Portable Sand Distribution Machine Design

This assignment details the design of a portable sand distribution machine aimed at improving the efficiency and quality of casting processes. The machine is designed to be easily transferable between small and large industries, operating for 15 hours before requiring a one-hour reboot. Key features include efficient heat dissipation through air gaps, accurate piston and valve diameter calculations, and even sand distribution across casting materials to minimize defects. The project emphasizes collaboration between mechanical and electrical engineering teams.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 3

CE 3.1 Project Information
Name of the project: Automatic Pneumatic Ramming Machine
Location of the project: [PLEASE FILL]
Project Duration: [PLEASE FILL]
Organization: [PLEASE FILL]
Role and Designation during the time: Team Leader
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
I considered moulding industries as one of the target market for the third project
considering the development of an automatic pneumatic ramming machine that can be utilized
by these industries for the production. These industries use sand ramping for casting the desired
products however, human errors can lead to certain deformations and defective products can be
developed. I proposed an automated system that will be helpful in evenly distributing the sand on
the cast material and eliminate the defects in casting. I analysed that approximately 10% of the
castings are being rejected within the industries due to human errors and uneven distribution of
the sands during casting. Thus, the developed system will be helpful in eliminating these 10%
defective items and allowing the industries to produce product without any defects. I selected the
idea of fabricating the “PNEUMATIC RAMMER” that can be operated pneumatically those will
be applicable in evenly distributing the sand packaging during moulding.

CE 3.2.2 Objectives developed for the project
As a lead role, it was my duty to manage the project objectives and motivate every team
member towards the successful delivery of the project and gaining better production and output.
I developed the following set of objectives for motivating and concentring the team towards the:
 To develop an innovative product that can gain the attention of the industries
 To develop an automated pneumatic ramming machine that can allow even
distribution of the sands for moulding
 To follow the specified timeline and accomplish all the operational activities
within the expected deadline
 To increase the efficiency of moulding industries and eliminating the defects
produced because of the human errors
 To manage the budget of the proposed system minimum as much possible
CE 3.2.3 My area of work
I managed the responsibilities and roles of every team member associated with me during
the execution of this project. I developed a communication plan that allows every individual to
communicate on the related topics and raise if there is any concern, and others had to propose
certain solutions and every individual had to agree on the proposed solution. I had to design the
pneumatic cylinder and solenoid valve for developing the sophisticated model that can allow
efficient and effective moulding. I proposed the entire work progress and depicted them in the
following block diagram and assigned different jobs to every individual associated with this
project:

Figure 1: Block Diagram of Proposed Work
I designed and calculated all the parameters in manner to propose the pistons and piston
rods same as that it could fit within the lathe and fit perfectly. I developed the following design
and fabrication of the pneumatic ramming machine as described in the following figure:

Figure 2: Design and Fabrication of the Pneumatic Ramming Machine
CE 3.2.4 Project Group
CE 3.2.5 My responsibilities throughout the project
I had the responsibility to manage the entire team roles and continuously monitor the
progress and development of the project in manner to make sure that the project is moving in the
right path and estimated constraints are being accomplished in an efficient and effective manner.
I managed to accomplish the entire project management through utilizing the management and
leadership qualities. I took the responsibility of designing and calculations those were one of the
crucial section for the entire project delivery and tried to manage them in an efficient and
effective manner. I had to assure that the growth and development of the project is moving in the
same direction as that was expected theoretically. I managed to deliver the entire project in an

efficient and effective manner and the calculated output was efficient enough to allow the
industries to use the machine rather than the employees or staffs.
CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the theory of the project
Human errors are the possible cause that lead to the less efficiency while utilizing the
machines within the industries. A solution was necessary that could possibly lead towards
enhancing the efficiency of the organization through eliminating the human errors and leading to
the even distribution of the sand over the casting materials. The automatic Pneumatic Ramming
machine was developed that will allow the industries to evenly distribute the sand over the
casting materials for molding the respective product and assure that there is not any defects in the
produced product. An effective model had been proposed that will allow the industrialist to
evenly spread the sand over the casting materials and stop the products from being produced
damaged.
CE 3.3.2 Engineering knowledge and skills applied in the project
I designed the pneumatic cylinder and the solenoid valve after calculating every
parameter and assured that the valve and pistons are exactly fitting with each other and there are
not any gaps. I used the pneumatic cylinder as described in the above picture that has the
following technical details:
Size: ¼”
Pressure: 0 to 10 kg / cm2

Media: Air
I considered the following parameters for the calculation and design of the proposed
design:
Diameter of the piston = 32mm
Pressure available from the compressor = 1000000Pa (10 bar)
Force = Area * Pressure
Cross sectional Area of the cylinder = π*32*32/4 = 804.352mm2
Thereafter, I did the surface grinding on the piston rod and piston and the following
quantitative measures were identified:
Tolerance = 32 ± 0.02
Working stroke length = 65mm
Total stroke length = 135 mm
The piston force F = P * A = 106*804.352*10-6 = 804.352 N
The diameter of the piston = 32mm
CE 3.3.3 Identified issues and their solutions
3.3.3.1 Issues
The developed project should be of compatible size in manner to make sure that the
machines and devices can be used within the industries. I assumed that the developed system

should be capable of fulfilling the operational activities of the small and large industries. I
identified that the piston and valve are not being fitted as the piston was not stable.
3.3.3.2 Solutions
I kept the project of portable size that can be transferred without any difficulties and can
be easily fit within the small or large industries. The proposed machine is capable of
accomplishing the operational activities of the small and large industries and I kept the system
efficient that it can be operated for fifteen hours and will need to reboot for an hour after every
fifteen hours. In manner to manage the piston and valve diameter I executed the above
mentioned calculation and kept a difference of .02mm around the diameter of the piston that
allows lathe fitting for the rods.
CE 3.3.4 Plan to produce creative and innovative work
I kept the portable size of the machine that allows the system to be used within any size
of the industry and can bear a heavy load for a long duration. The reboot system has been
developed through providing air gaps that will be helpful in extracting the heat in very faster
way. Due to the movement of the piston, I identified that the machine is being heated and so, it
becomes necessary to place air gaps and assure that the heat exchange between the machine and
the environment is faster. The developed system will efficiently and effectively distribute the
sand over the casting material and allowing the industries to limit the defects at zero level.
CE 3.3.5 Collaborative work
The project needed the members from mechanical and electrical branches and hence, we
collaborated for the successful and efficient delivery of the project without altering the quality
and standard of the proposed machine. I managed the team however, same contribution was

experienced from my teammates who responsibly accomplished their sector of job without
lagging in the timeline and standard. I divided he project into phases and assigned different roles
to every team member that was successfully accomplished and lead the project to the success.
CE 3.4 Project Review
CE 3.4.1 Project Overview
I considered the moulding industry as my next target and analysed the ways through
which the present scenario can be enhanced for much better productivity. I found that the almost
10% of the products being reject due to the deformation in the products being produced after the
casting. It was the time that I would take a deep interest and propose an automatic machine that
will allow even distribution of the sands over the casting materials and allowing the industries to
produce less defective products.
CE 3.4.2 My contribution to work
I contributed in the management and leading the entire team and keep them motivated
towards accomplishing the objectives set in the prior of the project. I managed the designing and
calculation of the developed design that was helpful in leading the project successfully. The idea
was proposed by me however; the entire team was responsible for the successful delivery of the
project. I successfully developed the machine that could be helpful in evenly distribution of the
sand over the casting material and eliminating the human errors to the extend level.