Motorised Dual Side Shaping Machine with IoT Integration

Year : 2026 | Volume : 13 | Issue : 02 | Page : 26 35
By

Sarthak D. Shivtare,

Atul A. Surve,

Kirti R. Shinde,

Sanika G. Gorad,

Mangesh B. Bankar,

  1. Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
  2. Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
  3. Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
  4. Student, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India
  5. Assistant Professor, Department of Mechanical Engineering, Rajgad Technical Campus, Dhangawadi, Pune, Maharashtra, India

Abstract

This work presents the design, fabrication and testing of a Motorised Dual Side Shaping Machine intended for small-scale workshops and educational laboratories, enhanced by an Internet of Things IoT based motor control system using the ESP32 microcontroller. The machine employs a 250 watt geared motor as the prime mover, transmitting power through a chain and sprocket mechanism to a 20 mm mild steel shaft supported on pedestal bearings (P204), where a plain crank disc mounted on the shaft drives a scotch yoke mechanism that converts rotary motion into precise linear reciprocating motion required for the shaping operation. Unlike conventional single-tool shaping machines, this design incorporates cutting tools on both sides of the reciprocating ram, enabling simultaneous material removal from two faces of the workpiece securely held in a jaw vice mounted on the machine table, with the entire assembly mounted on a robust welded mild steel frame structure ensuring rigidity and vibration resistance during operation. The machine offers significant advantages including doubled productivity, reduced cycle time, low manufacturing cost, and ease of maintenance, while demonstrating practical application of fundamental mechanical engineering concepts such as scotch yoke kinematics, power transmission, and machine tool design. The IoT system allows remote online control of a DC motor including start/stop operations and variable speed regulation from 0% to 100% through a web-based interface accessible via Wi-Fi, with a HC-SR04 ultrasonic sensor integrated to detect human proximity within a configurable safety distance, automatically halting the motor when a person is detected in the danger zone, and a real-time status dashboard continuously displaying the motor state, current speed level, and ultrasonic sensor readings to ensure operators always have full situational awareness. This system demonstrates a practical, low-cost and scalable approach to industrial-grade IoT motor safety control.

Keywords: Dual side shaping, scotch yoke mechanism, ESP32 IoT control, ultrasonic safety system.

[This article belongs to Trends in Machine design ]

How to cite this article: Sarthak D. Shivtare, Atul A. Surve, Kirti R. Shinde, Sanika G. Gorad, Mangesh B. Bankar. Motorised Dual Side Shaping Machine with IoT Integration. Trends in Machine design. 2026; 13(02):26-35.
How to cite this URL: Sarthak D. Shivtare, Atul A. Surve, Kirti R. Shinde, Sanika G. Gorad, Mangesh B. Bankar. Motorised Dual Side Shaping Machine with IoT Integration. Trends in Machine design. 2026; 13(02):26-35. Available from: https://journals.stmjournals.com/tmd/article=2026/view=253819

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Regular Issue Subscription Original Research
Volume 13
Issue 02
Received 30/03/2026
Accepted 14/05/2026
Published 15/06/2026
Publication Time 77 Days

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