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TECHNICAL REPORTON
FABRICATION OF PADDER MACHINE FOR
UTILIZATION IN MAGNETIZED INK PADS
Applied Physics Computer & Instrumentation Centre
Pakistan Council of Scientific & Industrial Research(PCSIR) Labs. Complex, Karachi
22nd April, 2013
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TITLE OF REPORT:Fabrication of Padder-Machine for Utilization in Magnetic Ink Pads
COORDINATOR: Dr. Muhammed Yaqub, CSO
ASSOCIATES:
Electrical / Electronic Design:
Mr. Arif Karim, SSO
Mr. Faisal Ghazanfar, SO
Mr. Ajeet Kumar, JE
Mr. Kashif Hussain, JTO
Mechanical Design:
Mr. Akhtar Ali Khan, TO
Mr. Anis Ahmad, TA
Mr. Mazhar-ul-Islam, EO
BACKGROUND:
PCSIR Labs, Complex Karachi was assigned a huge challenge from the Election
Commotion of Pakistan to produce Indispensable Election Ink and Magnetic Ink for the
specialized stamp pads. To maintain the Quality of the filling process for magnetized ink
in pads, there was an urgent need for efficient machine for compression of pads to
ensure the specific quantity of ink in it. The task was assigned to Dr. Muhammad Yaqub,
Chairman Quality Control – II to fabricate the said machine, very short time, to enhance
the production process.
The experts of APCIC took the challenge and worked day and night to fabricate an
efficient but low cost compression machine of ink pads in controlled environment.
Dr. Yaqub along with the experts visited the plant for finding provision for enhancement
of the process. After the detailed study and analysis of the production process, a
bottleneck was found in the padding process. To overcome the problem following
possible solutions were proposed:
1. Fabrication of Efficient Manual type padding machine which was currently
utilized in the process
2. Fabrication of automatic roller-type padding machine
3. Fabrication of padding machine (roller type) with conveyer belt for feeding and
collecting the pads
4. Automating the overall process of Dipping in Ink, Moving, Pressing, Weighingand Sorting the acceptable pads for others
Choice No.1 was not an efficient solution, Choice No.3-5 were time consuming and
costly solutions. After detailed discussion with the team members and the stack-holders
it was decided that Choice No.2, Automatic roller type padding machine, would be the
best choice because of its simplicity and very low cost and could be fabricated in very
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short time. An amount of Rs. 10,000/- was provided by the Election Ink Coordinator,
with the approval of DG/KLC.
OBJECTIVES:
The main objectives are as follows: The machine will help in speeding-up the padding process, which will in-turn increase
the production of ink-pad.
The machine has been developed from indigenous materials and components, so that
its maintenance could be made low cost, easy and prompt as compared to the imported
ones.
It will work as a backup unit for presently installed machines for their any failure or
shutdown.
TECHNICAL DESIGN AND PROJECT TIME LINE: The fabrication work was started on 5
thApril 2013. The work was executed in the
following phases / steps:
The components were procured from the local market. The proposed machine would
comprise of two – rollers with compatible AC motors and pressing attachments and gear
system for smooth motor drives. A very basic apparatus was fabricated initially and
tested. After pressing of pads the acceptable range of pad weights should be between
25 to 30 gm. However, it was found that the weight of the pad after pressing through
basic machine was 35, which means there is a need of some improvements.
Two high power motors were now added with the same assembly but the problemremained.
Finally, it was decided to visit Shairshah (local market) for suitable rollers and
compatible gear-motors. After thorough searching of market two rollers and a gear
motor was purchased. The improved machine was then fabricated in further two more
days, tiring and restless effort. The padding process was tried and fortunately with the
grace of Almighty the required weight was achieved.
During next few days a power supply along with speed/direction control was
successfully developed and installed in the machine along with a pad-feeding tray and
plastic platform for collecting the remaining ink from the pads. On 16
thApril 2013, the machine was installed in the pilot plant. To test the efficiency of
the machine around 1000 pads were processed through the machine and only 25 of
them were found below standard, i.e. the calculated efficiency of the machine is ~95%
which is quite satisfactory.
The Election-Ink Coordinator and the DG-KLC observed the working of the machine and
they were quite satisfied with its working.
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DETAILS OF MACHINE DESIGN METHODOLOGY:
The machine is basically a paddler. It presses the pad for removing the extra ink in some
tolerance range, like producing pad with final weight between 25gm to 32gm. In this way, it
maintains quality with saving extra ink and thereby reduces cost price of pad.
The machine is designed in a user-friendly way. Two screws/knobs were given for weight
control, the user can adjust them to get the desired weight for pad. A metallic tray is given in
the bottom to collect the removed in and its drainage to a reservoir so as to recycle it in the
process. A direction-reversal switch is given to remove any stuck pad. Two plastic pate-forms
are given in the machine for feeding and collecting ink-pads. The machine is single phase
220Vac. The salient features are as follows:
Pressing speed: 750 pads/hr
Power Consumption: 150 watt
Supply: 220 V ac
Dimension: 3 x 1.5 x 2 ft Weight: ~5kg
ACHIEVEMENTS:
The major achievements are as follows:
The machine has been successfully developed from locally available material and
components so that its further development and maintenance can be made efficient.
Presently the machine can produce ~750 pads per minute with around 3~8 percent
rejection.
The machine is single phase with a maximum wattage of 150Watts.
The weight of the pressed pads can be controlled with two given screws as shown in
figure-2.
The speed and direction of the roller can be controlled as and when required.
The machine is compact and light weight, can be handled even by a single operator.
NET RESULT:
The project has been successfully completed and a prototype Padder-Machine is installed in
PPD. It was initially tested for 2 days and then reserved as a backup for the other two
operational machines.
FUTURE DIRECTION:
As the machine uses DC-voltages, it can be easily backed-up by battery without any
losses. In this way it can be run in case of power failure/ load-shedding.
The machine can be modified by increasing the length of rollers so that more than one
supply lines can be made and in-turn increasing the production.
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A conveyer belt can be attached for feeding and collecting pads. This will increase the
productivity by optimizing skilled manpower and resources.
ACKNOWLEDGMENTS:
Mr. Didar Memon, PSO
Mr. Farhan Aziz, RA
Mr. Noman Saeed, JTO
PREPARED BY:
------------------------------- -------------------------------Mr. Arif karim Mr. Akhtar Ali KhanSenior Scientific Officer Technical Officer
------------------------------ ------------------------------Mr. Faisal Ghazanfar Mr. Ajeet Kumar Scientific Officer Junior Engineer
-------------------------------------Dr. Muhammad YaqubChief Scientific Officer Head of Centre, APC&IC, KLC
APPROVED BY:
-------------------------------------Mrs. Askari BegumChief Scientific Officer Director GeneralPCSIR Laboratories Complex,Karachi, Pakistan