Comprehensive Design of 5-Head Multi-Boring Machine
Budget: ₹600 – ₹1,500 INR
FIVE HEAD MULTI BORING MACHINE – COMPLETE ENGINEERING DESIGN REQUIREMENT
IMPORTANT DESIGN PHILOSOPHY
This project is NOT intended to assemble purchased boring heads or purchased machine modules.
This project is intended to DESIGN, ENGINEER, MACHINE, FABRICATE, ASSEMBLE and COMMISSION a complete industrial 5-head multi-boring machine from raw materials and standard industrial components.
Every fabricated component must be designed.
Every machined component must be dimensioned.
Every assembly must have exploded drawings.
Every mechanism must be fully explained.
Every subsystem must be fabrication-ready.
No black-box assemblies.
No purchased boring units.
No purchased gearbox assemblies.
No purchased spindle banks.
All major systems must be engineered.
---
MACHINE TYPE
Industrial Five Head Multi Boring Machine
Applications:
• Modular Furniture
• Cabinets
• Kitchens
• Wardrobes
• Office Furniture
• Panel Processing
Materials:
• MDF
• HDHMR
• Particle Board
• Plywood
• Block Board
• Solid Wood
---
MACHINE CONFIGURATION
5 Independent Boring Heads
Configuration:
Head 1:
Vertical Top
Head 2:
Vertical Top
Head 3:
Vertical Top
Head 4:
Horizontal Left
Head 5:
Horizontal Right
Alternative configuration options must also be provided.
---
CAPACITY
Maximum Panel Length:
3000 mm
Maximum Panel Width:
1200 mm
Maximum Panel Thickness:
60 mm
Minimum Panel Thickness:
9 mm
Drilling Diameter:
3 mm – 35 mm
Drilling Depth:
0 – 60 mm
---
DESIGN DELIVERABLE REQUIREMENT
Provide complete:
A.
Mechanical Engineering
B.
Fabrication Engineering
C.
Machining Engineering
D.
Electrical Engineering
E.
Pneumatic Engineering
F.
Control Engineering
G.
Assembly Engineering
H.
Manufacturing Engineering
I.
Maintenance Engineering
---
DRAWINGS REQUIRED
1.
General Arrangement Drawing
2.
Complete Assembly Drawing
3.
Exploded Assembly Drawing
4.
Fabrication Drawings
5.
Machining Drawings
6.
Section Views
7.
Tolerance Drawings
8.
Sub-Assembly Drawings
9.
Parts Identification Sheets
10.
Service Drawings
---
FRAME ENGINEERING
Provide complete fabrication drawings.
Material:
100×100×4 mm
100×50×3 mm
75×50×3 mm
50×50×3 mm
Include:
• Pipe cut lengths
• Weld locations
• Weld sequence
• Frame leveling system
• Foundation design
• Structural load analysis
---
WORK TABLE SYSTEM
Provide:
1.
Table Frame
2.
Work Surface
3.
Panel Supports
4.
Fence System
5.
Reference Stops
6.
Panel Clamping System
7.
Positioning Guides
8.
Alignment Procedures
Table Flatness:
≤0.10 mm
---
VERTICAL BORING HEAD ENGINEERING
Provide complete design.
For each vertical head:
1.
Spindle Housing
2.
Spindle Shaft
3.
Bearing Arrangement
4.
Gear Drive
5.
Belt Drive
6.
Motor Mount
7.
Depth Stop System
8.
Quick Tool Change
9.
Exploded Assembly
10.
Machining Drawings
---
MULTI-SPINDLE BORING BANK
Provide complete engineering.
No purchased boring bank.
Design:
1.
Spindle Layout
2.
Spindle Gears
3.
Gear Train
4.
Housing
5.
Bearing System
6.
Lubrication
7.
Tool Holders
8.
Adjustment Mechanism
9.
Exploded Assembly
Typical Spacing:
32 mm System
Provide:
11 Spindle
21 Spindle
35 Spindle variants
---
HORIZONTAL BORING HEAD ENGINEERING
Provide complete design.
Include:
1.
Spindle Housing
2.
Drive System
3.
Gear Train
4.
Bearing System
5.
Tool Holders
6.
Depth Adjustment
7.
Position Adjustment
8.
Exploded Assembly
---
HEAD POSITIONING SYSTEM
Provide:
1.
Linear Guides
2.
Guide Rail Design
3.
Bearing Blocks
4.
Adjustment Mechanism
5.
Locking System
6.
Scale System
7.
Position Indicators
---
HEAD FEED SYSTEM
Provide complete engineering.
Options:
Mechanical Feed
Pneumatic Feed
Servo Feed
Include:
1.
Cylinder Sizing
2.
Feed Mechanism
3.
Guide System
4.
Return Mechanism
5.
Force Calculations
6.
Speed Calculations
---
DRILL DEPTH CONTROL
Provide:
1.
Depth Stops
2.
Scales
3.
Micrometer Adjustment
4.
Locking System
5.
Repeatability Analysis
Target:
±0.1 mm
---
PANEL CLAMPING SYSTEM
Provide:
1.
Pneumatic Clamps
2.
Pressure Beam
3.
Clamp Cylinders
4.
Mounting System
5.
Air Circuit
6.
Safety Interlocks
---
DRIVE SYSTEM
Provide complete engineering.
Include:
1.
Motor Selection
2.
Pulley Calculations
3.
Belt Calculations
4.
Gear Calculations
5.
Shaft Calculations
6.
Bearing Calculations
7.
Power Transmission Drawings
Motor Range:
1–3 HP per head
---
SPINDLE ENGINEERING
Provide complete machining drawings.
Include:
1.
Spindle Shaft
2.
Bearing Seats
3.
Threads
4.
Tool Interface
5.
Runout Specifications
6.
Heat Treatment Requirements
Target Runout:
≤0.02 mm
---
GEARBOX ENGINEERING
Provide complete design.
No purchased gearbox.
Include:
1.
Gear Calculations
2.
Gear Drawings
3.
Housing Drawings
4.
Bearing Arrangements
5.
Lubrication System
6.
Assembly Drawings
---
PNEUMATIC SYSTEM
Provide:
1.
Complete Pneumatic Circuit
2.
FRL Selection
3.
Cylinder Calculations
4.
Valve Selection
5.
Air Consumption Analysis
6.
Safety Circuit
Operating Pressure:
6–8 Bar
---
ELECTRICAL SYSTEM
Provide:
1.
Single Line Diagram
2.
Panel Layout
3.
Motor Wiring
4.
Contactor Layout
5.
Overload Protection
6.
Emergency Stop
7.
Cable Routing
8.
Terminal Layout
---
PLC AND AUTOMATION
Provide:
1.
PLC Architecture
2.
I/O Mapping
3.
Sensor List
4.
Actuator List
5.
Machine Cycle Logic
6.
HMI Screens
7.
Alarm System
8.
Diagnostic System
---
MANUFACTURING DOCUMENTATION
Provide:
1.
Complete BOM
2.
Raw Material List
3.
Machining List
4.
Bearing List
5.
Fastener List
6.
Gear List
7.
Fabrication Sequence
8.
Machining Sequence
9.
Assembly Sequence
10.
Commissioning Procedure
---
CRITICAL SUB-ASSEMBLIES REQUIRING FULL ENGINEERING
• Frame
• Work table
• Vertical boring heads
• Horizontal boring heads
• Multi-spindle boring banks
• Spindle shafts
• Gear trains
• Gearboxes
• Linear guide systems
• Clamping systems
• Pneumatic systems
• Electrical systems
---
FINAL OBJECTIVE
Create a fully engineered industrial Five Head Multi Boring Machine where major mechanical systems are designed and manufactured from raw materials, including:
• Frame
• Table
• Vertical boring heads
• Horizontal boring heads
• Multi-spindle banks
• Gear trains
• Spindles
• Gearboxes
• Clamping system
• Pneumatics
• Electrical system
• PLC automation
Deliver a complete fabrication-ready, machining-ready and assembly-ready engineering package comparable to Vitap, Maggi, SCM, Biesse and Weeke industrial multi-boring machines.
IMPORTANT DESIGN PHILOSOPHY
This project is NOT intended to assemble purchased boring heads or purchased machine modules.
This project is intended to DESIGN, ENGINEER, MACHINE, FABRICATE, ASSEMBLE and COMMISSION a complete industrial 5-head multi-boring machine from raw materials and standard industrial components.
Every fabricated component must be designed.
Every machined component must be dimensioned.
Every assembly must have exploded drawings.
Every mechanism must be fully explained.
Every subsystem must be fabrication-ready.
No black-box assemblies.
No purchased boring units.
No purchased gearbox assemblies.
No purchased spindle banks.
All major systems must be engineered.
---
MACHINE TYPE
Industrial Five Head Multi Boring Machine
Applications:
• Modular Furniture
• Cabinets
• Kitchens
• Wardrobes
• Office Furniture
• Panel Processing
Materials:
• MDF
• HDHMR
• Particle Board
• Plywood
• Block Board
• Solid Wood
---
MACHINE CONFIGURATION
5 Independent Boring Heads
Configuration:
Head 1:
Vertical Top
Head 2:
Vertical Top
Head 3:
Vertical Top
Head 4:
Horizontal Left
Head 5:
Horizontal Right
Alternative configuration options must also be provided.
---
CAPACITY
Maximum Panel Length:
3000 mm
Maximum Panel Width:
1200 mm
Maximum Panel Thickness:
60 mm
Minimum Panel Thickness:
9 mm
Drilling Diameter:
3 mm – 35 mm
Drilling Depth:
0 – 60 mm
---
DESIGN DELIVERABLE REQUIREMENT
Provide complete:
A.
Mechanical Engineering
B.
Fabrication Engineering
C.
Machining Engineering
D.
Electrical Engineering
E.
Pneumatic Engineering
F.
Control Engineering
G.
Assembly Engineering
H.
Manufacturing Engineering
I.
Maintenance Engineering
---
DRAWINGS REQUIRED
1.
General Arrangement Drawing
2.
Complete Assembly Drawing
3.
Exploded Assembly Drawing
4.
Fabrication Drawings
5.
Machining Drawings
6.
Section Views
7.
Tolerance Drawings
8.
Sub-Assembly Drawings
9.
Parts Identification Sheets
10.
Service Drawings
---
FRAME ENGINEERING
Provide complete fabrication drawings.
Material:
100×100×4 mm
100×50×3 mm
75×50×3 mm
50×50×3 mm
Include:
• Pipe cut lengths
• Weld locations
• Weld sequence
• Frame leveling system
• Foundation design
• Structural load analysis
---
WORK TABLE SYSTEM
Provide:
1.
Table Frame
2.
Work Surface
3.
Panel Supports
4.
Fence System
5.
Reference Stops
6.
Panel Clamping System
7.
Positioning Guides
8.
Alignment Procedures
Table Flatness:
≤0.10 mm
---
VERTICAL BORING HEAD ENGINEERING
Provide complete design.
For each vertical head:
1.
Spindle Housing
2.
Spindle Shaft
3.
Bearing Arrangement
4.
Gear Drive
5.
Belt Drive
6.
Motor Mount
7.
Depth Stop System
8.
Quick Tool Change
9.
Exploded Assembly
10.
Machining Drawings
---
MULTI-SPINDLE BORING BANK
Provide complete engineering.
No purchased boring bank.
Design:
1.
Spindle Layout
2.
Spindle Gears
3.
Gear Train
4.
Housing
5.
Bearing System
6.
Lubrication
7.
Tool Holders
8.
Adjustment Mechanism
9.
Exploded Assembly
Typical Spacing:
32 mm System
Provide:
11 Spindle
21 Spindle
35 Spindle variants
---
HORIZONTAL BORING HEAD ENGINEERING
Provide complete design.
Include:
1.
Spindle Housing
2.
Drive System
3.
Gear Train
4.
Bearing System
5.
Tool Holders
6.
Depth Adjustment
7.
Position Adjustment
8.
Exploded Assembly
---
HEAD POSITIONING SYSTEM
Provide:
1.
Linear Guides
2.
Guide Rail Design
3.
Bearing Blocks
4.
Adjustment Mechanism
5.
Locking System
6.
Scale System
7.
Position Indicators
---
HEAD FEED SYSTEM
Provide complete engineering.
Options:
Mechanical Feed
Pneumatic Feed
Servo Feed
Include:
1.
Cylinder Sizing
2.
Feed Mechanism
3.
Guide System
4.
Return Mechanism
5.
Force Calculations
6.
Speed Calculations
---
DRILL DEPTH CONTROL
Provide:
1.
Depth Stops
2.
Scales
3.
Micrometer Adjustment
4.
Locking System
5.
Repeatability Analysis
Target:
±0.1 mm
---
PANEL CLAMPING SYSTEM
Provide:
1.
Pneumatic Clamps
2.
Pressure Beam
3.
Clamp Cylinders
4.
Mounting System
5.
Air Circuit
6.
Safety Interlocks
---
DRIVE SYSTEM
Provide complete engineering.
Include:
1.
Motor Selection
2.
Pulley Calculations
3.
Belt Calculations
4.
Gear Calculations
5.
Shaft Calculations
6.
Bearing Calculations
7.
Power Transmission Drawings
Motor Range:
1–3 HP per head
---
SPINDLE ENGINEERING
Provide complete machining drawings.
Include:
1.
Spindle Shaft
2.
Bearing Seats
3.
Threads
4.
Tool Interface
5.
Runout Specifications
6.
Heat Treatment Requirements
Target Runout:
≤0.02 mm
---
GEARBOX ENGINEERING
Provide complete design.
No purchased gearbox.
Include:
1.
Gear Calculations
2.
Gear Drawings
3.
Housing Drawings
4.
Bearing Arrangements
5.
Lubrication System
6.
Assembly Drawings
---
PNEUMATIC SYSTEM
Provide:
1.
Complete Pneumatic Circuit
2.
FRL Selection
3.
Cylinder Calculations
4.
Valve Selection
5.
Air Consumption Analysis
6.
Safety Circuit
Operating Pressure:
6–8 Bar
---
ELECTRICAL SYSTEM
Provide:
1.
Single Line Diagram
2.
Panel Layout
3.
Motor Wiring
4.
Contactor Layout
5.
Overload Protection
6.
Emergency Stop
7.
Cable Routing
8.
Terminal Layout
---
PLC AND AUTOMATION
Provide:
1.
PLC Architecture
2.
I/O Mapping
3.
Sensor List
4.
Actuator List
5.
Machine Cycle Logic
6.
HMI Screens
7.
Alarm System
8.
Diagnostic System
---
MANUFACTURING DOCUMENTATION
Provide:
1.
Complete BOM
2.
Raw Material List
3.
Machining List
4.
Bearing List
5.
Fastener List
6.
Gear List
7.
Fabrication Sequence
8.
Machining Sequence
9.
Assembly Sequence
10.
Commissioning Procedure
---
CRITICAL SUB-ASSEMBLIES REQUIRING FULL ENGINEERING
• Frame
• Work table
• Vertical boring heads
• Horizontal boring heads
• Multi-spindle boring banks
• Spindle shafts
• Gear trains
• Gearboxes
• Linear guide systems
• Clamping systems
• Pneumatic systems
• Electrical systems
---
FINAL OBJECTIVE
Create a fully engineered industrial Five Head Multi Boring Machine where major mechanical systems are designed and manufactured from raw materials, including:
• Frame
• Table
• Vertical boring heads
• Horizontal boring heads
• Multi-spindle banks
• Gear trains
• Spindles
• Gearboxes
• Clamping system
• Pneumatics
• Electrical system
• PLC automation
Deliver a complete fabrication-ready, machining-ready and assembly-ready engineering package comparable to Vitap, Maggi, SCM, Biesse and Weeke industrial multi-boring machines.