As the time consumed for the loosening of the bolt manually requires more time and reduces the rate of production. The Automation is done. It saves a lot of time and also increases the rate of production. The manual loosening of main bearing bolt and cap is not only a time consuming process but it is also quite tedious and prone to human errors .Hence automation is done to reduce the errors. The Automation of Main Bearing Bolt and Cap loosening reduces the part damage and increases the efficiency of the product. The thread chip-off and operator errors are also reduced. And also the requirement of skilled technician is reduced, which automatically reduces the time consumed for various allowances.

1. http://www.iaeme.com/IJMET/index.asp 41 editor@iaeme.com
International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 2, February 2017, pp. 41–49, Article ID: IJMET_08_02_006
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=8&IType=2
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
AUTOMATION OF MAIN BEARING BOLT AND CAP
LOOSENING MACHINE FOR AUTOMOBILE
CRANKSHAFT
S. Arun
Assistant Professor, Mechanical Department, Veltech, Avadi, Chennai, India
SK. Nagoorvali
Assistant Professor, Mechanical Department, Veltech, Avadi, Chennai, India
K. Sunil Kumar
Assistant Professor, Mechanical Department, Veltech, Avadi, Chennai, India
G.S. Mohan
Assistant Professor, Mechanical Department, T.J.S. Engineering College, Gummidipoondi, India
ABSTRACT
As the time consumed for the loosening of the bolt manually requires more time and reduces the
rate of production. The Automation is done. It saves a lot of time and also increases the rate of
production. The manual loosening of main bearing bolt and cap is not only a time consuming
process but it is also quite tedious and prone to human errors .Hence automation is done to reduce
the errors. The Automation of Main Bearing Bolt and Cap loosening reduces the part damage and
increases the efficiency of the product. The thread chip-off and operator errors are also reduced.
And also the requirement of skilled technician is reduced, which automatically reduces the time
consumed for various allowances.
Key words: Automobile crankshaft assembly, automobile bolt design, crankshaft assembly.
Cite this Article: S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan. Automation of Main
Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft. International Journal of
Mechanical Engineering and Technology, 8(2), 2017, pp. 41–49.
http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=8&IType=2
1. INTRODUCTION
The scope of this project confines to the assembly line “AUTOMATION OF MAIN BEARING BOLT
AND CAP LOOSENING MACHINE". The main bearing bolt and cap that are fixed in the MIP (Made In
Part) section is removed in the assembly to facilitate the insertion of the crank shaft. This is done manually
using pneumatic gun and other special tools. This might Cause damage to bolt head, missing of process,
human fatigue, time delay and less productivity [1]. So Automation is done which is results in reduction of
time consumed, avoid human error and also increase the efficiency [3]. All of which leads to increase the

2. S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan
http://www.iaeme.com/IJMET/index.asp 42 editor@iaeme.com
production known as “AUTOMATION OF MAIN BEARING BOLT AND CAP LOOSENING
MACHINE”.
2. DESCRIPTION
In Engine plant all operations are done by Automation Process. But the Main Bearing Bolt and Cap
loosening is done manually. As it (The Bolt and Cap loosening) is done manually as shown in the figure
1.There are various problems that occurs, moreover it is not completely reliable as there are chances of
human errors due to fatigue and other factors and also the time consumed on the process is more[4]. Hence
Automation is done.
Figure 1 Manual Main Bearing Bolt loosening
3. PROBLEM IDENTIFICATION
3.1. Quality
The manual operation affects the quality in the form of part damage and thread chip-off in bolt. This is due
to the loosening of the bolt in main bearing cap.
3.2. Ergonomics
Ergonomics is said to be relationship between men and machine during manual operation. The ergonomics
is affected due to human fatigue, operational errors and the time consumed for various allowances.
3.3. Scrap
Scrap is also increased during manual operation and it causes Bolt damage and thread chip off and it leads
to increase in burr.

3. Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft
http://www.iaeme.com/IJMET/index.asp 43 editor@iaeme.com
4. METHODOLOGY
Figure 2 Methodology
5. PROCESS INVOLVED
Figure 3 front view of automation of main bearing bolt and cap loosening machine
It works on Hydro-Pneumatic pressure .The block is input to the conveyor by the pick and place robot
and the block moves to the various sections through the conveyor. In the main bearing bolt and cap
loosening session the block is raised and the bolt and cap are loosened by the hydro-pneumatic system[7].It
automatically loosens the main bearing nut and cap in cylinder block and also it is sensed automatically by
the sensor. And it is consist of 10 spindle and each spindle operates simultaneously for bolt loosening [9].
And it is consisting of 5 clamps for loosening the main bearing cap. Its takes only less time for operation.
When compare to manual operation time.
REDUCED PRODUCTION RATE
INCREASED CYCLE TIME
TIME REQUIRE MORE TO LOOSEN THE BOLT
SINCE IT IS DONE MANUALLY
AUTOMATION OF MAIN BEARING BOLT
LOOSENING

4. S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan
http://www.iaeme.com/IJMET/index.asp 44 editor@iaeme.com
5.1. 2D Designs Layout
Figure 4 2D Machine view
5.2. 2D Machine View
Figure 5 2D Machine View
5.3. 3D Machine View
Figure 6 3D Machine view

5. Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft
http://www.iaeme.com/IJMET/index.
5.4. 3D Model
Figure 7
5.5. Solid Works Model in Assembled View
6. CALCULATION
i) To find Mass of plate/self weight:
Mass of the plate = density * volume
=3*130*100*2.7=91.26*10³gm
ii) To find Bending Moment in Maximum:(M max)
M max= WL² / 8
To find W: (consider the load as 2500N)
W= (91.26+2500)*9.81/1300
= 23.32 N
Therefore
M max = 23.32*(1.3)² / 8
= 4.92Nm
iii) To find Maximum Deflection (Y max)
Y max = (5/384)*(WL4 / EI)
Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft
IJMET/index.asp 45
3D Design of main bearing bolt loosening machine
Assembled View
Figure 8 3D Assembly
To find Mass of plate/self weight:
Mass of the plate = density * volume
To find Bending Moment in Maximum:(M max)
To find W: (consider the load as 2500N)
To find Maximum Deflection (Y max)
Y max = (5/384)*(WL4 / EI)
Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft
editor@iaeme.com
esign of main bearing bolt loosening machine

6. S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan
http://www.iaeme.com/IJMET/index.
iv) To find Moment of inertia (I):
I = bd³/12
= 1000*30³/12 =2250*10³ mm4
Therefore,
Y max = (5/384) *(23.32*(1300^4)/70*10³*2250*10³)
= 5.506 Nm
v) To Find Maximum Load Bearing Capacity
Force considered as 107.5N
٦max = force/area
Force =107*30*1000
= 3.22MN
The stress due to load
٦max= (2500+91.26)*9.81/(30*1000)
=1.01 N/mm²
7. DESIGN CALCULATION FOR COLU
i) To find moment of Inertia about X
IXX = (b1d³1 – b2d³2)/ 12
= (135*115³-115*95³)/12
ii) Moment of Inertia about Y-Y-axis:
IYY= (115*135³-95*115³)/12
= 11.53*10^6 mm4
Slenderness Ratio= L/rc
Where, I=Arc²
Therefore 11.53*10^6= 4500*r²
rC=50.61mm
Therefore slenderness ratio = 1285/50.61= 25.39
S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan
JMET/index.asp 46
Y max = (5/384) *(23.32*(1300^4)/70*10³*2250*10³)
To Find Maximum Load Bearing Capacity
Force considered as 107.5N
force/area
Force =107*30*1000
= 3.22MN
max= (2500+91.26)*9.81/(30*1000)
CALCULATION FOR COLUMN
Figure 9 Column
To find moment of Inertia about X-X axis
b2d³2)/ 12
115*95³)/12 = 8.89*10^6 mm4
axis:
herefore slenderness ratio = 1285/50.61= 25.39
S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan
editor@iaeme.com

7. Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft
http://www.iaeme.com/IJMET/index.asp 47 editor@iaeme.com
Hence, slenderness ratio is less than 40 column is a short column’s. So Euler’s theory cannot be used. And
Euler’s theory it’s only applicable for long column.
iii) Determination of Rankine value:
1/Pr = 1/Pe + 1/ Pc
Where, Pe= Buckling load
Pc= crushing load
iv) To find Buckling load
Pe= (4*3.14*3.14*EI)/Le²
= (4*3.14*3.14*1.4*10^5*11.52*10^6) / 1285 =5.0779*10^6N
Pe=2.09*10^7N
v) To find crushing load:
Stress=Pc/A
Stress= 152N/mm² for ASTM A36 steel bar
Therefore, stress=152*(135*115-95*115)=2.34*10^6
1/Pr=1/(5.0779*10^10) + 1/( 2.34*10^6)
Pr=1.97MN
8. DESIGN CALCULATION FOR UPPER FRAME
Assuming the top frame as a Fixed Beam which has uniform distributed load about 2500kg and the load
gets equally distributed.
Figure 10 Upper frame
i) To find self weight
Self weight = density* volume
Volume=1350*(140*95-120*95) =5805cm³
Density = 7.85 gm/cc for A36 Steel bar
Therefore, self weight = 5805*7.85=45.56*10³ gm
ii) To find Maximum Deflection Y max:
Y max = WL³/384EI
= (1250+45.56)*9.81*1070³/(384*2*10³*578.4*10³)
= 0.09 mm
iii) To find maximum bending moment
M max= WL/24
= ((1250+4556)*9.81*1070)/24
= 506.63 Nm

8. S. Arun, SK. Nagoorvali, K. Sunil Kumar and G.S. Mohan
http://www.iaeme.com/IJMET/index.asp 48 editor@iaeme.com
iv) To find stress due to load
Max.stress = load/area
Load carrying capacity
= 1250*(140*95-120*75)
=0.5375*10^7 N
= 5.37MN
Max.Stress
= (1250+45.56)*9.81/(140*95-120*75)
= 0.5741 N/mm²
9. DESIGN CALCULATION FOR BOLT LOOSENING
Figure 11 Bolt loosening Machine view
Force = Torque/distance
Torque required for loosening the Bolt in main bearing cap so, torque about 5 to 6 kgfm
In this torque formula we find the force value: We considered the torque value is 5.5 kgfm
Force =5.5/ (0.01) = 5393.66 N.
9.1. Process Time Calculation for Manual & Automation Loosening Tabular Column
Table 1 Process time calculation
SI.NO Manual of
Bolt
loosening
(Sec)
Automation of
Bolt loosening
(Sec)
Manual of
Cap
loosening
(Sec)
Automation of
Cap loosening
(Sec)
Time saving
for bolt
loosening
(Sec)
Time saving
for Cap
loosening
(Sec)
1 15.75 8.73 33.68 12.64 7.02 21.04
2 16.12 7.53 32.15 13.72 8.59 18.43
3 14.28 8.39 30.01 13.14 5.89 16.87

9. Automation of Main Bearing Bolt and Cap Loosening Machine for Automobile Crankshaft
http://www.iaeme.com/IJMET/index.asp 49 editor@iaeme.com
10. CONCLUSION
Success full implementation of Main Bearing Bolt and Cap loosening machine resulted in transformation
from manual processing to automatic processing, hence eliminating the workmen’s fatigue. The
achievements on implementation of the main bearing bolt and cap loosening machine is
• Improved overall efficiency
• Avoid scrap and burr
• Avoid part damage
Thus the existence of main bearing bolt and cap loosening machine turns up the statistics friendlier to
higher standards.
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