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(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
KGS BASED CONTROL FOR PARKING BRAKE CABLE
MANUFACTURING SYSTEM
*Geeta Khare & **Dr. R.S. Prasad
Abstract: centralized and distributed digital control
and its pros and cons have been studied.
In today’s competitive production
Here an attempt is made to overcome the
environment, process industries, demand a
disadvantages of above system to improve
totally integrated control and optimization
efficiency as well as profit level by going
solution that can increase productivity,
into minute details from root to top level
reliability and quality while minimizing
i.e. on line operator up to management or
cost. Automation is a step beyond
supervisor level, the system named as
mechanization. For automation of
KGS i.e. Kaleidoscopic Governing
production plant either centralized or
systems. Paper presents, the technical
distributed control system are used. There
viability of ‘KGS’ system how it is
are standardized approaches and standard
efficient in various ways to optimize
hardware & software available worldwide
output, improve profit margin and reliable
as per the requirement. Investment in
for output prediction in the operation of
process control system is also an important
manufacturing of PBC Cable which is
factor in improving product quality and
used in automobile sector.
lowering production cost while providing a
competitive edge to industries, which has Keywords: - Distributed Control
forced to others to improve their process systems, KGS, Conduit, Abutment, PBC
control technology. Various aspects of
*Geeta Khare, Principal, S.S.J.P, Asangaon, email id:-geetaharshu@gmail.com
**Dr.R.S.Prasad, Professor & Director, R.R.I.M.T., Lucknow
240 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
KGS BASED CONTROL FOR PARKING BRAKE CABLE
MANUFACTURING SYSTEM
Introduction:
Previously, industrial plant equipment, efficiency, operator efficiency and asset
such as pumps, motors and pneumatics, optimization. The ability to control the
was reliable and kept water flowing or process with accuracy, flexibility and high
machines opening, having no intelligence availability is more important than ever to
and generally no interface apart from some increasing quality, productivity and
minimal manual controls. As technology providing a sustainable competitive
developed, sensors and actuators were advantage. It enables distributed control
added and closed loop control systems applications and devices that deliver
created, so simple interfaces informed the maximum reliability, survivability and
operator about temperature or revolutions responsiveness.
per minute, whilst data loggers and
The DCS largely came about due to
recorders provided history on graph paper.
increase availability of micro computers
Automation is a step beyond and the proliferation of microprocessor in
mechanization, provided human operators the world of process control. In the
with machinery to assist them with the industry reliable process are crucial
muscular requirement of work, automation success. To stay competitive a plant must
greatly decreases the need for human function smoothly and efficiently at all
sensory and mental requirements as well. times, delivering the best possible return
Centralization process control combined on investment at the lowest possible costs.
with increased mechanization has resulted The use of DCS is becoming popular and
in improve productivity. useful to control complex process in the
industry that involves multiple variables
For automation of production plant either
and control loops. EMERSON,
centralized or distributed control system
YOKOGAWA, FOXPRO and
are used. Automation plays an increasingly
HONEYWELL have widely used DCS
important role in the world economy. It
system in the industrial process for
has a notable impact in a wide range of
automatic control. The DCS acts as a
industries beyond manufacturing. Process
significant and critical role in human
system as a part of full plant automation
supervisory control of automated plant
should be designed to improve production
241 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
applied in diverse complex industries such requirement. Various aspects of
as power plant, refinery, chemicals, centralized and distributed digital control
pipeline and manufacturing and many and its pros and cons have been studied
more. There are standardized approaches and disadvantages of these systems are
and standard hardware & software improved in KGS system.
available worldwide as per the
KGS System:
The advancement in embedded technology ensures fast commissioning as all the cards
is used to take care of local parameters. It of compatible.
gives full facility to local operator to • It ensures a significant boost in
interact with the process using keyboard & productivity throughout the entire life
LCD display. The settable alarm method cycle of the plant.
& alert message reduce operating skills & • It is designed to provide higher plant
breakdown time. It has enough memory to availability and productivity.
take care of data. The data memory will be • Reduce plant down times as well as
refreshed every time & data of interest of operating and maintenance cost as only
management will be sent to a pc through card replacement in worst case.
simple Ethernet data highway. The pc • No skilled man power is required so all
memory if not enough to take care of all process control components reduce down
data of interest then it can be transferred to time in the case of problem or other events
special data storage element. The data of and minimize production losses.
interest of respective department is also • There is no single point of decision
stored at the PC of that department. We making and therefore there is no single
have provided simple embedded controller point of failure.
at each control section which not only • Increased reliability with decreased
takes care of its own section to optimize communication costs.
system but at the same time communicates
• DCS delivers the needed response time,
with supervisory pc and alerts for present
and enhances system survivability
status by giving data. This gives benefits
increases reliability and lower cost.
in following way.
• A simple PC can acquire data for MIS
• It ensures simple and fast engineering and
purposes.
no probability of programming errors and
• Date transparency up to the managerial
level in real time.
242 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
• Resolution can be increased.
Parking brake system: tremendous brake force i.e. 50-pound
The rear disc brake system consists of a individual the power to stop a two-ton
solid rear disc brake rotor and a single vehicle, when the parking brake is release,
piston rear disc brake caliper. The rear pressure against the piston is released the
brake pads and linings are held in position rear brake pads and linings return to their
between the rear disc brake caliper and the unapplied position. A broken cable
rear disc brake rotor by two guides, and an indicates brake failure which should be
M springs. It is not necessary to remove replaced. In picking a replacement
the rear disc brake caliper completely to primary consideration are quality, material
replace the rear brake pads and linings, and compatibility with car’s model.
which can be removed simply by pivoting Superior parking brake cables are outfitted
the rear disc brake caliper on its rear disc with weather resistant rubber or plastic.
support bracket. Hydraulics power is Experimentation:
provided to the rear disc brakes by a rear The Parking Brake Cable (PBC) system of
wheel brake hose attached to the rear disc automobile component industry with
brake caliper. Replaceable copper washers centralized controller is shown in fig. (1).
on either side of the rear wheel brake hose The KGS scheme is implemented for PBC
fitting prevent brake fluid leakage. To stop Line is shown in fig (2) which solves the
the car from rolling down on an inclined present problem they are facing with
plane, need a well maintained parking centralized control system. In KGS
brake also known as hand brake or scheme 10 controllers CP 1 to CP 10 are
emergency brake. The parking brake is used. The controller have two cards:
connected to the main brake system Microcontroller and input – output with
through the parking brake cable. A broken power supply respectively.
brake cable disconnect the parking the Microcontroller card has hardware with
brake to the system. The most common suitable software for respective unit. It
problem of hand brake is broken brake also has communication port for PC
cable which will disconnects the parking interface to provide data to PC. The real
brake to the system. While pulling the Time clock is an optional feature. All units
lever it transfers force to the brake fluid have same microcontroller and input-
which travels through the cable. The fluid output cards so they are compatible to each
amplifies the minuscule force applied to
243 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
other. The only change in software program required for each stage.
Conduit cutting
Conduit deburring
Conduit pilling
Conduit shaping section
Sleeve insertion Centralized controller
White abutment pressing
Black abutment pressing (2NOS) Fig 1.: centralized
prosess system
Metal abutment pressing
Cable pilling
Abutment section
T ‐ end pressing (1) & (2)
Ring pressing
Traction
Conduit cutting Cp 1
Conduit deburring Cp2
Conduit shaping section
Conduit pilling Cp3
Sleeve insertion Cp3 Fig 2.: KGS
system
White abutment pressing Cp4
Black abutment pressing (2NOS)
Cp5
Metal abutment pressing Abutment section
Cp6
Cable pilling
Cp7
Pressing section
T‐ end pressing (1) & (2) Cp8
Ring pressing
Cp9
Cp10
Traction
244 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
In manufacturing of parking brake cable it Cable pilling removes unnecessary sleeves
goes under number of operations from it is optional process and if required only it
conduit cutting to fitting. is used.
Third stage – pressing section. T end
First stage – conduit shaping section;
fitting and ring fitting which are used for
cutting takes place and its length is
cable clamping to the support.
decided on the basis of model of vacant
Finally, the traction; is tested for checking
and an application which is the most
load bearing capacity of cable. The cable
important parameter and its acceptable
is stressed by pneumatic action and load
tolerance is ± 1mm.
cell will indicate actual load. If it breaks
Conduit deburring - the ends of the
below set value alarm becomes on which
conduit are smooth and by removing extra
indicate that cable is faulty and to be
material left at the time of cutting and the
rejected.
surface is clean so and abutment can be
fitted reliably. Results & Conclusion:
Conduit pilling end part sleeve is removed
• The experimental results show the system
and cleaned.
functionality and performances. Verify
Second stage – next operation is related to
the closeness of the two results, the KGS
abutment fitting. Abutments are the
system have been found to be in very good
plastic and metal parts fitted on conduit for
agreement with the target value. By using
proper grip and movement limiting.
KGS Production efficiency for CAR 1 is
Three types of abutments like white, black
improved by 22% and CAR 2 efficiency
and metal are used in normal cases.
by 15% with reference to existing control
White abutment is fitted on one end where
system. From table 1 & 2 it is observed
as black abutment is on another end &
that CAR 1 maintenance takes only 5 cable
metal is fitted near the tip of the conduit of
times while for CAR 2 it is 20 cable time.
the both ends.
The KGS system shows positive impact on
efficiency and reliability of the plant
which are shown in graph 1 & 2.
245 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
Target value 100/day Target value 700/day
Existin KGS
KGS
Existing syste Day g Differenc Proble syste
Days system Difference Problem m s system e m m
1 100 0 N 100 1 700 0 N 700
2 100 0 N 100 2 700 0 N 700
3 80 ‐20 M 95 3 650 ‐50 M 680
4 100 0 N 100 4 700 0 N 700
5 88 ‐12 M 95 5 573 ‐27 M 680
6 75 ‐25 M 95 6 615 ‐85 M 680
7 0 ‐100 H 0 7 0 ‐700 H 0
8 0 ‐100 M 95 8 0 ‐700 M 680
9 100 0 N 100 9 700 0 N 700
10 130 30 N 130 10 777 77 N 777
11 100 0 N 100 11 710 10 N 710
12 105 5 N 105 12 730 30 N 730
13 32 ‐68 R 32 13 412 ‐288 R 412
14 0 ‐100 H 0 14 0 ‐700 H 0
15 50 ‐50 M 95 15 570 ‐130 M 680
16 96 ‐4 R 96 16 660 ‐40 R 660
17 50 ‐50 M 95 17 620 ‐80 M 680
18 31 ‐69 M 95 18 280 ‐420 M 680
19 82 ‐18 M 95 19 600 ‐100 M 680
20 43 ‐57 M 95 20 175 ‐525 M 680
21 0 ‐100 H 0 21 0 ‐100 H 0
22 114 14 N 114 22 810 110 N 810
23 81 ‐19 R 81 23 550 150 R 550
24 79 ‐21 R 79 24 800 100 N 800
25 102 2 N 102 25 700 0 N 700
26 76 ‐24 M 95 26 615 ‐85 M 680
27 118 18 N 118 27 500 ‐200 R 500
28 0 ‐100 H 0 28 0 ‐700 H 0
29 30 ‐70 M 95 29 230 ‐470 M 680
30 95 ‐5 R 95 30 750 50 N 750
31 75 ‐25 R 75 31 730 30 N 730
Table 1: PBC – CAR 1 Table 2 : PBC – CAR 2
N‐NO PROBLEM , M‐MAINTENANCE,
R – RAW MATERIAL, H ‐ HOLIDAY
246 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
140
120
100
NO OF PBC
80
EXISTING SYSTEM
60
KGS SYSTEM
TARGET
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
DAYS
Graph 1 : PBC CAR –1
900
800
700
600
NO OF PBC
500
EXISTING SYSTEM
400
KGS SYSTEM
300
TARGET
200
100
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
DAYS
Graph 2 : PBC CAR -2
247 http://sites.google.com/site/ijcsis/
ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 6, June 2011
• The net effect of reduced machine down
times resulting in higher productivity of
operators and less defects.
References:
• Process system has provided us with the [1] Bela G Liptak, “Process Control,” 3rd
ability to achieve higher production levels Edition, Butterworth Heinemaun
[2] Sanjeev gupta &S.C.Sharma Selection
with the same amount of resources. and application of advance control systems
Journal of scientific & Industrial Research –
• It can design, develop and produce the
April 2005
product according to customer’s request. [3] Bela G Liptak. “Process Measurement
And Analysis” Third Edition, Butterworth,
• There is flexibility to change standard Heinemaun
control strategies in the process with the [4] The Operator as IPL – Author, User
Centered Design Services, LLC, USA,
option of readjusting the controller Hydrocarbon Engineering September
parameters. 2005
[5] Control System Design – Graham C,
Goodwin, Steford F Graebe, Mario E Salgado.
The system is applicable to any plant by
Prentice Hall.csd. Newcastle.edu.au
proper selection of embedded controller. [6] The Engineering tool Box.com
[7] Resources, Tools and Basic
Interaction and decoupling of control loops
information for Engineering and Design of
can be programmed as per requirements. Technical Applications.
[8] www.publicservice.co.uk/feature_stor
KGS system offers a highly innovative y
distributed control system that helps the [9] www.businessdictionary.com/.../distri
buted-control-system
industry not only stay competitive but [10] www.ge-ip.com/ps/dcs
[11] www.helmarparts.com/Emergency_B
improve competitiveness over the long rake_Cables_
term – by optimizing, productivity, plant [12] www.cdxetextbook.com/brakes/brak
e/brakes/adjparkcable
availability, reduced downtimes and costs. [13] www.35pickup.com/ParkingBrakeCab
le3.jpg&imgrefurl
It is designed for the future to guarantee
[14] en.wikipedia.org/wiki/Parking_brake
compatibility with ongoing innovations. It
saves money during system upgrades.
248 http://sites.google.com/site/ijcsis/
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