Jayakavi Kannan

MECHANICAL ENGINEERING | M.ENG

DESIGN PROJECTS
 CONTENTS

SL No. TITLE PAGE No.

1 Automatic Tilting Mechanism For Welding Sheet metal- Concrete Mixer 3

2 Design And Fabrication Of E-Baja 7

3 Neon Light Bulb Glow Off Lock Checking – Special Purpose Machine 9

2
AUTOMATIC TILTING
MECHANISM FOR WELDING
SHEET METALS

CLIENT – Schwing Stetter, India

PROBLEM STATEMENT –
The existing vertical welding machines
present the operations are not capable for
welding sheet metals of different slant
heights.

SOLUTION –
Introducing an automatic tilting mechanism
2 D DRAWING OF BASE PLATE SCHWING STETTER – CONCRETE MIXER TRUCK
using ball screw, in the existing welding
machine reduces the project’s timeline and
cost.

The existing design data values were

collected from site and reverse engineered
the existing welding machine design to
accommodate the tilting mechanism.

VERTICAL TIG- WELDING MACHINE SHEET METAL HOLDER 3

PICTURE REFERENCES
FROM SITE

OPERATOR SETTING UP THE

MACHINE WITH A HOIST

OPERATOR REVIEWING
THE WELDING

4
SIDE VIEW OF AUTOMATIC
TILTING MECHANISM

TOPMOST
POSITION
OF
CARRIAGE

2 METER
WELD
AREA
PROVIED

BOTTOM
MOST
POSITION
OF
CARRIAGE

WHEN CARRIAGE IS AT THE WHEN CARRIAGE IS AT THE

TOP OF THE SETUP BOTTOM OF THE SETUP

5
SIDE VIEW OF AUTOMATIC
TILTING MECHANISM

AT MINIMUM ANGLE AT MAXIMUM ANGLE

6
DESIGN AND FABRICATION OF
E-BAJA

The Baja SAE Series is an annual

competition organized by the Society of
Automotive Engineers

OBJECTIVE –
Encourage undergraduate students to design,
manufacture and test and All-Terrain vehicle
prototype.
There are almost 100 participants, and it was ROLL CAGE DESIGN STEERING SUBSYSTEM
a good opportunity to put in practice the
knowledge acquired in class.

OUTCOME –
In 2018 we achieved the 3rd place in overall
design it has been the highest achievement in
the whole team’s history.

MATERIALS USED –
Rack and pinion gearbox – EN 353
Gearbox casing – Aluminum 6062–T6
Roll cage - AISI 1018
OUR ATV IN THE COMPETITION CUSTOM BUILT - RACK AND PINION GEARBOX

7
 STEERING SUBSYSTEM –
RACK AND PINION GEARBOX

ABSTRACT -
I was the Steering subsystem head and was
responsible for designing a rack and pinion
gearbox which has desired steering ratio,
zero play and sensitive steering

DESIGN OUTCOMES –
The newly designed gearbox is compared ACKERMANN STEERING MECHANISM STATIC STRUCTURAL ANALYSIS
with the original equipment manufacturer OF RACK AND PINION IN ANSYS
(OEM) rack and pinion gearbox based on
cost, weight and the steering gear ratio
parameter.

The results of the design shows that weight

of new rack and pinion gearbox is 14% less
than the OEM with nearly 30% reduction in
the cost achieving the desired steering ratio.

STEERING KNUCKLE- PVC PROTOTYPE FRONT SUSPENSION- PVC PROTOTYPE

ATTACHED TO AN OEM KNUCKLE ATTACHED TO HEM JOINTS

CARBON- SEAT DESIGN 8

 NEON LIGHT BULB GLOW OFF
LOCK CHECKING – SPECIAL
PURPOSE MACHINE

ABSTRACT-
I was involved in designing a special purpose
machine for IJL – India Japan Lighting Pvt
Ltd when working with Intercept Design
Solutions Pvt Ltd.

OBJECTIVE –
To design an electro-mechanical machine that ROLL CAGE DESIGN
can help the quality department of IJL in
inspecting the amber and parking bulbs of
different wattage. It is primarily used to
check the integrity of the bulb’s foot and
insulation as a single solution and is feature
rich with capable of measuring, displaying
and storing the test results for management
purposes with the help of an operator.

DRAWING OF THE SPM WITH BOM

9
 NEON LIGHT BULB GLOW OFF
LOCK CHECKING – SPECIAL
PURPOSE MACHINE

OUTCOME –
This machine is employed for

• Inspecting multiple bulbs with respect to

test - EN 60969 Lamp start time and EN
60969 Lamp warm-up time.
• The power system of this machine uses
frequency conversion speed regulation
system, which is of low noise and easy
for operation.
• Use of this machine to test ac/dc bulbs
during different voltage and temperature.

PROCEDURE –
• The test equipment and the measurement
device(s) shall be in a state such that the
lamp can immediately be started.
• Switch on power to the lamp and ISO - VIEW OF THE SPM ACTUAL MACHINE IN SITE
triggering equipment as required.
• The test shall run until the lamp starts
fully and remains alight. If after a
reasonable period the lamp does not start,
cease the test.
• Record luminous flux over time together
with ambient temperature and relative 10
humidity
Thank you for viewing my work!

Feel free to contact me:

jayakavi1996@gmail.com
(226) 961 2982