DESIGN OF ASSEMBLY FIXTURE FOR ON- LOAD

TAP CHANGERS
AN INDUSTRIAL PROJECT REPORT
Submitted By

G GOKULNATH Reg NO.: 311516114021

R PRAVIN Reg NO.: 311516114040

KS VIJAYAKUMAR Reg NO.: 311516114057

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

IN
MECHANICAL ENGINEERING

MEENAKSHI SUNDARARAJAN ENGINEERING COLLEGE

ANNA UNIVERSITY CHENNAI – 600 025

MARCH 2020

–
 ME6811 PROJECT WORK

DESIGN OF ASSEMBLY FIXTURE FOR ON- LOAD

TAP CHANGERS
AN INDUSTRIAL PROJECT REPORT
Submitted By

G GOKULNATH

R PRAVIN

K S VIJAYAKUMAR

In partial fulfillment for the award of the

degree of

BACHELOR OF ENGINEERING

IN
MECHANICAL ENGINEERING

MEENAKSHI SUNDARARAJAN ENGINEERING COLLEGE

ANNA UNIVERSITY CHENNAI – 600 025

MARCH 2020
 ANNA UNIVERSITY: CHENNAI – 600 025
BONAFIDE CERTIFICATE

Certified that this project report “DEISGN OF ASSEMBLY FIXTURE

FOR ON-LOAD TAP CHANGERS” is the bonafide work of
“GOKULNATH G (3115116114021), PRAVIN R (311516114040), and
VIJAYAKUMAR K S (311516114057)” who carried out the project under my
supervision.

SIGNATURE SIGNATURE

Dr. K. BALASUBRAMANIAN, Mr. V. MEGANATHAN,

HEAD OF THE DEPARTMENT, ASSISTANT PROFESSOR,
MECHANICAL ENGINEERING, MECHANICAL ENGINEERING,
MEENAKSHI SUNDARARAJAN MEENAKSHI SUNDARARAJAN
ENGINEERING COLLEGE, ENGINEERING COLLEGE,
No.363, Arcot Road, No.363, Arcot Road,
Kodambakkam, Chennai – 24 Kodambakkam, Chennai – 24

SUBMITTED FOR EXAMINATON HELD ON:

EXTERNAL EXAMINER INTERNAL EXAMINER

 ACKNOWLEDGEMENT

First and foremost we owe heartfelt thanks to our parents for their blessings
and their encouragement to do this project.

It has been a great privilege to undergo training at Easun – MR Tap

Changers (P) Ltd, Thiruninravur, Chennai and the experience of working
there has been highly enriching. The interaction with the company personnel of
varied designations provided us valuable insight regarding the industry and
functioning of the company.

We are really thankful to Dr. K. Balasubramanian, Head of the

Department, Mechanical Engineering at Meenakshi Sundararajan
Engineering College and our internal guide Assistant Professor Mr. V.
Meganathan, for their scholarly guidance and encouragement during the entire
course of our project work.

It gives us immense pleasure to express our regards and profound gratitude

to Mrs. B. Udhayachandrika, Human Resource of Easun – MR Tap Changers
Pvt. Ltd., for providing us the opportunity to add new dimensions in our
knowledge by setting project in this esteemed organization.

We would like to thank our guide Mr. V. Sachin Morey, Technical Head
(CQ – Supplier Quality) of Easun-MR Tap Changers Pvt. Ltd., for his expert
guidance throughout training and opportunity to do project work at Easun - MR,
Thiruninravur unit.

The acknowledgement will not be complete without a vote of thanks to the

entire team of the Development of Easun - MR tap changers Pvt. Ltd., for
their support. There are numerous other people whom we may not be able to
acknowledge here but their contribution is equally important in the success of
the project.
 TABLE OF CONTENTS

S. NO. TITLE PAGE

NO.

I ABSTRACT i

II LIST OF TABLES ii

III LIST OF FIGURES ii

1. INTRODUCTION 1

1.1 Introduction to tap changers 1

1.2 Introduction to on-load tap changers 1

2. COMPANY PROFILE 2

2.1 Easun - MR 3

2.2 Products 3

2.2.1 oltc 3

2.2.2 octc 3

2.2.3 Transformer monitoring unit 4

2.2.4 Dost 4

2.2.5 Boss 4

2.2.6 Hybrid technology 4

2.2.7 IBUS 4

2.2.8 Electric Vehicles (EV) 4

 4. TAP CHANGERS 5

4.1 No - load tap changers 6

4.2 On - load tap changers 7

4.2.1 Switching principle 8

4.2.2 Basic arrangements of regulating windings 8

4.2.3 Design concepts of on-load tap changers 8

5. PROBLEM IDENTIFICATION 9

5.1 Identification of issues 10

5.1.1 Man power requirement 12

5.1.2 Layout of FRP board 12

5.1.3 Rate of production of OLTC 12

6. SOLUTION 13

6.1 Solution to the problem of holding FRP board in selector 17

6.2 Introduction to the Assembly fixture 18

7. ASSEMBLY FIXTURE 18

7.1 Fixture 18

7.1.1 Objectives of fixtures 19

7.1.2 Design consideration in fixtures 21

7.1.3 Fixture design procedure 23

7.1.4 Locating principles of fixture 23

7.2 Assembly Fixtures 25

 7.3 Factors to be considered for design of fixtures 26

7.3.1 Component 27

7.3.2 Production requirements 28

7.4 Material analysis 29

8. DESIGN DIFFICULTIES 29
8.1 Problems occurred in the design assembly fixture for the 30
selector of newly designed OLTC 31
8.2
Major design difficulties 31
8.2.1 Assembly pattern of the components of the selector
31
8.2.2 Adjustment of clamping pressure
32
8.3 Correction
32
9. DESIGN OF ASSEMBLY FIXTURES PARTS FOR THE
SELECTOR 32

9.1 Basic design method and software used 33

9.11 Creo parametric 3.0 33
9.1.2 3D part design list of assembly fixture for selector 33
9.2 Design of base part of assembly fixture
34
9.3 Design of body part of assembly fixture
34
9.4 Design of detachable main arm part of assembly fixture
35
9.5 Design of clamping arm part of assembly fixture
36
9.6 Design of nut and bolt part diagram of assembly fixture
10. 37
PROCESS INVOLVDED IN THE PRODUCTION OF
ASSEMBLY FIXTURE 38
10.1 Required process for assembly fixture and material used in here
10.1.1 Materials used for fixture
39
10.2 Ma 39
chi 10.3 Welding process
nin 10.4 Heat treatment process 40
g
pro 10.4.1 Normalizing 41
ces
s 10.4.2 Annealing
42

11. 10.5 Surface treatment 43

ASSEMBLY OF THE PART DESIGNS OF THE ASSEMBLY 44
FIXTURE
45
11.1 Assembly introduction and software used
11.1.1 Creo parametric 3.0 46

11.2 Complete assembly part designs of the assembly fixture without 46

the FRP board 46
11.2.1 Isometric view
47
11.2.2 Side view
11.2.3 Top & bottom view 48

11.3 Complete assembly part designs of the assembly fixture with 49

the FRP board 50
11.3.1 Isometric view
11.3.2 Side view
12. 51
11.3.3 Top & bottom view
CONCLUSION 52

REFERENCES 53

54

55
 ABSTRACT
Our project is about making the assembly of selector in on load tap
changer easier than before. As the assembly of OLTC selector involves three
peoples, two for holding the fiber reinforced plastic board and one for
assembling the components of selector.
As a solution to this we proposed two designs of assembly fixtures for
holding the FRP board .These two designs are based on simple structural
dimensions of the FRP board, all the locking and tightening mechanisms are
based on nut and bold for one design and screw and lock & key method for
another design .Using this the manpower of two members can be saved and
used elsewhere in the industry.

Submitted by,
1. G.GOKULNATH

2. R.PRAVIN

3. K.S.VIJAYAKUMAR

External guide: Internal guide:

1. Mr. M.SACHIN MOOREY, 1. Mr. V.MEGANATHAN,

Technical head ( R&D) Assistant Professor, MSEC.

EASUN-MR, Thiruninravur.
1
2
CHAPTER 1
INTRODUCTION
1.1 INTODUCTION TO TAP CHANGERS :

A tap changer is a mechanism in transformers which allows for variable turn

ratios to be selected in distinct steps. And with this mechanism obtain this
variable turn ratio by connecting to a number of access points known as taps
along either the primary or secondary winding.

Tap changers exist in two primary types, no load tap changers (NLTC) which
must be de-energized before the turn ratio is adjusted and on load tap changers
(OLTC) which may adjust their turn ratio during operation. The tap selection on
any tap changer may be made via an automatic system, as is often the case for
OLTC, or a manual tap changer, which is more common for NLTC.

1.2 INTODUCTION TO OLTC:

On-load tap changer (OLTC), also known as On-circuit tap changer (OCTC), is
a tap changer in applications where a supply interruption during a tap change is
unacceptable, the transformer is often fitted with a more expensive and complex
on load tap changing mechanism. On load tap changers may be generally
classified as either mechanical, electronically assisted, or fully electronic.

Tap changers typically use numerous tap selector switches which may not be

switched under load, broken into even and odd banks, and switch between the
banks with a heavy-duty diverter switch which can switch between them under
load. The result operates like a dual-clutch transmission, with the tap selector
switches taking the place of the gearbox and the diverter switch taking the place
of the clutch.

3
 CHAPTER 2
COMPANY PROFILE

2.1 EASUN - MR
Easun - MR (EMR) is an Indo-German Joint Venture with the
Maschinenfabrick Reinhausen GmbH, (MR), Germany and the Easun Group of
India. Maschinenfabrick Reinhausen GmbH, (MR), Germany, the joint venture
partner in EMR are the technology leaders in voltage regulation equipment and
cater to the requirements of the Transformer manufacturers Worldwide.

MR has over 80 years of experience in design and development of Tap

Changers and with a view to enable localized production, considering market
requirements, has joined hands with the Easun Group in the present successful
venture of EMR with Equal Financial Stake. Easun - MR a No.1 Tap Changer
Manufacturer in India has been accepted by Utilities, Consultants and
Transformer Industry in one voice as superior Technology Solution Provider in
the Arena of Tap Changer with well proven credentials over the past 32 Years.

4
Fully Automated CNC machines, Semi Robotic Equipment have been installed
to bring out critical precision components. The integrated test
facilities incorporated with the latest measuring cum recording instruments are
available in-house. This test facility combined with the Advanced leak
Detection equipment and the latest measuring cum recording instruments are
also available in-house. This test facility enables Easun - MR to conduct all the
routine tests called for in the International Standards and all additional
reliability tests called by various users and consultants under one roof. A walk
in to the production floor of Easun - MR will give you a glimpse of the
technological prowess of our production process.

Fig 2.1 EASUN –MR ( Chennai unit)

5
2.2 PRODUCTS:

2.2.1 OLTC:
OLTC is a tap changer in where a supply interruption during a tap change is
unacceptable, the transformer is often fitted with more expensive and complex
on-load tap change mechanism. It is used to regulate the output
voltage.EASUN-MR developed several types of OLTC based on customer

needs.

2.2.2 OCTC:

Off-circuit tap changers are used for voltage adjustment in oil immersed
transformers. In contrast to on-load tap changers, off-circuit tap changers can
only operate when the transformer is deenergized.

2.2.3 TRANSFORMER MONITORING UNIT

The MR make advanced Transformer Monitoring Systems which are promoted

by Easun - MR monitor all parameters of transformer which can be individually
adapted to your specific requirements with the option of different add-on
modules. It is also possible to flexibly combine and adapt or expand the
functions with customized signal assignment of board input / outputs.

6
 CHAPTER 3

LITERATURE REVIEW

3.1 INTRODUCTION

The literature Review of literature is a systematic survey of the facts and figures
of previous researches on a particular topic. It is a collection of major findings
of past researches on a particular topic. It is useful to understand what has been
done on the topic during the past period. In every research, there are certain
preliminary works and the review of previous literature is one among them.
This is secondary source in the data collection aims to review the critical points
of current knowledge including substantive finding as well as theoretical and
methodological contribution to a particular topic. Mostly, review of literature is
associated with academic oriented literature; usually it precedes a research
proposal and result section. Aim of the literature review is to bring the reader up
to date with current literature on a topic and form the basis for another goal.
Literature on the utilization of digital and printed resources and other related
issues is given below

 Chang-Liang Liu, in his article “Systematic conceptual design of

modular fixture” published in 1994, he has carried out a study about
how modular fixture will become very useful in the future to come. He
explains that a fixture being modular can give some required functions
they want and it also opens the gateway for many creative ideas to
emerge. By reading this article we understood that the use of modular
fixtures.

7
Hai Li, in his article “Design and application of flexible fixture” published in
2016, he has carried out a study about how the fixture being

8
  flexible allows us to use work pieces of different measurements and
shapes which was helpful in our project.
 Mr. Uday C Ayashe, Mr. Adawit Ranpise, Mr. Mayur Mahajan, in their
article “Study of fixture and it modifications” published in 2018, they
have made an effort for others to understand how the modifications in
fixtures in key areas would bring them required result such
interchangeable location of the fixture and improvement in cycle times.
This article has been greatly helpful for us in understanding whether to
use modifications in our project

REFRENCES

 Liu, C.A, Systematic conceptual design of modular fixtures, International

journal for advanced manufacturing technology, 9 , 217-224(1994)
 Hai Li, Design and application of flexible fixture, Procedia CIRP, volume
56 2016, pages 528-532
 Uday C Agashe, Study of fixtures and its modifications, International
journal for research in applied science & engineering techonology,
ISSN:2321-9653, volume 6, issue 4, April 2018

9
 CHAPTER 4
TAP CHANGERS
4.1 TAP CHANGERS:

A tap changer is a mechanism in transformers which allows for variable turn

ratios to be selected in distinct steps. And with this mechanism obtain this
variable turn ratio by connecting to a number of access points known as taps
along either the primary or secondary winding.

Tap changers exist in two primary types, no load tap changers (NLTC) which
must be de-energized before the turn ratio is adjusted and on load tap changers
(OLTC) which may adjust their turn ratio during operation. The tap selection on
any tap changer may be made via an automatic system, as is often the case for
OLTC, or a manual tap changer, which is more common for NLTC.

Fig 4.1 Tap changers

10
4.1.1 NO-LOAD TAP CHANGERS:

No-load tap changer (NLTC), also known as Off-circuit tap changer

(OCTC) or De-energized tap changer (DETC), is a tap changer utilized in
situations in which a transformer's turn ratio does not require frequent changing
and it is permissible to de-energize the transformer system. This type of
transformer is frequently employed in low power, low voltage transformers in
which the tap point often may take the form of a transformer connection
terminal, requiring the input line to be disconnected by hand and connected to
the new terminal. Alternatively, in some systems, the process of tap changing
may be assisted by means of a rotary or slider switch.

No load tap changers are also employed in high voltage distribution-type

transformers in which the system includes a no load tap changer on the primary
winding to accommodate transmission system variations within a narrow band
around the nominal rating. In such systems, the tap changer will often be set just
once, at the time of installation, although it may be changed later to
accommodate a long-term change in the system voltage profile.

4.1.2 ON-LOAD TAP CHANGERS

On-load tap changer (OLTC), also known as On-circuit tap changer (OCTC), is
a tap changer in applications where a supply interruption during a tap change is
unacceptable, the transformer is often fitted with a more expensive and complex
on load tap changing mechanism. On load tap changers may be generally
classified as either mechanical, electronically assisted, or fully electronic.

Tap changers typically use numerous tap selector switches which may not be

switched under load, broken into even and odd banks, and switch between the
banks with a heavy-duty diverter switch which can switch between them under
load.

11
The result operates like a dual-clutch transmission, with the tap selector
switches taking the place of the gearbox and the diverter switch taking the place
of the clutch.

4.2 ON-LOAD TAP CHANGERS:

Power transformers equipped with on-load tap changers (OLTCs) have been the
main components of electrical networks and industrial applications for nearly 90
years. OLTCs enable voltage regulation and/or phase shifting by varying the
transformer ratio under load without interruption.

Fig4.2 Circuit diagram

12
4.2.1 SWITCHING PRINCIPLE:

The OLTC changes the ratio of a transformer by adding or subtracting to and

turns from either the primary or the secondary winding. The transformer is
therefore equipped with a regulating or tap winding which is connected to the
OLTC.

13
Fig 4.3 Principle winding arrangement of a regulating transformer

14
Fig 4.4 Switching element of tap changers

15
4.2.2 BASIC ARRANGEMENTS OF REGULATING
WINDINGS:

Linear arrangement is generally used on power transformers with moderate

regulating ranges up to a maximum of 20 %. The tapped turns are added in
series with the main winding and changes the transformer ratio. The rated
position can be any one of the tap positions.

Fig 4.5 Basic connections of tap windings

With a reversing change-over selector the tap winding is added to or subtracted

from the main winding so that the regulating range can be doubled or the
number of taps reduced. During this operation, the tap winding is disconnected
from the main winding. The greatest copper losses occur, however, in the
position with the minimum number of effective turns. This reversing operation
is realized using a change-over selector which is part of the tap selector or of the
selector switch.The rated position is normally the mid position orneutral
position.
The double reversing change-over selector avoids the disconnection of tap
winding during the change-over operation

16
4.2.3 DESIGN CONCEPTS OF ON-LOAD TAP CHANGERS:

Apart from tap selection, the most important task of an OLTC is the break
function or current (load) transferring action . After transferring the current, the
contact which “breaks” must be capable of withstanding the recovery voltage.
The required switching capacity for a specific contact in an OLTC is based on
the relevant step voltage and current but is also determined by the design and
circuit of the OLTC. The switching capacity itself is primarily a function of the
contact design, contact speed and arc-quenching agent.
Gas-immersed transformers, which are mainly used in Japan, dry-type
transformers and transformers with alternative insulating fluids meet these
requirements, which are increasingly being requested. Conventional tap
changers are not really suitable for this kind of regulating transformers, because
the use of mineral oil as a switching medium is – for the reasons mentioned
above – not desirable and would also require technically complex and expensive
overall solutions.
The first application of vacuum interrupters in reactor type OLTCs in the USA,
which started at the same time, was more successful. The size of the vacuum
interrupters at this time, particularly for the range of high currents, was not a
limiting factor because of the compartment-type design, but not so for the in
tank resistor-type OLTCs.
Looking at the overall profile of
 Quality
 Reliability
 Economy
 OLTC lifespan
 Range of ratings
at the present time and in the foreseeable future, vacuum switching technology
in OLTCs provides the best solution for today’s expectations.

17
With an OLTC comprising a diverter switch and a tap selector , the tap-change
operation takes place in two steps . The next tap is fi rst preselected by the tap
selector at no load. The diverter switch then transfers the load current from the
tap in operation to the preselected tap. The OLTC is operated by means of a
drive mechanism. The tap selector is operated by a gearing directly from the
drive mechanism. At the same time, a spring energy accumulator is tensioned,
which operates the diverter switch – after release at a very short time interval –
independently of the motion of the drive mechanism. The gearing ensures that
this diverter switch operation always takes place after the tap pre selection
operation has finished.

Fig4.6 Switching sequence of tap selector – diverter

18
Fig4.7 Design principle – diverter switch with tap selector

Fig4.8 Design principle – selector switch

19
 CHAPTER 5
PROBLEM IDENTIFICATION
5.1 IDENTIFICATAION OF ISSUES:
During the observation of an assembly of the newly designed selector , we
identified that the man power requirement and the rate of the production of the
newly designed OLTC could be improved ,which would be profit for the
company. The basic layout for a newly designed selector will be based on fiber
reinforced plastic board like the old model of the selector of the OLTC . The
FRP board used in the newly designed selector of the OLTC is comprised of
four individual parts. where as the old selector of the OLTC is made up of
single cylindrical FRP board . Since the newly designed selector do have four
individual parts compared to single part of old selector, the man power
requirements vary hugely for the newly designed selector which we will discuss
in the following topics .:

From the above statement we know that two things which may be affect the
profit of the company due to one reason of the FRP board layout in the newly
designed selector of the OLTC is made up of four individual parts .

Rate of the
Man power
production of the
requirements
OLTC

Things to be improved

20
5.1.1 MAN POWER REQUIREMENTS:

One of the important issue as said in the previous page is the number of persons
required for the assembly of newly designed FRP board is three members one
for assembly and two for holding the FRP board during the assembly of
selector. As said in the before page things could be improved during the
assembly for that we need to understand the layout of the FRP board in both
newly designed selector layout and existing selector layout .

5.1.2 BASIC LAYOUT OF THE FRP BOARD USED IN NEWLY

DESIGNED SELECTOR OF THE OLTC:

21
Fig 5.1 FRP board without groove Fig 5.2 FRP board with groove

As shown in the previous page the boards shown two different components of
newly designed selector of the OLTC . these above shown boards of two each
different design form the final layout of the of the FRP board used in selector of
the OLTC which comprises of four boards (two FRP boards with groove etched
in it and two FRP boards without groove etched in it) the final diagram will be
displayed down below .

Fig 5.3 Final layout of the FRP board used in the selector of the OLTC

22
5.1.3 RATE OF PRODUCTION OF THE OLTC:

Since two members are required for holding and one member for assembly of
the components in the selector of the OLTC the rate of producing the newly
designed is slow and could be improved by using some mechanical device to
hold the board and use those two extra members used for holding in the
assembly of another newly designed OLTC and because of this the actual rate
of production of OLTC can be improved . For instance the FRP board layout of
the old OLTC does not require any members for holding the board hence the
rate of its production and man power requirements are already at their efficient
level ,for understanding the layout of the board will be given down below

Fig 5.4 FRP board layout of the old selector of the OLTC

CHAPTER 6

SOLUTION

6.1 SOLUTION TO THE PROBLEM OF

HOLDING FRP BOARD IN THE
SELECTOR OF THE OLTC:

As mentioned in the previous chapter of

identification of issues the problem of holding the FRP board during assembly
can be done by a mechanical device. Generally for work holding, jigs and

23
fixtures are used since jigs are used where self-adjustment of the work holding
is required since the work piece may differ in size slightly , but here since the
dimensions of the FRP board are pretty much constant in the contact areas
between the work holding device and work piece , fixture are favored here since
its does not need all the guiding elements that the jigs need for their guiding. So
the solution to the above discussed problem would be using assembly fixture for
holding the two FRP boards with groove steadily and after the completion of the
assembly of electrical components to the FRP board the FRP boards with
groove not etched in it will slide in the grove to complete the final layout of
FRP board used in the selector of the newly designed OLTC

6.2 BASIC INTRODUCTION TO THE ASSEMBLY FIXTURE:

Assembly fixture is used to assemble mini part of the components with ease.
The process can be carried on the part and desired component can be achieved.
It is a work holding device that holds, supports and locates the workpiece for a
specific operation but does not guide the cutting tool. Fixtures involved during
assembly is called assembly fixture, we will be discussing them in detail in the
following chapter

CHAPTER 7
ASSEMBLY FIXTURE
7.1 FIXTURE
Fixture is a workpiece-locating and holding device used with machine tools. It
is also used in inspection welding and assembly. Fixture does not guide the
cutting tool, but is always fixed to machine or bench. By using fixture,
responsibility for accuracy shifts from the operator to the construction of
machine tool.

24
When a few parts are to be machined, workpiece clamp to the machine table
without using fixture in many machining operations. However, when the
numbers of parts are large enough to justify its cost, a fixture is generally used
for holding and locating the work.

Fig 7.1 Basic fixture

Fixture is used for locating and holding the workpiece. Fixture is always fixed
to machine or bench. Fixture is generally used for mass production. Fixture
reduces operator’s fatigue. The fixture also follows the principle of locating and
clamping. The various types of fixture such as vise, milling, grinding, facing,
turning, faceplate and boring fixture are explained with examples in this unit.
The design of fixture depends upon the shape and size of workpiece. The fixture
may be different for different workpieces.

25
7.1.1 OBJECTIVES OF FIXTURE:

After studying this unit, you should be able to understand

 the design consideration in fixtures, and

 types of fixture and its industrial application.

7.1.2 DESIGN CONSIDERATION IN FIXTURES:

 The main frame of fixture must be strong enough so that deflection

of the fixture is as minimum as possible. This deflection of fixture is
caused because of forces of cutting, clamping of the workpiece or
clamping to the machine table. The main frame of the fixture should
have the mass to prevent vibration and chatter.

 Frames may be built from simple sections so that frames may be

fastened with screws or welded whenever necessary. Those parts of
the frame that remain permanently with the fixture may be welded.
Those parts that need frequent changing may be held with the
screws. In the situation, where the body of fixture has complex
shape, it may be cast from good grade of cast iron.

 Clamping should be fast enough and require least amount of effort.

 Clamps should be arranged so that they are readily available..

 Clamps should be supported with springs so that clamps are held

against the bolt head wherever possible.

 If the clamp is to swing off the work, it should be permitted to swing

as far as it is necessary for removal of the workpiece.

 All locator’s clamps should be easily visible to the operator and

easily accessible for cleaning, positioning or tightening.

26
  Provision should be made for easy disposal of chip so that storage of
chips doesn’t interfere with the operation and that their removal
during the operation doesn’t interfere with the cutting process.

 All clamps and support points that need to be adjusted with a wrench
should be of same size. All clamps and adjustable support points
should be capable of being operated from the fronts of the fixture.

 Workpiece should be stable when it is placed in fixture. If the

workpiece is rough, three fixed support points should be used. If
workpiece is smooth, more than three fixed support points may be
used. Support point should be placed as farthest as possible from
each other.

7.1.3 FIXTURE DESIGN PROCEDURE:

In the design of a fixture, a definite sequence of design stages is involved. They

can be grouped into three broad stages of design development.

27
  Stage One deals with information gathering and analysis. These include
product analysis such as the study of design specifications, process planning,
examining the processing equipment and considering operator safety and ease
of use. In this stage, all the critical dimensions and feasible datum areas are
examined in detail.

 Stage Two involves the consideration clamping and locating schemes.A

clamping scheme is devised in such a way that it will not interfere with the tools
or cutters and are fully compatible with proposed locating surfaces or areas. The
locating scheme, using standard elements such as pins, pads, etc. is designed to
be consistent with clamping and tool-guiding arrangements.
 Stage Three is the design of the structure of the fixture body frame.This is
usually built around the workpiece as a single element which links all the other
elements used for locating, clamping tool-guiding, etc. into an integral frame
work.
The above procedures are quite general and can be modified depending on the
relative importance of the various elements in providing for the required
accuracy of the workpiece to be located and secured into the fixturing device.
With the popular adaptation of modular fixturing elements, the fixture body
frame is usually a standard block with fixed arrays of locating and fixing holes
or slots. It becomes a matter of selecting the most suitable body frame to
accommodate the various elements, provide good support of the workpiece and
access to cutters and tools.

7.1.4 LOCATING PRINCIPLES OF FIXTURE:

One of the principal purposes of a fixture is to locate the workpiece

surfaces for performing a machining operation. This is usually done with
respect to a nurnber of factors to be considered such as the reference datum,
28
supporting surfaces, features that are likely to obstruct the tool movement or
access direction, etc. In general, the following surfaces should be distinguished:

 Active surfaces
These are surfaces to be machined, i.e. surfaces which are subjected to
the action of cutting tools.

 Supporting and locating surfaces

These are surfaces by means of which the work piece is to be located
with respect to set-to-size cutting tools.

 Clamping surfaces
Clamping surfaces are subjected to the clamping forces for obtaining
invariant location. Clamping surfaces are usually not finish-machined surfaces
as clamping marks could damage the finish.

 Datum surfaces
Datum surfaces are reference surfaces where the dimensions are to be
maintained and measured.

 Free surfaces
Free surfaces are surfaces not involved in the set-up for the particular
machining operation.

7.2 ASSEMBLY FIXTURES:

The successful running of any mass production depends upon the inter
changeability to facilitate easy assembly and reduction of unit cost. Mass
production methods demand a fast and easy method of positioning work for

29
accurate operations on it.
Fixtures are production tools used to accurately manufacture duplicate and
interchangeable parts. Jigs and fixtures are specially designed so that large
numbers of components can be machined or assembled identically, and to
ensure interchangeability of components.
Assembly fixture is used to assemble many part of the component with ease.
The proses can be carried on the part and desired component can be achieved.

Fig 7.2 Basic assembly fixture

7.3 FACTORS TO BE CONSIDERED FOR DESIGN OF

FIXTURES:

7.3.1 Component:

30
Design to be studied carefully Ensure work is performed in a proper sequence
Maximum operations should be performed on a machine in single setting.
7.3.2 Production requirements:
Design to be made on basis of actual production requirements. Then comes
decision on manual and automatic tooling arrangements.
7.3.3 Location:
• Location should ensure equal distribution of forces
throughout all sequence of operation.
• Location should be hard resistant, wear resistant and
high degree of accuracy.
• Movement of workpiece should be restricted.
• Should be fool proofed to avoid improper locations of
the workpiece.
• Should facilitate easy and quick loading of workpiece.
• Redundant locators should be avoided.
• Sharp corners must be avoided.
• At least one datum surface should be establised.
7.3 MATERIAL ANALYSIS:

Fixtures are made of variety of materials, some of which can be hardened to

resist wear.
 High speed Steel:
Cutting tools like drills, reamers and milling cutters.

 Die steels:
Used for press tools, contain 1% carbon, 0.5 to 1%
tungsten and less quantities of silicon and manganese.
 Carbon steels:

31
 Used for standard cutting tools.
 Collet steels:
Spring steels containing 1% carbon, 0.5% manganese
and less of silicon.
 Non shrinking tool steels:
High carbon or high chromium Very little distortion
during heat treatment. Used widely for fine, intricate press tools.
 Nickel chrome steels:
Used for gears.
 High tensile steels:
Used for fasteners like high tensile screws.
 Mild steel:
Used in most part of Jigs and Fixtures Cheapest
material Contains less than 0.3% carbon.
 Cast Iron:
Used for odd shapes to some machining and laborious
fabrication CI usage requires a pattern for casting Contains more than 2%
carbon has self lubricating properties can withstand vibrations and suitable for
base.

 Nylon and Fiber:

Used for soft lining for clamps to damage
to workpiece due to clamping pressure.

CHAPTER 8
DESIGN DIFFICULTIES

32
8.1 PROBLEMS OCCURRED IN THE DESIGN ASSEMBLY
FIXTURE FOR THE SELECTOR OF NEWLY DESIGNED
OLTC

Though the design of an assembly fixture for holding the FRP board is not that
complicated they do have some design limitations and those limitations comes
in the form dimension and assembly pattern of the components of selector of the
newly designed OLTC

8.2 MAJOR DESIGN DIFFICULTIES

As mentioned above the two design limitations are as follows

 Dimensional limitations
 Assembly pattern of the components of the selector
 Adjustment of clamping pressure

8.2.1 DIMENSIONAL LIMITATIONS

Since only about 5mm so we have only little space to work that’s why we have
two clamping at both sides of the board for that stability. The diagram for the
clamping arm with main and detachable arm is given the will be shown in 3D
design and explained in detail in chapter 9

8.2.2 ASSEMBLY PATTERN OF THE COMPONENTS OF THE

SELECTOR

The assembly pattern of the layout of the FRP board in selector is like this , the
first two boards that are to be hold during the assembly of the selector is the
FRP board with the groove etched in it , and after the whole assembly of
electrical and all components in selector of the newly designed OLTC , the FRP
boards without groove etched in it will be inserted. This pattern of assembly of

33
FRP boards in this selector of the newly designed OLTC affects the design of
clamping arm area space significantly. The 3D design of clamping arm will be
shown in chapter 9.

8.2.3 ADJUSTMENT OF CLAMPING PRESSURE:

The clamping unit should exert only light pressure enough to hold work piece if
any greater pressure given during clamping then such action would cause severe
to the work piece, in this case FRP board. In order to adjust the amount of
pressure exerted on the FRP board we use nut and bolt as a tightening element
limit the amount of pressure.

8.3 CORRECTION:

In order to eliminate dimensional, assembly pattern of the selector and clamping

pressure, we use 3 design modifications as said in the before passages. These 3
design modifications are as follows:

 Detachable arm
 Clamping on both sides
 Nut and bolt tightening mechanism

The diagrams for all the three above mentioned 3D design diagrams will be
given in chapter 9.

CHAPTER 9

34
 DESIGN OF ASSEMBLY FIXTURES PARTS FOR THE
SELECTOR

9.1BASIC DESIGN METHOD, SOFTWARE USED AND 3D

PRT DESIGN LISTS OF ASSEMBLY FIXTURE FOR
SELECTOR

This topic explains about basic design method that has been followed in
industry for long and also the software used for creating 3d design. And the
mechanical device we are going to design today is assembly fixture. Since
designing a complex mechanical device will take more time we will first design
all the 3D parts of the assembly fixture. And then assemble all 3D parts to get
the final 3D design of assembly fixture. The following pages in this chapter will
show 3D diagrams of each part of the assembly fixtures

9.1.1 CREO PARAMETRIC 3.0

The software used in this project for designing the parts of the assembly fixtures
is CREO parametric version 3.0. it I a very popular software used by many
professional, academic students and also some industries in their R&D
department. They use mainly because they are very easy to use and also has
many features and flexibilities. For all that same reason we also chose CREO
parametric

9.1.2 3D PRT DESIGN LISTS OF ASSEMBLY FIXTURE FOR

SELECTOR

There are several parts in the design of assembly fixture for selector and they
are base, body, detachable main arm, detachable clamping arm, nut and bolt.
The 3D designs for the respected parts will be shown one by one from the
following page.

35
9.2 DESIGN OF BASE PART DIAGRAM OF ASSEMBLY
FIXTURE.

This is the foundation for the two main body of the assembly fixtures to be
welded for required length between them. They provide stable support since
they have great area of surface contact they also absorb all the physical
conditions that are to be experienced by the fixture for holding the work piece.
The following subtopic will show the 3d part diagram for the base part.

Fig 9.1 3D part diagram of base

36
9.3 DESIGN OF BODY PART DIAGRAM OF ASSEMBLY
FIXTURE

This is the part that is to be welded on to the base. There are two body parts for
holding two FRP boards with groove. These body parts also contain an arm
which will be welded since at start of installing FRP board we need more
horizontal area for some initial holding while the workers do tightening of nut
and bolt. The diagram will be given below

Fig 9.2 3D part diagram of body

37
9.4 DESIGN OF DETACHABLE MAIN ARM PART DIAGRAM
OF THE ASSEMBLY FIXTURE

This part is detachable arm it provides same function as the arms fitted on the
body do but only difference is they can be removed. Their removal function can
be very useful after all FRP boards has been assembled as the removal whole
work setup out of fixture will be not possible if the arm is welded and they are
tighten by using nut and bolts and respective holes are also designed and drilled
to match the main arm position to give stability

38
Fig 9.3 3D part diagram of detachable main arm

39
9.5 DESIGN OF DETACHABLE CLAMPING ARM PART
DIAGRAM OF THE ASSEMBLY FIXTURE

This part also a detachable one, since the FRP board we use is not strong like
metal we need to adjust clamping pressure so the work piece does not gets
damaged. The board also may come in slight variation in thickness so by using
nut and bolt for tightening and using detachability for flexibility we get good
function out of the fixture device.

Fig 9.4 3D part diagram of detachable clamping arm

40
9.6 DESIGN OF NUT AND BOLT PART DIAGRAM OF THE
ASSEMBLY FIXTURE

This part is responsible for all the tightening and also in the detachable process
of the main and clamping arm. They provide flexibility in clamping pressure
and also in accommodating the slightly varied thickness in FRP board.

Fig 9.5 3D part diagram of nut

Fig 9.6 3D part diagram of bolt

41
 CHAPTER 10

PROCESSES INVOLVED IN THE PRODUCTION OF

ASSEMBLY FIXTURE

10.1 REQUIRED PROCESS FOR ASSEMBLY FIXTURE AND

MATERIAL USED IN HERE

This topic explains the processes that would be necessary to make these 3D
designed part components of the assembly fixture into real world product if
necessary, since we are not doing the fabrication we are giving our choices that
we took in the production of parts of the assembly fixture for the selector. All
the choices made and ratings given are solely based on readings and standards
from the best materials from all the best sources and also some input by the
company. In this process of producing we use machining, welding, heat
treatment, surface treatment and surface finish for the required quality and also
for required function standards

10.1.1 MATERIALS USED FOR FIXTURE:

Mostly used material for fixture are as follows

 Mild steel
 Aluminum
 Brass
 Carbon steel

Out of these four we chose Mild steel, since took economy and also ease of
machining and welding into account to facilitate easy production of the parts for
the company

42
10.2 MACHINING PROCESS

Machining is any of various processes in which a piece of raw material is cut

into a desired final shape and size by a controlled material-removal process. The
machining would be very important in the production of fixture of selector since
each and every mm matters efficient machining is required for such machines.
Three principal machining processes are as follows

 Turning
 Drilling
 Milling

TURNING: Turning operations are operations that rotate the workpiece as the
primary method of moving metal against the cutting tool. Lathes are the
principal machine tool used in turning.

DRILLING: Drilling operations are operations in which holes are produced or

refined by bringing a rotating cutter with cutting edges at the lower extremity
into contact with the workpiece. Drilling operations are done primarily in drill
presses but sometimes on lathes or mills.

MILLING: Milling operations are operations in which the cutting tool rotates to
bring cutting edges to bear against the workpiece. Milling machines are the
principal machine tool used in milling.

Then are also other machining such as shaping, planning, boring, broaching and
sawing. By using all the above said futures the machining pf parts of assembly
fixture for selector can be done. There also few other important processes as
mentioned before to come which we will discuss in detail in the following pages
of the chapter 10

43
10.3 WELDING PROCESS:

This process is important for the joining of body to the base and arm to the
body. Welding is a fabrication or sculptural process that joins materials, usually
metals or thermoplastics, by using high heat to melt the parts together and
allowing them to cool causing fusion. Welding is distinct from lower
temperature metal-joining techniques such as brazing and soldering, which do
not melt the base metal.

In addition to melting the base metal, a filler material is typically added to the
joint to form a pool of molten material (the weld pool) that cools to form a joint
that, based on weld configuration (butt, full penetration, fillet, etc.), can be
stronger than the base material (parent metal). Pressure may also be used in
conjunction with heat, or by itself, to produce a weld. Welding also requires a
form of shield to protect the filler metals or melted metals from being
contaminated or oxidized.

Many different energy sources can be used for welding, including a gas flame
(chemical), an electric arc (electrical), a laser, an electron beam, friction, and
ultrasound. While often an industrial process, welding may be performed in
many different environments, including in open air, under water, and in outer
space. Welding is a hazardous undertaking and precautions are required to avoid
burns, electric shock, vision damage, inhalation of poisonous gases and fumes,
and exposure to intense ultraviolet radiation. The welding we chose is arc
welding because its simple and sufficient then to get the dimensions correct for
the FRP board to perfectly lean on it instead in slant position. Doing welding
perfectly and correctly is a an absolute essential. Main areas in which the weld
would be need are as follows

 Between body and the base

 Between the body and the main arm

44
10.4 HEAT TREATMENT PROCESS:

This process is a very essential because we need that little bit more hardness and
other physical characteristics out of the material we use one way of doing is
heat treatment process. Heat treating (or heat treatment) is a group of industrial,
thermal and metalworking processes used to alter the physical, and sometimes
chemical, properties of a material. The most common application is
metallurgical. Heat treatments are also used in the manufacture of many other
materials, such as glass. Heat treatment involves the use of heating or chilling,
normally to extreme temperatures, to achieve the desired result such as
hardening or softening of a material. Heat treatment techniques include
annealing, case hardening, precipitation strengthening, tempering, carburizing,
normalizing and quenching. Although the term heat treatment applies only to
processes where the heating and cooling are done for the specific purpose of
altering properties intentionally, heating and cooling often occur incidentally
during other manufacturing processes such as hot forming or welding.

The material we chose is mild steel though its improvement after heat treatment
process may not be major but it still improves nonetheless since any material
containing iron is bound to improve hardness and other physical characteristics.
There are also other areas where we need little bit softness for example
clamping arm surface that comes in contact with work piece so that it doesn’t
damage the FRP board in the process

Various heat treatment processes we chose are as follows

 Normalizing
 Annealing

Detailed discussion of the above two heat treatment processes will be in the
following pages.

45
10.4.1 NORMALIZING:

Normalizing is one of the heat treatment process. Normalizing is a technique

used to provide uniformity in grain size and composition throughout an alloy.
The term is often used for ferrous alloys that have been austenitized and then
cooled in open air. Normalizing not only produces pearlite, but also martensite
and sometimes bainite, which gives harder and stronger steel, but with less
ductility for the same composition than full annealing.

In normalizing process the process of heating the steel to about 40 degree

Celsius above its upper critical temperature limit held at this temperature for
sometime and then cooled in air. Normalizing is also well suited for thin
machines since cooling rate will be faster so we choose normalizing for all the
parts of assembly fixture except the clamping arm since it requires softness

Parts that we choose to use normalizing are as follows

 Body
 Base
 Detachable main arm
 Nut
 Bolt

The diagram for these parts mentioned above can be found in chapter 9 where
they are detailed with diagrams. The only part left out of it is clamping arm
which will require different kind of heating process called annealing. The
process of annealing and its details will be given in the following pages.

So the normalizing is well suited option for small thickness machines because
of cooling rate and also by using mild steel we save money and also we can
have that machining flexibility because of the mild steel.

46
10.4.2 ANNEALING:

Annealing is one of the heat treatment process. Only part to be annealed is

clamping arm. Annealing consists of heating a metal to a specific temperature
and then cooling at a rate that will produce a refined microstructure, either fully
or partially separating the constituents. The rate of cooling is generally slow.
Annealing is most often used to soften a metal for cold working, to improve
machinability.

In ferrous alloys, annealing is usually accomplished by heating the metal

beyond the upper critical temperature and then cooling very slowly, resulting in
the formation of pearlite. In both pure metals and many alloys that cannot be
heat treated, annealing is used to remove the hardness caused by cold working.
The metal is heated to a temperature where recrystallization can occur, thereby
repairing the defects caused by plastic deformation. In these metals, the rate of
cooling will usually have little effect. Most non-ferrous alloys that are heat-
treatable are also annealed to relieve the hardness of cold working. These may
be slowly cooled to allow full precipitation of the constituents and produce a
refined microstructure.

Ferrous alloys are usually either "full annealed" or "process annealed." Full
annealing requires very slow cooling rates, in order to form coarse pearlite. In
process annealing, the cooling rate may be faster; up to, and including
normalizing. The main goal of process annealing is to produce a uniform
microstructure. Non-ferrous alloys are often subjected to a variety of annealing
techniques, including "recrystallization annealing," "partial annealing," "full
annealing," and "final annealing." Not all annealing techniques involve
recrystallization, such as stress relieving.

By choosing annealing and normalizing as a heat treatment process the

materials may achieve the required properties

47
10.5 SURFACE TREATMENT:

Surface treatment is for further need of addition of some properties needed for
some parts in our case nuts and bolts. The surface treatment we choose based on
the materials we got zinc electroplating A process known as zinc plating is
frequently used to protect metals such as iron and steel against the relentless
forces of corrosion. Zinc plating involves the electrodeposition of a thin coating
of zinc metal onto the surface of another metal object, known as a substrate. The
zinc coating creates a physical barrier that prevents rust from reaching the
underlying metal surface. Zinc is chosen because of its innate ability to fight
corrosion. In fact, zinc is often referred to as the corrosion-prevention
workhorse. It protects the nuts and bolts in assembly fixtures as said above

10.6 SURFACE FINISH

We choose to select different surface finish ratings for different group of parts
of assembly fixture. Surface finish, also known as surface texture or surface
topography, is the nature of a surface as defined by the three characteristics of
lay, surface roughness, and waviness. It comprises the small, local deviations of
a surface from the perfectly flat ideal. The surface finish in industrial terms will
be given in roughness average only.

The roughness average or Ra is given in both micrometer and micro inches

ratings in the bill of materials table in chapter 12

NOTE: All the processes detailed in chapter 10 are based on books and
company staff advices since we don’t need to do fabrication our project is only
design, the main purpose of adding this chapter is for educational purpose and
on the suggestion of technical head.
48
 CHAPTER 11

ASSEMBLY OF THE PART DESIGNS OF THE ASSEMBLY

FIXTURE

11.1 ASSEMBLY INTRODUCTION AND SOFTWARE USED

This assembly process of different parts of the assembly fixture is continuation

of design process detailed in the chapter 9. This assembly process assembles all
parts based on many constraints. There are three main constraints we use in this
assembly process and they are as follows.

 Co-incidence
 Distance
 Parallel

With these three main constraints assembly of all parts in place is possible.
After the assembly check whether it is fully constrained if not then do a new
constrain of any suitable constraint mentioned above. After that color different
parts different color for easy identification.

11.1.1 CREO PARAMETRIC 3.0:

Its not only useful for its design but also very useful for the assembly also. The
CREO parametric as mentioned in chapter 9 is also widely used for assembly by
many peoples

49
11.2 ASSEMBLY FIXTURE DESIGN DIAGRAMS:
11.2.1 COMPLETED ASSEMBLY PART DESIGNS OF THE
ASSEMBLY FIXTURE WITHOUT THE FRP BOARD
(ISOMETRIC VIEW)

Fig 11.1 Isometric view of assembly fixture

50
11.2.1 COMPLETED ASSEMBLY PART DESIGNS OF THE
ASSEMBLY FIXTURE WITHOUT THE FRP BOARD (SIDE
VIEW)

Fig11.2 Side view of assembly fixture

51
11.2.3 COMPLETED ASSEMBLY PART DESIGNS OF THE
ASSEMBLY FIXTURE WITHOUT THE FRP BOARD
(TOP&BOTTOM VIEW)

Fig11.3 top view Fig11.4 Bottom view

52
11.2.4 COMPLETED ASSEMBLY PART DESIGNS OF THE
ASSEMBLY FIXTURE WITH THE FRP BOARD
(ISOMETRIC VIEW)

Fig11.5 Isometric view of assembly fixture with FRP board

53
11.2.5 COMPLETED ASSEMBLY PART DESIGNS OF THE
ASSEMBLY FIXTURE WITH THE FRP BOARD (SIDE VIEW)

Fig11.6 Side view of assembly fixture with FRP board

54
11.2.6 COMPLETED ASSEMBLY PART DESIGNS OF THE
ASSEMBLY FIXTURE WITH THE FRP BOARD
(TOP&BOTTOM VIEW)

Fig 11.7 Top view Fig 11.8 Bottom view

55
 CHAPTER 12

RESULTS AND DISCUSSIONS

12.1 RESULTS OF THE 3D DESIGN AND ASSEMBLY OF FRP

BOARD IN SELECTOR OF NEWLY DESIGNED OLTC

As seen in the previous chapter the 3D design and assembly of FRP

board in selector of the newly designed OLTC has been successfully
executed using 3D design software such as creo parametric. As shown
the assembly of fixtures for FRP board of the selector in the previous
chapter. The clamping of arm with FRP board is fully constrained
which indicates that the design assembly fixture will hold the FRP
board stable without any problem during the assembly of the selector.

As mentioned in chapter 8 the difficulties during assembly of FRP

board in selector is resolved by inserting dual clamping design,
adjustment of clamping using nut and bolt and by keeping the
assembly pattern unchanged. Because of the assembly fixture the
company would save man-power resources that can be allotted to
some other work or some other assembly. Due to the above actions
the company could improve the Rate of production of newly designed
OLTC which turn would be beneficial to the company and it would
also give them some profit in the business.

The major humane benefits that are to be obtained by using this

fixture for holding the FRP board would put less strain on workers
physically holding the FRP board.

56
 12.2 BILL OF MATERIALS

S.NO DESCRIPTION DIMENSIONS QUANTITY (HEAT SURFACE

TREATMENT / FINISH
(mm) SURFACE (Ra)
TREATMENT)/ (micrometer
(Material used) or
microinches)

Length Breadth Thickness

01. Base 500 500 20 1 Normalizing/ 12.5\500

Mild steel

02. Body 1500 20 50 2 Normalizing/ 12.5\500

Mild steel

03. Arm 50 213 28 4 Normalizing/ 12.5\500

Mild steel

04. Detachable 50 213 58 4 Normalizing/ 12.5\500

arm Mild steel

05. Clamping arm 268 45 50 8 Annealing/ 12.5\500

Mild steel

Zinc 1.6\63
06. Nut M10 12 electroplating
/ Mild steel
Zinc
electroplating 1.6\63
07. Bolt M10 12 / Mild steel

57
12.3 DISCUSSION OF ALL THE CHOICES MADE DURING
DESIGN AND ALSO PREDICTED PROCESS OF ASSEMBLY
FIXTURE PARTS

All the design process choices seen in before chapters have been by keeping
flexibility, the ease to use and economical viable reasons, All the design and
process are as follows

12.3.1 DESIGN CHOICES THAT ARE MADE DURING THE

DESIGN OF ASSEMBLY FIXTURE PARTS

 Detachable clamping arm and detachable main arm

 Clamping on both sides of the FRP board
 Adjustment of clamping pressure using nut and bolt

12.3.2 PROCESS CHOICES THAT ARE MADE DURING THE

MAKING OF ASSEMBLY FIXTURE PARTS

All the process choices that are to be listed below are made by keeping the
functionality of fixtures, life of the fixture device and other physical entities that
could affect the working of fixture and those process choices are as follows.

 Normalizing for all the parts in assembly fixture except clamping arm for
increasing hardness wear and tear resistance.
 Annealing for only clamping arm due to the softness required for the parts
that are in contact with work piece.
 Zinc electroplating for nut and bolt to increase surface wear and tear.
 Roughness for all the except nut and bolt should be 12.5 and for nut and
bol

58
 CHAPTER 13

CONCLUSION

We had enormous practical experience throughout the course of our project

work in Easun - MR, Thiruninravur . We are, therefore, happy to state that the
inculcation such of mechanical aptitude proved to be very useful. Undoubtedly
the joint venture had all the merits of interest and enthusiasm shown by all of
us. The credit goes to the healthy coordination of our batch colleagues in
bringing out a resourceful fulfillment of our assignment described by the
university. The design criterion imposed challenging problems which however
were welcome by us due to the availability of expert guidance.

The main vision of our project is to eliminate the wastage of time, men
and material required for assemble the OLTC. We are overwhelmed at the
arriving of the targeted mission. It is achieved by implementing the fixture
proposed. The fixture which we designed overcome all the design constraints of
the OLTC. The requirements of man power reduced for assembling of OLTC if
the fixture for assembly proposed in our project is implemented successfully by
the department of development.

We are privileged for working with one of the prestigious tap-changer

manufacturers. The amount of knowledge we gained over the period of time is
priceless and will be thankful for the organization for granting us the
opportunity to carry out our project work.

59
REFRENCES

 Liu, C.A, Systematic conceptual design of modular fixtures, International

journal for advanced manufacturing technology, 9 , 217-224(1994)
 Hai Li, Design and application of flexible fixture, Procedia CIRP, volume
56 2016, pages 528-532
 Uday C Agashe, Study of fixtures and its modifications, International
journal for research in applied science & engineering techonology,
ISSN:2321-9653, volume 6, issue 4, April 2018
 P.H. Joshi , jigs and fixtures design manual, second edition, ISBN 0-07-
140556-9

60