1.

INTRODUCTION

Industrial processes are complex; they consist of people, processes,

products, information system & data, material processing & handling systems, etc.
The modeling of industrial processes is important due to the cost, complexity and
implementation time associated with these processes.
The modeling tools are required to design industrial processes and
optimize them. To fully represent a system or process, many different modeling tools
are available. Some examples include flowcharts, 2D and 3D data flow diagrams,
plant layouts, part designs, virtual prototypes, organization charts, process plans, and
charts and so on. New representation schemes and tools are being developed all the
time.
A number of different views of model information are needed most of
the times. It is extremely difficult for user to interact with multiple tools and views
simultaneously. Moreover, no single tool or computing environment currently exists
that allow all the different modeling representations to co-exists and be viewed
simultaneously in an intelligible way.
In big industries, numbers of factors are influenced by a decision. As
these factors interact with each other, any changes in decision may create big
complications.
To deal with these problems, various conventional modeling methods
are available, they are as follows:
1) Mathematical modeling
2) Physical modeling
3) Analog or schematic modeling
4) Network models
In addition, various types of mathematical modeling techniques are
1) Allocation model
2) Sequencing model
3) Routing model
4) Queuing model
5) Transportation models

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6) Dynamic programming models etc.
There are some difficulties with these conventional modeling techniques as:

1. These techniques need huge data collection which may incur large cost and time
2. The entire process study is based on observations in the past
3. The greatest difficulty is time factor. The management has to make decisions
at the right time and a optimum solution to the problem
4. Mathematical models are applicable to only specific category of problems.

The modeling and simulation of industrial processes in virtual

environment, using VRML, provides an excellent solution over all the problems
encountered in industry right from designing, manufacturing to dispatching. Modeling
in virtual environment determines the effect of various alternative policies without
disturbing the real system. It helps in selecting the best policy with prior assurances
that its implementation will be beneficial, as the actual experimentation with system
may be uneconomical.

A software environment is needed that allows representations to be

combined and show relationships between models. The Virtual Reality Modeling
Languages (VRML) provides that common environment for integrating the
manufacturing or industrial process models.

In the present work, working and operation of agro machines fabricated

at Mahavir Electromechanical Works, Akola are modeled and visually simulated in
the virtual environment by using various commercially available design and
simulation software packages.

2
 2. REVIEW OF LITERATURE

The aim of dissertation work carried out was to develop the web ready
multimedia computer application software for modeling and simulation of the agro
machines in virtual environment, being the latest and heavily demanding field for
researchers.

In support of the basic idea of application software development and

the necessary conceptual backing for the assumptions made, the diversified literature
was surveyed along with the electronic one on the internet.

The entire study to be carried out was split in to modules, since it was
consisting of use of various softwares to develop the individual application, which
constituted the base for the development of next application software.

In the field of Production Engineering, at present, computers are used

for making the prototypes, process picture sheets, drafting and conceptualizing of
many related theoretical works.

Modern manufacturing systems and industrial robots are advanced

automation systems that utilize computers as an integral part of their control.
Computers are now a vital part of automation. They control stand-alone
manufacturing systems, such as various machine tools, welders, and laser beam
cutters. They run production lines and are beginning to take over control of an entire
factory. (Yoram Koren, 1983). [1]

Visualization has always been recognized as the most effective means

of communication new ideas and design among designers, engineers and others. One
of the most recognized aids of CAD is its ability to provide its uses with visual
displays of the object and scenes they model on CAD systems. (Mikell P. Groover,
1996). [2]

3
 Computer Graphics is a topic of rapidly growing importance in the
field of Computer Aided Engineering. Representation of geometry of a component
using computer software is called a geometric model. (P. Radhakrishnan, C.P.,
Kothandarman, 2000). [3]

Modeling is the art of abstracting or representing a phenomenon and

geometric modeling is no exception. Geometric modeling and simulation via
computers have reached a level to replace the real-life prototypes or tests. Solid
modeling has been acknowledged as the technological solution to automating and
integrating design and manufacturing functions. (Ibrahim Zeid, 1998). [4]

A model, in general, is able to incorporate only the essential features of

the problem situation, leaving out the details. Consequently, the results of model
analysis have to be tempered with the intuitive and decision-making skills of the
manager so that the influence of these undefined factors is taken cognizance of in the
decision making process. (Ramjee Kapoor, 1991). [5]

Simulation is a process that employees some kind of model or

simplified representation of certain features of some physical or logical system. A
simulation model may be physical model, a mental conception, a mathematical model,
or some combination of all these. (Dr. Surendera Kumar, Dr. A.K. Jha, 1993). [6]

Simulation has been gaining in acceptance as a tool which enables

industrial and manufacturing engineers to perform extensive analysis of problems
they face on a daily basis. (P. Radhakrishnan, S. Subramanyan, 1994). [7]

3D Studio is a major enhancement of the leading 3D animation

software for a PC. Using 3D Studio, anything can be created that is imagined.
(Michael T. Peterson, 1999). [8]

Virtual Reality Modeling Language (VRML) is the tool for creating 3D

virtual experiences on the World Wide Web. VRML2 is simple enough that you will

4
be learning how to create worlds using a simple text editor. WordPad is an excellent
choice for this task. (Chris Marrin, Bruce Campbell, 1997). [9]

IT (information Technology) has created another type of information -

virtual reality (VR). VR enables people to interact with three dimensional computer
generated environments that incorporate sight, sound, touch (and perhaps one day
taste and smell). (James A. Senn, 1998). [10]

HyperText Markup Language (HTML) is the language that puts the

face on the web. In the words of the World Wide Web Consortium (W3C), HTML
exists “to publish information for global distribution”. It acts as a universally
understood language, a kind of publishing mother tongue that all computers may
potentially understand. (Rick Darnell, et al, 1999). [11]

A database can be defined as a collection of data in a single location,

designed to be used by different programmers for a variety of applications. (P.
Radhakrishnan, C.P. Kothandarman, 2000).

Database processing includes many features that make data and

information accessible to people and that help safeguard the existence of the database.
(James A. Senn, 1998).

Software has been produced that uses the geometric database produced
when the part was designed with CAD to make the NC program. This joining of CAD
and CAM is the key to producing an automated factory. (Gary R. Bartoline, 1989).
[12]

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 3. COMPUTER APPLICATIONS IN INDUSTRIES

3.1 SCOPE IN MANUFACTURING INDUSTRIES

Computers have had significant impact on design and manufacturing

information functions. They are used in process planning and scheduling to perform
these functions more efficiently. The computers are also used in production to monitor
and control the manufacturing operations. In quality control, computers are used to
perform inspections and performance testes on the product and its components.
Computers also assist in viewing the assembly of various components through
geometric modeling technique. There are design packages available to perform
applications, such as, mass property calculations, tolerance analysis, finite element
modeling and analysis, mechanism analysis and simulation.

Apart from these basic applications some other applications of

computers include the study of molecular structures in chemistry, medical research,
animation, aircraft flight simulation, structural design in aircraft, ship building and
automobile industries, integrated circuits and printed circuit design in the electronic
industry, town planning and architectural design, pipe routing and layout in chemical
plant design, mesh data preparation for finite element analysis and drafting, etc. In the
design and production operations of modern manufacturing firm, the computer has
become a pervasive, useful and indispensable tool.

The “Fig. 3.1” represents the scope for computerization in the

manufacturing industries. Computer aided design and automated drafting are utilized
in the conceptualization, design, and documentation of the product. Process planning
and scheduling are also done with the help of computers. Computers are also used to
perform the quality control functions. The machines and other equipment are also
controlled with the help of computers. The data base generated in the design phase by
the computers is utilized in the manufacturing phase.

6
 Fig. 3.1: Scope of Computers in Manufacturing Industries

3.2 COMPUTERS IN DESIGN

The use of computer in design and drafting occupations is the most

significant engineering development to occur. Computer graphics is a topic of rapidly
growing importance in the field of Computer Aided Engineering. It is also an
extremely effective medium for communication. The wide acceptance and application
of computers in engineering industry, is mainly due to the following developments:
 Development of interactive computer graphics and analysis software which
prompts the user with the queries and information on the video display unit and
guide the users to solve the problems.
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 Development of interactive graphic workstations with powerful graphic facilities,
availability of computers with enhanced memory and faster computing speed at
affordable prices
 Reduction in product life cycle
 Increasing product complexity.
The conceptual design packages, solid modeling packages and
packages like finite element analysis and kinematics analysis available today can
accelerate the design process. Similarly, computer aided design helps in increased
design productivity by reducing the time for developing conceptual designs, analysis
and drafting.

3.3 COMPUTERS IN MANUFACTURING

Computer Aided Manufacturing (CAM) technology is concerned with

three main areas: NC (Numerical Control), Process Planning and Robotics. CAM is a
system in which computer technology is utilized as integral equipment and it oversees
many aspects of manufacture such as planning, managing, monitoring and controlling
various phases of manufacturing process and/or plant.

The integration of the use of computers into the product design and
development process has benefited engineering industry in several ways. Benefits
derived due to the implementation of computers in industrial applications are helpful
in the following areas:

i) Tools and fixture design for manufacturing.

ii) Process planning.
iii) Preparation of assembly lists and bill of materials.
iv) Inspection and quality control.
v) Coding and classification of components
vi) Production planning and control.
vii) Assembly sequence planning, etc.

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 In this way, the advances in computer science and technology have
resulted in the emergence of very powerful hardware and software tools that offer
scope for use in the entire design process and visual simulation of the industrial
processes.

3.4 COMPUTER MODELING AND SIMULATION

3.4.1 INTRODUCTION

The recent years have seen the emergence of high performance

automated manufacturing systems driven by the quest for increased productivity,
flexibility and competitiveness. These systems are necessarily flexible and thus highly
capital intensive. Modeling and performance evaluation played a vital role in the
design and operation of such high performance manufacturing systems and have
received widespread attention of researchers in the last decade.

Modeling is defined as idealized representation of an industrial process

situation. Models of industrial processes are broadly classified as qualitative or
quantitative. Qualitative models capture logical aspects of system evolution such as
controllability, stability, existence of deadlocks in system operations, etc. Quantitative
models, on the other hand highlights the quantitative system performance in terms of
throughput and the lead time. Quantitative modeling is specifically called as
performance modeling.

Decisions Disturbance
s
Material Product

Energy Manufacturing
System Scrap
Labor

Technology Waste

Fig. 3.2: Manufacturing System: Input – Output Model

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 The manufacturing system can be represented by input - output model
as shown in “Fig. 3.2”. The inputs are material, energy, labor and technology. The raw
material is converted into final quality product. Labor in the form of blue - collar and
white collar workers is needed for designing the product, operating the equipment,
loading and unloading of the work piece, and for inspection, plant layout, sequencing
and scheduling of parts, loading of parts etc. The second kind of inputs are
disturbances, these include government action, material fluctuation, competition,
equipment failures and labor problems.

The manufacturing process produces three outputs, the completed

work piece or the quality product satisfying required engineering specifications, scrap
and waste.

Similarly, simulation has been gaining in acceptance as a tool which

enables industrial and manufacturing engineers to perform extensive analysis of
problems they face on a daily basis. In simulation, engineers make a model of the
manufacturing facility. A simulation model may be physical, a mental conception, a
mathematical model, a computer model, or some combination of all of these. The
object of the process is to provide an experimental model for the accumulation of data
on the target system. It comprises the steps of experiment definition, modeling,
computer implementation, definition, validation and data gathering.

3.4.2 COMPUTER MODELING & SIMULATION

Modeling involves the development of a mathematical description of

the geometry of an object. The mathematical description allows the image of the
object to be displayed and manipulated on a graphics terminal. The modeling can be
in 2D or 3D. In three dimensional modeling, one has the option of 3D wire-frame
modeling, surface modeling or solid modeling.

In general, there are three types of models, namely, wire-frame, surface

and solid, in common use. This comes under the geometric modeling. The highest
level of sophistication in geometric modeling is 3D modeling. Solid modeling is an

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efficient tool for the real 3D representation of an object. This method enable designer
to visualize an object in terms of its basic geometry primitives joined together by
Boolean operations.

In wire frame modeling the object is represented by its edges. The

object appears as if it is made out of thin wires. There are number of software
packages available to create 2-D or 3-D wire frame models. Essentially a wire frame
model of a 3-dimensional object consists of a finite set of points together with the
edges connecting various pairs of these points, so that a drawing of these points and
edges aids the visualization of the object.

In a number of applications, it is sufficient to describe the boundary of

a solid object in order to specify its shape without ambiguity. In such applications, the
boundary is a collection of faces forming a closed surface. Such types of models are
called as the surface models. This technique uses the basics of the surface geometry to
build up the shapes and is especially useful where there is a need to model complex
surfaces say for aerodynamic or automotive styling work. Though surface models are
better that wire frame models, they have their own limitations. They don't have
knowledge of volume, so cannot easily be used to calculate mass properties, create
sections or remove hidden lines completely.

Solid models are complete, unambiguous representations of the three

dimensional objects. They can be built with either primitives or boundary
representations. In the primitive approach, elementary shapes are combined in a
building block fashion to create a new shape. So called, Boolean logic commands,
such as union, difference, and intersection, aid in forming new shapes. With boundary
definition, 2D surfaces are swept through space to trace out volumes.

Computer simulation is a technique for examining performance of the

model of a real system as it operates over a period of time. The state of the modeled
manufacturing system can be observed while the computer program runs and statistics
measuring its performance can be automatically collected.

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 The capability to address system interactions dynamically is one
characteristic distinguishing simulation from other problem solving models, such as
queuing theory and linear programming. Simulation is particularly appropriate in
situations where the size and complexity of the manufacturing problems make other
analysis techniques difficult to apply.

There are three major activities in a simulation process, namely, model

development, model execution and model output. The purpose of building the
simulation may be comparison, prediction or investigation.

Almost every factory floor now uses a general purpose or a custom-

built simulator for decision making and analysis. A simulation model enables an
engineer to perform a “what-if analysis without disturbing an existing system”. Some
extensive analysis can be performed on a system that is being performed. Simulation
tool therefore allows the development of an efficient design before any physical
changes have been initiated. Simulation can effectively save development time and
financial resources thereby delivering to its user’s productivity and reduced
manufacturing cost. Simulation is the actual running of the model system to gain
insight into its performance. It is used to understand better the expected performance
of the real system and to test the effectiveness of the system design.

3.5 TRENDS IN SIMULATION

One of the most important developments in recent past is the ability to

define portions of the system graphically. Graphic definition provides significant
benefits over textual modeling. The model can be developed more quickly. Today's
simulation technology allows drawings to be digitized onto the graphics screen.

Another development and the one with great potential, involves

capturing the system description directly from a CAD system. Transferring the
description from the CAD file directly to the simulation system can reduce model
development time several fold.

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 Model execution focuses primarily on the execution of the
programming statements generated during model development. More has been done
to have the simulation system perform additional functions. The only important
development is interactive execution which allows the modeler to interface with the
model as it is being executed. The interactive execution offers the modeler greater
control over experimentation; the model can be stopped at any time and slightly
modified. Then execution is continued to determine the effect of that change.

Traditionally, simulation has provided vast amounts of statistical data

in the form of tables. It was the responsibility of the modeler to analyze this data and
summarize what it meant. Today, those who are not familiar with the model's creation
can understand the result of the simulation effort as it is brought to life by graphic
animation. Animation allows the viewer to “see” the system operating with the flow
of materials and interactions of processes. The most advanced systems present the
model in three dimensions, where it can be viewed from any angle or distance. The
more advanced simulation systems can be integrated with other design tools.

3.6 SOFTWARE FOR MODELING & SIMULATION

The software used for the modeling and simulation of the industrial
processes were as follows and are discussed in the subsequent paragraphs.

 Pro/E
 3 D Studio
 VRML

3.6.1 Pro/E

Pro/E was chosen as modeling software for the simple reason that it is
parametric modeling software so the changes in the part as well as assembly can be
made easily whenever required. The design department of Mahavir Electromechanical
Works Pvt. Ltd keeps on modifying the machines based on customer complaints and
market research data. Every new machine fabricated in Mahavir Electromechanical

13
Works Pvt. Ltd is slightly modified than the previous machine. The modification and
improvement is a continuous process in Mahavir electromechanical works Pvt. Ltd.
First the modification is done on the production drawings created in AutoCAD, and
then they are handed over to people on the shop floor for fabrication. As the company
uses 2D production drawings, manufacturing people many times do not completely
get the idea of the design engineer. Even if they get the idea then they find it difficult
to relate the modified part with the assembly. It is better to communicate such design
changes by 3D models of machines because they are very close to actual machines.
3D models crated in AutoCAD can also serve the purpose but modifying the
individual parts in AutoCAD assembly is quite difficult in other words, we can say
that 3D assembly created AutoCAD is rigid and cannot accommodate design changes
easily. In view of the above situation, it was decided to create 3D models of the
machines using parametric modeling software such as Pro/E. The bi-directional
associative nature of Pro/ENGINEER is the second reason for choice of this software.
There is a bi-directional associativity between all modes of Pro/ENGINEER. The bi-
directional associative nature of a software package is defined as its ability to ensure
that if any modification is made in a particular model in one mode, the modification is
reflected in the same mode as well as in other modes also. For example, if you make
any change in a model in the part mode and generate it, the changes will be
highlighted in the assembly mode also. Similarly, if you make any change in a part in
the assembly mode, after regeneration, the change will be highlighted in the Part
mode also. This bi-directional associativity also correlates the two-dimensional (2D)
drawing view generated in the Drawing mode and the solid model created in the Part
mode of Pro/ENGINEER. This means that if you modify the dimensions of the 2D
drawing view in the Drawing mode, the change will be automatically reflected in the
solid model and also in the assembly after regeneration. Likewise, if you modify the
solid model in the Drawing mode. Thus, bi-directional associativity means that if
modification is made to any one application, it change the output of all the other
modes related to the model. This nature relates the various modes available in
Pro/ENGINEER.

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 The second important reason for using Pro/Engineer is that assemblies
and parts created in Pro/E can be converted into AutoCAD format but reverse of this
is not possible. So creating the assemblies and parts in Pro/E serves the dual purpose.
3.6.2 3D STUDIO

3D Studio is a major enhancement of the leading 3D animation

software for a PC. Using 3D Studio, anything can be created that is imagined. The
modeling method in this software creates objects out of various sub objects such as
vertices, faces and edges. The materials can be assigned to the created objects which
make scenes jump to life. The software has numerous features like the user interface,
modeling, editing, composition, materials, rendering and environments. One of the
most powerful features of 3D Studio is its capability to animate almost any geometry,
light, camera or modifier. The computer animation is achieved by displaying a series
of individual frames at a speed fast enough to create the illusion of motion.

3.6.3 VIRTUAL REALITY MODELING LANGUAGE (VRML)

The World Wide Web added an interesting new twist to the use of 3D
graphics. VRML is an exciting new development. The features of this language are
described in a separate Chapter.

3.7 GEOMETRIC MODELLING APPLICATIONS

The agro machines discussed in chapter 4 were geometrically modeled

with the help of commercially available computer graphics software package,
Pro/Engineer. 3D models of following agro machines were created.

1) Destoner
2) Gravity separator
3) Air seed classifier
4) Automatic weighing machine (weigher)

A 3D model of destoner was generated with the help of popular

graphics package. The machine was given the operational movements by using the

15
animation package. Destoner is the machine which separates the stones from grain
like no other machine. The simulation of this machine includes obtaining the power
from electric motor with the help of belt. The power from electric motor is given to
the shaft on which eccentric are mounted which in turn produce the oscillating motion
of deck. Simultaneously, blower directs the air flow from the bottom of the deck
which forms air cushion. Destoner is an excellent machine for cleaning food grains by
removing stones, mud balls, and metal pieces etc. Fig.3.3 shows the working principle
of destoner.

Fig.3.3 Working Principle of Destoner

The gravity separator is the second agro machine which was modeled
and simulated in the similar manner i.e. 3D model was created in Pro/E and
simulation carried out in 3D max studio. Gravity separator is designed to separate
particles of same size but of different specific gravity (like rain damaged, insects
attacked, or low grade seeds).

The material is fed continuously on the surface of oscillating deck. The

pressurized air permeate through porous deck surface made up of wire mesh and
creates fluidized bed. These causes the seed particles to orient themselves as per their
specific weight. Fig 3.4 shows the working principle of gravity separator.

16
 Fig 3.4 Working Principle of Gravity Separator

The video clip created for this machine starts with transparent blower
casings which becomes non- transparent the next moment. Such type of arrangement
was made so that customers can see the working of blowers.

The third machine taken for modeling and simulation was air seed
classifier. This machine does not contain any moving parts. The video clip created for
this machine is capable of showing the complete construction of the machine. The
grains are sucked pneumatically which can be clearly seen in the video clip.

The last machine which was modeled and simulated was automatic
weighing machine. The simulation of automatic machines shows that the grains are
fed from the storage bin to the bag. As soon as the weight of the bag approaches to the
set weight, one of the openings of the storage bin (coarse feed) closes. The grains are
now fed from the fine feed. As the weight of the bag becomes equal to the set weight,
the fine feed also closes immediately. The gunny bag is then decamped and belt
conveyor is operated so that bag is conveyed away from the machine and next cycle
of operation can be started.

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 4. AGRO MACHINES UNDER STUDY

Mahavir Electromechanical Works Pvt. Ltd. is engaged in

manufacturing of agro machines supplied all over India. The assembly of the
machines is quite complex and size is considerable, therefore the marketing people
were finding it difficult to give live demonstration of the actual machines to their
customer. By carefully analyzing the problems reported by marketing people, it was
felt that virtual 3D working models would be very useful to tackle the above problem.
The brief descriptions of the machines taken for the dissertation work are as follows.

4.1 MAHAVIR D-SERIES DESTONER

Destoner assures unbeatable reliability and performance. Most

effective solution for separation of stones, mud balls and dust from seeds/grains.

4.1.1 APPLICATION

For continuous separation of stones from a stream of granular material,

simple and dependable separation on the basis of the difference in terminal velocity of
the material and of the heavy impurities such as stone, metals, glass etc.

4.1.2 WORKING PRINCIPLE

The gravity-fed grain is spread by a feeder across the entire width of

the machine. On separation screen, the stream of material is stratified according to its
specific gravity by the oscillating motion of the screen and the air flowing through the
material from bottom to top. The light particles collect at the top and the heavy ones
including the stones at the bottom. The lower layers of stones flow upward and are
separated out. The stone free stream of materials float on cushion of air, flowing

18
slowly towards the material outlets. The inclination of the screens, the air volume and
final separation can be individually adjusted to achieve the optimum degree of
separation.

4.1.3 DUST COLLECTION SYSTEM

Some products are contaminated with dust chaff and other light
impurities, which are to be separated. The provision of special fan for removing the
said impurities can be given as an optional arrangement.
Adjustment: All the adjustments provided in the machine are simple and user
friendly.

4.1.4 MACHINE CAPACITY

Due to the wide variation in separation requirements, MFPL cannot

guarantee these specific capacities; however, estimates in the table are conservative
and have been equaled or exceeded when the destoner and other associated equipment
have been installed and operated properly. The destoner requires a firm foundation, an
adequate clean air source and uniform feed rate.

Table 4.1: Technical Specification of Destoner

Model Capacity Power in HP Dimensions

Length - 1300 mm
2 HP Width - 960 mm
D-2 3 HP Height - 2000 mm
2 TPH
D-1.5 (With dust Deck size
collection) 870 x 740 mm

4.2 MAHAVIR G-SERIES GRAVITY SEPARATOR

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 Mahavir Gravity Separator is used to separate any of dry particles similar in
size & shape, but having different in specific weight. Gives best result in gradation of
seed as well as grains.

4.2.1 WORKING PRINCIPLE

It works on principle of Gravity (weight) difference in the particles. For

efficient density separation of different variety of seed or grain, proper adjustment of
deck inclination (longitudinal & transverse), deck oscillation speed & setting of air of
multi fan is necessary. The above adjustment can be done very easily while machine is
in running condition.

4.2.2 DUST CONTROL

Certain seed/ grains contain dust; chaff & other light impurities which creates
pollution in atmosphere. To control this air pollution, system can be provided with an
optional arrangement based on customer requirement.

Features:

• Blower of aerodynamic design gives very high efficiency and avoids noise.
• Sturdy & compact design.
• Easy airflow adjustment.
• Filters provided to avoid entry of dust in blowers.
• Rectangular deck ensures excellent separation.
• Multi fan arrangement ensures exact airflow requirement in different deck areas.

Table 4.2 Technical Specification of Gravity Separator

No. of Dimension in mm
Model Capacity Power
Fan
MG-1 3 Fans 1 TPH 5.0 HP

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 MG-2 5 Fans 2 TPH 7.5 HP 2200 x 1150 x 650
MG-4 7 Fans 4 TPH 10.0 HP

4.3 MAHAVIR A-SERIES AIR CLASSIFIER

This machine is the effective solution for separating light seed / grain,
dust, impurities from good quality grain/ seed.

4.3.1 WORKING PRINCIPLE

The seed/grain is initially fed to feeding hopper, through feeding

hopper grains are pneumatically conveyed to top classifying feed chamber. The grains
are conveyed through rectangular conveying duct. Stones, chaff dust are separated out
from grains & are collected in top feed chamber. From top feed chamber, grains are
fed to classifying duct where high velocity air stream separates light grains, light
impurities from good quality grain. Separate chute is provided for collecting good
quality grain, light grains, dust & chaff.

Special Features:
• Grading of grain is done by high velocity air stream.
• Removes dust, light impurities, trash from grain.
• Low quality immature grain and broken grains are separated from good quality
grain.
• Self-pneumatic feeding, hence no need of bucket elevator.
• Glass panel is provided to observe process of separation and for accurate
adjustment.
• No screen, deck or any moving part, hence maintenance free.

Table 4.3 Technical Specification of Air Classifier

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 Model Electrical Power Capacity
MEPL 4 7.5 HP 4 TPH
MEPL 2 5.0 HP 2 TPH
MEPL 1 3.0 HP 1 TPH

4.4 MAHAVIR W - SERIES WEIGHER

Special Features:

• Electronic Setting Facility.

• Load Cell based
• Accuracy 0.1%
• Range 20-100 Kgs.
• Capacity - 60 Bags of 100 Kgs. per hour.
• Facility of Conveyor.
• Facility of stitching of gunny bag.
• Structure - Powder coating, hence long life.
• Easy clamping & decamping of Gunny bag.
• Storage bin capacity - 750 Kgs.
• Only one Operator requires operating the machine.
• Pneumatically operated feed gate system.

Table 4.4 Technical Specification Series Weigher

Model Capacity Power Reqd. Dimension (Mtr.)

WS –100 20-100 Kgs. 2 HP (Conveyor) 3 x 1 x 2.5

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 5. METHODOLOGY

Marketing people of Mahavir Electromechanical reported following problems.

1) Considering the complexity and size of machine, the transportation of the
machines is costly to give live demonstration at customer site.
2) Considerable amount of grain is needed for demonstration (trial run).
3) Three-phase power supply is needed to run such heavy machines.
4) Firm foundation is required for trail run.
5) All the technicians associated with the machines are required to remain
present at the time of trail run.
6) All the accessories and spares should be available for demonstration. As the
machines are manufactured on job order basis, there is less possibility that all
the spares will get available.

By carefully analyzing the problems reported by marketing people, it

was felt that virtual 3d working models would be very useful to tackle the above
problem.

5.1 METHODOLOGY ADOPTED TO TACKLE THE PROBLEM

Keeping in view all the aspects of problem, it was decided that the 3d
models of the machines must be created. Pro/E was chosen as modeling software for
this purpose. All the parts of machines were modeled in part mode of Pro/E and then
they were assembled in assembly mode of Pro/E. Choosing Pro/E, as modeling
software was beneficial in following aspects.
1. As the design department keeps on modifying the Agro machines as per
customer requirements, frequent modifications are allowed by Pro/E being a
parametric modeling package.

23
 2. Due to bi-directional associative nature of Pro/E, parts modified in part mode
get automatically updated in assembly mode. This process is quiet easy as
compared to modifying the parts in assembly created in AutoCAD.
5.2 SIMULATION OF MECHANISMS AND PROCESS IN 3DS
MAX STUDIO

The simulation of mechanism can be done in Pro/E as well, but in this

case, it was needed to simulate the grains also, to show the simulation of process. All
the assemblies were exported in 3ds max studio format and then they were simulated.

5.3 SEQUENTIAL ORDER FOR CREATING VRML OUTPUT

Following is the methodology adopted for creating final VRML output:

5.3.1 PART MODELING

Individual parts of the machines were created in part mode with the
actual dimensions. The scale of the individual parts while modeling was taken as 1:1
and units were inches but units of parts are not important as any part can be converted
in any units in Pro/E i.e. the part modeled in inches can be converted to millimeters.
The unit conversion option provides two options to the user, one option is called same
size i.e. one inch will be converted into its respective size in millimeters the meaning
is that 1 inch part will have the new size of 20.54 millimeters after conversion. The
same number option converts the dimension, as 1 inch equals to 1 millimeter. The
conversion process is very fast and simple; therefore units do not carry any meaning
in Pro/E and can be decided at the time of manufacturing.

5.3.2 SIMULATION
The assemblies created in Pro/E were exported to 3DS max studio for
process and mechanism simulation. The mechanism can be given motion in Pro/E as
well but in this case it was not only the mechanism which was required to be shown in
motion but the process simulation was also important i.e. the grains in the process
were required to be shown in motion. These constraints forced to choose 3DS max

24
studio as simulation software. 3DS max studio has the facility called particle system,
which enables the user to show the behavior of particles such as grains in motion.

5.3.3 PRESENTATION IN VRML

The simulation created in 3DS max studio was exported in VRML
format for final presentation. VRML enables you to view the simulation interactively
i.e. user can take walk around the machine, go inside the machine to see its
mechanism in working, view it from different angles etc. the experience is same as
viewing the machines in real world. The VRML is shareware software available on
Internet. The user can download it from Internet, after installation it gets plug in with
Internet explorer.

5.4 VRML AND VISUAL SIMULATION OF INDUSTRIAL

PROCESSES

5.4.1 INTRODUCTION

VRML is the tool for creating 3D virtual experiences on the World

Wide Web. Even though it is in its infancy, it allows one to realize his vision and
make them available to everyone on the web. Internet Explorer and Cosmo Player are
the browsers used to visualize the VRML world. The numbers that indicate size in
VRML are stated in meters. The VRML file format allows user to create a scene graph
(structure of the world being created), for world using simple words and punctuation.
Every point in the world can be described by a set of three numbers, called
coordinate.

Virtual Reality (VR) represents a computer interface technology that is

designed to go beyond classical two dimensional constraints. Unlike the keyboard,
mouse, monitor or graphical user interfaces, VR allows user to interact with real time
3D graphics in a more intuitive and natural manner. In VR, the user becomes a part of
the 3D environment that is created. In virtual worlds, it is possible to get a 360 degree
view of the computer generated environment.

25
 VRML enable the designers to experiment freely without rebuilding
the physical model every time, it offers an enormous potential to economic and the
chances to improve design quality. Virtual modeling is a reliable predictor of decision
making process. These types of models are more reliable estimator of production cost
and schedule because the models are based on actual processes.

This type of application develops pre-production hardened system

which are verified, does not actually undergo actual runs. Another important thing is
modeling and simulation can significantly improved production flexibility, hence
reducing the fixed cost.

Some applications of vital worlds are static. So in advance system

highly realistic simulation implemented, as it need a great amount of computing
power. The reason why virtual systems are not being used widely, because of cost
factors. The cost of high resolution display is still high. Such type of software
provides engineers the tools needed to perform their technical jobs efficiently and free
them form tedious and consuming tasks that require little or no technical know- how.

In more advanced systems, it become possible for the user to move

around inside a virtual model or environment, drive through it, lift items, hear and feel
things. Here, the users are immersed in the virtual world. The special devices are used
to immerse the user in the virtual world and track his movement in it. These devices
vary depending on the level of immersibility in the virtual reality. A transmitter
mounts on top of a standard monitor and a virtual world can be experienced with the
help of light weight plastic glasses. A more immerse experience is afforded by Head
Mounted Displays (HMD s). These have tiny monitors, which are generally cathode
ray tubes or liquid crystal displays, in front of each eye to generate images. These are
equipped with trackers, which are devices that provide numeric coordinates to identify
the current position or orientation of an object or user in real space. Output image is
based upon the position of the user's head and neck. At the relatively higher end the
data glove wired with sensors and connected to a computer system uses magnetic
tracking for gesture recognition and navigation through a virtual environment. These
give the real touch effect.

26
 The benefit with VR is the ability to work in a virtual environment
without the attendant danger, impracticality or greater expense that would be
encountered in the same environment if it were physical.
5.4.2 THE VIRTUAL REALITY ENVIRONMENT

The virtual reality environment serves to place a human operator

“within” a computer generated or virtual environment. It provides, “interactive” 3D
viewing and the ability to manipulate complex components before their design is
finalized. This allows early checks to be made on the practicability of design which
are still only defined in electronic form.

The VRML viewer provides the facility to the users to navigate

through the application. VRML viewer consists of the controls like, “Walk”, “Pan”,
“Go To”, “Turn”, “Study”, “Zoom Out”, “Straighten up”, “View”, “Restore”, etc.
With these controls one can have a walk through the environment. The features like
Light effects, collision prevention and speed control are also provided by the VRML
viewers.

Walk: This enable a user to walk forward or backward as desired.

Pan: It is used for horizontal rotation of screen from right to left or vice versa. The
pan is often using to move the screen from one object to another or to see more off a
landscape will fit in frame.
Turn & Roll: Able to rotate the object left or right as desired, only difference
between them is that is used for continuous rotation.
Go To: When clicked user will zip towards the particular position.
Study: With this user can study the specific object from each and every position
Restore: Gives the initial view of object as it was displayed earlier.

The virtual environment and the controls explained above are

represented in Fig 5.1. When clicked on any *.wrl file, the Internet Explorer or
Netscape Navigator web browser automatically opens the VR environment. By using
the buttons on left hand side and bottoms user can have a walk through in the
application.

27
 Figure 5.1 VR Environment Screen

Virtual reality thus offers vast potential for optimizing design and
exploiting alternative options.

The only way to get similar motions using 2D is by using movies, such
as MPEG, or image based formats, such as shock wave from macro media. Both of
these techniques create huge files that are extremely slow to download over the web,
and are not as flexible. With 3D and VRML, one can go literally anywhere in the 3D
world & can walk upped a sign to read it, look over the shoulders to see where a
sound is coming from, or walk up the flight of stairs to go into a second story office.

5.5 VRML APPLICATIONS AND PROGRAMMING

5.5.1 INTRODUCTION

28
 Virtual environments can be used for automobile design and
engineering. It can also be used for simulation digital prototyping and surface
modeling. Engineers can locate and analyze potential problems much faster, reducing
long term costs.
Architects and planners can interactively visualize these entire design
processes before pouring concrete, virtual construction can save money as design
faults can be easily discovered. Virtual reality can also be used in the aircraft industry.
Boeing has used virtual reality to evaluate the accessibility of aircraft cabins for
maintenance workers. It can also be used for defense applications, flight simulation
for mission planning, war games and the like are all possible, not to mention, design
of aircraft, tanks, ships and sophisticated weapons. For situation where hazardous
condition prevails, personnel can be trained in virtual environment to reduce errors in
the field.
Medicine and scientific research can also benefits from virtual reality.
Virtual surgery is one such area. Computer models and specialized interactive devices
mimic surgical tool to allow medical personnel to practice surgical procedure.
Interactive 3D modeling and stereo viewing allow you to visualize and manipulate
complex molecules in real time.

The efforts have been made to model and visually simulate the
industrial processes. Various software packages were used to generate, animate and
simulate the manufacturing and handling processes. The popular graphics package
was used as a 2D and 3D drafting tool to create the basic objects. After that the
animation package was used to give the respective operating motions to those basic
objects. The animated objects then were positioned at the respective places with
appropriate orientations inside the factory environment. The factory layout was also
geometrically modeled as an individual object.

The basic objects geometrically represented by wire-frame models,

were then imported into the 3D Studio animation software package. The respective
basic operational motions were given to those objects with the help of animation
package. The material textures were also assigned during this process to the objects.
The limitation of animation package didn't allow the user and avatar to interact with

29
the animated objects. The beauty of VRML lies in getting interacted with the virtual
environment by touch sensing, proximity sensing, lighting and assignment of the
suitable sounds to the objects. In the present application, the appropriate sounds were
tried to synchronize with the machining operations. The 3D Studio animation package
provides the facility to transform all the database generated in .3DS graphics file
format in the VRML file format which is designated by the *.wrl file extension and
can be edited with the help of any text editor. Apart from this, some of the VRML
codes for assignment of sounds and textures for the objects were written and
embedded in the main source code.

Fig. 5.2 VR Environment & Visual Simulation (View 1)

The visually simulated machines models are represented in Fig. 5.2

and Fig.5.3. These figures represent the views of inside virtual environment of the
industry.

30
 Fig. 5.3 VR Environment & Visual Simulation (View 2)

5.6 VRML PROGRAMMING

In order to place objects relative to each other, VRML provides user

with the ability to transform the position and orientation of objects. The transform
node contains a list of children, which can be the set of shapes to be transformed. The
transform node basically determines where in the virtual world the origin of a set of
objects (its children) will be. This transform effectively creates a local coordinate
space for its children.
VRML has several simple geometric shapes that one can use to build
much more complex objects, like, box, cone, cylinder and sphere. The appearance

31
node of VRML is used to apply color to a geometric model. But it has the capability
to apply much more rich appearances to geometry, like image textures.
The programming in VRML starts with a header line, which indicates
the VRML file, it’s version and ISO standard that allows characters in the file to be
read by a text editor. The sample part program source codes are given below.
5.6.1 DEFINING A SHAPE
#VRML V2.0 utf8
# Produced by 3D Studio MAX VRML97 exporter, Version 6, Revision 0.56
# MAX File: destonerfinal2.max, Date: Sat Jul 02 22:13:57 2005

DEF Layer:Handles01 Transform {

translation 397.5 27.89 –247.2
children [
Shape {
appearance Appearance {
material Material {
diffuseColor 1 0 0.498
}
}
}
]
}

5.6.2 DEFINING A OBJECT FROM PRIMITIVES

#VRML V2.0 utf8
# Produced by 3D Studio MAX VRML97 exporter, Version 6, Revision 0.56
# MAX File: factory2.max, Date: Tue Jul 26 10:32:26 2005

DEF Cylinder02 Transform {

translation 0.1291 0.2365 -1.575
rotation -1 0 0 -1.571
children [
Transform {
translation 0 1.575 0
children [

32
 Shape {
appearance Appearance {
material Material {
diffuseColor 0.6863 0.5412 0.5412
ambientIntensity 1.0
specularColor 0 0 0
shininess 0.145
transparency 0
}
}
geometry Cylinder { radius 0.5906 height 3.15 }
}
]}
]
}
]
}

5.6.3 DEFINING ANIMATION

DEF VSep149 Transform {

translation 0 0 0
children [
DEF VIFS141 Transform {
translation 0 0 0
children [
Shape {
appearance Appearance {
material Material {
diffuseColor 0.5882 0.5882 0.5882
ambientIntensity 1.0
specularColor 0 0 0
shininess 0.145

33
 transparency 0
}
texture ImageTexture {
url "../maps/belt.jpg"
}
5.6.4 ASSIGNING SOUND

# destoner sound
Sound {
location 152 26.65 -163.3
source AudioClip {
url "../sounds/destoner.wav"
pitch 1
stopTime -1
loop TRUE
}
minBack 200
minFront 600
maxBack 300
maxFront 800
direction -1 -1 -1
}

5.7 DATABASE GENERATION

During development of the applications in different software, a huge

database was generated. This database can be further utilized for other applications.
The source code generated after completion of entire application was nearly equal
2, 25,659 lines. The program can be edited with the help of any text editor. Program
has the modular structure. Even if any module is removed from the program, the
resulting program can be executed with out affecting the remaining modules. The
program does not accept any syntax error in any of the module. Unless and until the
syntax is removed, the program will not continue its execution. The generated
database constitutes mostly the numerical values of vertices of geometrical shapes or
34
objects, texture values of the surfaces, color intensities and their values, coordinate
values of the animated objects, etc. Apart from this, the touch sensing and proximity
sensing values are also available for the further reference.

6. APPLLICATIONS, ADVANTAGES, LIMITATIONS AND

FUTURE SCOPE

6.1 APPLICATIONS OF SIMULATION

Simulation finds application in following areas

1. Marketing of the agro machines in absence of actual product.
2. Training for technicians and customers.
3. Display of products in trade fares and exhibitions. Simulation will be
supporting element to the actual product.

6.2 USE OF VRML (VIRTUAL REALITY MODELING

LANGUAGE) FOR PRESENTATION

VRML was chosen as presentation software as VRML is shareware

software. Any user can download the plug in from Internet. The VRML format also
enables to upload the models on web when required. In the future, it is proposed that
all the models will be uploaded on web, which will eliminate the need to carry the CD
along with marketing person. Any customer having the access to Internet can
download the working models from Internet and view them on his own.

6.3 FOLLOWING ARE THE ADVANTAGES OF 3D WORKING

MODELS

1. 3d working models are as real as actual machines. They give the same feeling
as that of actual machine.

35
 2. They are very informative in case of explaining complex mechanisms and
processes as in our case.
3. The virtual models created are interactive. Customer can see the working
machine models interactively i.e. they can walk around the machine, go inside
the machine, and view it from various angels. The phenomenon is very similar
to playing games on computer.

6.4 ADVANTAGES OF SIMULATIONS

Simulation offers following advantages

 The first biggest advantage of the computer simulation reported by marketing

department was that they have saved cost of trail run of the agro machines. In the
absence of the computer simulation, the cost of repeated trail run would have been
definitely more.
 Simulation helped in debugging. This was the opinion of the design department at
Mahavir electromechanical works. The real value of simulation proved to be the
ability to identify and fix design flaws.
 A simulation proved to be useful for analysis. Computer simulation gave clues
and alternative strategies to designer and maintenance engineer.
 Simulation was found to be useful for training. If accurate simulations are created
and numbers of runs are taken then it was observed that the operators learned
which areas of the process require special attention. Simulated training can play a
key role in making training meaningful, interesting, and timely.
Besides this simulations can be helpful in

1. Avoiding injuries or deaths.

2. Avoiding loss of production.
3. Avoiding damaged equipment (cost to repair with spare or new parts plus
downtime).
4. Avoiding Startup and restart costs.
5. Avoiding wasted feedstock costs.

36
 6. Avoiding wasted energy costs (grains, electricity, etc.)

6.5 LIMITATIONS OF VIRTUAL REALITY

Though virtual reality systems use many CAD or modeling programs

to give the user access to a large number of conventionally generated worlds, these
systems are not always capable of matching the needs of today's real systems.

There is a fundamental shortfall in virtual worlds, in the sense that, the

interaction with virtual environment is limited. Simple virtual world are static, there
is little scope for interaction, other than moving the user's view point. Highly realistic
simulation is complicated to implement, as it needs a great amount of computing
power. The reason why reality systems are not being used widely is the cost factor.

With the cost of high resolution virtual reality systems coming down,
virtual should be a part of mainstream information technology in near future.

6.6 FUTURE SCOPE

With the developments happening as fast as they are, the only thing
which can be said with certainty is that, VRML is changing rapidly and by all
indications, and will continue to do so well in future. Several companies are
scrambling to make multi-user technology available.

Today this work is in its infancy. The look of an avatar is limited.

Persistence is a step along the road to virtual world. Persistence would allow the user
to enter into a world carrying status, which has just been created, place it in the center
of plaza, and them leave. Anyone else wandering in that plaza, will admire the beauty
of placement and if another user tips the status, it will fall to the ground, broken into
pieces.

37
 The benefits of VR to the user are obvious. Customers will be able to
try their product before they actually buy and of course, during the trial, entertainment
will also be added to the concept. VR will buy and of course, during the trial,
entertainment will also be added to the concept. VR will allow perspective home
buyers to simulate their future houses and move around inside as if they are living in
the yet-built houses.

VRML enable the designers to experiment freely without rebuilding

the physical model every time. It offers an enormous potential to economize and the
chances to improve design quality. VR is a reliable predictor of decision making
process. These types of models are more reliable estimator of production cost and
schedule because the models are based on actual processes. Another capability of
VRML is adding sound to the world which can make simple world much reachable
and more interesting. VRML produce geometrical shapes instead of the mathematical
simple models required to create a fast and realistic virtual environment.

The application of VR will also advance the training institutes for

training the air force or commercial pilots without getting loss of man and machine. In
advance, it will prove be more accurate than market survey. Virtual environments can
be used for automobile design engineering. It can be used for simulation digital
prototyping and surface modeling. Engineers locate and analyze potential problems
much faster, reducing long term costs.

Medicine and scientific research can also benefits from virtual reality.
Virtual surgery is one such area. Computer models and specialized interactive devices
mimic surgical to allow medical personnel to practice surgical procedure. Interactive
3D modeling and viewing allow one to visualize and manipulate complex molecules
in real time.

At present, all the machines presented in virtual reality do not have any
control panel. The simulation runs on its own and user have hardly any control over
the start and stop of the simulation. Once started, simulations keeps on running and
user can not see the intermediate stage. In future, the models can be equipped with

38
control panel so that they can be more realistic and close to the actual machines. Most
of these machines employ air for several purposes such as separation, suction,
conveying etc. At present the flow of air is not simulated as we can not see the flow of
air unless it contains the dust or smoke. The flow of air can be simulated in the future.
The whole dissertation is organized on compact disk, which is supposed to be carried
whenever it is required to run the simulation. In the future, if the company have any
plan to develop the web site (which is essentially required in these days to promote
the product), then the models can be uploaded on company’s website. This will
eliminate the need of carrying the CD and the products can be viewed in virtual
environment at any time from the PC having internet connection facility. The beauty
of the VRML is that it do not requires any specific softwares except a small plug in
(like VRML viewer or Cosmo player) which can be downloaded from the internet
within few minutes.

39
 7. DISCUSSION AND CONCLUSIONS

Visualization in many scientific fields (e.g. engineering, biochemistry,

physics, and astronomy) has been greatly aided by computer graphics. Once translated
into visual images, even very complex data can be easily interpreted. In addition to
illustrating data, computer graphics can also be used to design experiments and
analyze probabilities in advance to narrow the range of variables to be tested.
Computer – aided design is used extensively in the automotive, aeronautic, electronic,
and textile industries. Computer graphics can be used to aid the imagination in all
types of design, from choreography to architecture. Because simulation is generally so
much cheaper than staging a performance of an entire dance troupe, for example,
and so easily edited, CG allows more experimentation in the design phase. Instead of
being forced to commit to a certain path fairly early on, a designer can take all manner
of permutations of an idea to their logical completion before making a decision (or
presenting options to decision –makers). The software handles the computations,
freeing the designer to focus on comparing the results of different routes rather than
on figuring out the results.

The caveat to this is that a 3D simulation of an experiment is only as

good as the premises on which it is based. It is easy to be convinced by a visual
simulation, because vision involves its own mental processes separate from our
analytical minds. When using 3D to simulate a test that would be expensive in the real
world, bear in mind that the assumptions of the simulations need to be carefully
analyzed before you commit to a course of action.

Visualization has always been recognized as the most effective means

of communicating new ideas and design among designers, engineers and others. And
a new concept of virtual realism has come into scene which enhances the practical

40
visualization of object. What makes the concept of VR so exhilarating is the fact that
it allows the user to feel that they are within the system, rather than outside it as in
case of traditional computers.
This system of VRML is a pioneering effort in the field of modeling
and visual simulation of industrial processes which is the upcoming concept till date.
However, with the technical advancement in the field of virtual reality and the
demand for better and efficient processes or industrial applications, the need for
VRML with much wider knowledge base must be required. This can create a virtual
world in front of real world.

The resulted VR environment was the outcome of applications derived

from the individual software packages. Previous application each time constituted the
base for next application to be developed. Though, initial modeling of operational
activities in industries are complex and time consuming, once modeled graphically, it
is easy to animate and represent in the VR environment.

The processes modeled in the VR environment can be helpful in multi-

tier applications like, process planning, routing & scheduling, machine capacity
planning, motion and time study, work place design, ergonomic study, product
display, employee training, etc.

The above dissertation was carried out keeping in view the need and
difficulty of marketing department of the company. As Pro/E was chosen as modeling
software there are much more possible uses of 3d assemblies created in Pro/E. Pro/E
can be used to create tool path generation for manufacturing of part. The rapid
prototype of parts as well as assemblies can be created by exporting the assemblies in
Pro/E to *.stl format (*.stl format is used in rapid prototype process). The parts
created in Pro/E can be optimized as well as analysis can be carried out on them.
Automated inspection devices can be coupled with Pro/E to have automatic inspection
but this can be applicable where mass production is required. Besides marketing, the
moving 3d models of machines are useful in educating the farmers or workers
regarding the operation of machines. The moving 3d virtual models will be also useful
to the company to display their products in trade fairs or exhibitions of agro machines.

41
 LITERATURE CITED

1. David S. Kelley; Pro/Engineer instructor, Tata McGraw- Hill Publishing

Company Limited, 2001.
2. Chris Marrin, Bruce Campbell; Teach Yourself VRML 2 in 21 days,
Techmedia, New Delhi –2,1997
3. Prof. Shyam Tickoo, Pro/ENGINEER Wildfire for Engineers & Designers,
Dreamtech press, New Delhi-2, 2004
4. Cat Woods, Alexander Bicalho, Chris Murray; Mastering 3ds max 4;BPB
publication, 2002
5. Koren Yorarm – “Computer Control of Manufacturing Systems”, Mc Graw
Hill International Editions (1983).
6. Groover M. P. & Zimmers E. W. – “CAD/CAM”, Prentice Hall of India Pvt.
Ltd., New Delhi (1993).
7. Radhakrishnan, P., Kothandarman C. P. – “Computer Graphics & Design”,
Dhanpat Rai Publications, New Delhi, (2000).
8. Zeid Ibrahim – “CAD/CAM Theory & Practice”, Tata Mc Graw Hill, New
Delhi, (1998).
9. Kapoor Ramjee – “Computer Assisted Decision Models”, Tata Mc Graw Hill
Publishing Company Limited, New Delhi, (1991).
10. Surendra Kumar & Jha A.K. – “CAD/CAM”, Dhanpat Rai & Sons, New
Delhi, (1993).
11. Radhakrishnan P. & Subramanyan S. – “CAD/CAM/CIM”, Wiley Eastern
Limited, New Delhi (1994).
12. Peterson M. T. – “3 D Studio Max 3”, Techmedia, New Delhi, (1999).
13. Senn James A. – “Information Technology in Business”, Prentice Hall
International, Inc., New Jersey, (1998).
14. Darnell Rick, et al. – “HTML 4”, Techmedia, New Delhi, (1999).

42
 15. Bartoline Gary R. – “Fundamentals of CAD”, Galgotial Publishing Pvt. Ltd.,
New Delhi, (1989).

WEB URLs

1) http://www.3dsite.eom/n/sites/3dsite/cgi/VRML-index.html
2) http://www.aereal.com/instant/
3) http://www.trivista.com/vrml/
4) http://www.itl.nist.gov/iaui/ovrt/projects/mfg/SIMA/vrml97/vimhtml.f
m.html#HRD1
5) http://web3d.about .com/compute/3dgraphics/library/weekly/aa071398
.htm
6) http://www.web3d.org/
7) http://www.acm.org/pubs/contents/proceedings/graph/330160/
8) www.ptc.com
9) http://www.parallelgraphics.com/

43
 APPENDIX-I

TROUBLESHOOTING

1) CD not play
Remedy: Clean the lens of your CD Rom, writer or DVD Rom with the help
of lens cleaner CD.
2) You cannot hear Sound or Music.
Remedy: Check that your sound card is properly installed. Check whether the
speaker is powered on and adjusted to audio able level.
3) Unable to see VRML Models
Remedy: Install VRML plug in provided on the CD. Restart your computer
and then try again.
4) Unable to see the complete page of multimedia
Remedy: Your text size may not be adjusted properly to display the whole
page. Go to view menu, View >> Text size >> Smallest.
5) Cannot browse the content of CD properly
Remedy: Update your internet explorer to at least version 6 or more
6) Unable to view a *.avi files
Remedy: Install window media player or any other suitable media player (mp3
or Jet player) to view AVI files.
7) Cannot view *.max files
Remedy: Install 3DS Max 6 software or above.
8) Unable to view *.prt or *.asm files
Remedy: Install Pro / E 2001 of Pro / E Wildfire

Remember that the above version of Pro/E can be installed in Windows XP or later.

44
 APPENDIX-II

FILE FORMATS AND RESPECTIVE APPLICATION SOFTWARE

*.prt:- This is the pro/Engineer file format used in Pro/E part mode. Files with *.prt
extension can be opened with Pro/Engineer.
*.asm:- This file formats stores the assembly of components in Pro/ENGINEER
assembly mode. Files with *.asm extensions can be opened in Pro/ENGINEER.
*.avi: This file format contain the video created from 3Ds max studio as a video
output of *.max file. You can watch the video files with window media player or any
suitable software, which is used for watching the video such as jet player or winamp.
*.wrl: This file contains the simulation in VRML environment. You can open files
with *.wrl extension in Internet explorer. Ensure that you have already installed any
one of the VRML plug in provided on the CD-ROM of this dissertation or you can
download it from Internet, as it is shareware software.
*.max: This file format contains simulation created in 3DS max studio software. You
can open files with extension in 3DS max studio software.

APPENDIX -III

45
 CORTONA VRML CLIENT USER'S GUIDE
The following sections contain the description of the Cortona VRML Client main
controls:
THE CORTONA VRML CLIENT WINDOW
With Cortona VRML Client you can see and explore 3D worlds.
Cortona VRML Client will start automatically when you open a file containing
VRML world. There are two parts of the Cortona VRML Client window:

1. Toolbars:
o The vertical toolbar, which contains buttons used to specify navigation
type in a world.
o The horizontal toolbar, which contains buttons with predefined actions
to change your position in a world.
2. The 3D window, which shows VRML world.

There is also pop-up menu, which you access by pressing the right
mouse button while the pointer is over toolbars or 3D window.
Some worlds do not allow you navigating in a world, so toolbars may be invisible.

NAVIGATING IN CORTONA VRML CLIENT

Moving through a 3D space is similar to moving a camera. Think of a
video camera that captures images in the real world and converts them into electronic
signals for viewing on a screen; it has a position and orientation, and these are
independent attributes. Your movements in the world continually position and orient
that camera. Use the camera controls on the vertical toolbar to move the camera
through the 3D Space. This concept assumes that there is a real person viewing and
interacting with the VRML world. Nevertheless, the VRML author may place any
number of viewpoints (or cameras) in the world - interesting places from which the
user might wish to view the world. Only one viewpoint may be active at a time. This
section describes the mechanisms that Cortona VRML Client provides for navigating
in a three-dimensional space.

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Using Viewpoints
A viewpoint describes a position and orientation for viewing the scene.
The VRML author will probably want to guide the user to the best vantage points for
viewing it. Not all worlds contain viewpoints, but when they do, you can use them.
To activate a viewpoint, do one of the following:

• Click the VIEW in the horizontal toolbar or choose

viewpoints from the pop-up menu, and then select a viewpoint from the list of
the predefined viewpoints.
• Click the arrow buttons to move to the next or previous viewpoint. You can
also press Page Down or Page Down keyboard button.

Note:
If there are no predefined viewpoints in a world, the Empty message appears.
Moving around: Walk, Fly, and Study
There are three main navigation modes that Cortona VRML Client
offers: WALK, FLY, and EXAMINE. You can switch the navigation mode by clicking
buttons on the vertical toolbar (click STUDY to enter EXAMINE mode). Each
navigation mode may have several options: PLAN, PAN, TURN, and ROLL. The
combination of navigation mode and its option determines the possible camera motion
and its orientation. Please note that the VRML author has an opportunity to specify
which navigation paradigm should be used in the scene by default. Some worlds don't
allow the user to use navigation controls, but they may provide on-screen cues to
navigation.

You can navigate with the mouse, the keyboard, or both mouse and keyboard. To
move around a 3D world using the mouse:

1. Choose a navigation mode.

2. Position the pointer anywhere in the 3D window and press the left mouse
button.
3. Move the mouse while holding down its left button. The direction in which
you drag the mouse determines the camera motion.

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 4. Release the left mouse button to stop moving.

Note: The distance that you drag the mouse determines the speed with which the
camera moves. If you stop moving the mouse, the camera will continue moving until
you release the mouse button. To accelerate the camera's movement or rotation, press
SHIFT, CTRL or SHIFT+CTRL.

and
Use WALK+PLAN to move in a horizontal plane.

Forward - move closer

Backward - move further

Right - turn to the right

Left - turn to the left

Note: Move the mouse forward or backward while holding down the Space key to
turn upward, downward.
Move the mouse left or right while holding down the ALT key to move left or right.

and
Use WALK+PAN to move left or right in a horizontal plane.

Forward - move closer

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 Backward - move further

Right - move right

Left - move left

Note: When you move the camera right or left, the world will appear to move in the
opposite direction.

and
Use WALK+TURN to change the angle of the camera in a world.

Forward - turn upward

Backward - turn downward

Right - turn to the right

Left - turn to the left

and
Use FLY+PLAN to move left or right.

Forward - move the camera forward towards its longitudinal axis

Backward - move the camera backward

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 Right - turn the camera to the right around its vertical axis

Left - turn the camera to the left around its vertical axis

Note: The camera's vertical axis may be inclined in a 3D Space.

Move the mouse while holding down the ALT key to switch FLY+PAN.
Move the mouse while holding down the Space key to switch FLY+TURN.
Move the mouse while holding down the ALT+Space keys to switch FLY+ROLL.

and
Use FLY+PAN to move up, down, left, or right within a single vertical plane.

Forward - move up

Backward - move down

Right - move right

Left - move left

Note: When you move the camera, the world will appear to move in the opposite
direction.

and
Use FLY+TURN to turn the camera.

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 Forward - turn the camera upward around its horizontal axis

Backward - turn the camera downward around its horizontal axis

Right - turn the camera to the right around its vertical axis

Left - turn the camera to the left around its vertical axis

and
Use FLY+ROLL to incline the camera.

Right - incline to the left

Left - incline to the right

and
Use STUDY+PLAN to examine an object from various angles.

Forward - move the camera forward

Backward - move the camera backward

Right, Left - move the camera around the central point which is defined by
the center of bounding box of the geometry in the 3D scene.

and

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Use STUDY+TURN to examine an object from various angles.

Forward, Backward, Right, and Left - move the camera around

the central point which is defined by the center of bounding box of the geometry in
the 3D scene.

Note: Move the mouse while holding down the ALT key to switch STUDY+PAN.
Move the mouse while holding down the Space key to switch STUDY+PLAN.
Move the mouse while holding down the ALT+Space keys to switch STUDY+ROLL.

and
Use STUDY+ROLL to incline the camera around the central point which is defined
by the center of bounding box of the geometry in the 3D scene.

Right - incline to the left

Left - incline to the right

Note: The VRML author can choose the rotation center in the EXAMINE navigation
mode. By default, when in EXAMINE mode, Cortona VRML Client sets the center of
rotation in the center of the bounding box of the scene geometry. But it is possible to
change this center by specifying three additional values in the avatar Size field of the
Navigation Info node. According to the VRML specification, the first three values are
the avatar dimensions, while additional values may be used for browser-specific
purposes. In Cortona VRML Client the fourth, fifth and sixth values specify the center
of scene rotation in the world coordinates X, Y and Z.

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Use GOTO to move close to object in a world. Select GOTO in the toolbar and then
click on an object in the world. You'll move directly to it.
Restore, Fit, and Align
Cortona VRML Client provides three mechanisms that can help to re-orient a camera
if you have lost your way in a world. Unlike the navigation tools, these buttons invoke
predefined actions that take place as you click on them.

Use RESTORE to automatically return to the loaded world's original active

viewpoint.

Use FIT to make the scene view fully visible in the Cortona VRML Client 3D
window.

Use ALIGN to position the camera's horizontal and longitudinal axes parallel to the
scene horizontal plane.

Using Keyboard for Navigating

You can control the camera using keyboard commands. The
functionality for buttons corresponds to the movement of your mouse and depends on
the navigation type, its option, and the specified skin. Please note that the following
description of keyboard commands is presented for the FLY+PLAN navigation and
the Default skin.

• Arrow Up - move closer.

• Arrow Down - move further away.

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 • Arrow Right - turn to the right.
• Arrow Left - turn to the left.
• Arrow Up on the numeric keypad - move closer.
• Arrow Down on the numeric keypad - move further.
• Arrow Right on the numeric keypad - move to the right. If the STUDY mode -
move the camera around the center of rotation.
• Arrow Left on the numeric keypad - move to the left. If the STUDY mode -
move the camera around the center of rotation.
• 7 on the numeric keypad - turn the camera downward around its horizontal
axis.
• 9 on the numeric keypad - turn the camera upward around its horizontal axis.
• 1 on the numeric keypad - incline to the right. Note: It is not available in
WALK mode.
• 3 on the numeric keypad - incline to the left. Note: It is not available in WALK
mode.
• Gray Plus - move up in the case of FLY mode.
• Gray Minus - move down in the case of FLY mode.
• 1 on the alphanumeric keyboard - incline to the right. Note: It is not available
in WALK mode.
• 2 on the alphanumeric keyboard - incline to the left. Note: It is not available in
WALK mode.
• 3 on the alphanumeric keyboard - turn downward. If the STUDY mode - move
the camera around the center of rotation.
• 4 on the alphanumeric keyboard - turn upward. If the STUDY mode - move
the camera around the center of rotation.
• Page Down - next viewpoint.
• Page Up - previous viewpoint.
• Pause - Enables or disables Cylinder Sensor, Plane Sensor, Sphere Sensor, and
Touch Sensor in Cortona VRML Client.

To accelerate the camera's movement or rotation: Press SHIFT, CTRL or

SHIFT+CTRL and one of the above keys simultaneously.

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The ALT and SPACE keys allow the user to quickly change the navigation option to
PAN and TURN accordingly in the FLY navigation mode (to ROLL and PLAN in the
STUDY mode). The ALT and SPACE keys simultaneously pressed activate ROLL in
the FLY navigation mode or PAN in STUDY.

Setting Cortona VRML Client Options

The following options are supported from the pop-up menu of 3D window:

• Viewpoints. Activates a list of the predefined viewpoints.

• Headlight. Cortona VRML Client automatically includes a light for the
viewer in every world. The headlight always shines directly in front of the
camera. You can switch the headlight on and off.
• Navigation. You can select a navigation mode.
• Speed. Controls the rate at which a camera moves through a world.
• Full Screen. This hides most screen elements so that you can view the whole
scene. To close Full Screen, press ESC or F11.
• Hide/Show Toolbars. You can show or hide toolbars.
• Show/Hide Console. Shows or hides the VRML console containing errors or
warnings (for VRML developers).
• Preferences. Modifies settings for Cortona VRML Client such as screen
appearance, a render mode, and other options.
• Help. Lets you view the online Help system and general information about
Cortona VRML Client.

You can configure Cortona VRML Client options according to your preferences. To
change settings, choose Preferences from the right-button pop-up menu. The Parallel
Graphics Cortona Control dialog box is displayed:

General

• Loading. The Show progress check box determines whether the current state
of the loading process is shown. If the Wait for all resources is selected, the

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 scene will not be shown until all resources are loaded. If it is cleared, the
scene’s geometry will be shown immediately after the main wrl file loading.
• Appearance. You can change a background color of Cortona VRML Client
3D window: Click the Background color box at the General tab, click the
desired color from the palette, and then click OK. VRML authors can also
control a color that simulates ground and sky.
• Display frame rate. Allows you to display the frame rate on the status bar.
• Console mode. Shows or hides the VRML console containing errors or
warnings. The Console Mode attribute is set to Auto launch by default. This
shows the VRML console if errors or warnings occur.
• CPU load. Determines the degree of acceleration for Cortona VRML Client
render. This allows you to specify the processor usage in the range from 0
(minimum frame rate, maximum the processor idle time) to 100 (maximum
frame rate).

Scene
Scene location. Shows the currently opened VRML file and lists the
files you have recently opened. To quickly reopen one of these files, click it in the
Scene location list box and then click Apply. You can also open a document on your
computer hard disk or on a network drive that you have a connection to by clicking
the Browse button.

Renderer
Allows you to select a rendering mode. To draw the 3D image, Cortona
VRML Client provides two hardware renderers: OpenGL and DirectX. If your system
has hardware acceleration for either OpenGL or Direct3D (note: you must have
DirectX 5 or greater installed), choose the appropriate renderer. Using hardware
renderers can introduce limitations. Select a renderer to compare the performance and
visual quality of hardware versus software rendering and set your preferences
accordingly.

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Renderer options

• Dither colors if needed. Controls whether Cortona VRML Client dithers

while rendering. Dithering improves the quality of rendering, but may lower
performance.
• Motion blur effect. Apply a motion blur effect. This actually makes an image
seem a little blurred in motion.
• Wireframe rendering mode. The object appears to be outlined with wires
rather than solid.
• Anti-aliasing. The technique for smoothing out jaggies in showing curves on
computer monitor. There are two different modes: Idle-time and Real-time. If
the Idle-time option is on, it is applied only for static scene. Whereas selecting
Real-time initiates smoothing even in the viewer movement but results in
decreasing frame rate.
• Do not render textures. To turn the textures on or off.
• Limit textures size. All textures are optimized for speed.
• Optimize texture for quality. All textures are optimized for quality. Note that
if you select both Optimize texture for speed and quality, the renderer uses the
available resources to optimize speed and quality simultaneously.
• Use textures mip-mapping. When the scene contains acutely angled
polygons that disappear into the distance, mixes low- and high-resolution
versions of the same texture to reduce the jagged effect.
• Advanced alpha blending. Alpha blending is the name for the alpha channel
control, and it's used to simulate effects such as placing a piece of glass in
front of an object so that the object is completely visible behind the glass,
unviewable, or something in between. Advanced alpha blending turns a
particular rendering method on for better quality of translucent faces. The
processor should support MMX additional instructions.
• Extended Z-buffer. If the check box is selected, this sets the 32-bit Z-buffer
for the software renderer (R98). The default is 16-bit.
• Phong lighting model. A particular method for computing the apparent color
of a face at a particular point. It improves the quality of lighting, but lower

57
 performance. Note that this option is available only for R98 Renderer in the
Intel Pentium III optimization mode.
• Realistic fog. A method for computing the color for every pixel in the frame
buffer to simulate fog. It improves the quality, but lower performance.
• Strict VRML97 compliance. When selected, Cortona VRML Client renders
VRML scene in accordance with the VRML97 Specification. If it is turned off
(the default), simplified lighting equations and rendering techniques, which
provide higher performance, are used.
• Optimization. Turns the optimization rendering mode on or off, if possible.
• Renderer version. This is accessible only for Direct3D renderers. Allows you
to select a Revanche DX5 rendering mode in the case you have DirectX 7 or a
later version installed.

Navigation

• Navigation mode. This allows you to select the navigation mode from a list of
available navigation paradigms.
• Travel speed. Sets the rate at which the viewer travels through a scene. The
following are the typical values for the rates, in metres per second:
Slowest=0.0625, Slower=0.25, Normal=1, Faster=4, Fastest=16. If the speed
field of the Navigation Info is specified in the VRML file, the corresponding
speed factors are multiplied.
• Animate viewpoint. Sets the Viewpoint transition rules that specify how
Cortona VRML Client interprets the transition from the old viewpoint to the
new one. Auto - defined by the jump field of the Viewpoint node of a new
location. Always - a jump with the transition effect. Never - instantaneous
transition.
• Collision detection. By default, Cortona VRML Client will allow you to pass
through objects in your path. To prevent from passing through objects, select

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 Always in the Collision detection box at the Navigation tab. Select Auto to use
the collision method specified by VRML author.
• Headlight on. Mark the check box to turn the headlight on.
• Show hidden viewpoint. This allows you to see all viewpoints of the scene in
the VIEW list including those that do not have a description (a Viewpoint's
description field is empty).

APPENDIX –IV

TERMINOLOGY

CD: Compact disk

PC: Personal computer
*: Wildcard use in computers to search files.
Plug in: Small software, which will enhance the capabilities of the basic software.
Shareware software: Software having no proprietary. Free to use without paying cost
of the software.
PTC: Parametric Technology Corporation
Cosmo Player: Cosmo Player is one of the browsers used to view *.wrl files (VRML
files)
CORONTA VRML: It is another software/plug-in used to view *.wrl files.

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 APPENDIX –V

ORGANIZATION OF CD-ROM

CD- ROM drives have become integral part of every PC. As the
dissertation work was based on software, it was decided to organize all the work on
CD-ROM. The high storage capacity of the CD-ROM enables to store huge amount of
data on it. The following article explains how the dissertation work is organized on
CD-ROM .The CD is auto run i.e. as soon as you will insert the CD into drive, it will
automatically start to show you the front page.
DISSERTATION REPORT IN PDF FORMAT: This link enables to view the
complete dissertation report in Portable data format (PDF). Title wise classification is
available for quick reference. If your PC is not having the Acrobat reader installed on
it then you require installation of acrobat reader on your PC to view the pages in PDF
format.
SYNOPSIS: This link enables you to view synopsis of the dissertation work. The
link is located below the link dissertation report on left hand side.

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VRML PLUG IN: This link is below the synopsis link on left hand side. The
machine models in VRML format can be viewed with VRML plug in. VRML plug in
is shareware software available on Internet. The setups of most popular VRML plug
in such as CORTVRML or COSMOPLAYER are available on the CD-ROM so that
you can quickly install the VRML plug in on your PC to see the machine models
without any trouble. The purpose of providing setup of VRML software is to save the
valuable time of user to connect to the internet and download the software.
ACROBAT READER: Acrobat Reader is software, which enables you to view the
pages in PDF format. The dissertation report on the CD-ROM is available in PDF
format. If your PC is not having the acrobat reader installed on it then you can install
the software from this link. This link contains the compressed setup file required for
installation of acrobat reader.
LINKS TO IMPORTANT SITES: This links connects you to the various sites on
World Wide Web containing the information of agro machines and software used in
this dissertation work.
AGRO MACHINES IN Pro/E WILDFIRE FORMAT: This link is located at the
top on right hand side. The link contains part and assembly files of the Agro Machine
models created in Pro/E wildfire. If your PC have Pro/E installed on it then you can
view the parts and assemblies created in Pro/E. the part files have *.prt extensions
whereas assembly files have *.asm extensions.
AGRO MACHINES IN 3DS MAX STUDIO FORMAT: This link contains the
simulation files of agro machines created in 3DS max studio. These files can be
opened in 3DS max studio software. As all the files are created in 3DS max studio
version 6, user is advised to use version 6 or later to view the files. The version 6 of
3DS max studio or later can be loaded on windows XP operating system.
AGRO MACHINES IN VRML FORMAT:
Agro machine files created in VRML format are linked to this link.
You can view these files in Internet explorer having VRML plug in installed in it.
AGRO MACHINES IN AVI FORMAT: This link will take you to agro machines
stored in AVI format. AVI is a format, which enables you to see the video on
computer. You can open these files in any video viewing software like Window media
player, jet player or nay other suitable player, which is installed on your PC to view
video file formats.

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POWER POINT PRESENTATION:
This link contains the power point presentation related with this
dissertation work.

ACKNOWLEDGEMENT
I wish to place on record my deep sense of gratitude to my research
guide, Prof. D.S. Ingole, Asst. Professor, Department of production engineering,
college of engineering, Badnera for his constant encouragement, keen interest and
valuable advice during the tenure of this work. I am greatly benefited from his
guidance and the freedom he allowed me to pursue the work. This work would not
have been seen the light of the day without his help.
I owe my sincere thanks to Prof. S.G. Patil, H.O.D; Dept. of
Production Engineering and Prof. S.V. Bansod, course co-ordinator for his valuable
guidance and co-operation during my work.
It seemed a bit of tough task when I initiated my dissertation but Prof.
S.K. Patil, Lecturer, college of engineering and technology, Akola & consultant in
R&D department of Mahavir Electromechanical Works Pvt. Ltd and Prof. A.M. Jain,
former Lecturer, College of Engineering & Technology, Akola & owner of Mahavir
Electromechanical Works Pvt. Ltd. gave me the words of inspiration and I proceeded
and therefore I am very much indebted to him and take this opportunity to express my
sincere gratitude to him.

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 I am thankful to Dr. A.B. Marathe (Principal), Prof. C.V. Deshmukh
(H.O.D.), Prof. S.C. Makwana, Asst. Professor and other staff members of
Production Engineering Department, C.O.E.& T; Akola who had directly and
indirectly helped me.
I am thankful to Mr. Anirudha Patokar for his untiring efforts in
compilation of CD-ROM, design of attractive CD cover and helping me in particle
system of 3DS max studio.
Finally, I thank my family members for their forbearance towards my
long period of absence from home in pursuit of my dissertation work.

Dipak V. Shirbhate
M.E. (Final)
Dept. Of Production Engg;
Badnera

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