Technical Report Padder Machine

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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



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



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.



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.



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



Machine Description:

DC Gear

Motor

Electric Panel

Rollers

Force Adjustme

Screws

Tray

Pad Insert

Window

Rollers

Soaked P

Tray

Ink Draina

Force Adjustment

Screws

Figure-1

Figure-2

Technical Report Padder Machine

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