Upscaling of used Sari Cutting Machine for Handlooms Operated by Visually challenged

IndividualsBy

Dr. Suhas JoshiProfessor, Department of Mechanical Engineering (PI)

Dr. Bakul RaoAssociate Professor, CTARA (Co-PI)

Student InvestigatorsVikalp Jambhulkar (Dual degree MTech) and Alap Kshirsagar (B. Tech.)

Indian Institute of Technology Bombay, IndiaJanuary 2012

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Preamble

Grameen Shramik Pratishthan – An NGO

Swadhar- Training cum production center

• Trains visually challenged people for

handloom weaving.

• Provide stable employment opportunity

• Currently employs 65 visually challenged

individuals.

Door Mats

Floor Mats

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Mat Making Process

Stitching of Sari Cutting of sari bundles

Wrapping the ribbons around sticks

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Mat Making Process

Weaving Process Weaving machines at GSP

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Need for the Machine Earlier Method

• Ribbons are made by tearing the Sari

• 2-3 hours for cutting 7-9 Saris

• Consumes 30% time of the weavers

• Variation in the size and loose fibers

• Usage of razor blades is dangerous

Current Method

• A machine is used for cutting folded Sarees for making ribbons

• Variation in the size and entanglement of ribbons.

• Time consuming and productivity is very less

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Objectives and Scope

• Primary objective was to evolved an easy method of ribbon making and development of proto-type.

• Accordingly, Yogendra Meena (Dual Degree M.Tech.) student has worked on it last year to evolve two proto-types of scale 1/3rd scale.

• The objective of this proposal is to take one the prototypes (the second prototype) ahead for upscaling so as to develop a real life machine.

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Design: Single Layer Cutting

Design 1: Single layer cutting of sari with multiple cutters in series

Design 2: Single layer cutting of sari with multiple reciprocating cutters in series

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Design: Multiple layer cutting

Design 3: Simultaneous cutting of multiple layers of saris with

multiple blades

Design 4: Simultaneous cutting of multiple layers of saris with single blade

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Prototype 1: Single Layer Cutting1. The stitched sari is wound on the roller2. The sari is passed through the stretching rollers3. The sari gets cut as it passes through the cutters4. Ribbons formed gets wrapped around the bobbins5. The bobbin shaft is rotated using the pedal mechanism6. After the whole sari is cut, the bobbins are taken out and they are used in weaving

Passing of sari through the stretching rollers

The sari gets cut between the cutters and gets collected in bobbins

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Prototype 2: Multiple Layer Cutting1. The stitched sari is wound on the roller2. The roller is mounted on the machine and is

rotated using the pedal mechanism3. While the sari bundle is rotating the circular cutter

is pressed on it4. The cutter is pressed till the whole bundle is cut

and then it is released5. The sari is cut into ribbons on the roller, the

ribbons are taken out and can be used for weaving

The sari is wrapped around the wooden roller

Cutters are pressed on the rotating wooden sari roll to get the ribbons

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Problems Faced

Single Layer Cutting Machine

• Initial cut has to be made.

• Attaching ribbons on the bobbins; around 25 bobbins.

• Both are very time consuming processes.

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Problem Faced

Multiple Layer Cutting Process

• Very large force is needed to cut, experimental results show that the force get to as high as 50 N for single cutter

• The cutter gets stuck while it is slightly inside the bundle

• Poor finish of the ribbons; loose fibers are formed

• Ribbons are not cut on bobbins Force measurement using dynamometers

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New Design: Multiple Layer Cutting

4. When the cutters are moving, the sari bundle is pressed into the cutters by pushing the platform

5. The ribbons are produced on the bobbins which can be taken out for weaving

1. The circular blade mounted on a shaft and is rotated by motor

2. The shaft holders are stationary

3. The sari is wrapped on the bobbin rollers which is mounted on moving platform

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New Design: Single Layer Cutting

3. The ribbons generated are wrapped around the bobbins

4. The bobbin shaft will be rotated by using a pedal mechanism

1. The sari passes through the stretching rollers

2. The sari is cut by the reciprocating motion of straight blades

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Approach for manufacturing the machine

1. Design of the machine components in detail, involves

selection of materials, designing of component sizes and

tolerances.

2. Design of manufacturing processes for various components

3. Fabrication of the components

4. Assembly of the machine

5. Testing of the machine

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Budget for the project

Sr. No. Item Cost (Rs.)

1. Raw materials, wood steel and aluminium 25, 000/-

2. Paddling arrangement 4, 000/-

3. Fabrication cost 40, 000/-

4. Research Assistant @Rs. 12,000/- per month for 1

year

1, 44, 000/-

5. Miscellaneous expense including travel 25, 000/-

Total 2, 38, 000/-

Budget bifurcation

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Timeline for the project

Activity October –

Dec. 2011

January-

March 2012

April-June

2012

July-Sept.

2012

First Prototype

Machine Development

Machine testing

Machine transfer &

installation

Duration of Project: One year

Deliverable: Sari cutting machine of real-life size