Design and Analysis of Storage Rack for Rubber coated Rolls and Vertical Carousal Rack for Calendared Rubber Sheet Rolls

Abstract

The roll is an important component of the machines used in the industries like textile,paper and steel etc. The surface finish and hardness of the roll is very important because it is used to pass out certain value thickness of paper, cloth etc. It has to handle very carefully because it is coated by rubber with accurate surface finish. The calendared rubber sheet roll is the wooden roll covered with calendared rubber sheets used in the binding of rubber rolls mentioned above. The present process being adopted involve the storing of rolls randomly one on other because there is no specific structure for storage of roll. This leads to: Damage of the rolls Increase in NCs (Non Conformation) Damage to calendared rubber sheet Pick-up time for selected rolls is very high Congestion on the shop floor The purpose of this project to design and analyze the storage rack for the rubber coated rolls and calendar Sheet rolls. In this project two type of storage structures are designed: 1. Storage Rack for Rubber Coated Rolls 2. Vertical Carousal Rack for Calendared Rubber Sheet Rolls Information is collected about the utilization of shop floor in storage. This leads to the available space area for storage structure. The size of calendared sheet rolls is fixed but size of rubber coated rolls is not fixed. So in order to design widely used storage rack, last six months production data are studied and scatter chart is prepared. Then alternative conceptual designs of the structure are made. By studying the pros and cons best layout is selected. Design calculation is made for all the components of both structures. Stability of the structure is considered during the design calculation. The geometric modeling of each component for both the structure is carried out in modeling software for better understanding. These components are assembled to final assembly. Critical components of both the structures are analyzed using finite element software. For Storage Rack for Rubber Coated Rolls, plate with support beam, track, column and contact stress between wheel and track is analyzed using finite element software. For Vertical Carousal Rack for Calendared Rubber Sheet Rolls, frame is most critical component so it is analyzed. A system of storage of rolls is designed to eliminate the above mentioned difficulties. Bill of material for both the structure is prepared. It is estimated that the total cost of manufacturing Storage Rack for Rubber Coated Rolls is around 2 lack and that for total cost of Vertical Carousal Rack for Calendared Rubber Sheet Rolls is around 1.25 lack. The space saving by both the structures is calculate by comparing the earlier space requirement and space requirement by these structures. Space saved by Storage Rack for Rubber Coated Rolls 37.50% of earlier space requirement and that by use of Vertical Carousal Rack for Calendared Rubber Sheet Rolls 70.00% of earlier space requirement. The monetary benefit due to space saving by Storage Rack for Rubber Coated Rolls is Rs. 7.2 lack and that by Vertical Carousal Rack for Calendared Rubber Sheet Rolls is Rs.9.44 lack. Estimated time saving by the use of vertical carousal rack 40 min per shift. Time saving cause the reduction in the cost of labour and overhead. Monetary benefit from this time saving is 1, 24,384 Rs per year.