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This document provides information about a pneumatic sheet cutting machine project. It includes sections on the introduction, pneumatic system components, working principle, design and drawings, applications and disadvantages. The pneumatic sheet cutting machine uses a pneumatic double acting cylinder connected to a moving cutting tool to cut sheet metal. It is powered by compressed air and is portable in size for easy transport. The machine aims to automate the sheet metal cutting process typically done manually in small to medium industries.
This document provides information about a pneumatic sheet cutting machine project. It includes sections on the introduction, pneumatic system components, working principle, design and drawings, applications and disadvantages. The pneumatic sheet cutting machine uses a pneumatic double acting cylinder connected to a moving cutting tool to cut sheet metal. It is powered by compressed air and is portable in size for easy transport. The machine aims to automate the sheet metal cutting process typically done manually in small to medium industries.
This document provides information about a pneumatic sheet cutting machine project. It includes sections on the introduction, pneumatic system components, working principle, design and drawings, applications and disadvantages. The pneumatic sheet cutting machine uses a pneumatic double acting cylinder connected to a moving cutting tool to cut sheet metal. It is powered by compressed air and is portable in size for easy transport. The machine aims to automate the sheet metal cutting process typically done manually in small to medium industries.
Submitted in partial fulfillment of the requirement for the award of
DIPLOMA IN MECHANICAL ENGINEERING BY Under the guidance of -------------------------------- 2004-2005 DEPARTMENT OF MECHANICAL ENGINEERING CERTIFICATE Register number: _________________________ This is to certi! th"t the #ro$ect re#ort tit%e& PNE'MATIC (HEET C'TTING MACHINE submitte& b! the o%%o)ing stu&ents or the ")"r& o the Di#%om" engineering is recor& o bon"*&e )or+ c"rrie& out b! them, Done b! Mr. / Ms_______________________________ In partial fl!ll"#nt $f t%# r#&ir#"#nt f$r t%# a'ar( $f (#)r## in Di#%om" in Mech"nic"% Engineering During The Ye"r-./001-/0023 44444444444444444 444444444444444 He"& o De#"rtment Gui&e C$i"*at$r# +4,+5,. -at#: (ubmitte& or the uni5ersit! e6"min"tion he%& on 44444444444 44444444444444444 4444444444444444 Intern"% E6"miner E6tern"% E6"miner --------------------------------------------------------------------------------- AC7NO8LEDGEMENT --------------------------------------------------------------------------------- AC.N/01E-GEMENT At this #%e"sing moment o h"5ing successu%%! com#%ete& our #ro$ect9 )e )ish to con5e! our sincere th"n+s "n& gr"titu&e to the m"n"gement o our co%%ege "n& our be%o5e& ch"irm"n 2 )ho #ro5i&e& "%% the "ci%ities to us, 8e )ou%& %i+e to e6#ress our sincere th"n+s to our #rinci#"% 2 or or)"r&ing us to &o our #ro$ect "n& o:ering "&e;u"te &ur"tion in com#%eting our #ro$ect, 8e "re "%so gr"teu% to the He"& o De#"rtment Pro, ,,2 or her constructi5e suggestions < encour"gement &uring our #ro$ect, 8ith &ee# sense o gr"titu&e9 )e e6ten& our e"rnest < sincere th"n+s to our gui&e ,,9 De#"rtment o Mech"nic"% or her +in& gui&"nce < encour"gement &uring this #ro$ect, 8e "%so e6#ress our in&ebt th"n+s to our TEACHING "n& NON TEACHING st":s o MECHANICAL ENGINEERING DEPARTMENT9 ,.COLLEGE NAME3, --------------------------------------------------------------------------------------- PNEUMATIC SHEET CUTTING MACHINE --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------- CONTENT( --------------------------------------------------------------------------------- CONTENTS CHAPTER NO TITLE PAGE No. Synopsis 1 Introduction 2 neumatic system ! "omponents and #escription $ %or&ing principle ' #esign and drawings ( )pplications and #isad*antages + )d*antages , -ist of materials . "ost estimation 1/ "onclusion 0ibliography hotography --------------------------------------------------------------------------------- S3N/PSIS --------------------------------------------------------------------------------- SYNOPSIS 1he sheet metal cutting process is a main part of the all industries2 3ormally the sheet metal cutting machine is manually hand operated one for medium and small scale industries2 In our pro4ect is PNEUMATIC SHEET METAL CUTTING MACHINE. )utomation in the modern world is ine*itable2 )ny automatic machine aimed at the economical use of man5 machine5 and material worth the most2 In our pro4ect is solenoid *al*e is used for automation2 1he sheet metal cutting machine wor&s with the help of pneumatic double acting cylinder2 1he piston is connected to the mo*ing cutting tool2 It is used to cut the small si6e of sheet metal2 1he machine is portable in si6e5 so easy transportable2 --------------------------------------------------------------------------------------- CHAPTE4-, --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- INT4/-UCTI/N --------------------------------------------------------------------------------------- CHAPTER-1 INTRODUCTION 1his is an era of automation where it is broadly defined as replacement of manual effort by mechanical power in all degrees of automation2 1he operation remains an essential part of the system although with changing demands on physical input as the degree of mechani6ation is increased2 #egrees of automation are of two types5 *i62 7ull automation2 Semi automation2 In semi automation a combination of manual effort and mechanical power is required whereas in full automation human participation is *ery negligible2 Need For Automt!o" )utomation can be achie*ed through computers5 hydraulics5 pneumatics5 robotics5 etc25 of these sources5 pneumatics form an attracti*e medium for low cost automation2 1he main ad*antages of all pneumatic systems are economy and simplicity2 )utomation plays an important role in mass production2 8eduction of lab our and material cost 8eduction of o*erall cost Increased production Increased storage capacity Increased safety 8eduction in fatigue Impro*ed personnel comfort --------------------------------------------------------------------------------------- CHAPTE4-2 --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- PNEUMATIC S3STEM --------------------------------------------------------------------------------------- CHAPTER-# PNEUMATIC SYSTEM 1he sub4ect of pneumatics might probably be termed as compressible fluid mechanics2 It deals with the use of pressuri6ed gas as a source of power2 1he pressure energy of gas is directly con*erted into force to do the required wor& with high efficiencies of con*ersion2 1he pneumatic cylinder utili6es a low pressure fluid2 It has the ad*antage that cylinder construction can be simplified reducing cost2 It can be used for high speed operations2 neumatics is widely associated with low cost automation2 It generally offers the lowest initial and operating cost and simple5 fle9ible control systems2 1hough pneumatic system is the study properties of air other gases5 we are concerned with the study of air2 CHARACTERISTICS OF COMPRESSED AIR$ 1he greatest ad*antage of pneumatic system is the a*ailability of wor&ing medium free of cost and it plentiful2 "ompressed air can also be transported easily and can be easily stored in a reser*oir2 )nother notable ad*antage is the insensiti*eness of compressed air to temperature fluctuations2 It ensures reliable operation e*en under e9treme conditions of temperature2 "ompressed air offers no ris& of e9plosion: hence no e9pensi*e protection cost is required2 "ompressed air is a *ery fast wor&ing medium where speed and force ar infinitely *ariable2 CHARACTERISTICS OF PNEUMATICS$ 1. Com%re&&!'!(!t) ) pneumatic fluid is compressible2 "ompressibility plays a ma4or role in the actuation of piston5 i2e25 opening a *al*e does not mo*e the piston immediately5 rather sufficient fluid must flow into the *olume to increase the pressure until the force o*ercomes that on the other side2 "ompressibility is the energy storage of a fluid2 )s it is possible to store compressed fluids and transport them5 pneumatics has the ad*antage of transportability2 )nother ad*antage of the energy storage capacity is the small compressor charging a tan& can supply a system ha*ing high pea& loads but small a*erage loads2 #. Le*+e Se(!"+ Pro'(em& Se*eral methods are used to minimi6e lea&age2 ;ne is to use a low operating pressure2 )nother method to pre*ent lea&age is sealing2 <ood sliding and rotating sealing are to obtain in pneumatics is because of low *iscosity of the fluids #iaphragms and bellows are used to a*oid sliding seats2 ,. Lo- .!&/o&!t)$ ) highly encounted problem due to low *iscosity is that of sealing2 1hey pro*ide less *iscous damping due to low *iscosity hence sliding parts wear considerably2 1his adds the necessity for e9ternal sources of lubrication2 )nother problem is that the pneumatic cylinder should be thinner enough to maintain a laminar flow inside2 1. Lo- De"&!t) 7luids especially gases are usually of low density2 -ow density fluids require large mechanical wor& and more time for high pressure build up2 #. 0!de R"+e o1 Tem%erture& 1he limitations often may lead to a *iew point that the use of pneumatic equipment is coupled with high cost2 It is pro*ed to be false5 howe*er5 since a calculation of production cost includes not only the power cost but also all other compared with wages5 installation cost5 and maintenance cost that they are insignificant2 ,.,. AD.ANTAGES OF PNEUMATIC SYSTEM O.ER OTHER SYSTEM$ 12 ;utput power of the pneumatic system can be easily controlled 22 neumatic system is not affected by o*er loading !2 1he pneumatic system can be used at *arious wor&ing temperature $2 )ir can be easily distributed through pipelines o*er *ery long distances '2 neumatic enables high wor&ing speeds (2 It is a maintenance free system +2 neumatic enables the application of force *ery gently which is not only beneficial to pneumatic components but also the equipment which they are installed2 ,2 1he wor&ing fluid which is stored in the storage tan& can be ta&en through number of lines which eliminates the use of indi*idual power sources say electric motor and many other machine parts2 ,.2 SPECIFICATION OF PNEUMATIC ELEMENTS$ 1he *arious pneumatic elements are specified according to different standards2 1he standard *aries depending upon the manufacturers2 1. Dou'(e /t!"+ C)(!"der$ Stro&e length = '/ mm iston #iameter = $/ mm >a9imum ;perating ressure = 12 bar 1emperature range = 12/" to ?,/" >aterial = )luminium alloy Seals = olyurethane ;@ ring = 3itrile 22 So(e"o!d D!re/t!o"( Co"tro( 3(3e %e ha*e used 'A2 solenoid *al*e as the directional control *al*e2 Boltage = 2!/ *olts 7requency = '/ C6 >a9imum ;peration ressure = 1/ bar ort si6e = + mm !2 F(o- /o"tro( .(3e Te/4"!/( Dt ort si6e D /2(!' 9 1/ E F m ressure D /-, 9 1/ 5 3AmF >edia D )ir Guantity D 1 2. Co""e/tor& Te/4"!/( dt >a9 wor&ing pressure D 1/ 9 1/ 5 3AmF 1emperature D /-1// H " 7luid media D )ir >aterial D 0rass 5. Ho&e& Te/4"!/( dte >a9 pressure D 1/ 9 1/ 5 3AmF ;uter diameter D ( mm = ( 9 1/ I Jm Inner diameter D !2' mm = !2' 9 1/ I Jm --------------------------------------------------------------------------------------- CHAPTE4-6 --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- C/MP/NENTS AN- -ESC4IPTI/N --------------------------------------------------------------------------------------- CHAPTER-, COMPONENTS AND DESCRIPTION 1he ma4or components of these systems are5 "ompressor neumatic "ylinder Solenoid Bal*e Cose and fitting Seals "ontrol 1imer "ircuit 7low control *al*e COMPRESSOR$ 1he air under high pressure is gi*en by a compressor2 It is dri*en by an electric motor2 1he compressor deli*ers air to inlet of the cylinder2 )n air compressor as the same indicates is a machine to compress the air and to raise its pressure2 1he air compressor suc&s air from the atmosphere5 compresses it and then deli*ers the same under a high pressure to a storage *essel from the storage *essel it may be con*eyed by a pipeline to a place where the supply of compressed air is required2 Since the compression of air requires some wor& to be done on it5 therefore compressor must be dri*en by some prime mo*er2 1he compressed air is used for many purposes such as for operating pneumatic drills5 ri*ets5 paint spraying and supercharging of internal combustion engines etc25 It is also used in the operation of lifts5 rams5 pumps and *aricty of other de*ices in industry2 "ompressed air is suc&ed for producing ballast of air in blast furnaces and bessemer con*erter2 C(&&!1!/t!o" o1 A!r Com%re&&or 1he air compressor may be classified in many ways but the following are important of *iew2 12 )ccording to wor&ing a2 8eciprocating "ompressor b2 8otary "ompressor 22 )ccording to action a2 Single acting compressor b2 #ouble acting compressor !2 )ccording to number of stages a2 Single stage compressor b2 >ulti stage compressor RECIPROCATING COMPRESSOR$ 1hey are a*ailable in great *ariety including special machine for unusual requirements >a9imum compression compression ratio may be as high as 1/ per stage2 1wo stage compressors are a*ailable for compression ratios greater than eight2 1here different type of piston type reciprocating air compressor are a*ailable2 1hey are 12 Bertical 22 Cori6ontal !2 8adial $2 1he most commonly used one is hori6ontal air cooled type reciprocating air compressor for a pressure range ( to 12 KgAcm72 Co"&tru/t!o" It is similar to that of an internal combustion LI"M engine consisting of cost-iron or aluminum body with an oil tan&5 the base piston with piston rings5 *al*es5 connecting rods5 cran&s5 cran& shaft and bearing etc2 If the piston is mo*ing down air is suc&ed in through the suction *al*e and a filter and is compressed in return stro&e2 ;il le*el gauges5 oil filling screw and oil outlet screw etc are also important parts of an air compressor2 1he pressure switch is connected to the dri*ing motor and is set such that it automatically trips off5 disconnecting the electrical connection to the motor as soon as the recei*er achie*es the desired set pressure2 1he safety *al*e is set to the same pressure limit and in case of the pressure e9ceeds this limit5 it automatically opens and e9cess pressure is e9hausted to the atmosphere5 thus limiting the system pressure to the desired le*el2 1he drain *al*e drains off the condensate produced at the condenser and the recei*er piston rings are used around the piston to ma&e it airtight2 1he first stage cylinder is called the low-pressure cylinder L-M where air is drawn from the atmosphere and is compressed initially2 1he second cylinder is called the second-stage cylinder5 which is of smaller diameter and it is also called high-pressure cylinder LCM2 Cere the initially compressed air from first - cylinder is further compressed to high pressure2 %hen air is compressed5 considerable heat is generated5 this heat must be dissipated at least in units5 where pressure e9ceeds 2 bar2 1he main machine is cooled by air circulation on water circulation2 C4r/ter!&t!/& o1 Dou'(e /t!"+ /om%re&&or& 7or the same sped and cylinder *olume5 air deli*ery is double that of a single acting compressor2 1hey are mostly suitable for large capacity2 "ylinders are mostly water-cooled2 1hey are normally used for continuous and hea*y-duty wor&s2 Cigher speed of piston while reducing the si6e of the compressor may contribute to greater wear of piston rings5 cylinder liners and pic&ings2 referable range of piston speed ad*ocated2 7or small capacity compressor !// mAmin 7or large capacity compressor-2'mAmin -ower discharge temperature Lmostly 2$/H" for single stage compressorsM2 1he ultimate choice of an air compressor is decided considering two main factors2 1hey areD ;ne should go for a small compressor for each machine LorM Should one ha*e a centrali6ed compressor power houseN 1he portable answer will depend on pipe line layout5 system requirement and the distance of the user machine from the plant2 PNEUMATIC CYLINDER$ "ylinder is a de*ice which con*erts fluid power into liner mechanical force and motion2 1hese cylinders are widely used in industrial pneumatic systems2 1hese cylinders are also called as linear motors and reciprocating motors pneumatic cylinders are designed for a *ariety of ser*ices2 neumatic cylinders are designed for a *ariety of ser*ices2 neumatic cylinders transforms the flow of pressured fluid into a push or pull of the piston rod since out system uses double acting cylinders we shall see some details about them2 #ouble acting cylinders are in one in which fluid force can be applied to the mo*able element in two directories2 1he force e9erted by the compressed air mo*es the piston in two directories in a double acting cylinder2 1hey are used particularly2 1he piston is required to perform wor& not only on the ad*ance mo*ement but also on the return2 In principle5 the stro&e length is unlimited5 although buc&ing and bending must be considered before we select a particular si6e of piston diameter5 rod length and stro&e length2 1he main component of any pneumatic system is the cylinder5 which recei*ers air under pressure and the pressuri6ed air helps to mo*e the piston to and fro2 1he force acting on the piston will be equal to the product of the pressure of air and the area of the cylinder2 1he amount of air deli*ered into the cylinder into the cylinder decides the rate of doing wor&2 ) cylinder is a hollow circular section with the top and bottom flange pro*ided to pre*ent the lea&age of air2 1he compressed air is used to actuate the piston2 In order to mo*e the piston to and fro5 the air is supplied to the top and bottom of the cylinder alternati*ely2 "ylinder is mainly classified into two types namely5 Single acting cylinder2 #ouble acting cylinder2 In single acting cylinder5 using the spring pro*ided around the piston rod attains the return stro&e5 but it is not efficient2 So5 the double acting cylinder is used in which the return stro&e is attained using compressed air2 Dou'(e A/t!"+ C)(!"der In this the force e9erted by the compressed air mo*es the piston in two directions2 1hey are used partially when the piston is required to perform wor& not only on the ad*ance mo*ement but also on the return stro&e2 1his principle5 the stro&e length is unlimited5 although buc&ing and bending must be considered before selecting the particular si6e of piston diameter5 rod length and stro&e length2 1he different parts of double acting cylinder areD 12 0arrel 22 iston rod !2 1op "o*er $2 0ottom "o*er '2 %iper "o*er (2 8etaining ring +2 iston ,2 iston guide .2 0earing "ap 1/2 O;@ ring for piston guide 112 Ce9agonal soc&et head screw 122 "hec& nut 1he double acting cylinder is made up of cast aluminium2 1he inner and outer surface of the cylinder should be machined accurately2 1he internal diameter of the cylinder should be accurate in order to pro*ide a smooth surface for the pac&ing2 1he appearance of the outer diameter should be good2 1he outer most part of the bottom and top co*er contains internal threads for inserting bolts to clamp the cylinder2 In case of double acting cylinder a force is de*eloped in both the directions2 1he mo*ing member inside the cylinder is nothing but a piston which is found to be mo*ing forward and bac&ward due to high-pressure air2 1he cylinder top and lower plate are flanged together by means of bolts and nuts2 1he bottom of the cylinder is also flanged with end co*ers for the mo*ement of the piston in reciprocating manner2 1he bottom end co*er has a bore in center whose diameter is slightly larger than piston rod diameter2 1he force during the return stro&e is less compared to that of the forward stro&e because in the former5 the piston rod co*ers some area so that the air cannot concentrate in the piston rod area2 2.2.1. Prt& o1 P"eumt!/ C)(!"der P!&to" 1he piston is a cylindrical member of certain length which reciprocates inside the cylinder2 1he diameter of the piston is slightly less than that of the cylinder bore diameter and it is fitted to the top of the piston rod2 It is one of the important part which con*erts the pressure energy into mechanical power2 1he piston is equipped with a ring suitably proportioned and it is relati*ely soft rubber which is capable of pro*iding good sealing with low friction at the operating pressure2 1he purpose of piston is to pro*ide means of con*eying the pressure of air inside the cylinder to the piston of the oil cylinder2 <enerally piston is made up of )luminium alloy-light and medium wor&2 0rass or bron6e or "I-Cea*y duty2 1he piston is double acting type2 1he piston mo*es forward when the high- pressure air is turned from the right side of cylinder2 1he piston mo*es bac&ward when high pressure acts on the piston from the left side of the cylinder2 1he piston should be as strong and rigid as possible2 1he efficiency and economy of the machine primarily depends on the wor&ing of the piston2 It must operate in the cylinder with a minimum of friction and should be able to withstand the high compressor force de*eloped in the cylinder and also the shoc& load during operation2 1he piston should posses the following qualities2 a2 1he mo*ement of the piston not creates much noise2 b2 It should be frictionless2 c2 It should withstand high pressure2 P!&to" Rod 1he piston rod is circular in cross section2 It connects piston with piston of other cylinder2 1he piston rod is made of mild steel ground and polished2 ) high finish is essential on the outer rod surface to minimi6e wear on the rod seals2 1he piston rod is connected to the piston by mechanical fastening2 1he piston and the piston rod can be separated if necessary2 ;ne end of the piston rod is connected to the bottom of the piston2 1he other end of the piston rod is connected to the other piston rod by means of coupling2 1he piston transmits the wor&ing force to the oil cylinder through the piston rod2 1he piston rod is designed to withstand the high compressi*e force2 It should a*oid bending and withstand shoc& loads caused by the cutting force2 1he piston mo*es inside the rod seal fi9ed in the bottom co*er plate of the cylinder2 1he sealing arrangements pre*ent the lea&age of air from the bottom of the cylinder while the rod reciprocates through it2 C)(!"der Co3er P(te& 1he cylinder should be enclosed to get the applied pressure from the compressor and act on the pinion2 1he cylinder is thus closed by the co*er plates on both the ends such that there is no lea&age of air2 )n inlet port is pro*ided on the top co*er plate and an outlet ports on the bottom co*er plate2 1here is also a hole drilled for the mo*ement of the piston2 1he cylinder co*er plate protects the cylinder from dust and other particle and maintains the same pressure that is ta&en from the compressor2 1he flange has to hold the piston in both of its e9treme positions2 1he piston hits the top plat during the return stro&e and hits the bottom plate during end of forward stro&e2 So the co*er plates must be strong enough to withstand the load2 C)(!"der Mou"t!"+ P(te&$ It is attached to the cylinder co*er plates and also to the carriage with the help of O-@ bends and bolts2 CONTROL .AL.E$ Barious types of control *al*es are used to regulate5 control and monitor the air energy for control of direction pressure5 flow5 etc2 neumatic energy is regulated and controlled by pneumatic *al*es2 7unctionally *al*es are di*ided into four ma4or groups2 #irection "ontrol 7low "ontrol In our pro4ect electrically actuated solenoid operated 'A2 #" *al*es are used2 Solenoid is another name for an electromagnet2 #irection control *al*es are *ery often actuated by electromagnets2 )n electromagnet is a temporary magnet2 ) magnetic force is de*eloped in an electromagnet when electrical current passes through it and force drops down as soon as it is de energi6ed2 1his electromagnet is commonly termed as solenoid2 1he proper wor&ing of a solenoid operated *al*e depends on the reliability of the electromagnets2 It ensures Guic& and sure action -ong life2 Pasy maintenance2 -ess wastage of energy2 So(e"o!d .(3e 1he directional *al*e is one of the important parts of a pneumatic system2 "ommonly &nown as #"B5 this *al*e is used to control the direction of air flow in the pneumatic system2 1he directional *al*e does this by changing the position of its internal mo*able parts2 1his *al*e was selected for speedy operation and to reduce the manual effort and also for the modification of the machine into automatic machine by means of using a solenoid *al*e2 ) solenoid is an electrical de*ice that con*erts electrical energy into straight line motion and force2 1hese are also used to operate a mechanical operation which in turn operates the *al*e mechanism2 Solenoids may be push type or pull type2 1he push type solenoid is one in which the plunger is pushed when the solenoid is energi6ed electrically2 1he pull type solenoid is one is which the plunger is pulled when the solenoid is energi6ed2 1he name of the parts of the solenoid should be learned so that they can be recogni6ed when called upon to ma&e repairs5 to do ser*ice wor& or to install them2
2.5.1. Prt& o1 So(e"o!d .(3e 1. Co!( 1he solenoid coil is made of copper wire2 1he layers of wire are separated by insulating layer2 1he entire solenoid coil is co*ered with an *arnish that is not affected by sol*ents5 moisture5 cutting oil or often fluids2 "oils are rated in *arious *oltages such as 11' *olts )"5 2!/ *olts )"5 $(/ *olts )"5 '+' Bolts )"5 ( Bolts #"5 12 Bolts #"5 2$ Bolts #"5 11' Bolts #" Q 2!/ Bolts #"2 1hey are designed for such frequencies as '/ C6 to (/ C62 #. Frme 1he solenoid frame ser*es se*eral purposes2 Since it is made of laminated sheets5 it is magneti6ed when the current passes through the coil2 1he magneti6ed coil attract the metal plunger to mo*e2 1he frame has pro*isions for attaching the mounting2 1hey are usually bolted or welded to the frame2 1he frame has pro*isions for recei*ers5 the plunger2 1he wear strips are mounted to the solenoid frame5 and are made of materials such as metal or impregnated less fiber cloth2 ,. So(e"o!d P(u"+er 1he Solenoid plunger is the mo*er mechanism of the solenoid2 1he plunger is made of steel laminations which are ri*eted together under high pressure5 so that there will be no mo*ement of the lamination with respect to one another2 )t the top of the plunger a pin hole is placed for ma&ing a connection to some de*ice2 1he solenoid plunger is mo*ed by a magnetic force in one direction and is usually returned by spring action2 Solenoid operated *al*es are usually pro*ided with co*er o*er either the solenoid or the entire *al*e2 1his protects the solenoid from dirt and other foreign matter5 and protects the actuator2 In many applications it is necessary to use e9plosion proof solenoids2 2.5.#. 0or*!"+ o1 So(e"o!d .(3e 1he solenoid *al*e has ' openings2 1his ensure easy e9hausting of 'A2 *al*e2 1he spool of the 'A2 *al*e slide inside the main bore according to spool position: the ports get connected and disconnected2 1he wor&ing principle is as follows2 Po&!t!o"-1 %hen the spool is actuated towards outer direction port O@ gets connected to O0@ and OS@ remains closed while O)@ gets connected to O8@ Po!&!t!o"-# %hen the spool is pushed in the inner direction port O@ and O)@ gets connected to each other and O0@ to OS@ while port O8@ remains closed2 HOUSE AND FITINGS$ It is pro*ided for the passage of compressed air from the compressor outlet to the operating *al*e2 1wo separate pipes also connect the operating *al*e with the wor&ing cylinder pressure drop through and air line depends on the flow rate5 pipe diameter5 pipe length and pipe geometry2 It can be determined directly for straight pipes of any gi*en length2 ) small chaining bore si6e can ha*e mar&ed effect on pressure drop5 where as e*en doubling the pipe length5 will only result in doubling the pressure drop2 ressure drop through bends and fittings can only be determined by empirical tests5 since it is specific to the internal geometry in*ol*ed2 8igid pipes howe*er are less manipulated through remain form of bends with arrangements increase and *ariable air ha*e to flow and the flow itself may be of fluctuating or pulsating nature2 In this case it is thus normally based on practical recommendation2 SEALS$ Seal is an important component of a pneumatic system and is used to pre*ent the air lea&age through the 4oint2 1his pro4ect passes the static seal which are used to pre*ent the lea&age through the stationary surface2 >aterial of the seal is 1eflon tape2 1eflon has the following properties %ithstand the system pressure and temperature without any damage2 8esist the wear and abrasion2 8eco*er from deformation2 8esists the ad*erse effects such as deterioration and shrin&ing caused by the system air2 Seals are de*ices for closing gaps to pre*ent lea&age or ma&e pressure 4oints and also to pre*ent the entry of air and dirt from outside into the system2 1he material of seal must be compatible with the fluid medium2 It is a circular ring made of synthetic rubber2 It is used for pro*iding tight sealing between the piston and the cylinder wall2 It pre*ents air lea&age from the top and bottom of the cylinder2 Seals for air cylinder and *al*es are not normally called upon to seal pressure higher than about 2 bars2 Since the fluid to be seated is a gas5 Lin our case airM rubbing speeds tends to be high and the seal the seal may ha*e to be operated under dry conditions with minimal lubrication2 CONTROL TIMER CIRCUIT$ Need 1or T!mer C!r/u!t$ >ain purpose to timer circuit is to actuate the solenoid *al*e at regular inter*al of time to achie*e proper lubrication at the desired inter*al2 ELECTRONIC CONTROL TIMING UNIT$- 2 6 7 IC 555 8 , # 1 18 , 2917 # 12 2 1, 6 Cere the ''' I" has been used as a multi *ibrator2 1he output of I" ''' is fed to the input pin Lpin no 1$M of "# $/1+ continues counting2 1he output of the I" becomes a*ailable at pin 3os2 !5 2 and $2 1he output pulse of any one of output pin triggers Luts ;3M the 1riac and current starts flowing across the load connected2 1his process continues on other pins at different time inter*als and the cycle continues2 1he frequency inter*al L1imeM of the cycle can be ad4usted by the pre-set loo& connected to pin ( of ''' 1imer I"2
#,9. A<C I<P IC 555 TIMER 1he I" SP A 3P ''' monolithic circuit is a highly stable controller capable of producing accurate time delays or oscillations2 )dditional terminals are pro*ided for triggering or resetting if desired2 In the timing operations5 the time is precisely controlled by one e9ternal resistor and a capacitor5 by the operation as an oscillator5 the free running frequency and the duty cycle are both accurately contributed with the e9ternal 8" constants2 PIN DIAGRAM$ GROUND SUPPLY >.//? TRIGGER DISCHARGE OUTPUT THERSOLD RESET CONTROL PIN NO$ 1 It is ground terminal2 PIN NO$ # 1he trigger *oltage to the lower comparator is applied2 It has constant *oltage that is atleast one third of the supply *oltage5 when trigger *oltage falls below this le*el the flip-flop changes its state and output becomes high2 PIN NO$ , It is the output terminal5 in low state output is equal to 6ero and when at higher state output is equal to Bcc2 PIN NO$ 2 It controls the flip flop directly2 It turns the de*ice to its original position when reset pin is connected to ground the output is appro9imately equal to 6ero2 %hen reset is not used it is connected to Bcc2 PIN NO$ 5 It is the control *oltage terminal2 It is connected to ground through a capacitor of /2/1 R72 )ny e9ternal *oltage at pinD ' will change both the threshold *oltage and the trigger *oltage reference le*el2 PIN NO$ 8 1hreshold *oltage of upper comparator is applied from this terminal2 1he resistor 8t connected to Bcc and pinD ( is grounded by an e9ternal capacitor2 1he output is high capacitor charges by resistor 8t2 %hen the capacitor changes to the threshold le*el5 the output becomes low2 PIN NO$ 7 It is the discharge pin for e9ternal capacitor2 Usually pinD + is connected with pinD ( directly to by a resistor2 %hen the output becomes low then the e9ternal capacitor discharges by internal discharge transistor remains at cut-off and the e9ternal capacitor charges to Bcc2 PIN NO$ 6 It is the positi*e supply terminal2 ) dc *oltage from ?' to ? 1' can be applied2 T4e !m%ort"t 1eture& o1 IC555 /" 'e &ummr!@ed & 1o((o-&. 12 1iming range from microseconds to hours2 22 >ono-stable and )stable operation is possible through I"'''2 !2 1he duty cycle can be ad4usted according to our necessity2 $2 It has the ability to operate from a wide range of supply Boltage2 IC 555 SPECIFICATION Supply Boltage LBccM = $2' to 1'B Supply "urrent LBcc='BA2M = ! to (m) Supply "urrent LBcc=2'BA2M = 1/ to 1'm) ;utput "urrent = 2//m) Lma9imumM ower dissipation = (//mw FLO0 CONTROL .AL.E$ 7low "ontrol Bal*es are fitted to all the distribution tubes2 1his *al*e is made of brass2 0oth the ends ha*e stepped surface to insert hoses2 ) handle is pro*ided to control the flow of oil in e*ery *al*e2 >? Te/4"!/( Dt$ Si6e D S ressure D / to 1/ &g A cm2 >edia D )ir > ' ? Pur%o&e$ 1his *al*e is used to speed up the piston mo*ement and also it acts as an one way restriction *al*e which means that the air can pass through only one way and it can@t return bac&2 0y using this *al*e the time consumption is reduced because of the faster mo*ement of the piston2 --------------------------------------------------------------------------------------- CHAPTE4-4 --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- 0/4.ING P4INCIP1E --------------------------------------------------------------------------------------- CHAPTER-2 0OR;ING PRINCIPLE 1he compressed air from the compressor is used as the force medium for this operation2 1here are pneumatic double acting cylinders5 solenoid *al*e: flow control *al*e and timer unit used 21he arm from the compressor enters to the floe control Bal*e2 1he controlled air from the flow control *al*e enters to the solenoid *al*e2 1he function of solenoid *al*es all of air correct time inter*al2 1he 'A2 solenoid *al*e is used2 In one position air enter to the cylinder and pusses the piston5 so that the cutting stro&e is obtained2 1he ne9t position air enters to the other side of cylinder and pusses the piston return bac&5 so that the releasing stro&e is obtained2 1he speed of the cutting and releasing stro&e is *aried by the timer control unit circuit2
--------------------------------------------------------------------------------------- CHAPTE4-5 --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- -ESIGN AN- -4A0INGS --------------------------------------------------------------------------------------- CHAPTER-5 DESIGN AND DRA0INGS PNEUMATIC CYLINDER De&!+" o1 P!&to" rod$ -oad due to air ressure2 #iameter of the iston LdM = $/ mm ressure acting LpM = ( &gfAcm7 >aterial used for rod = " $' Tield stress L8 y M = !( &gfAmm7 )ssuming factor of safety = 2 7orce acting on the rod LM = ressure 9 )rea = p 9 L9d7 A $M = ( 9 UL 9 9 $7 : A $ V = +!2!( Kgf #esign StressL8 y M = 8y A 7/ S = !( A 2 = 1, KgfAmm7 = A L9 d7 A $ M ; d = < $ p A 9 W 8 y X = < $ 9 +'2!( A U9 9 1,V = < '2!! = 22! mm ; >inimum diameter of rod required for the load = 22! mm %e assume diameter of the rod = 1' mm De&!+" o1 /)(!"der t4!/*"e&&$ >aterial used = "ast iron )ssuming internal diameter of the cylinder = $/ mm Ultimate tensile stress = 2'/ 3Amm7 = 2'// gfAmm7 %or&ing Stress = Ultimate tensile stress A factor of safety )ssuming factor of safety = $ %or&ing stress L f t M = 2'// A $ = (2' KgfAcm7 )ccording to O-)>PS PGU)1I;3@ >inimum thic&ness of cylinder L t M = ri U< Lf t ? pM A Lf t p M -1 V %here5 ri = inner radius of cylinder in cm2 f t = %or&ing stress LKgfAcm7M p = %or&ing pressure in KgfAcm7 ; Substituting *alues we get5 t = 22/ U < L(2' ? (M A L (2' (M -1V t = /2/1. cm = /21. mm %e assume thic&ness of cylinder = 22' mm Inner diameter of barrel = $/ mm ;uter diameter of barrel = $/ ? 2t = $/ ? L 2 9 22' M = $' mm De&!+" o1 P!&to" rod$ D!meter o1 P!&to" Rod$ 7orce of piston 8od LM = ressure 9 area = p 9 9/4 Ld7M = ( 9 L9 A $M 9 L$M7 = +!2!( Kgf )lso5 force on piston rod LM = L9A$M Ld p M7 9 f t = LYA$M 9 LdpM7 9 (2' +!2!( = LYA$M 9 LdpM7 9 (2' ; dp7 = +!2!( 9 L$AYM 9 L1A(2'M = /21' dp = /2!, cm = !2, mm 0y standardi6ing dp = 1' mm Le"+t4 o1 %!&to" rod$ )pproach stro&e = 1(/ mm -ength of threads = 2 9 2/ = $/mm P9tra length due to front co*er = 12 mm P9tra length of accommodate head = 2/ mm 1otal length of the piston rod = 1(/ ? $/ ? 12 ? 2/ = 2!2 mm 0y standardi6ing5 length of the piston rod = 2!/ mm --------------------------------------------------------------------------------------- CHAPTE4-+ --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- APP1ICATI/NS = -ISA->ANTAGES --------------------------------------------------------------------------------------- CHAPTER-8 APPLICATIONS AND DISAD.ANTAGES APPLICATIONS$- 1his machine is *ery useful for small scale industries 1his machine is used to cut the roller sheet metal )ll Industrial )pplication DISAD.ANTAGES$- %hile wor&ing5 the compressed air produces noise therefore a silencer may be used2 Cigh torque can not be obtained -oad carrying capacity of this unit is not *ery high2LZ'/ 3M --------------------------------------------------------------------------------------- CHAPTE4-? --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- A->ANTAGES --------------------------------------------------------------------------------------- CHAPTER-7 AD.ANTAGES
1he pneumatic is more efficient in the technical field Guic& response is achie*ed Simple in construction Pasy to maintain and repair "ost of the unit is less when compared to other machine 3o fire ha6ard problem due to o*er loading "omparati*ely the operation cost is less 1he operation of cutting is faster because the medium used to operate is air "ontinuous operation is possible without stopping --------------------------------------------------------------------------------------- CHAPTE4-@ --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- 1IST /A MATE4IA1S --------------------------------------------------------------------------------------- CHAPTER-6 LIST OF MATERIALS S(. No. De&/r!%t!o" At). MATERIAL /12 /22 /!2 /$2 /'2 /(2 /+2 /,2 . 1/2 112 122 #ouble acting cylinder Solenoid Bal*e 1imer 7low "ontrol Bal*es Coses %ire Stand 0ase 0oard Cose "ollar 8educer 7i9ed cutting plate >o*ing "utting late 1 3o2 1 3o2 1 3o2 1 3o2 2 > 2> 1 3o2 1 3o2 ( 3;2 1 3;2 1 3;2 1 3;2 P3, )-U2 P-P"18;3I" )-U2 ;-TU8P1P3P - >S >S 08)SS2 08)SS S2S S2S --------------------------------------------------------------------------------------- CHAPTE4-B --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- C/ST ESTIMATI/N --------------------------------------------------------------------------------------- CHAPTER-= COST ESTIMATION 1. MATERIAL COST$ S(. No. De&/r!%t!o" At). MATERIAL COST >RS? /12 /22 /!2 /$2 /'2 /(2 /+2 /,2 . 1/2 112 122 #ouble acting cylinder Solenoid Bal*e 1imer 7low "ontrol Bal*es Coses %ire Stand 0ase 0oard Cose "ollar 8educer 7i9ed cutting plate >o*ing "utting late 1 3o2 1 3o2 1 3o2 1 3o2 2 > 2> 1 3o2 1 3o2 ( 3;2 1 3;2 1 3;2 1 3;2 P3, )-U2 P-P"18;3I" )-U2 ;-TU8P1P3P - >S >S 08)SS2 08)SS S2S S2S TOTAL B #. LACOUR COST -)1CP5 #8I--I3<5 %P-#I3<5 <8I3#I3<5 ;%P8 C)"KS)%5 <)S "U11I3<D "ost = ,. O.ERHEAD CHARGES 1he o*erhead charges are arri*ed by >anufacturing cost >anufacturing "ost = >aterial "ost ? -abour cost = = ;*erhead "harges = 2/[ of the manufacturing cost = TOTAL COST 1otal cost = >aterial "ost ? -abour cost ? ;*erhead "harges = = 1otal cost for this pro4ect = --------------------------------------------------------------------------------------- CHAPTE4-,0 --------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------- C/NC1USI/N --------------------------------------------------------------------------------------- CHAPTER-19 CONCLUSION 1his pro4ect wor& has pro*ided us an e9cellent opportunity and e9perience5 to use our limited &nowledge2 %e gained a lot of practical &nowledge regarding5 planning5 designing drawing5 purchasing5 computing and machining while doing this pro4ect wor&2 %e feel that the pro4ect wor& is a good solution to bridge the gates between institution industries2 %e are proud that we ha*e completed the wor& with the limited time successfully2 1he machine is wor&ing with satisfactory conditions2 %e are able to understand the difficulties in maintaining the tolerances and also quality2 %e ha*e done to our ability and s&ill ma&ing ma9imum use of a*ailable facilities2 In conclusion remar&s of our pro4ect wor&5 let us add a few more lines about our impression pro4ect wor&2 1he chief ad*antage of our system is that5 it cutting speed is *aried2 1he fast operation is done by the timer unit2 1his pro4ect is a low cost automation pro4ect2 --------------------------------------------------------------------------------------- CIC1I/G4APH3 --------------------------------------------------------------------------------------- CICLIOGRAPHY 12 ) 1e9t 0oo& of >achine #esign----82S2Khurmi Q \2K2<upta5 Purasia ublishing Couse *t2 -td25 1..+2 22 0uild Tour ;wn #igital "loc&s----8upendra K2 Sharma5 1ata >c<raw Cill ublications2 1...2 !2 7luid ower with )pplications----)ntony Psposito*5 1ata >c <raw Cill ublications5 1..,2 $2 7PS1; "ontrol 1echnical #ata 0oo&----7PS1; "ontrol *t2 -td25 1..,2 '2 -inear Integrated "ircuits----#2 8oy "houdhury5 Shail \ain5 3ew )ge International L*tM -td ublishers5 1...2 (2 2S2<2#esign #ata 0oo&5 7aculty of >echanical Pngg: 2S2<21ech25 >AS #B rinters5 2///2 +2 neumatic "ontrol System----Stroll Q 0ernaud5 1ata >c <raw Cill ublications5 1...2 ,2 neumatic System---->a4umdhar5 3ew )ge India International LM -td ublishers5 1..+2 .2 Strength of >aterials----S2 8amamurtham Q 82 3arayanan5 #hanpat 8ai ublishing "orporation5 1..,2 --------------------------------------------------------------------------------------- PH/T/G4APH3 ---------------------------------------------------------------------------------------