AUTOMATION OF CONDENSER AND RADIATOR

TUBES STACKING AND CLEANING PROCESS

A PROJECT REPORT

Submitted by

P. ABDUL RAHMAN (11808114002)

R. MUTHU (11808114067)
S. SANTHAKUMAR (11808114092)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

VELTECH MULTITECH Dr. RANGARAJAN

Dr. SAKUNTHALA ENGINEERING COLLEGE

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2012
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “AUTOMATION OF CONDENSER AND

RADIATOR TUBES STACKING AND CLEANING PROCESS” is the bonafide

work of P. ABDUL RAHMAN (11808114002), S. SANTHAKUMAR

(11808114092) and R. MUTHU (11808114067) at Visteon Automotive Systems

India Private Limited who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Mr. M. K. Jawahar , M.E. Mr. D. Satish Kumar, M.B.A, M.E,

(Ph.D).

HEAD OF THE DEPARTMENT SUPERVISOR

Assistant professor, Assistant professor,

Department of Mechanical Engineering, Department of Mechanical Engineering,

Veltech Multitech Dr. RR Dr. SR Veltech Multitech Dr. RR Dr. SR

Engineering College, Engineering College,
Avadi, Avadi,
Chennai 600062. Chennai 600062.

ii
 CERTIFICATE OF EVALUATION

S.No Name of the Title of the project Name of the internal guide
students

1. P. Abdul Rahman Mr. D Satish Kumar,

(11808114002) M.B.A, M.E, (Ph.D)
Asst. Professor,
Automation of
Department of Mechanical
Condenser and Radiator
Engineering,
2. tubes stacking and
R. Muthu Veltech Multitech Dr. RR
cleaning process
(11808114067) Dr. SR Engineering
College.

3. S. Santhakumar
(11808114092)

This is to certify that the project entitled “AUTOMATION OF CONDENSER

AND RADIATOR TUBE STACKING AND CLEANING PROCESS” is the bonafide

record of work done by the above students who carried out the project work under our

guidance during the year 2011- 2012 in partial fulfillment of the award of Bachelor of

Engineering degree in Mechanical Engineering of Anna University Chennai.

Submitted for the Viva-voce held on ……………….……………..at Veltech

Multitech Dr. RR Dr. SR Engineering College.

INTERNAL EXAMINER ` EXTERNAL EXAMINER

iii
 ACKNOWLEDGEMENT

We take this opportunity to express our sincere gratitude to our chairman Col.

Prof. Dr. R. Rangarajan, B.E (Mechanical), B.E (Electrical), MS (Automobile),

D.Sc for his kind words and enthusiastic motivation which has inspired us a lot in

completing this project.

We are deeply indebted to our Principal Prof. Dr. Venkataraman Shankar,

M.E, Ph.D for being a source of inspiration throughout my study in this college.

We thank our Head of the Department Mr. M. K. Jawahar, M.E and our

internal guide Mr. D Satish Kumar M.B.A, M.E (Ph.D) for their guidance and

encouragement at each and every stage of our project work and also guiding us

properly throughout the reviews.

We also express our heartiest thanks to Mr. L. Prabhu, Head of the

Department - CCS for his invaluable guidance.

With profound respect, we express our deep sense of gratitude and sincere

thanks to our external guides, Mr. S Ram Kumar (Manufacturing Engineer – CCS)

and Mr. D. Karthikeyan (Design Engineer-CCS) for their invaluable guidance and

suggestions throughout this project.

iv
Space for pasting project
certificate

v
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT xi
LIST OF TABLES ix
LIST OF FIGURES x

1. INTRODUCTION 1

1.1 PROBLEM DEFINITION 1

1.2 PRESENT CLEANING PROCESS 2
1.3 TUBE DATA AND DIMENSIONS 4
1.4 CAUSE AND EFFECT FOR 5
INEFFECTIVE CLEANING

2. LITERATURE REVIEW 6

2.1 MATERIAL PROPERTIES AND 6

SELECTION ACCORDING TO UNIIVERSITY
OF CAMBRIDGE
2.1.1 Aluminum 6
2.1.2 Mild steel 6

3. AUTOMATION IN TUBE CLEANING & 8

STACKING PROCESS

3.1 FIRST CONCEPT WORKING 8

3.1.1 Limitations 10
3.2 SECOND CONCEPT WORKING 10
3.2.1 Limitations 11
3.3 THIRD CONCEPT WORKING 11
3.3.1 Limitations 13

vi
 3.4 FOURTH CONCEPT WORKING 13
3.4.1 Advantage 14
3.4.2 Requirements 15
3.5 FIFTH CONCEPT WORKING 15
3.5.1 Advantages 15
3.6 RESULTS AND DISCUSSIONS 17

4. FINAL MODEL 18

4.1 REQUIREMENTS 18
4.2 FINAL MODIFICATIONS IN FIFTH 18
CONCEPT
4.3 STANDARD PARTS AVAILABLE 20
4.3.1 Pneumatic compact cylinders 20
4.3.1.1 Application 21
4.3.2 Stopper Cylinders 21
4.3.2.1 Application 21
4.3.3 Linear Swivel Clamp cylinder 22
4.3.3.1 Application 22
4.3.4 Induction Motor 22
4.3.4.1 Application 23
4.3.5 Proximity Sensors 23
4.3.5.1 Application 24
4.4 PARTS TO BE FABRICATED 24
4.5 ASSEMBLY OF THE FINAL MODEL 28
PROPOSED
4.6 MATERIALS USED 29
4.6.1 Mild Steel 29
4.6.2 Aluminum 30
4.6.3 Nylon 31

vii
5. COST ANALYSIS 32

5.1 COSTS OF STANDARD PARTS 32

5.2 MATERIAL COSTS FOR OTHER PARTS 33
REQUIRING FABRICATION
5.3 BILL OF MATERIALS 41
5.4 ANALYSIS AND COST COMPARISION 43

6. CONCLUSION 45

7. REFERENCES 46

8. APPENDICES 47

viii
 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1.1 Radiator Tube Part Family list 4

4.1 List of other components requiring fabrication 25

5.1 Standard part cost and part description 32

5.2 Bill of materials 42

5.3 Analysis and comparison of cost for the five concepts 43

ix
 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1.1 Tube Cleaning Process in Visteon’s Overseas Plant 3

1.2 Process Flow in Condenser Tube cleaning Process 3
1.3 A typical Condenser Tube 4
1.4 Cause and effect diagram for ineffective cleaning of 5
tubes
2.1 Variation of Young’s modulus with density 7
3.1 First Concept - working 9
3.2 Second Concept - working 11
3.3 Third Concept - working 12
3.4 Fourth Concept - working 14
3.5 Fifth Concept - working 16
4.1 Final modifications in fifth concept 19
4.2 A typical Pneumatic Compact Cylinders 20
4.3 A typical Stopper Cylinder 21
4.4 A typical Twist cylinder 22
4.5 A typical Induction motor 23
4.6 Inductive type proximity sensors 24
4.7 Assembly of the final model proposed 29

x
 ABSTRACT

Visteon mainly concentrates on the quality of their product. Concerning quality,

minute problems affected the final output. So a problem that created many issues in

the customer end was considered.

The problem criteria relates with the post tube milling process that is the condenser

and radiator tube cleaning. The present cleaning method is done manually.

Limitations of the present method are that the tubes are produces at high speeds (for

example 240 tubes/ min). It is not possible to control the rate of production of the

tubes, so it requires more manpower for the cleaning process. It leads to many

disadvantages such as erosion in tubes, stacking of tubes is difficult, more

manpower is required, remains of burrs and coolant, more time is required for the

entire process.

This project is aimed to design an automation process for this on going issue. In

total, 5 concepts were modeled in CATIA. The fifth concept was accepted by

Visteon for which complete modeling, drafting and costing was done. Since the

concept meets the requirements it would benefit Visteon in terms of automation,

less manpower, customer satisfaction, work accuracy and cost effective process.

xi
 CHAPTER 1
INTRODUCTION

Visteon Automotive India Private Ltd was established in the year 1997. Their
key products are classified under 4 different sections namely,
i. Interiors
ii. Lighting
iii. Electronics
iv. Climate
This project is assigned under the Climate Control Division. Three scopes were
defined, namely lean manufacturing, quality improvement and machine system
development. Visteon mainly concentrates on the quality of their product, hence
Quality improvement is chosen.

1.1 PROBLEM DEFINITION

Concerning quality, minute problems affected the final output. So a problem
that created many issues in the customer end was given. The problem criteria relates
with the post process of the tube mill of condenser and radiator tube cleaning.
Limitations of the present method are that the tubes are produces at high speeds (for
example 240 tubes/ min) it is not possible to control the rate of production of the
tubes, so it requires a more manpower for the cleaning process. Due to this, it leads to
the following disadvantages,
i. Causes erosion in tubes
ii. Stacking of tubes is difficult
iii. More manpower is required

1
iv. Remains of burrs and coolant
v. Complaint from customer end since manual cleaning process is not efficient
vi. More time is required for the entire process
Our project concern is to design an automation process for this on going issue.

1.2 PRESENT CLEANING PROCESS

In Chennai plant, tubes cleaning and stacking process is done with manpower
completely. It requires a minimum of 4 to 5 labors to stack and clean the tubes. Tubes
are produced at very high rate (for example 240 tubes/min). This production rate
varies with respect to the tube dimensions. It can go up to a maximum of 350 tubes
per minute. Presently the tubes are brought to the cleaning area through a conveyor.
The conveyor cannot stack the tubes evenly so one or more labor would stack the
tubes in trays and simultaneously other labor would clean the tubes with compressed
air.
After cleaning, the trays are manually loaded for the core building process. The
process flow of the cleaning process is shown in Figure 1.1. This process would be
perfect for the first set of tubes but the following sets would experience a decrease in
level of accurate cleaning. This leads to customer dissatisfaction and other limitations
such as time constraints, remains of burr in the tube, more manpower and erosion
would make the process not beneficial.
Figure 1.2 refers a similar cleaning process done for removing the burrs and
coolant from the tubes. This process is done with a help of a guided rail. The guided
rail carries a blower which is adaptable only to a certain tube width. The labor would
place the set of tubes in front of the blower and would move the blower with the help
of the rail. This type of cleaning is present in one of Visteon’s overseas plant. The
problem in this type of cleaning is that, it also involves manual labor, the cleaning is
not efficient since the blower hole is very constrain, various tube widths cannot be

2
cleaned and moreover maintenance of the setup is the major problem in this type of
cleaning.

Focus Focus
Area Area

Tube Tube Stacking Manual Arranging Manual Cleaning

Mill For Cleaning

Manual loading
In trays

Core
Assembly Focus
Area

Figure 1.1 Process Flow in Condenser Tube cleaning Process

Figure 1.2 Tube Cleaning process in Visteon’s Overseas Plant

3
1.3 TUBE DATA AND DIMENSIONS
Condenser and Radiator tubes are manufactured with different dimensions in
Visteon in order to meet the requirements of the customer. Maximum tube length is
approximately 700mm and minimum length is around 346mm. The various
dimensions of the radiator tube part family are shown in Table 1.1. Condenser and
radiator tube are manufactured in the same way through the milling process. The tube
resembles a scale which is hollow as shown in Figure 1.3.

702 mm

18.5 mm

Figure 1.3 A Typical Condenser Tube

Table 1.1 Radiator Tube Part Family list

4
1.4 CAUSE AND EFFECT FOR INEFFECTIVE CLEANING
After considerations and experimentations, it is found that the various reasons
for ineffective cleaning is based on the 4M’s which are Man , Machine, Material and
Method as shown in figure 1.4.
The physical ability of a person mainly depends upon his strength, skill and
training. When any one of these is lacking then there is a possibility for ineffective
cleaning. Here the machine indicates the Tube Mill. The tube mill has a cutting speed
of around 4 cuts per second. Since the machine speed is too high it requires the tube
being milled requires coolant which becomes the main reason for the post tube mill
cleaning process
The method of cleaning is completely dependant upon the manual labor. So the
first set would be perfectly cleaned whereas at the end of the shift, there would be a
drop in the efficiency of cleaning. Material properties have a greater effect. While
brazing a material, if it not done properly then remains of burrs would lead to
problems like erosion.

Man Machine

Speed
Training
Training
Skill
Skill Lubricant
Strength
Strengt
h
Coolant Ineffective
Cleaning

Cost Manual
Properties cleaning
Brazing Stacking

Material Method

Figure 1.4 Cause and effect for ineffective cleaning of tubes

5
 CHAPTER 2
LITERATURE REVIEW

Material selection plays a vital role in fabricating a component. University of

Cambridge illustrates the reasons why certain materials are chosen for machining, its
design strength and design weakness.

2.1 MATERIAL PROPERTIES AND SELECTION ACCORDING TO

UNIIVERSITY OF CAMBRIDGE

2.1.1 Aluminium
Aluminium is a lightweight, reasonably cheap metal widely used for packaging
and transport. It has only been widely available and used for the last 60 years. Raw
aluminium has low strength and high ductility (ideal for foil). Strength is increased by
alloying, e.g. with Si, Mg, Cu, Zn, and heat treatment. Some alloys are cast, others are
used for wrought products. Aluminium is quite reactive, but protects itself very
effectively with a thin oxide layer. The surface can be "anodized", to resist corrosion
and to give decorative effects. Design strengths are high strength-to-weight ratio,
high stiffness-to-weight ratio, high electrical and thermal conductivity, easy to shape
and easy to recycle. Design weaknesses are the difficulty to arc weld.

2.1.2 Mild Steel

Steels are the most important engineering materials, and cover a wide range of
alloys based on iron and carbon. The strength of iron-carbon alloys, particularly after
heat treatment, has been exploited for thousands of years (since the "Iron Age").
6
Modern steels and ferrous alloys have mostly been developed since the Industrial
Revolution. Mild steel contains 0.1-0.2%C. They are cheap, strong steels used for
construction, transport and packaging. All steels have a high density and a high
Young's modulus. The strength of mild steel is improved by cold working. It is
inherently very tough. Mild steel rusts easily, and must be protected by painting,
galvanizing or other coating. Design strengths are high strength-to-weight ratio, high
stiffness-to-weight ratio, and good strength with high toughness, high stiffness very
cheap, easy to shape, easy to weld and easy to recycle. Design weaknesses are high
density, poor electrical and thermal conductivity.

Figure 2.1 indicates the variation of Young’s modulus and density for various
materials

Figure 2.1 Variation of Young’s modulus with density

7
 CHAPTER 3
AUTOMATION IN TUBE CLEANING AND STACKING PROCESS

To overcome all the limitations in manual cleaning process, automation

concepts were proposed to replace manpower. The major requirements or areas to be
concentrated are
i. Automated stacking of tubes
ii. Automated loading of tubes in trays/bins
iii. Automated cleaning process either through blowing process or suction
Since CATIA software has a better 3D visualization than other packages, the
concepts were visualized through CATIA. Totally 5 various proposals were made.
After many considerations such as cost factor, space constraints, availability of
resources and time, the Fifth concept was finalized by Visteon.

3.1. FIRST CONCEPT - WORKING

The system mainly consists of a hopper, a secondary conveyor and the main
conveyor. Finished tube products from tube mill initially enter into a hopper engaged
with a constrained conveyor. Then it is transferred to the secondary conveyor for
aligning the tubes in a single plane. The job of the secondary conveyor is to ensure
whether the tubes are aligned linearly. The speed of the conveyor is slowed down
since it ensures not to mess up with transferring the tubes to the main conveyor. The
main conveyor is used to carry the tubes for cleaning process as shown in Figure 3.1.
The main conveyor is inclined to a certain degree (approx 35 degree). The blowing
process is done on one side the conveyor belt. For complete cleaning of the tubes
minimum of 3 blowing holes are provided. The main conveyor has barriers to separate
sets. The blowing process takes place with the help of compressed air through the
8
appropriate holes provided as shown in Figure 3.1. After the cleaning process is
completed, the tubes are collected in trays. To avoid slip of tubes, a thin rod is
provided in the sides of the conveyor.

Hopper

Secondary
conveyor

Main
conveyor

Blowing
holes

Figure 3.1 First Concept - working

9
3.1.1 Limitations
i. Tubes with different dimensions cannot be arranged.
ii. Since the tubes are produced at 240 pieces/min (average) it is very difficult to
arrange in a single plane.
iii. Slip of tubes may occur frequently.
iv. Cleaning is not done completely.
v. Frequent monitoring is required. Thereby increasing the labor cost.
vi. Automation is less.

3.2 SECOND CONCEPT - WORKING

Since the conveyor type of cleaning process has many limitations, conveyors
are completely eliminated in this concept. Arm A & B, loading and unloading end are
the moving parts available in this mechanism as shown in Figure 3.2. The tubes are
arranged in bins and engaged to the loader in steps. Arm A reciprocates and pushes
the bin to the blowing area. The blower rises as the bin reaches the area. The bins are
locked on either side so that they don’t get displaced. Now the blower comes in
contact with the tubes with zero offset. Blowing process takes place on one side and
the other side collects the coolant waste and burrs. After blowing process arm B is
used to push the bin to the unloading end. The process repeats for the remaining bins.
The advantages of this type of cleaning are that manual work is completely
eliminated and it is an easy way of cleaning. The process requires only a single labor
for maintaining the milling as well as the cleaning process. His job is just to load the
bins in the loading area.
The setup requires proximity sensors for part detection. It also incurs two or
more servo mechanism for the movement of the loading and the unloading end. The
arms also may even require servo mechanism for reciprocating since it has to travel a
distance of around 1.5m for which cylinders are not possible. So the use of servo
mechanisms would affect the cost factor.
10
 Arm B Arm A

Loading
end
Unloading
end

Figure 3.2 Second Concept - working

3.2.1 Limitations
i. It is a semi-automatic process. Automated stacking is not possible which the
main target is.
ii. The setup is not cost efficient.
iii. Blowing cannot be done for different dimensions.
iv. Many number of moving parts.

3.3 THIRD CONCEPT - WORKING

Modifications made on second concept led to the visualization of the third one.
The main parts in this automation process are vertical arm, stacker A & B, Plate A &
B, arm A & B, hopper and an unloader/unloading mechanism as shown in Figure 3.3.
The tubes from hopper are directed towards the stacker A through a conveyor. Plate A
11
is used to support the tubes and it slides down in steps. The plate A moves into the
stacker B and when the required number of sets (approx 150) is achieved the tubes get
locked in stacked B and simultaneously plate B enters into stacker A to support the
remaining tubes. Stacker B has inclination control and before inclination the bins will
be locked and placed in the base through a reciprocating mechanism. Now the stacker
B drops the tubes through the extract window at the front. Arm A provides the push to
the blowing area. The remaining process is similar to that of the process in the second
concept.
Automated stacking was achieved in this concept. The entire setup is fully
automated even the bins are loaded automatically. Since more number of moving parts
is used, payback years are more and the cost factor does not benefit this setup.

Plate B

Stacker A
Plate A

Stacker B
Arm A
Arm B

Figure 3.3 Third Concept - working

12
3.3.1 Limitations
i. More number of moving parts.
ii. Payback years are more.
iii. As the tubes reaches the stacker A, slip of tubes may occur.
iv. During blowing process, tubes may disproportionate from its position.

3.4 FOURTH CONCEPT - WORKING

In consideration of the cost and to reduce the number of moving parts, the
reciprocating arms were eliminated. The parts available in this setup are a hopper,
vertical arm, Stacker A & B, guide rail, bin loading mechanism and an unloader/
unloading mechanism as shown in Figure 3.4. Tubes from hopper are collected in the
same manner from hopper as in Third Concept expect a barrier is provided over
stacker A, so that slip may not occur.
Stacker A and Stacker B function similar to the process in Third Iteration.
Stacker B drops the tubes into the bins locked in roller support. A vertical arm comes
in contact with the bins and pushes it to the suction area. The vertical arm locks the
bins from the top to avoid displacement of tubes. Both blowing and suction can be
used for cleaning. In order to reduce the number of parts and better efficiency of
cleaning, suction is used instead of a blower. After cleaning process the vertical arm
itself moves the bin to the unloading area.
The major advantage of this setup is that the overall cost is less when compared
to the third concept since many moving parts have been eliminated. Here this is a
requirement of servo mechanisms to operate the bin loader and the unloading
mechanism. So the servo mechanisms have to been replaced in order to benefit the
cost factor.

13
3.4.1 Advantages
i. Fully automated.
ii. The setup is cost efficient in concern to the previous concept.
iii. Less number of moving parts.
iv. Less manpower is required.
v. Slip of tubes is not possible.
vi. Payback years are less.

Vertical arm

Hopper

Unloading
end

Bin Loading

Figure 3.4 Fourth Concept working

14
3.4.2 Requirements
i. Minute modifications required for satisfying cost factor.
ii. Alternate method to replace Servo mechanisms.
iii. Base and support columns should be provided to the entire setup.

3.5 FIFTH CONCEPT - WORKING

The main aim of visualizing this concept is to fulfill the requirements estimated
in the fourth concept. Servo mechanism elimination, cost factor and supports were
mainly concentrated. Guide rails are provided to drive the vertical arm (as shown in
Figure 3.5) in order to replace the servo parts. The induction motor drives the arm in
the guide rail. The process begins as the tubes from hopper are collected in the same
manner as in the previous concepts. Tubes get collected in stacker 1 which are
balanced by and remains there until a certain amount is filled (approx 100 tubes). As
the amount is achieved, plate A opens and the tubes get into stacker 2. As soon as the
certain amount reaches stacker 2, the plate A again closes to hold the remaining tubes.
The movable walls lock the tubes in stacker 2 and with the help of a linear rotary
clamp cylinder (90 cylinders), the stacker bends down to the bin position The
movable walls retract, then arm A comes in contact, takes the bin to the cleaning area,
cleaning process takes place and the same arm drops the bin in the unloading area.
Finally the product is unloaded manually.
Each an every cost factor was considered and major cost incurring parts were
eliminated. The main three requirements which are automated stacking of tubes,
automated loading of tubes in trays/bins and automated cleaning was achieved in this
type of setup.

3.5.1 Advantages
i. Cost efficient.
ii. Servo parts are completely eliminated.
15
 iii. A single labor is enough to maintain the whole process whereas, currently 5
labors are required.
iv. Any dimension can be cleaned.
v. Payback years are less.
vi. No complication in automation.

Arm A
Stacker 1

Linear
guide rail

Suction
unit

Linear rotary
clamp cylinder

Cleaning
area

Figure 3.5 Fifth Concept working

16
3.6 RESULTS AND DISCUSSIONS
In total, 5 concepts were made in due course of finalizing the design concept of
tube cleaning semi automatic process
 1st Concept – cannot clean tubes of different dimensions, slip of tubes and
ineffective cleaning
 2nd Concept – too many moving parts, cost is high
 3rd Concept – space constraints were imposed
 4th Concept – semi automatic process was requested due to cost factor

The 5th Concept was accepted by Visteon since number of elements used is less, cost
was less and it is a semi automatic process. Standardization of elements was adopted
in the 5th Concept. Automation products for standardization were referred from
MISUMI, SMC, FESTO books and catalogues.

17
 CHAPTER 4
FINAL MODEL

The Fifth concept was accepted by Visteon in which certain modification was
required in terms of implementation. FESTO, MISIMI and SMC are the leading
producers of automated parts. So standardization of parts was referred from those
catalogues.

4.1 REQUIREMENTS
After certain considerations such as space, damage to parts and implementation,
the following changes were required
i. Linear guide for the suction unit should be provided so that for different
dimensions, the suction unit can be adjusted.
ii. Another cylinder mechanism to transfer tubes from stacker 1 to stacker 2 so
that damage of tubes can be eliminated.
iii. Columns supporting cylinders can be replaced by L clamp structures as
holding device in order to reduce space.

4.2 FINAL MODIFICATIONS IN FIFTH CONCEPT

In order to fulfill the requirements certain changes were made in the fifth
concept.
i. Suction unit was provided with an adjustable linear guide (as shown in
Figure 4.1) so that the unit can be adjusted according to the tube dimensions.
ii. Cylinder mechanism was provided to transfer tubes from stacker 1 and 2 in
order to reduce tube damage as shown in Figure 4.1

18
iii. L clamp structures were provided for cylinders (as in Figure 4.1) as holding
devices in order to reduce space.

Guide rail for

suction unit

L clamp
structure

Additional
cylinder

Figure 4.1 Final modifications in fifth concept

19
4.3 STANDARD PARTS AVAILABLE
The standardization of parts was done. MISUMI FESTO and SMC catalogues
and books were referred for the standard parts available. Cylinders such as linear
cylinders, stopper cylinders and linear rotary clamp cylinders were chosen. Sensors
and control valves come along with the cylinders. Exceptional to cylinders, three other
places require sensors for part detection so inductive proximity sensors are used. The
linear guide is driven by induction motor.

4.3.1 Pneumatic compact cylinders

Pneumatic cylinders (sometimes known as air cylinders) are mechanical

devices which use the power of compressed gas to produce a force in a reciprocating
linear motion (a typical compact cylinder is shown in Figure 4.2). 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.

Figure 4.2 A typical Pneumatic Compact Cylinder

20
4.3.2.1 Application
Except stopper cylinder and twist cylinders, other cylinders used in this
automation process are pneumatic compact cylinder.

4.3.2 Stopper cylinder

These are type of pneumatic cylinders and have been designed for stopping
loads in conveyance applications. Excellent resistance to radial loads and it is a
Compact cylinder. They are mainly used for applications in fields such as Packaging,
Handling, Transfer and Industries. A typical stopper cylinder is shown in Figure 4.3.

Figure 4.3 A typical stopper cylinder

4.3.2.1 Application
This cylinder is been used to stop/ lock the cylinders once it has been dropped
into the stacking end and also to hold the bin while cleaning process takes place.

21
4.3.3 Linear swivel clamp cylinders/ twist cylinders
Twist Clamp Cylinder combines linear and 90-degree rotary motion with an
internal pin/cam mechanism (a typical twist cylinder is shown in Figure 4.4). The
rotary action moves a clamping arm away from the work piece, allowing for easy
loading and unloading of parts. As the cylinder extends, the pin follows the groove
and creates 90 degrees of rotary motion

Figure 4.4 A typical twist cylinder

4.3.3.1 Application
The linear swivel clamp cylinder/ twist cylinder is used to twist the position of
stacker 2 from vertical to horizontal so that it drops the tubes in the stacking end.

4.3.4 Induction motor

An Induction /Asynchronous motor shown in Figure 4.5 is a type of AC
motor where power is supplied to the rotor by means of electromagnetic induction.
These motors are widely used in industrial drives, particularly poly phase induction
motors, because they are rugged and have no brushes. Single-phase versions are used

22
in small appliances. Their speed is determined by the frequency of the supply current,
so they are most widely used in constant-speed applications, although variable speed
versions, using variable frequency drives are becoming more common. The
advantages of using an induction motor are that it is maintenance free, four quadrant
operations are possible and losses are less.

Figure 4.5 A typical Induction Motor

4.3.4.1 Application
Here Induction motor is used to drive the linear drive over which the vertical
arm is used to slide horizontally.

4.3.4 Proximity sensors

A proximity sensor is a sensor able to detect the presence of nearby objects

without any physical contact (a typical sensor is shown in Figure 4.6). 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 proximity sensor's target. Different
proximity sensor targets demand different sensors. For example,
a capacitive or photoelectric sensor might be suitable for a plastic target;
23
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. A proximity
sensor adjusted to a very short range is often used as a touch switch.

Figure 4.6 Inductive Type Proximity Sensors

4.3.4.1 Application

The proximity sensors are used here to sense the part in stacker 1, presence of
tubes in the stacking end and cleaning process completion

4.4 PARTS TO BE FABRICATED

The standard parts are readily available in the market, but certain parts have to
be machined according to the requirements. The major parts are the Bottom Support,
Extracting end plate, Guide column, Linear guide rail, Linear guide slide, Stacker 1,
24
Stacker 2, Stacker 1 & 2 Tube carry, Tube locker, Stacking end plate and Unloading
end plate as shown in Table 4.1.

Table 4.1 List of other components requiring fabrication

S. NO PART NAME PART

1. Extracting end plate

2. Stacking end plate

3. Unloading end plate

4. Guide rail

25
5. Guide slide

6. Guide column

7. Stacker 1

8. Stacker 2

26
9. Tube locker

10. Stacker2 Tube Carry

11. Bottom Support

12. Vertical Support Hand

27
 13. Stacker1 Tube carry

14. Horizontal Column of

Linear guide

15. Extractor

16. Vertical support tube

locker

4.5 ASSEMBLY OF THE FINAL MODEL PROPOSED

Figure 4.7 indicates the overall view of the model with all the standards parts
and the other parts listed in table 4.1

28
 Figure 4.7 Assembly of the final model proposed

4.6 MATERIALS USED

The various materials used in this setup are Mild Steel for rigid parts,
Aluminum for the light weight components and Nylon is used for lockers.

4.6.1 Mild Steel

Mild steel is the most common form of steel because its price is relatively low
while it provides material properties that are acceptable for many applications. Low
carbon steel contains approximately 0.05–0.15% carbon and mild steel contains 0.16–
0.29% carbon; making it malleable and ductile, but it cannot be hardened by heat
29
treatment. Mild steel has a relatively low tensile strength, but it is cheap and
malleable; surface hardness can be increased through carburizing. It is often used
when large quantities of steel are needed, for example as structural steel. The density
of mild steel is approximately 7.85 g/cm3 (7850 kg/m3 or 0.284 lb/in3) and
the Young's modulus is 210 GPa (30,000,000 psi).
It has the following advantages:
i. Mild steel is ductile and can be easily machined.
ii. Generation of heat is less than that of steel machining. So, the tool can have
better life and you can do more machining.
iii. Cost factor is of prime importance as other steel are more costly than
Mild steel.
iv. Mild steel, a grade of steel that does not harden when heated and chilled
with cold water, so further machining can be easy.
v. Mild steel is easily available.
vi. No need to change the tool repeatedly and no special tools are required for
machining.
vii. Cutting speed and feed does not required special skills.

4.6.2 Aluminium

Aluminium is the third most abundant element (after oxygen and silicon), and
the most abundant metal, in the Earth's crust. It makes up about 8% by weight of the
Earth's solid surface. Aluminium metal is too reactive chemically to occur natively.
Instead, it is found combined in over 270 different minerals. The chief ore of
aluminium is bauxite. Aluminium is remarkable for the metal's low density and for its
ability to resist corrosion. The most useful compounds of aluminium, at least on a
weight basis, are the oxides and sulfates. Despite its prevalence in the environment,
aluminium salts are not known to be used by any form of life. The yield strength of
pure aluminium is 7–11 MPa, while aluminium alloys have yield strengths ranging
30
from 200 MPa to 600 MPa. Aluminium has about one-third
the density and stiffness of steel. It is easily machined, cast, drawn and extruded. It
has the following advantages:

i. Corrosion resistant
ii. Excellent strength-to-weight ratio
iii. High thermal electrical conductivity
iv. Durable
v. Reflective
vi. Non-combustible
vii. Does not spark

4.6.3 Nylon

Nylon is a generic designation for a family of synthetic polymers known

generically as polyamides. Nylon is one of the most commonly used polymers. Solid
nylon is used for mechanical parts such as machine screws, gears and other low- to
medium-stress components previously cast in metal. Engineering-grade nylon is
processed by extrusion, casting, and injection molding. Solid nylon is used in hair
combs. Type 6,6 Nylon 101 is the most common commercial grade of nylon, and
Nylon 6 is the most common commercial grade of molded nylon. It has the following
advantages:

i. It is an inexpensive material. It can be woven and spun in many

different ways.
ii. Nylon is hardwearing and is ideal for making plastic gear mechanisms.
iii. High elongation.
iv. Excellent abrasion resistance.

31
 CHAPTER 5
COST ANALYSIS

Material cost was established for the individual parts based on the weight,
density and cost per kg. The standard part’s cost were referred from Visteon’s
suppliers such as MISUMI and FESTO

5.1 COST OF STANDARD PARTS

Table 5.1 indicates the cost of the standard parts available in the market with
their part description.

Table 5.1 Standard part cost and part description

S No. Part Name Part Number Cost in
Rupees
1. Linear swivel clamp cylinder 535502 CLR-50-50-R-P 1000.00
RHS
2. Linear swivel clamp cylinder 535503 CLR-50-50-L-P 1000.00
LHS
3. Compact cylinder 156000 ADVU-12-150-P 1000.00
4. Compact cylinder (4 nos) 156000 ADVU-12-100-P 2250.00
5. Compact cylinder (4 nos) 156000 ADVU-12-40-P 1750.00
6. Vertical Support Cylinder 150921 SLE-50-480-KF- 2000.00
A-G
7. Extractor Linear guide (2 nos) SEWTLZ30-400 2000.00
8. Compact cylinder (2 nos) 156000 ADVU-12-35-P- 1000.00

9. Stopper cylinder 555572 DFST-50-30-L- 1500.00

Y4-A
32
 10. Linear drive unit 40000.00
(approx)

5.2 MATERIAL COST FOR OTHER PARTS REQUIRING FABRICATION

The other parts include bottom support, legs, unloading end plate, loading end
plate, extracting end plate, tube carry, Stacker1, Stacker2,

i. BOTTOM SUPPORT

Bottom support

Leg

Length = 1.85 m, breadth = 1.45 m, thickness = 0.03 m, Density = 7860 kg/m3

Material = Mild Steel

Volume = length x breadth x thickness

= 1.850 x 1.450 x 0.03
= 0.080475 m3

Mass = Density x Volume

= 7860 x 0.080475
= 633.33 kg

Cost of Mild Steel = 70 per kg

Material Cost = 633.33 x 70 = Rs. 44333.000

33
Legs for bottom support
Diameter = 0.1 m, thickness = 0.07 m, density = 7860 kg/m3
Material = Mild Steel
Volume =  r2 h
= 3.14 X 0.052 x 0.07
Volume = 0.0005495 m3
Mass = Density x Volume
= 7860 x 0.0005495
Mass = 4.324 kg
Total Mass (6 nos.) = 4.324 x 6 = 25.94 = 26 kg (approx.)
Cost of Mild Steel = 70 per kg

Material Cost = 26 x 70
Material Cost = Rs. 1820.000

ii. UNLOADING END PLATE

Unloading end plate

Leg

Length = 0.80 m breadth = 0.5 m, thickness = 0.01 m, Density = 2700 kg/m3

Material = Aluminum

Volume = length x breadth x thickness

= 0 .80 x0.50 x 0.01
34
 = 0.004 m3

Mass = Density x Volume

= 2700 x 0.004
= 10.8kg

Cost of Aluminum = 300 per kg

Material Cost = 10.8 x 300 = Rs. 3240.000

Legs for Unloading end plate

Diameter = 0.08 m, thickness = 0.08 m, density = 2700 kg/m3
Material = Aluminium
Volume =  r2 h
= 3.14 x 0.042 x 0.08
= 0.0004 m3
Total Volume (4 nos.) = 0.004 x 4
= 0.0016 m3

Mass = Density x Volume

= 2700 x 0.0016
= 4.32 kg

Cost of Aluminium = 300 per kg

Material Cost = 4.32 x 300 = Rs. 1296.000

Total material cost for unloading end = Rs. 4536.000

(Unloading end plate + legs)

35
iii. EXTRACTING END PLATE

Secondary plate

Extracting end plate

Legs

Length = 0.830 m, Breadth = 0 .370 m, Thickness = 0.01 m, Density= 2700 kg/m3

Material = Aluminium

Volume = length x breadth x thickness

= 0 .830 x 0.370 x 0.01
= 0.003 m3

Mass = Density x Volume

= 2700 x 0.003
= 8.291 kg
Cost of Aluminium = 300 per kg
Material Cost = 8.291 x 300 = Rs. 2487.510

Secondary plate
Diameter = 0.460 m, thickness = 0.050 m, density = 2700 kg/m3
Material = Aluminium

Volume = length x breadth x thickness

= 0.460 x 0.050 x 0.01
= 0.0023 m3
Mass = Density x Volume

36
 = 2700 x 0.0023
= 6.21 kg
Cost of Aluminum = 300 per kg
Material Cost = 6.21 x 300 = Rs. 1863.000

Legs for extracting end plate

Diameter = 0.08 m, Thickness = 0.08 m, Density = 2700 kg/m3
Material = Aluminum

Volume =  r2 h
= 3.14 x 0.042 x 0.08
= 0.0004 m3
Total Volume (4 nos.) = 0.004 x 4
= 0.0016 m3

Mass = Density x Volume

= 2700 x 0.0016
= 4.32 kg
Cost of Aluminum = 300 per kg
Material Cost = 4.32 x 300 = Rs. 1296.000

Total material cost for extracting end = Rs. 3969.810

(Extracting end plate + secondary plate + legs)

37
iv. STACKING END PLATE

Secondary plate

Stacking end plate

Legs

Length = 1.0 m, breadth = 0.45 m, thickness = 0.01 m, density = 2700 kg/m3

Material = Aluminium

Volume = length x breadth x thickness

= 1.0 x 0.45 x 0.01
= 0.0045 m3

Mass = Density x Volume

= 2700 x 0.0045
= 12.15kg

Cost of Aluminium = 300 per kg

Material Cost = 12.15 x 300 = Rs. 3645.000

Secondary plate
Diameter = 0.230 m, thickness = 0.350 m, density = 2700 kg/m3
Material = Aluminium

Volume = length x breadth x thickness

= 0.230 x 0.350 x 0.01

38
 = 0.0008 m3

Mass = Density x Volume

= 2700 x 0.0008
Mass = 2.173 kg
Cost of Aluminium = 300 per kg
Material Cost = 2.173 x 300 = Rs. 652.050

Legs for staking end plate

Material = Aluminum
Diameter = 0.08 m, thickness = 0.08 m, density = 2700 kg/m3

Volume =  r2 h
= 3.14 x 0.042 x 0.08
= 0.0004 m3
Total Volume (4 nos.) = 0.004 x 4
= 0.0016 m3

Mass = Density x Volume

= 2700 x 0.0016
= 4.32 kg

Cost of Aluminium = 300 per kg

Material Cost = 4.32 x 300 =Rs. 1296.000

Total material cost for stacking end = Rs. 5593.050

(Stacking end plate + secondary plate + legs)

39
v. STACKER 2
Length= 0.800 m, breadth = 0.420 m, thickness= 0.035 m, density = 2700 kg/m3
Material = Aluminum

Volume = length x breadth x thickness

= 0.800 x 0.420 x 0.035
= 0.0117 m3
Hollow Volume = 0.7 x 0.014 x 0.420 = 0.0042 m3
Total Volume = 0.0117 – 0.0042 = 0.0075 m3

Mass = Density x Volume

= 2700 x 0.0075
= 20.25.kg
Cost of Aluminum = 300 per kg

Material Cost = 20.25 x 300 = Rs. 6075.000

vi. GUIDE COLUMNS

Guide column

Leg

Base plate

Material = Square Tube

40
 Length= 1.500 m, breadth = 0.100 m, thickness = 0.020 m, density = 7860 kg/m3

Volume = length x breadth x thickness

= 1.500 x 0.100 x 0.020
= 0.003 m3
Total Volume (2 nos.) = 0.003 x 2 = 0.006 m3

Mass = Density x Volume

= 7860 x 0.006
= 47.22 kg
Cost of Aluminium = 150 per kg
Material Cost = 47.22 x 150 = Rs. 7083.000

Similarly the costs for other parts were calculated and the entire estimate was
made. The Bill of Materials includes the details about the material used; density of the
respective material used, dimensions such as length, breadth, thickness, diameter,
mass and volume are indicated. The material cost/ kg indicates the price of the
material currently available in market. Costs of standard parts available in market are
also included. Material costs are calculated for every part and overall material cost is
estimated to be Rs. 143631.470. The machining cost for the entire setup accounts to
Rs. 29050 (more details in Appendix 3). Hence the overall cost including material and
machining cost accounts to Rs 172681.47

5.3 BILL OF MATERIALS

Table 5.2 indicates the bill of materials prepared for the entire setup including
the standard parts and other parts. The table includes the part name, description,
dimensions, material and cost.

41
 Table 5.2 Bill of Materials

S No. Product Part Number Type Source Quantity Dimensions Material Approx.
Description mm Cost
1. Bottom support Part 1 1850*1450 / Thick Mild Steel 46153.000
100
2. Unloading end Part 1 800*500 / Thick 10 Aluminum 4536.000
/ leg dia 80 / thick
80
3. Extracting end Part 1 830*370,460*50 / Aluminum 3969.810
Thick-10 / leg dia
80 / Thick 80
4. Stacking end Part 1 1000*450/Thick Aluminum 5593.050
10/230*350/thick
30/Leg dia 80/
Thick 80
5. Guide column Part 2 1500*100/thick 20/ Tube( 9384.975
LEG- square)
100*100/Thick
20/50*50/thick 500
6. Stacker2 Part 1 800*35/thick 420 Aluminum 6075.000

7. Linear/swivel 535502 CLR- Assembly Festo 1 Cadenas 1000.000

clamp RHS 50-50-R-P PARTsolutio
8. Linear/swivel 535503 CLR- Assembly Festo 1 Cadenas 1000.000
clamp LHS 50-50-L-P PARTsolutio
9. Compact 156000 Part Festo 1 Cadenas 1000.000
cylinder ADVU-12-150- PARTsolutio
P
10. Stacker2 tube Part 1 700*100 / Thick 5 Aluminum 283.500
carry
11. Compact 156000 Assembly Festo 4 Cadenas 2250.000
cylinder ADVU-12-100- PARTsolutio
P
12. Compact 156000 Assembly Festo 4 Cadenas 1750.000
cylinder ADVU-12-40-P PARTsolutio
13. Stacker1 Part 1 750*45 / Thick 135 Aluminum 3690.300

14. Stacker1 Part 1 200*50/Thick Mild Steel 1391.000

supporting 20/25*150/thick
column 100/25*150/thick
650
15. Tube carry Part 2 Aluminum 400.000
Stacker1 holder
16. Tube locker Part 1 370*50 /thick 10 Nylon 53.187
LHS
17. Tube locker Part 1 370*50 /thick 10 Nylon 53.187
RHS

18. Compact 156000 Assembly Festo 2 Cadenas 1000.000

cylinder ADVU-12-35- PARTsolutio
P-
19. Stacker1 tube Part 2 700*50/Thick Aluminum 241.750
carry 5/700*5/thick 35
20. Tube locker Part 4 Aluminum 800.000
cylinder holder

42
21. Horizontal Part 1 1035*100 / thick 20 Mild Steel 254.500
column of
linear guide
22. Vertical 150921 SLE- Assembly Festo 1 Cadenas 2000.000
Support 50-480-KF-A- PARTsolutio
Cylinder G

23. Vertical Part 1 700*350 /Thick 10 Aluminum 1984.500

Support hand

24. Vertical support Part 4 Nylon 500.000

tube lock
25. Extractor Part 1 M S Sheet

26. Extractor SEWTLZ30- Assembly MISUMI 2 2000.000

Linear guide 400
27. Stopper 555572 Assembly Festo 1 Cadenas 1500.000
cylinder DFST-50-30- PARTsolutio
L-Y4-A
28. Linear drive 2 40000.000
unit (approx)
Total = Rs. 143631.470

5.4 ANALYSIS AND COST COMPARISION

Table 5.3 enunciates the reasons why the fifth concept has been chosen in terms
of cost factor and requirements fulfillment.

Table 5.3 Analysis and comparison of cost for the five concepts
CONCEPT NO. ANALYSIS AND COST COMPARISION

1 It has more limitations. The requirements are not fulfilled.

2 It has more number of moving parts. Considering the two
moving arms, each one would cost approximately around Rs
50000 and ssother costs include machining cost, other
material cost, standard part cost, sensors, actuators etc.
which would make the setup more costly.
3 Automation requirements are fulfilled. Similar to concept 2
it has more number of moving parts and it requires servo
mechanisms at 4 four places which would account more.

43
4 Automation requirements are fulfilled. Number of servo
mechanisms is reduced.
5 Automation requirements are fulfilled. All heavy moving
parts are eliminated. Servo mechanisms are also eliminated.

44
 CHAPTER 6
CONCLUSION

The problems in manual cleaning of condenser and radiator tubes are erosion in
tubes; stacking of tubes is difficult; more manpower is required; remains of burrs and
coolant; more time is required for the entire process. To overcome these problems
automation is recommended. Accordingly, five concepts were developed and 3D
models were generated in CATIA. The fifth concept meets all the requirements such
as automated stacking; automated loading of tubes in bins and automated cleaning. It
would benefit them in terms of automation, less manpower, customer satisfaction and
work accuracy. Standardization of parts and costing were done. The cost of the fifth
model is less when compared to the other four because the investment in this
automation process is less and has minimum number of payback years. Hence fifth
model is recommended for the automation of condenser and radiator tubes stacking
and cleaning process.

45
 CHAPTER 7
REFERENCES

1. Henry Harrison Kelley (1913) ‘Radiators’ W.R.C. Smith Publishing Company,

University of Chicago, Frederick Rollins Low Vol 30;3203-3214.
2. Chang, F. C. (1997). ‘History of Condensers – Handbook of use of condensers’,
Olagoe Olabisi, New York. Marcel Dekker. pp 61-84.

3. Suarez, H., Barlow, J. W. and Paul, D. R. (1984) ‘Properties of Materials’, –

Journal of Applied Material Science. Vol 29; 3253-3259. pp.380-408

Websites
1. www.festo.com
2. www.us.misumi-ec.com
3. www.smcin.com

46
 APPENDIX 1
Gantt Chart of Project Timeline in Visteon

47
 APPENDIX 2
Project review in Visteon

48
 APPENDIX 3
Total cost including material and machining cost for the final model

49