Design and development of low cost automation system at fuel filling station on vehicle assembly line

Abstract

Nowadays for any industry to survive in the competitive market, automation is required. Low Cost Automation (popularly known as LCA) is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing production process or/and machinery, with a view to improving the productivity. Automation improves the quality of the product as well as reduces the cost of production. Different components, instruments and techniques are used to implement the low cost automated system. In the Tata Motors car plant Pune, Indica, Indigo, Zest and Bolt cars are manufactured on their mixed model type of assembly line. These cars are different models with domestic and export categories. This dissertation focuses on the design and development of LCA based fuel filling system on vehicle assembly line. The problem occurs at fuel filling station because of manual categorization of vehicle model with fuel type and selection of fuel dispenser unit with appropriated quantity by the operator. The new design of LCA based fuel filling system categorizes vehicle model with fuel type and energizes appropriate fuel dispenser unit with quantity by the Programmable Logic Controller (PLC). The design and development of LCA based fuel filling system is done on the basis of study of existing system, LCA based system layout and dimensional layout by minimizing human intervention in the process. The selection and installation of the components scanner, LED display board and PLC technique is decided on the basis of system task, application requirement, station area and industrial safety points. The ladder diagram’s simulation results helps to implement the LCA based fuel filling system and pilot run of system results in reduction of cycle time, reduction of rework which leads to lower down the rework time and cost.