CHAPATTI MACHINE (PRESS AND BAKING) MACHINE

1. CHAPATTI MACHINE (PRESS AND BAKING) MACHINE Submitted by, SURIYAPRAKASH P VINOTH P S VISHNU SUBBU S YUVARAJA G Supervisor : Mr.S.A.GOKULAKRISHNAN.,M.E. Assistant professor

2. CONTENTS • Introduction • Objective • Methodology • Design of components • Bill of materials • Fabrication • Working principle • Cost Estimation • Advantages • Application • Future scope • Conclusion

3. INTRODUCTION-CHAPATTI MACHINE • Chapatti maker is a device which is used to produce the chapatti without man power. • Here we are using pneumatic chapatti maker. • This project is developed for the users to make chapatti using air pressure. • It is used to consuming the less energy, power and labor work Main components of Chapatti machine: • Piston and cylinder arrangement • chapatti maker • Air Hoses • Compressor • Pressure control valve

4. DOUBLE ACTING CYLINDER • Pneumatic cylinders sometimes known as air cylinders are mechanical devices which use the power of compressed air or gas to produce a force in a reciprocating linear motion. • Like hydraulic cylinders, something forces a piston to move in the desired direction. • The piston is a disc or cylinder, and the piston rod transfers the force it develops to the object to be moved. • Engineers sometimes prefer to use pneumatics because they are quieter, cleaner, and do not require large amounts space for fluid storage

5. COMPRESSOR • An air compressor is a machine which takes in air at a certain pressure and delivers the air at a higher pressure. • Everything on earth is subjected to the absolute atmospheric pressure (pa), this pressure cannot be felt. • Compression ratio is expressed by the discharge pressure measured in the generally accepted unit of bars

6. CONTROL VALVES • Control valves are valves used to control conditions such as flow, pressure, temperature and liquid level by fully or partially opening or closing in response to operator. • The opening or closing of control valves is usually done by push button, cam operated, spring return, solenoid, etc. • A control valve consists of three main parts are Valve's actuator, Valve's positioned and Valve's body.

7. 5/3 DIRECTION CONTROL VALVE • A directional control valve with four ways, five ports, and three positions.

8. CHAPATTI MAKER • It has a two steel faced opposite each other and joined at one end. • Chapatti powder which will be baked is make small ball kept in between two faces of the steel plate. • Then the two faces of the steel plates is pressed and the ball is converted into the flat circle surface. • Then it is heated with the help of thermal heater which fixed inside the steel plate.

9. PNEUMATIC SYSTEM SPECIFICATIONS • Allowed gas types: Compressed Air or Nitrogen (N2), in compressed gaseous form only. • Maximum actuation pressure: 10 bars is the maximum pressure required for activation. • Pneumatic circuit setup: Components are connected with plastic tube with an outside diameter of 4 or 6 mm. Push the tubing into the push-in connector as far as it will go. • Electric motor: 10HP, 415V (±10%), 50Hz (±5%), 3 phase AC supply is required to run compressor. • Flow rate: 1 liter per second.

10. OBJECTIVE • In our project we are providing pneumatic operated chapatti machine instead of manually operated chapatti machine. • In general, long bar element is provided for manual pressing which is replaced by pneumatic cylinder to press the chapatti. This process is done by the help of air compressor. • The double acting cylinder is attached at the top of the chapatti maker. Since the design is as same as manual operated but more efficient. • When the piston extends the chapatti maker moves down and press the chapatti. • At the same time when the piston retracts the chapatti maker moves up and the chapatti maker is released. Due to this development time is saved and the production is increased.

11. METHODOLOGY Designing of Chapatti machine Analysis Purchasing ofcomponents Machining Assembly Inspection Final product

12. DESIGNING OF CHAPATTI MACHINE

13. BILL OF MATERIAL

14. BILL OF MATERIAL

15. FABRICATION • The pneumatic cylinder is fitted (by means of welding) with the top of the Chapatti maker of the chapatti machine. • After that the chapatti machine is mounted on the table. The table is designed to withstand the force produced by the chapatti machine. • The rod of the cylinder is fitted with the chapatti maker to move up and down. • The rod and chapatti maker is connected by means of bolt and nut. • After assembling the chapatti machine, air supply connection are given from the compressor.

16. ASSEMBLY OF THE CHAPATTI MACHINE

17. WORKING PRINCIPLE • This process is done by the help of air compressor. A double acting cylinder is connected at the bottom of the chapatti maker. • When the high-pressure of air is rushed out of the cylinder in one hole side. The cylinder is rotated in the downward direction. • When the piston is rotated, in the downward direction and it moves the upper disk of the chapatti maker downwards. • When the air is stopped, the platform also stops. When high-pressure air is rushed out of the cylinder in another hole, the piston is rotated in the upward direction and thus it moves the upper disk of the chapatti maker upwards.

18. COST ESTIMATION

19. COST ESTIMATION

20. COMPARISON MANUAL MACHINE • Voltage and Type ˗ • Manual operation - More • Manual Load - Required • Output - 100 Products per hour PNEUMATIC MACHINE • Voltage and Type • Manual operation -415V, 3 Phase, AC Supply • Manual Load - Less • Output - 150 Products per hour

21. COMPARISON CHART

22. ADVANTAGES • Easy to operate and clean • Saves money • Uniform size of chapatti & uniform baking quality • 100% hygienic machine • Less space and fuel consumption • Simple, robust & very compact design requires no special skill to operate • Uses LPG Infrared for heating & temperature is controlled by flow control valves • All parts comes in contact with dough are made out of food grade material. • Quite less noise due to friction free materials & hence requires minimum maintenance

23. APPLICATION • This machine is very useful for food industries. • This machine is used press the chapatti. • It is used for Hostels, Hospitals and Hotels.

24. FINAL PRODUCT SPECIFICATION • Type : Pneumatic type chapatti machine • Compressor : Air Compressor • Flow rate : 1 Liter per Second • Storage tank : 100 Liter storage capacity • Electric motor : Any type with 10HP, 415V (±10%), • 50Hz (±5%), 3 Phase AC Supply

25. CONCLUSION & FUTURE SCOPE • We completed the project successfully by Chapatti machine with nearly 50% of increased output when compared to manual chapatti machine. • We have manufactured Chapatti making machine. This machine has given much needed relief to workers in the meal preparation department of Institutes, Lagers, Hospitals, Schools and College Hostels, Industrial Canteens, Railway & Defense establishments. The machine produces home-like Chapattis in most hygienic way. • The cost of this project is comparatively low when it will be mass produced. If the problems are rectified, this will have a good scope in future and become a completely successful one.

26. REFERENCES • http://www.ciri.org.nz/bendworks/bending.pdf • http://www.pdf4me.net/view.php?url=http://classes.engr.oregonstate.edu/mime/winter2010/ie337-001/Laboratories/7.Metal%20Forming_bending-1.pdf • http://www.pdf4me.net/view.php?url=http://www.sonexaircraft.com/documents/instruction_sheets/bending_flat_parts.pdf • http://www.scribd.com/doc/44248472/Presses • http://www.scribd.com/doc/38482439/5-Reports-1-31 • http://ranier.hq.nasa.gov/Team116/2003/lessons/lesson7-pneumatics.pdf • http://www.scribd.com/doc/12594808/Final-Year-Project-Reportground-Source-Cooling-System • http://www.cottonyarnmarket.net/OASMTP/Pneumatic%20Air%20Compressor.pdf

27. PHOTOGRAPHY DOUBLE ACTING CYLINDERS 5/3 DIRECTIONAL CONTROL VALVE

28. PHOTOGRAPHY MANUAL CHAPATTI MACHINE ASSEMBLED VIEW OF CHAPATTI MACHINE