Applied Physics Computer & Instrumentation Centre

TECHNICAL REPORT
ON

FABRICATION OF PADDER MACHINE FOR

UTILIZATION IN MAGNETIZED INK PADS

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, Weighing and 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 5th April 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 problem remained. 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 16th April 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 Senior Scientific Officer -----------------------------Mr. Faisal Ghazanfar Scientific Officer ------------------------------Mr. Akhtar Ali Khan Technical Officer -----------------------------Mr. Ajeet Kumar Junior Engineer

------------------------------------Dr. Muhammad Yaqub Chief Scientific Officer Head of Centre, APC&IC, KLC

APPROVED BY:
------------------------------------Mrs. Askari Begum Chief Scientific Officer Director General PCSIR Laboratories Complex, Karachi, Pakistan

Machine Description:
Rollers DC Gear Motor

Force Adjustment Screws Pad Inserting Window

Tray

Electric Panel

Figure-1
Force Adjustment Screws Rollers

Soaked Pad Tray

Ink Drainage

Figure-2