where contact erosion would be a problem for conventional relay contacts. Owing
to environmental considerations about significant amount of mercury used and modern
alternatives, they are now comparatively uncommon

Polarized relay
A polarized relay places the armature between the poles of a permanent magnet
to increase sensitivity. Polarized relays were used in middle 20th Century telephone
exchanges to detect faint pulses and correct telegraphic distortion. The poles were on
screws, so a technician could first adjust them for maximum sensitivity and then apply a
bias spring to set the critical current that would operate the relay.

Ratchet relay
This is again a clapper type relay which does not need continuous current through its
coil to retain its operation. A ratchet holds the contacts closed after the coil is
momentarily energized. A second impulse, in the same or a separate coil, releases the
contacts.

Coaxial relay
Where radio transmitters and receivers share a common antenna, often a coaxial relay is
used as a TR (transmit-receive) relay, which switches the antenna from the receiver to
the transmitter. This protects the receiver from the high power of the transmitter. Such
relays are often used in transceivers which combine transmitter and receiver in one unit.
The relay contacts are designed not to reflect any radio frequency power back toward
the source, and to provide very high isolation between receiver and transmitter
terminals. The characteristic impedance of the relay is matched to the transmission
line impedance of the system, for example, 50 ohms.

Contactor

A contactor is a heavy-duty relay used for switching electric motors and lighting
loads, but contactors are not generally called relays. Continuous current ratings for
common contactors range from 10 amps to several hundred amps. High-current contacts
are made with alloys containing silver. The unavoidable arcing causes the contacts to
oxidize; however, silver oxide is still a good conductor.[4] Contactors with overload
protection devices are often used to start motors. Contactors can make loud sounds
when they operate, so they may be unfit for use where noise is a chief concern.

A contactor is an electrically controlled switch used for switching a power circuit,

similar to a relay except with higher current ratings.[5] A contactor is controlled by a
circuit which has a much lower power level than the switched circuit.

Contactors come in many forms with varying capacities and features. Unlike
a circuit breaker, a contactor is not intended to interrupt a short circuit current.
Contactors range from those having a breaking current of several amperes to thousands
of amperes and 24 V DC to many kilovolts. The physical size of contactors ranges from
a device small enough to pick up with one hand, to large devices approximately a meter
(yard) on a side.

Contactors are used to control electric motors, lighting, heating, capacitor banks,
thermal evaporators, and other electrical loads

Solid-state relay
A solid state relay (SSR) is a solid state electronic component that provides a
similar function to an electromechanical relay but does not have any moving
components, increasing long-term reliability. Every solid-state device has a small
voltage drop across it. This voltage drop limits the amount of current a given SSR can
handle. The minimum voltage drop for such a relay is a function of the material used to
make the device. Solid-state relays rated to handle as much as 1,200 amperes have
become commercially available. Compared to electromagnetic relays, they may be
falsely triggered by transients and in general may be susceptible to damage by
extreme cosmic ray and EMP episodes

Solid state contactor relay

A solid state contactor is a heavy-duty solid state relay, including the necessary
heat sink, used where frequent on/off cycles are required, such as with electric heaters,
small electric motors, and lighting loads. There are no moving parts to wear out and
there is no contact bounce due to vibration. They are activated by AC control signals or
DC control signals from Programmable logic controller (PLCs), PCs, Transistor-
transistor logic (TTL) sources, or other microprocessor and microcontroller controls.
Buchholz relay
A Buchholz relay is a safety device sensing the accumulation of gas in large oil-
filled transformers, which will alarm on slow accumulation of gas or shut down the
transformer if gas is produced rapidly in the transformer oil.

Forced-guided contacts relay

A forced-guided contacts relay has relay contacts that are mechanically linked
together, so that when the relay coil is energized or de-energized, all of the linked
contacts move together. If one set of contacts in the relay becomes immobilized, no
other contact of the same relay will be able to move. The function of forced-guided
contacts is to enable the safety circuit to check the status of the relay. Forced-guided
contacts are also known as "positive-guided contacts", "captive contacts", "locked
contacts", "mechanically-linked contacts", or "safety relays"

Overload protection relay

Electric motors need over current protection to prevent damage from over-loading
the motor, or to protect against short circuits in connecting cables or internal faults in
the motor windings.[6] The overload sensing devices are a form of heat operated relay
where a coil heats a bimetallic strip, or where a solder pot melts, releasing a spring to
operate auxiliary contacts. These auxiliary contacts are in series with the coil. If the
overload senses excess current in the load, the coil is de-energized.

This thermal protection operates relatively slowly allowing the motor to draw higher
starting currents before the protection relay will trip. Where the overload relay is
exposed to the same environment as the motor, a useful though crude compensation for
motor ambient temperature is provided.
The other common overload protection system uses an electromagnet coil in series with
the motor circuit that directly operates contacts. This is similar to a control relay but
requires a rather high fault current to operate the contacts. To prevent short over current
spikes from causing nuisance triggering the armature movement is damped with
a dashpot. The thermal and magnetic overload detections are typically used together in a
motor protection relay.

Electronic overload protection relays measure motor current and can estimate motor
winding temperature using a "thermal model" of the motor armature system that can be
set to provide more accurate motor protection. Some motor protection relays include
temperature detector inputs for direct measurement from a thermocouple or resistance
thermometer sensor embedded in the winding.

Vacuum relays
A sensitive relay having its contacts mounted in a highly evacuated glass housing, to
permit handling radio-frequency voltages as high as 20,000 volts without flashover
between contacts even though contact spacing is but a few hundredths of an inch when
open

Pole and throw

Since relays are switches, the terminology applied to switches is also applied to relays; a
relay switches one or more poles, each of whose contacts can be thrown by energizing
the coil in one of three ways:

 Normally-open (NO) contacts connect the circuit when the relay is activated; the
circuit is disconnected when the relay is inactive. It is also called aForm A contact
or "make" contact. NO contacts may also be distinguished as "early-make"
or NOEM, which means that the contacts close before the button or switch is fully
engaged.
 Normally-closed (NC) contacts disconnect the circuit when the relay is activated; the
circuit is connected when the relay is inactive. It is also called form B contact or
"break" contact. NC contacts may also be distinguished as "late-break" or NCLB,
which means that the contacts stay closed until the button or switch is fully
disengaged.
 Change-over (CO), or double-throw (DT), contacts control two circuits: one
normally-open contact and one normally-closed contact with a common terminal. It
is also called a Form C contact or "transfer" contact ("break before make"). If this
type of contact utilizes a "make before break" functionality, then it is called a Form
D contact.

The following designations are commonly encountered:

 SPST – Single Pole Single Throw. These have two terminals which can be
connected or disconnected. Including two for the coil, such a relay has four terminals
in total. It is ambiguous whether the pole is normally open or normally closed. The
terminology "SPNO" and "SPNC" is sometimes used to resolve the ambiguity.
 SPDT – Single Pole Double Throw. A common terminal connects to either of two
others. Including two for the coil, such a relay has five terminals in total.
 DPST – Double Pole Single Throw. These have two pairs of terminals. Equivalent to
two SPST switches or relays actuated by a single coil. Including two for the coil,
such a relay has six terminals in total. The poles may be Form A or Form B (or one
of each).
 DPDT – Double Pole Double Throw. These have two rows of change-over
terminals. Equivalent to two SPDT switches or relays actuated by a single coil. Such
a relay has eight terminals, including the coil.
The "S" or "D" may be replaced with a number, indicating multiple switches connected
to a single actuator. For example 4PDT indicates a four pole double throw relay (with
12 terminals).

EN 50005 are among applicable standards for relay terminal numbering; a typical EN
50005-compliant SPDT relay's terminals would be numbered 11, 12, 14, A1 and A2 for
the C, NC, NO, and coil connections, respectively.

DIN 72552 defines contact numbers in relays for automotive use;

 85 = relay coil -
 86 = relay coil +
 87 = common contact
 87a = normally closed contact
 87b = normally open contact

Applications

Relays are used for:

 Amplifying a digital signal, switching a large amount of power with a small

operating power. Some special cases are:
 A telegraph relay, repeating a weak signal received at the end of a long wire
 Controlling a high-voltage circuit with a low-voltage signal, as in some types
of modems or audio amplifiers,
 Controlling a high-current circuit with a low-current signal, as in
the starter solenoid of an automobile,
 Detecting and isolating faults on transmission and distribution lines by opening and
closing circuit breakers (protection relays),
  Time delay functions. Relays can be modified to delay opening or delay closing a
set of contacts. A very short (a fraction of a second) delay would use a copper
disk between the armature and moving blade assembly. Current flowing in the
disk maintains magnetic field for a short time, lengthening release time. For a
slightly longer (up to a minute) delay, a dashpot is used. A dashpot is a piston
filled with fluid that is allowed to escape slowly. The time period can be varied by
increasing or decreasing the flow rate. For longer time periods, a mechanical
clockwork timer is installed.
 Vehicle battery isolation. A 12v relay is often used to isolate any second battery
in cars, 4WDs, RVs and boats.
 Switching to a standby power supply.
Relay application considerations

Selection of an appropriate relay for a particular application requires evaluation of many

different factors

 Number and type of contacts – normally-open, normally-closed, (double-throw)

 Contact sequence – "Make before Break" or "Break before Make". For example,
the old style telephone exchanges required Make-before-break so that the
connection didn't get dropped while dialing the number.
 Rating of contacts – small relays switch a few amperes, large contactors are rated
for up to 3000 amperes, alternating or direct current
 Voltage rating of contacts – typical control relays rated 300 VAC or 600 VAC,
automotive types to 50 VDC, special high-voltage relays to about 15,000 V
Operating lifetime, useful life - the number of times the relay can be expected to operate
reliably. There is both a mechanical life and a contact life. The contact life is naturally
affected by the kind of load being switched: switching while "wet" (under load)
causes undesired arcing between the contacts, eventually leading to contacts that weld
shut or contacts that fail due to a build up of contact surface damage caused by the
destructive arc energy.

 Coil voltage – machine-tool relays usually 24 VDC, 120 or 250 VAC, relays for
switchgear may have 125 V or 250 VDC coils, "sensitive" relays operate on a few
milliamperes
 Coil current - including minimum current required to operate reliably and minimum
current to hold. Also effects of power dissipation on coil temperature at various duty
cycles.
 Package/enclosure – open, touch-safe, double-voltage for isolation between
circuits, explosion proof, outdoor, oil and splash resistant, washable for printed
circuit board assembly
 Operating environment - minimum and maximum operating temperatures and other
environmental considerations such as effects of humidity and salt
 Assembly – Some relays feature a sticker that keeps the enclosure sealed to allow
PCB post soldering cleaning, which is removed once assembly is complete.
 Mounting – sockets, plug board, rail mount, panel mount, through-panel mount,
enclosure for mounting on walls or equipment
 Switching time – where high speed is required
 "Dry" contacts – when switching very low level signals, special contact materials
may be needed such as gold-plated contacts
 Contact protection – suppress arcing in very inductive circuits
 Coil protection – suppress the surge voltage produced when switching the coil
current
 Isolation between coil contacts
 Aerospace or radiation-resistant testing, special quality assurance
 Expected mechanical loads due to acceleration – some relays used
in aerospace applications are designed to function in shock loads of 50 g or more
 Size - smaller relays often resist mechanical vibration and shock better than larger
relays, because of the lower inertia of the moving parts and the higher natural
frequencies of smaller parts.[2]Larger relays often handle higher voltage and current
than smaller relays.
 Accessories such as timers, auxiliary contacts, pilot lamps, and test buttons
 Regulatory approvals
 Stray magnetic linkage between coils of adjacent relays on a printed circuit board.

There are many considerations involved in the correct selection of a control relay for a
particular application. These considerations include factors such as speed of operation,
sensitivity, andhysteresis. Although typical control relays operate in the 5 ms to 20 ms
range, relays with switching speeds as fast as 100 us are available. Reed relays which
are actuated by low currents and switch fast are suitable for controlling small currents.

As for any switch, the current through the relay contacts (unrelated to the current
through the coil) must not exceed a certain value to avoid damage. In the particular case
of high-inductancecircuits such as motors, other issues must be addressed. When a
power source is connected to an inductance, an input surge current which may be
several times larger than the steady current exists. When the circuit is broken, the
current cannot change instantaneously, which creates a potentially damaging spark
across the separating contacts.

Consequently for relays which may be used to control inductive loads, we must specify
the maximum current that may flow through the relay contacts when it actuates,
the make rating; the continuous rating; and the break rating. The make rating may be
several times larger than the continuous rating, which is itself larger than the break
rating.
Derating factors
Control relays should not be operated above rated temperature because of resulting
increased degradation and fatigue. Common practice is to derate 20 degrees Celsius
from the maximum rated temperature limit. Relays operating at rated load are also
affected by their environment. Oil vapors may greatly decrease the contact tip life, and
dust or dirt may cause the tips to burn before their normal life expectancy. Control relay
life cycle varies from 50,000 to over one million cycles depending on the electrical
loads of the contacts, duty cycle, application, and the extent to which the relay is
derated. When a control relay is operating at its derated value, it is controlling a lower
value of current than its maximum make and break ratings. This is often done to extend
the operating life of the control relay. The table lists the relay derating factors for typical
industrial control applications

Undesired arcing

Switching while "wet" (under load) causes undesired arcing between the contacts,
eventually leading to contacts that weld shut or contacts that fail due to a build up of
contact surface damage caused by the destructive arc energy.[7]

Inside the 1ESS switch matrix switch and certain other high-reliability designs, the reed
switches are always switched "dry" to avoid that problem, leading to much longer
contact life.[8]

Without adequate contact protection, the occurrence of electric current arcing causes
significant degradation of the contacts in relays, which suffer significant and visible
damage. Every time a relay transitions either from a closed to an open state (break arc)
or from an open to a closed state (make arc & bounce arc), under load, an electrical arc
can occur between the two contact points (electrodes) of the relay. The break arc is
typically more energetic and thus more destructive.

The heat energy contained in the resulting electrical arc is very high (tens of thousands
of degrees Fahrenheit), causing the metal on the contact surfaces to melt, pool and
migrate with the current. The extremely high temperature of the arc cracks the
surrounding gas molecules creating ozone, carbon monoxide, and other compounds. The
arc energy slowly destroys the contact metal, causing some material to escape into the
air as fine particulate matter. This very activity causes the material in the contacts to
degrade quickly, resulting in device failure. This contact degradation drastically limits
the overall life of a relay to a range of about 10,000 to 100,000 operations, a level far
below the mechanical life of the same device, which can be in excess of 20 million
operations

Protective relays

For protection of electrical apparatus and transmission lines, electromechanical relays

with accurate operating characteristics were used to detect overload, short-circuits, and
other faults. While many such relays remain in use, digital devices now provide
equivalent protective functions.
CHAPTER-5
 CHAPTER-5

SAFETY MEASURE IN INDUSTRIES

Safety Procedures are becoming more commonplace in the Construction and

Building Industries. Principle Contractors are implementing Safety Procedures, and they
are also expecting Sub-Contractors to provide Safety Procedures for the work they are
performing. Construction Safety Procedures include Asbestos Removal, Air
Compressors, Circular Saws, Demolition Work, Electrical Power Tools, Hiab Cranes,
Nail Guns, Scaffolding, Working on Roofs, Safety Harnesses and more.

How to Develop A Safety Procedure

Safety Procedures are not complicated to develop. Firstly, complete a Job Safety
Analysis Sheet. Some common steps include:

• Risk Assessments

• Pre-Planning

• Pre-Start Checks

• Site Safety

• Personal Protective Equipment

• First Aid

• General Safety Information

• Maintenance

• Job Completion
It is also recommended to review:

• State and Federal Legislative Requirements

• Industry Standards

• Manufacturer's Recommendations (Where Applicable)

• Accident and Prosecution Case Studies

• International Industry Information

 OHS Systems

Developing OHS Systems in your workplace can seem overwhelming at first, but
by breaking it down into chunk size pieces. Many OHS Consultants believe that you
need to start your OHS Systems by creating a mountain of paper work covering every
area of your business. While documentation is important, you need to be practical. For
example, if you have an engineering workshop with no OHS Systems in place, and your
employees are tripping over equipment and materials , then start by cleaning up the
workshop and re-organize it so it is easier to keep tidy.

Each company needs to conduct a basic risk assessment as to where their greatest
dangers are, and how to minimize them. Once you start asking the right questions,
continuing to develop a Safety Culture becomes more a way of life, rather than a choir.
After all no employer wants an injury at their workplace.
  Beyond the basics

Once you have began to consider your risks and implemented improvements to
reduce the hazards, you are on your way to developing a structured OHS System. Once
a workplace realizes what daily steps need to be taken in order to work safely, they then
have the job of making sure everyone follows them. This is where a written OHS Policy
Manual or Safety Manual comes into play. A standard set of Safety Policies and
Procedures relating to your workplace becomes an agreement for employees and
contractors to adhere to whilst working. They should sign off on a OHS Policy Manual,
and they should also sign off on each OHS Procedure that relates to their workplace
responsibilities.

 Safety Procedures Explained

A Safety Procedure is developed by Employer's, Principle Contractors and Sub-

Contractors for work that they are performing. It details how specific risks in the
workplace will be managed.

No matter what industry you are in, we can provide Safety Procedures for
Construction, Industrial, Manufacturing and Professional Services. Our team of Safety
Consultants is constantly developing new procedures for all types of plant, equipment
and workplace processes. Procedures are developed after consulting with manufactures
recommendations, Australian Standards, Industrial Relations and other Government
bodies who provide valuable information for developing the safest procedures..

 Safety Procedure Format

There are many different types of Safety Procedure formats, however a

compressive procedure can only be developed after a risk assessment has been
conducted. Once the risks and hazards have been identified, a review of federal and state
legislative requirements, national standards, manufacturer's recommendations and
industry information including case studies needs to be conducted.

Graph on accident report in industries

CHAPTER-6
 CHAPTER-6

PRINCIPAL OF SAFETY CUTTING TOOL MACHINE

This project is developed for the safety cutting operation in Small scale and large
scale industries. Every Industry follow the safety man hours, many programs are
conducted for the safety working in the industry.

The industries are knee about the safety measure to the workers for the
development in their business, and then only the projects will be allocated for the
company from the clients. However some accidents are occurred by the workers while
they are working with the machinery. Major accidents are happened to the workers
when they work with cutting tool machine.

Cutting tool machine is widely used in many industries because all the industries
have cutting operation. In previous years the cutting tool is operated by manual
operation by switching on and off, and it creates many accidents to the workers. Later to
avoid these accidents and to develop the safety measure CNC machine was introduced.

CNC MACHINE

CNC Machining is a process used in the manufacturing sector that involves the
use of computers to control machine tools. Tools that can be controlled in this manner
include lathes, mills, routers and grinders. The CNC in CNC Machining stands for
Computer Numerical Control.

On the surface, it may look like a normal PC controls the machines, but the
computer's unique software and control console are what really sets the system apart for
use in CNC machining.
 Under CNC Machining, machine tools function through numerical control. A
computer program is customized for an object and the machines are programmed with
CNC machining language (called G-code) that essentially controls all features like feed
rate, coordination, location and speeds. With CNC machining, the computer can control
exact positioning and velocity. CNC machining is used in manufacturing both metal and
plastic parts.

First a CAD drawing is created (either 2D or 3D), and then a code is created that
the CNC machine will understand. The program is loaded and finally an operator runs a
test of the program to ensure there are no problems. This trial run is referred to as
"cutting air" and it is an important step because any mistake with speed and tool position
could result in a scraped part or a damaged machine.

There are many advantages to using CNC Machining. The process is more precise
than manual machining, and can be repeated in exactly the same manner over and over
again. Because of the precision possible with CNC Machining, this process can produce
complex shapes that would be almost impossible to achieve with manual machining.
CNC Machining is used in the production of many complex three-dimensional shapes. It
is because of these qualities that CNC Machining is used in jobs that need a high level
of precision or very repetitive tasks.

If you are considering a career in CNC Machining, it would be useful to have a

background in mathematics, industrial arts and mechanical drafting, as well as computer
usage.
WORKING OF SMART CUTTING TOOL MACHINE

Even though well equipment like CNC machine was introduced by the industries
the accidents rate reduced only for the 80%, but the remaining error arise to the accident
with the CNC cutting tool.

To avoid these accidents in the industries we are introducing the new concept in
the machine called SMART cutting tool machine, in this project we are going to operate
the machine with full safety. In the existing process the cutting blade will slowed down
with the power off stage in the motor, in our proposed system we are placing the PIR
(passive infrared) sensor near to the cutting blade once the human object is sensed
beyond the point, the sensor will sense and it automatically pull the motor below the
table level by whit worth mechanism.

The pull down operation is performed by actuator, electric actuator is used in our
project, and 12v is triggered to the actuator with the sense of the PIR sensor through the
relay card unit. Relay unit is used to trigger the actuator with 12v.

The actuator is coupled with the CAM operator, the length of the CAM is around
8inch, top end is 4.5 inch and the bottom end is 3.5 inch. Top end is coupled to the
Cutting blade and the bottom end is coupled to the CAM operator.

So once the sensor is sensed means it actuates the actuator with the 12v supply
from relay card unit. So once the actuator is triggered it automatically pull down the
cutting blade below the table level through the CAM operator. By this kind of operation
0% of Accidents is occurred in the industries.
CHAPTER-7
 CHAPTER-7

COSTING OF PROJECT

S.no Particular Total quantity COST.Rs/unit Total cost

1 Frame 1 2000 2000

2 Bearing (Ball) 1 150 150

3 Whitworth 1 400 400

mechanism
4 Motor 1 800 800

5 CAM operator 1 1000 1000

6 Single cutting Blade 1 800 800

7 Pneumatic piston 1 1200 1200

8 5/2 Solenoid valve 1 1500 1500

9 Nut and Bold 10 15 150

10 Photo electric sensor 1 1400 1400

11 Relay board unit 1 800 700

12 Pneumatic hose 4mtrs 40 160