Fuzzy Logic Application, Control and Monitoring of Critical Machine Parameters in a Processing Company

The processing company under study found out that the boiler was the key machine and needs artificial intelligence monitoring and control. It was simulated under Matlab software and oil level, and pressure and temperature were to be modelled and controlled using the programmable logic controller (PLC) with a fuzzy logic controller as the main brain of control. The company is for processing of fruits to produce juice

Method of lines based on finite element technique to analyse electromagnetic problems

A hybrid scheme called finite element method of lines is described and proposed for modelling and analysis of generalized computational electromagnetic problems with emphasis on a number of irregular waveguide. This finite element based method of lines is developed by combining finite element method and the method of lines, so that it not only has high flexibility to treat geometrically and compositionally complex problems but also maintains high accuracy of semi-analytical technique. Analytical and numerical algorithmic building blocks of this new scheme are discussed such as geometry discretization, element mapping, element trial functions, reformulation and computational issues of non-linear ordinary differential equations. The results therefore show that this new technique is able to efficiently solve complex problems as compared with the conventional method of lines. MATLAB was used to compute the solutions of various problems

Cleaner production : theory and applications, case for Zimbabwe

Abstract: Regardless of its size or nature, industry generates waste and is responsible for implementing the practices of pollution prevention and waste management in its day-to-day operations. Whether it is dirty water or toxic wastes, industrial pollution is all the same in one way: it reduces a business’s profitability. Implementation of Cleaner Production (CP) urges environmental, health and safety department managers, industrial environmental consultants and personnel across all industries to employ a forwardthinking and tested technology of process improvements that will reduce waste generation, reduce the resources requirements to manufacture a product, and, most important to the life a business, increase revenues. Successful implementation of cleaner production improves their productivity, profitability, competitiveness, environmental compliance and working conditions of shop floor employees with minimum financial inputs. This book starts by explaining CP concepts, techniques and strategies. It further gives CP methodologies and case studies of those industries in which CP was successfully implemented. The authors also usher you through all sorts of exercises to test your understanding. I hope the book will encourage all stakeholders to think about what they can do to tackle the rising generation and inappropriate management of waste. Both producers and consumers of goods much work on the betterment of waste management. Every organization must strive to have the tools, technologies and financial resources to adopt CP. All sectors of society need to engage into an integrated life-cycle management of goods. The more efficient and less wasteful manufacturing and consumption processes will be, the less pressure there will be on essential resources and the better human health and the environmental will be protected. As a fellow veteran production engineer, I encourage you to recognise that this field is changing and improvements are being made that empower today’s business leader to minimize waste management generation. This book can be used as a guide if you wish to adopt CP technologies in your organizations

Development of a fuzzy logic power optimization system for a refrigeration plant

Despite the fact that electrical power is a major overhead in industrial refrigeration plants, this resource still lacks full utilization in some plants of some organizations in developing countries. An unfortunate consequence of this predicament is that these organizations end up paying for more power than they have actually consumed or even necessarily need. This research however addresses solutions to the above concerns through the development of a power optimization system. Since power optimization is a broad subject the scope was only limited to power factor correction and compressor capacity control. The developed optimal design consisted of replacing part of the inductive load by a fuzzy controlled synchronous motor. The torque angle at the synchronous motor shaft was continuously regulated by the automatic compressor capacity control schematic. Simulations carried out using MATLAB RB2010 are also presented

Design of a fuzzy logic control system for monitoring gearbox jamming in a bottle washer machine

The purpose of this research was to come up with an intelligent monitoring tool to reduce the number of breakdowns of a beverage company bottle washer. The Fuzzy Logic system was derived among other artificial intelligent systems to be best appropriate to solve the breakdown challenges of the bottle washer. A gearbox is always jamming and it is not easy to troubleshoot the breakdown cause and fuzzy logic is a tool that was used for monitoring. The researchers carried out a company audit, interviews and administered questionnaires in order to gather relevant data. The results were used in intelligent condition-based-maintenance modelling to solve the problem using fuzzy logic system and it was found that oil level should be always above 40% otherwise the gearbox will be made to stop. Torque is supposed to have a range of values accepted from 0-8 000Nm beyond that we consider the stoppage of the gearbox. Very higher torques above 10000Nm damages the machinery

Design of a power saving industrial conveyor system

Abstract: This paper looked at the design of a power saving conveyor system which involves sizing, selection and cost benefit analysis of its installation. This paper focuses on factors that cause high belt power consumption and costs which are high starting torque and more operating hours hence there is design of drive control system consisting of soft starters and variable speed drives to reduce starting torque and load detecting switching system to reduce number of operating hours. The average power savings considering all the factors of reducing the system operating hours to the average of 12 hours a day and drive control system that reduces the starting power were calculated to be 47%. The annual costs of power consumption were reduced from $86212 to$40520 resulting in the payback period after investing to be 8 months. After doing cost benefit analysis it was ascertained that installation, operation and maintenance costs of the designed system are less than that occur on the initial system hence the design is worthy to install since it results in cost savings and increase in system life. The are some recommendations for the designed system which are clean ventilated environment to promote adequate cooling, belt protection against overload to avoid stops and also soft starters , variable speed drives and sensors protection against overvoltage and overcurrent so that the drive control system will not fail

Design of a rice transplanter for Zimbabwean farmers

Abstract: Rice is a crop of growing importance in Zimbabwe but with a production of only 700 metric tonnes. This is because in wetlands it is largely grown by broadcasting of seeds and seedlings; and manual transplanting of seedlings. In practicing the said method however, farmers are exposed to musculosketal disorders as well as back problems due to the repetitive bending as well as the awkward posture needed in performing the task. Though manual transplanting gives uniform crop stand it is quite expensive and requires lot of labour besides involving lot of drudgery. Singh et al., 1985 reported that transplanting takes about 250-300 man hours/ha which is roughly 25 per cent of the total labour requirement of the crop. The rice production in Zimbabwe has also been very low because the common rice types were affected by the local climatic conditions however in 2014 businessman and farmer struck a deal with renowned Chinese agricultural scientist for National Hybrid Rice Research and Development Centre in Changsha in Hunan Province to start a pilot hybrid rice production exercise that could easily transform Zimbabwe into a major rice growing hub in the SADC region using varieties suitable to local conditions. This paper aims to design an ergonomic rice transplanter suited for the Zimbabwean climate and terrain. The mechanical transplanting of rice has been considered the most promising option, as it saves labour, ensures timely transplanting and attains optimum plant density that contributes to high productivity. Mechanization of rice sector will lead to higher productivity with releasing of work force to other sectors

Design of a bench saw cutting machine for wood with automatic braking system

Abstract: This research paper explores the design of an automatic safety brake mechanism on a manual circular table saw machine which stops the blade from rotating when human flesh is detected in the blade proximity. Fatal injuries are occurring, human thumbs and entire hand cutting during operation when operator accidentally touches the spinning blade. It has become a matter of concern to develop the safety mechanism which can be retrofitted on old-model table saw machines used to train students at a university wood workshop. The researchers made use of capacitive proximity sensors to detect human flesh and then automatically activate the brake pawl to the rotating blade, D.C. injection brake voltage which abruptly stop the running motor. The design procedure confirmed the quick release of the safety mechanism within 0.25 seconds as revealed from the simulation of circuits in Proteus software. With this design it is possible to stop the spinning blade in 0.25 seconds, before the operator touches the spinning blade and also the mechanism is adoptable to all circular saw machines (panel saw, bench saws), thus making a work-safe environment on the circular saws

Design of an electrically powered bending machine : case of Zimbabwe

Abstract: This paper seeks to carry out design of a small scale electrically powered bending machine for a developing nation, case for Zimbabwe. The bending of metal is of great importance in the manufacture of products such as nut shelling machines and maize shelling machines. Currently being used at Company X engineering is a manual bending machine with a single operation hence this design will help to increase the number of metals being bent, an increase in the efficiency and production. The paper deals with manufacturing or bending of sheet metal by using power operated sheet bending machine. Especially discussion made the productivity analysis of manually or power operated sheet bending machine. Considering manual operation is replaced by power operated devices. It also gives information about limitation of manually operated sheet bending machine and power operated sheet bending machine. The existing machines are limited to a single operation. The aim of the research is to increase the number of bent parts and to place an adjustable table to suit the height of the user thereby reducing back pain internal injuries in the long run. The researchers visited the Company X to gather information concerning the problems faced by the employees. Material tests which are of great value were carried out and the use of software. A Plate Rolling Machine is a machine that will roll different kinds of metal sheet into a round or conical shape and a rod bending machine will roll or bend different kinds of metal sheet into right angles or circular shapes. The research aims at making it possible to do the operations on a single machine. We recommend the machine to be automated and the use of a servo motor to reduce human injuries at the workshop. Use of oils and maintenance is of great value to increase the life span of the machine

Design of a mechanical cleaning device P.I.G (pipeline intervention gadget) connecting two transfer lines in Zimbabwe

Abstract: In the Oil and Gas Industry, maintenance is done using a device or tool called a pig, chiefly to remove solids, dirt, and liquids from the pipelines. The aim of this work is to design and retrofit a pig which will clean 3 identical underground transfer pipelines linking 2 depots The movement of this tool is basically through the action of the fluid in the pipeline pushing it along as it is pumped from one point to another, hence no external power is needed in the device to help in its movement. Calculation based model analysis of the tool together with Solidworks simulations and results are included in detail, with all assumptions and limitations clearly stated and listed. The results show that the pig will move inside the pipe at a lower speed than the mean flow velocity which is good for the performance of the electronic systems installed on its body for pipeline inspection. Bypass hole is added on the central part of the pig body to control the speed as well as keep the cleaned dirt stirred and moving, being pushed by the pig as it performs its cleaning process