ARBA MINCH UNIVERSITY

ARBA MINCH INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING

A REPORT ON INTERNSHIP WORK AT

ARBAMINCH TEXTILE SHARE COMPANY S.C

PROJECT TITLE: DESIGN PNEUMATIC LIFTING PISTON CYLINDER

By:

GETNET TEBEJE ID: 877/11 SECTION B

02/06/2015 E.C
 CHAPTER ONE
1. INTRODUCTION
1.1 Company background and overview
AMTS. Co was established in 1991 GC to produce and satisfy very large need for
cotton blended fabric in the country.
It is located in state of south nation’s nationalities and peoples, Gamo zone, Arba
Minch
It is found in 5 km away from Arba Minch town and about 454 km from Addis
Ababa.
Construction of this company was carried out on a total area of 32400sq meter
The main product of the company
 100% cotton and poly/cotton twill weaves
 100% cotton, suiting plain I and II are examples
 100% polyester, 50/50pc, 60/35pc plain weave fabrics, example light
‘’abujedi’’
 Figure 1 background of the company

1.1.1 Benefits of the company

 Saves foreign currencies that would have been used for the importation of similar kinds
of fabrics.

 Provides job opportunities for over 558 peoples.

 Generates substantial revenue to the government in the form of taxes.

 Renders marked contribution to the overall industrial development of the state.

1.1.2 Objective of the company
 Manufacturing yarns of good quality at low price

 Manufacturing all kinds of finished grey clothes from cotton, synthetics, and fabrics.

 Preparing goods for both local and foreign markets.

 Working for economic change of stake holders in the company.

 Producing more working opportunities for peoples who have interest to work

1.1.3 Infrastructures and facilities

 Transport accessibility- there is well- constructed asphalt road

 Electric – there are supply of high-power electric line.

 Water- well treated own ground water

 Others- telephone, fax, email, and cafeteria.

1.2 Organizational structure
1.3 Production Flow
• Raw Material Store

Spinning
Department

Weaving
Department

packaging
1.4 Departments
A. Spinning department
The process of mixing different types of cotton coming from different places
having different quality.
There are six rooms in this department. These are blowing room, carding room,
drawing room, roving room, ring frame room, and open-end room.
Blowing Room: -This room is used to open, clean, blend or mix, dust removal and feed in the form of
chute to card or Marzulli machine. In this room there are different machine perform their function
sequentially.
Carding Machine: - It changes fiber flocks into fiber silver, separate each fiber independently
between cylinder and flat and major cleaning is achieved in licker-in.

Figure 2 carding machine

Draw Frame machine: - are used after carding in yarn manufacturing. This machine is divided in
two. Starter & finisher draw frames. Starter draw frame changes six slivers in to one. Finisher draw
frame take six outputs from starter draw frame and changes to one sliver, actually there are 36 total
slivers in to one.
 Figure 3 draw frame machine

Roving Frame: - is used to change input sliver to output roving. Electrically contains photocell, break &
clutch, motor, power switch, fuse, lots of limit switch contactor.

Ring Frame: - (Auto corner) is used to produce yarn from input roving. This machine is almost mechanical.

Fig 4 removing frame

II. Weaving department
 the room produces grey fabric from yarn
It have three main parts. These are
Warping machine
The main purposes of warp winding process are to form a suitable package for warping and checking and
cleaning the yarn from spinning defects.

Figure 6 warping machine

 Sizing machine
• Sizing: It changes different yarn beam to one beam this increases number of yarn ends. This step is necessary to

 Increase the smoothness of warp.

• Apply protective coating to the yarn to enable it so as to withstand complex stress in weaving machine

Figure 5 sizing machine

Pinacol machine
In pinacol machine to produce grey fabrics five and types of motions are required.
They are;
1. Slow motion: -motion that used to check weaving machine is in proper installation & this type of motion is carried out by slow
motion motor.

2. Sheading motion: -this is the up and down type of motion carried out by rotation of cams. Harness is the part of machine that moves
up and down for required target.

3. Let-off motion: -this type of motion is used to release or untwist the yarns.

4. Take-up motion: this type of motion is used to twist the fabrics after being interlace due to sheading and slay motion.

5. Slay-motion: -it is forth and back movement of pick finding due to 180-degree motion of gear in the slay box.

Figure 6 pinacol machine

Brushing machine
Brushing machine are designed to clean fabrics. Higher efficiency fabric cleaning is achieved. a highly efficient
dust collection of fiber.

Figure 7 brushing machine

Inspection machine
Inspection, in reference to quality management in the apparel
industry, can be defined as the visual examination or review of
raw materials.
 Figure 8 inspection machine

Fabric folding machine

Fabric folding is the process of winding fabrics in to clean, stretch free folded form for easy packaging and
transportation.
 Figure 9 fabric folding machine
1.3 maintenances in the company
• maintenance is keeping something in a good condition by checking or repairing it regularly.
• maintenance can be defined as a combination of actions carried out to repair, replace, service or modify the
components with an aim to bring the servicing unit to original
• 1.3.1 Procedure of maintenance
 describe the problem

 identify sign and record observations of anything unusual

 preparation for maintenance

 repair or preventive maintenance detail

 cheek out

 return to service

1.3.2 The basic objectives of maintenance are

 Reducing breakdowns

 Reducing downtime.

 Improving spares stock control.

 Improving equipment efficiency.

 Optimizing the useful life of equipment and

 Identifying and implementing cost reductions.

1.3.3 types of maintenance
1. planned maintenance and
2. unplanned maintenance
1. planned maintenance
• Basically, done for two purposes
 to prevent the occurrence of brake down
 if break down has occurred then to restore it to original condition
planned maintenance divided by into two
A. preventive maintenance and
B. corrective maintenance
1.3.3.1 preventive maintenance
• It is done to keep an equipment or machinery in a satisfactory operating condition through inspection,
lubricating, and replacement of certain components.

• The tasks are implemented before a problem is evident .

Advantages of Preventive Maintenance

 Reduction in downtime
 Reduction in loss of production
 Reduction in repair and replacement cost
 Less expenditure on maintenance personnel due to over time
 Fewer parts to be stored
 Higher safety level in the shop
1.3.3.2 Preventive Maintenance is divided into three categories
1. Running Maintenance: is done even when the machine or equipment is in service.

2. Shut-down Maintenance: is done when the machine is not in use.

3. Design-out Maintenance: Equipment's are designed that no maintenance should be required or at worst least maintenance
should be done.
1.3.3.3 Corrective Maintenance
Corrective maintenance: - is done to bring the machinery to original performance level, by minor adjustments

of certain knobs, or key units or replacing some worn-out parts. This could be occurring:
 Complete failure
 Minor failure
• Corrective Maintenance could be:
1. Shutdown Maintenance
2. Breakdown Maintenance
1.4 TYPICAL CAUSES OF EQUIPMENT BREAKDOWN
 Lack of lubrication
 Failure of cooling system
 Failure to replace worn-out parts
 Too high or too low voltage supply

1.5 common failures in maintenance

 Lost of customer
 High downtime
 High repair cost

1.5.1 Why things fail

1. Failure resulting from within the operation:

 Design failure

2. Failure resulting from material or information input

 Supplier failure

3. Failure resulting from customer actions

 Customer failure
• 1.5.2 Failure modes/Types of failure causes
 Welding: Of contacts due to an abnormal electrical current,

 Failure by corrosion: Materials can be degraded by their environment by corrosion processes,

such as rusting in the case of iron and steel.

 Fatigue failure: That occurs in structures subjected to dynamic and fluctuating stresses.

 Mechanical failure: That occurs in excessive deflection,

 Impact damage: - due to the impact of a projectile (bullet, shrapnel) or of a hard tool.

 Cut: - Loss of material due to the action of an edge tool.

 Scratch: - line-like loss of material due to the action of some pointed object.

1.6. Engineering department

I. Mechanical work shops
1.6.1 grinding wheel
Tapered wheel
• A straight wheel that tapers outward
towards the center of the wheel. This
arrangement is stronger and can
accept higher lateral loads. Tapered
face straight wheel is primarily used for
grinding thread, gear teeth .

Figure 10 grinding wheal

1.6.2 Shear (sheet metal) cutting
The machine may be foot powered, less commonly hand powered, or
mechanically or hydraulically powered. It works by first clamping the material
with a ram. A moving blade then comes down across a fixed blade to shear the
material. For larger shears the moving blade may be set on an angle or "rocked"
in order to shear the material progressively from one side to the other; this
angle is referred to as the shear angle.

Figure 11 guillotine shear metal

1.6.3 Bending machine (manufacturing)

• A bending machine is a forming machine tool. Its purpose is to

assemble a bend on a workpiece. A bend is manufactured by using a
bending tool during a linear or rotating move.

Figure 12 bench shear

1.6.4 Lath machine

 1.6.4 Lath machine

• A lathe is a machine tool that rotates a workpiece about an axis of

rotation to perform various operations
suchas cutting, sanding, knurling, drilling, deformation, facing,
and turning, with tools that are applied to the workpiece to
create an object with symmetry about that axis used
in woodturning, metalworking, metal spinning, thermal spraying,
parts reclamation, and glass-working.

Figure 13 lath machine

1.6.5 Milling (machining)
Milling is the process of machining using rotary cutters to remove
material by advancing a cutter into a workpiece. This may be done by
varying direction on one or several axes, cutter head speed, and
pressure.

Figure 14 milling machine

CHAPTER TWO
2. WORK, RESPONSIBILITIES, AND ASSIGNMENTS
2.1. procedure during tasks

• Attending punctually each work in days.

• Prepare a short review of daily activities at the end of each working day.
• Paying attention and asking about anything that is not clear.
• Listen carefully and take notes
2.2.1 Task one: - Observations of different types of machines
The first task should know the principle and working of all machines in the
company. This was the reason that the observation of different types of machines
has spent many days.
 2.2.2 Task two: - cleaning and lubrication of machines
Cleaning of machine is one way of preventive maintenance type all
machines should have need lubricating.

Figure 15 cleaning and lubricating graphi te

2.3. Task three: maintenance of motor belt
The purpose of this task is to repair the damaged main motor belt of the roving
frame machine. This problem is the roving machine completely inoperable. We
found out about this breakdown when we were with the senior mechanic, Mr.
Tariku, when the belt was smoking. What we did directly was to stop the roving
machine, drop the belt and take it to the workshop. After applying the adhesive to
the cut belt, we kept it on the heating machine for about 60 minutes.

Figure 16 maintenance of roving machine motor belt

2.4. Task four: specific observation of utility room
1.Air conditioner
Air conditioning is the process of removing heat from an enclosed space to achieve
a more comfortable interior environment (sometimes referred to as "comfort
cooling")
• Set environment-operating temperature.
• Waste removal (suction)
• Cleaning

Figure 17 air conditioner

2.Boiler
A boiler is a closed vessel in which fluid (generally water) is heated.
The fluid does not necessarily boil. The heated or vaporized fluid exits
the boiler for use in various processes or heating
applications. ] including water heating, central heating, boiler-based
power generation, cooking, and sanitation.

Figure 17 boiler
3.Water utility
Water utility: It is the controller of the water supply in the company. The water is
used for the boiler to generate steam, for drinking and other purposes.
Uses a row material as a chemical to clean the water
• Red artificial sand
• White sand
• Charcoal

Figure 18 water utility

4.Steam
Steam used for variety purpose, the most important being process heating,
drying or concentrating and distillation. steaming the operation by which.
coolants are fixed to the fabric.
They use some row materials as a chemical like gum, wax, hallow and starch.

Figure 19 steam
CHAPTER THREE
3.TECHNICAL ASPECT OF THE INTERNSHIP
I have been carrying out different procedures to interpret my
theoretical knowledge through practical tasks. Arba Minch University is
well known by the department of mechanical engineering this
department is well known by intelligent instructor they give
engineering knowledge. This helps me to share my useful idea for
AMTS.c
3.1. Objectives of the internship
3.1.1. Improvement of Practical Skill
have been highly practically skilled in operations of some machines. like
carding, drawing, ring, winding and some machines, and also simple
maintenance activities and use of hand tools.
3.1.3. I learned work together (Team Work)
I observed that teamwork is the great factor for success of the
company and to solve the problems, which face during the fabric
process. In our modification, teamwork plays a great role than
individual work that means in finding problems, sharing the ideas on
the problems, discussing on the ideas of the problems and with
company supervisors who support my ideas.
3.2. METHODS AND PROCEDURES
Step -1 collecting data using primary and secondary sources
Primary sources of data collection
Interview: -during practical work, preparing reasonable questions for
whom its concern was my habitual characteristic.
Observations: -every day during intern period I had been
observing how things were going on
Secondary sources of data collection
To search data under this method I read different written documents from
the manual of the machine of the company. In addition to this I used web
search related with Arba Minch textile Share Company, about
maintenance
3.3. Knowledge and acquaintances acquired
3.3.1. Technical skills gained
• Relating to textile machines, I have got its techniques or knowledge to operate
drawing and carding machine.
• How ground water that is used for different purpose, like steam generation, for
drinking to be treated is also categorized under my technical skills that I gained from
internship program.
3.3.2. Management skills gained
• How to organize different work divisions.
• How to treat employee of the company.
• How to solve conflicts
• Taking responsibility only on the concerning direction of work.
3.4. Challenges (problems) encountered during the internship period
• Very high temperature and the cotton dust while the overhead cleaner
motor moves to clean and these dusts are very harmful to breath.
• Shortage of well-educated person/profession/.
• Some difference on theoretical learning and practical skill.
• Most of the time supervisors of each department busy, due to this it is
difficult to get more information when I want their help.
3.5 Contributions
• I commented new method to increase the quality of product.
• I contributed in sharing knowledge with chief mechanic, to
department head and operators when some challenge is happening
on day today activity.
• I participate in different work divisions.
 CHAPTER FOUR
PROJECT (DESIGN PNEUMATIC LIFTING PISTON
CYLINDER)
• Pneumatic lifting piston cylinder (sometimes known as air
cylinder) are mechanical devices which use the power of
compressed gas to produce a force in a reciprocating linear
motion.
• Pneumatic systems in fixed installations, such as factories,
use compressed air because a sustainable supply can be
made by compressing atmospheric air. The air usually has
moisture removed, and a small quantity of oil is added at the
compressor to prevent corrosion and lubricate mechanical
components.
 Advantages of pneumatics
• Simplicity of design and control—Machines are easily designed using standard
cylinders and other components, and operate via simple on-off control.
• Reliability—Pneumatic systems generally have long operating lives and require
little maintenance. Because gas is compressible, equipment is less subject to shock
damage.
• Safety—There is a very low chance of fire compared to hydraulic oil. New
machines are usually overload safe to a certain limit.
Advantages of hydraulics
• Fluid does not absorb any of the supplied energy.
• Capable of moving much higher loads and providing much lower forces due to
the incompressibility.
• Supply more power than pneumatics.
• Can also do many purposes at one time: lubrication, cooling and power
transmission.
4.2. Statement of the problem
Railing machine in Arba Minch textile Share Company which used to produce the
yarn to traditional clothe production. This machine is bringing safety hazard on the
operators during doffing time lifting the beam to out the finished product (magi)
from the machine. This doffing process very difficult for the women (operator of
the machine) because the weight the machine. These waste the time, difficult for
the operators and it has hazard for worker. So, I observe this problem and solve by
designing this machine.

Figure 20 railing machine

4.3. OBJECTIVES OF THE PROJECT
4.3.1. General Objetive
• Design of pneumatic system cylinder for lifting shaft.
4.3.2. Specific Objectives
• To identifying each component of the pneumatic system cylinder.
• To select appropriate material for each part of the tool.
• To design each part (components) of the pneumatic system cylinder
• To design the parts drawings and full assembly of the pneumatic
cylinder by using solid work
4.3.3. Advantage Of the Project
This project gives different benefit for the company and also, i developing my
entrepreneurship by modifying different tool to solve the problem.
The benefit to the company
• ❖ Reduces hazards.
• ❖ Increase moral of the worker.
• ❖ reduce damage on the workers.

Figure 21phenoumatic lifting piston cylinder

4.3.4. Scope of the study
1.Design of parts
2. Detail drawing and assemble drawing
3. Verifying the mechanism
4. design the prototype
4.3.5. Limitation
I didn’t manufacture the proto type
I have not enough time to do
4.4. LITERATURE REVIEW
• Most of the earlier pneumatic control systems were used in the process control
industries, where the low-pressure air of the order 7-bar was easily obtainable
and give sufficiently fast response. Pneumatic systems are extensively used in the
automation of production machinery and in the field of automatic controllers. For
instance, pneumatic circuits that convert the energy of compressed air into
mechanical energy enjoy wide usage, and various types of pneumatic controllers
are found in industry. Certain performance characteristics such as fuel
consumption, dynamic response and output stiffness can be compared for
general types of pneumatic actuators, such as pistoncylinder and rotary types.
(Surly et al.1999).
• The final decision on the best type and design configuration for pneumatic
actuator can be made only in relation to the requirements of a particular
application. The pneumatic actuator has most often been of the piston cylinder
type because of its low cost and simplicity (Tabling et al.1963).
4.5. WORKING MECHANISM OF DESIGNED SYSTEM LIFTER

• The lifter raised and lowered by using pressurized air come from utility. The
pressurized air controlled by directional control valve. And also, it controls the
direction of pneumatic system cylinder at doffing time manual.
• The pressurized air inters to our system the piston moves upward. These forces
lift the beam up to required dimension. when we finished our work (doffing
process) by using directional control valve the piston became too their initial
position.
4.6. MATERIAL SELECTION
• Carbon
• Cast iron
• Alloy steels. Aluminum steels
• Nickel
• Mechanical properties: which includes Hardness, Softness, Ductility,
fatigue strengt.
• Physical properties: which includes Density, Color, Magnetic
property, Electrical and heat conductivity, Melting temperature,
• Chemical property: which includes Corrosion resistance to acids
Resistance to alkali and salts, resistance to other chemicals,
• Commercial factors: This includes Cost, Appearance, Availability,
Ease maintenance and repairing, easy to manufacturing.
Factors affecting Engineering Materials:
• Heat treatment that the material received during or after
manufacturing,
• Composition, from which elements the material is composed,
• Temperature, in which the material gives service.
 select material based on different consideration
• Availability of the materials,
• The cost of the materials.
• Suitability of the materials on manufacturing time and also working conditions
in service. Like: strength

Figure 22 working mechanism of pneumatic lifting

piston cylinder
4.7. METHODOLOGY
4.7.1. Method of data collection
• Primary data collection by interview the mechanic of the machine and the worker
which operate the machine.
• Secondary data collection by using internet sites and different books which
related to our design.
4.8. DESIGN ANALYSIS
4.8.1. Design Of Cylinder
• use the power of compressed gas to produce a force in reciprocating liner motion.
• It's a chamber where fuel is combusted and power is generated. The cylinder consists of a piston
an inlet. The piston moves up and down, and its reciprocating motion generates power that
moves the piston.
 Figure 23 design of cylinder

4.8.2. Design For Piston Rod

• Piston rods help in transmitting the power produced in the cylinder space to
the cross head. The lengths of these rods depend on the length the
manufacturers design
 Figure 24 design of piston rod

4.8.3. Design Of Bolt and Cylinder Cover

Bolts are used to fasten and assemble parts from
within aligned unthreaded holes, typically with the
use of a matching nut.

Figure 25 design of bolt

• The cylinder head/cover acts as a cover for the combustion chamber thereby
providing an enclosed space where the combustion can take place in the internal
combustion.

Figure 26 design of cylinder cover

4.8.4 design brush
• the piston cleaning ring is installed to protect against excessive
deposit build-up on the piston crown top land by scraping off the
deposits when the piston approaches top dead center (TDC).

Figure 28 design of brush

4.8.5 design of nut
• Nuts are almost always used in conjunction with a mating bolt to fasten multiple
parts together. The two partners are kept together by a combination of their
threads' friction (with slight elastic deformation), a slight stretching of the bolt,
and compression of the parts to be held together.

Figure 28 design of nut