AUTOMATIC POWER SAVING PUNCHING CONVEYOR

PROJECT WORK 2011-2012

SUBMITTED BY M.GANESAN S.GOWTHAMAN P.GUNASEKARAN M.GURUSAMY C.JANARTHANAN A.JEEVARATHINM

UNDER THE GUIDENCE OF Sri.A.SOUNDRRAJAN M.E.,

Submitted in partial fulfillment of the requirement for the award DIPLOMAINMECHANICAL ENGINEERING, By the state board of education, government of tamilnadu.

of technical

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC COLLEGE, COIMBATORE-641014. 1

CERTIFICATE
2

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT POLYTECHNIC COLLEGE COIMBATORE-641014

CERTIFICATE
This is to certify that the project report titled AUTOMATIC POWER SAVING PUNCHING CONVEYOR submitted by the following students for the award of diploma engineering is record of bonafide work carried out by them. Done by Mr: REGISTER NO:

In partial fulfillment of the requirement for the award of Diploma in Mechanical Engineering During the Year (2011-2012)
RECORD MARKS:

Guide

Head of Department

Submitted for the examination held on ___________

Internal Examiner

External Examiner

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT
At this pleasing moment of having successfully completed our project, we wish to convey our sincere thanks and gratitude to We would like to express our sincere thanks to our principal Smt.S.PADMINI.M.E., for forwarding us to do our project and offering adequate duration in completing our project.

We

are

also

grateful

to

the

Head

of

Department

Prof.

Sri.S.B.CHANDRAN.M.E., for her constructive suggestions & encouragement during

our project.

With deep sense of gratitude, we extend our earnest & sincere thanks to our guide Sri.A.SOUNDARRAJAN.M.E, Department of Mechanical for her kind guidance & encouragement during this project.

We also express our indebt thanks to our TEACHING staffs and OTHER staffs of MECHANICAL ENGINEERING DEPARTMENT, GOVERNMENT POLYTECHNIC COLLEGE.

AUTOMATIC POWER SAVING PUNCHING CONVEYOR

7

CONTENTS
8

CONTENTS & LIST OF FIGURES

CHAPTER NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. SYNOPSIS INTRODUCTION LITERATURE SURVEY DESCRIPTION OF COMPONENTS DESIGN AND DRAWINGS FABRICATION WORKING OPERATION ADVANTAGES AND LIMITATIONS APPLICATIONS LIST OF MATERIAL COST ESTIMATION CONCLUSION BIBLIOGRAPHY PHOTOGRAPHY 11 16 19 25 44 51 59 61 68 70 72 74 77 79 81 TITLE PAGE NO

SL. NO. 1.

FIGURE NAME PNEUMATIC CYLINDER SINGLE ACTING CYLINDER

PAGE NO

27 33

2. 3.

SOLINOIDE VALVE D.C. MOTOR MAGNETIC FLEX SIMPLE 2POLE DC ELECTRIC MOTOR ARMATURE COMMUTATER AND BRUSHES ELECTRIC MOTOR

34 36 38 38 39 42 64

4. 5.

TIMER UNIT IC 555 TIMER

10

Chapter-1

SYNOPSIS

11

CHAPTER-1
SYNOPSIS
In our project AUTOMATIC POWER SAVING PUNCHING

CONVEYOR beings with an introduction to pneumatic, its various applications. The conveyor will operate only the work pieces kept in the conveyor only. The remaining time the conveyor will be in off condition so that the power is saved. The conveyor Automation is very useful for material handling in modern engineering industries. The motor is used to drive the conveyor. The materials are transferred from one place to another place by using conveyor. In this conveyor itself, some operation (Example: - Number Punching, Addressing, Tested OK mark) are doing with the help of pneumatic power. This system gives smooth operation and smooth movement of the belts to the jobs at required time.

INTRODUCTION
This is an era of automation where it is broadly defined as replacement of manual effort by mechanical power in all degrees of automation. The operation remains an essential part of the system although with changing demands on physical input as the degree of mechanization is increased. Degrees of automation are of two types, viz. Full automation.

Semi automation. In semi automation a combination of manual effort and mechanical power is

required whereas in full automation human participation is very negligible. Need For Automation Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of these sources, pneumatics form an attractive medium for low cost automation.

12

The main advantages of all pneumatic systems are economy and simplicity. Automation plays an important role in mass production. For mass production of the product, the machining operations decide the sequence of machining. The machines designed for producing a particular product are called transfer machines. The components must be moved automatically from the bins to various machines sequentially and the final component can be placed separately for packaging. Materials can also be repeatedly transferred from the moving conveyors to the work place and vice versa. Conveyor Automation concept and principle are the most important things in factory design. Automation plays a vital role in mass production of a product, the machining operations decides the sequence of machining. The machines designed for producing a particular product are called transfer machines. Conveyor Automation is a specialized activity for a modern manufacturing concern. It has been estimated that about 60-70% of the cost production is spent in material transferring activities. Need for Conveyor Automation: o Reduction of lab our and material cost o Reduction of overall cost o Increased production o Increased storage capacity o Increased safety o Reduction in fatigue o Improved personnel comfort

ADVANTAGES
The Conveyor Automation is more efficient in the technical field Quick response is achieved Simple in construction Easy to maintain and repair Cost of the unit is less when compared to other robotics No fire hazard problem due to over loading
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 Comparatively the operation cost is less Continuous operation is possible without stopping

LIMITATIONS
While working, the compressed air (For Punching Operation) produces noise therefore a silencer may be used.

APPLICATIONS
o Discharge of work piece:-

The Conveyor Feed has a wide application in low cost automation industries. It can be used in automated assembly lines to carry up the finished product from workstation and place them in bins. It can also be used to pick raw material and place them on the conveyor belts.
o Punching operation:-

This unit can also be used in Punching Operation in the material at high speeds. The application of these units is limited to operations which involved moderate clamping forces.

14

Chapter-2

INTRODUCTION
15

CHAPTER-2

INTRODUCTION

This is an era of automation where it is broadly defined as replacement of manual effort by mechanical power in all degrees of automation. The operation remains an essential part of the system although with changing demands on physical input as the degree of mechanization is increased. Degrees of automation are of two types, viz. Full automation. Semi automation.

In semi automation a combination of manual effort and mechanical power is required whereas in full automation human participation is very negligible.

Need For Automation

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of these sources, pneumatics form an attractive medium for low cost automation. The main advantages of all pneumatic systems are economy and simplicity. Automation plays an important role in mass production.
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For mass production of the product, the machining operations decide the sequence of machining. The machines designed for producing a particular product are called transfer machines. The components must be moved automatically from the bins to various machines sequentially and the final component can be placed separately for packaging. Materials can also be repeatedly transferred from the moving conveyors to the work place and vice versa.

Automatic power saving punching conveyor concepts is the most important things in factory design. Automation plays a vital role in mass production of a product, the machining operations decides the sequence of machining. The machines designed for producing a particular product are called transfer machines. Automatic power saving punching conveyor is a specialized activity for a modern manufacturing concern. It has been estimated that about 60-70% of the cost production is spent in material transferring activities.

Need for Automatic power saving punching conveyor: Reduction of labour and material cost Reduction of overall cost Increased production Increased safety To reduce the inspection time Reduction in fatigue Improved personnel comfort
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Chapter-3

LITERATURE SURVEY
18

CHAPTER 3

LITERATURE SURVEY

PNEUMATICS The word pneuma comes from Greek and means breather wind. The word pneumatics is the study of air movement and its phenomena is derived from the word pneuma. Today pneumatics is mainly understood to means the application of air as a working medium in industry especially the driving and controlling of machines and equipment. Pneumatics has for some considerable time between used for carrying out the simplest mechanical tasks in more recent times has played a more important role in the development of pneumatic technology for automation. Pneumatic systems operate on a supply of compressed air which must be made available in sufficient quantity and at a pressure to suit the capacity of the system. When the pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the question of compressed air supply. The key part of any facility for supply of compressed air is by means using reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure and delivered the air at a high pressure.

19

Compressor capacity is the actual quantity of air compressed and delivered and the volume expressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature. The compressibility of the air was first investigated by Robert Boyle in 1962 and that found that the product of pressure and volume of a particular quantity of gas. The usual written as PV = C (or) PV = P2V2

In this equation the pressure is the absolute pressured which for free is about 14.7 Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly used system now a days. SELECTION OF PNEUMATICS Mechanization is broadly defined as the replacement of manual effort by mechanical power. Pneumatic is an attractive medium for low cost mechanization particularly for sequential (or) repetitive operations. Many factories and plants already have a compressed air system, which is capable of providing the power (or) energy requirements and the control system (although equally pneumatic control systems may be economic and can be advantageously applied to other forms of power).The main advantage of an all pneumatic system are usually economic and simplicity the latter

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reducing maintenance to a low level. It can also have out standing advantages in terms of safety. PNEUMATIC POWER Pneumatic systems use pressurised gases to transmit and control power. Pneumatic systems typically use air as the fluid medium because air is safe, low cost and readily available. The Advantages of Pneumatics: Air used in pneumatic systems can be directly exhausted back in to the surrounding environment and hence the need of special reservoirs and no-leak system designs are eliminated. Pneumatic systems are simple and economical. Control of pneumatic systems is easier. The Disadvantages of Pneumatics: Pneumatic systems exhibit spongy characteristics due to compressibility of air. Pneumatic pressures are quite low due to compressor design limitations (less that 250 psi).

PRODUCTION OF COMPRESSED AIR Pneumatic systems operate on a supply of compressed air, which must be made available in sufficient quantity and at a pressure to suit the capacity of the system. When

21

pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the question of compressed air supply. The key part of any facility for supply of compressed air is by means using reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure and delivered the air at a high pressure. Compressor capacity is the actual

quantity of air compressed and delivered and the volume expressed is that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature. Clean condition of the suction air is one of the factors, which decides the life of a compressor. Warm and moist suction air will result in increased precipitation of condense from the compressed air. Compressor may be classified in two general types. Positive displacement compressor. Turbo compressor

Positive displacement compressors are most frequently employed for compressed air plant and have proved highly successful and supply air for pneumatic control application.

The types of positive compressor

Reciprocating type compressor Rotary type compressor Turbo compressors are employed where large capacity of air required at low discharge pressures. They cannot attain pressure necessary for pneumatic control application unless built in multistage designs and are seldom encountered in pneumatic service.
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RECIPROCATING COMPRESSORS Built for either stationary (or) portable service the reciprocating compressor is by far the most common type. Reciprocating compressors lap be had is sizes from the smallest capacities to deliver more than 500 m/min. In single stage compressor, the air pressure may be of 6 bar machines discharge of pressure is up to 15 bars. Discharge pressure in the range of 250 bars can be obtained with high pressure reciprocating compressors that of three & four stages. Single stage and 1200 stage models are particularly suitable for pneumatic applications , with preference going to the two stage design as soon as the discharge pressure exceeds 6 bar , because it in capable of matching the performance of single stage machine at lower costs per driving powers in the range . ULTIMATE AIM The Automatic power saving punching conveyor can be widely used in low cost automation. The manpower requirement is negligible also reducing the manufacturing time of material.

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Chapter-4

DESCRIPTION OF COMPONENTS
24

CHAPTER-4

DESCRIPTION OF COMPONENTS

MAJOR PARTS

The major parts AUTOMATIC POWER SAVING PUNCHING CONVEYOR are described below: Pneumatic single Acting Cylinder 3/2 Single Acting Solenoid Valve Flow Control Valve Hose Collar and PU Connector Permanent Magnet D.C. Motor IR Sensor unit Timer Unit Conveyor Belt and Roller

25

1. PNEUMATIC CYLINDER:An air cylinder is an operative device in which the state input energy of compressed air i.e. pneumatic power is converted in to mechanical output power, by reducing the pressure of the air to that of the atmosphere. a) Single acting cylinder Single acting cylinder is only capable of performing an operating medium in only one direction. Single acting cylinders equipped with one inlet for the operating air pressure, can be production in several fundamentally different designs. Single cylinders develop power in one direction only. Therefore no heavy control equipment should be attached to them, which requires to be moved on the piston return stoke single action cylinder requires only about half the air volume consumed by a double acting for one operating cycle.

b) Double acting cylinders: A double acting cylinder is employed in control systems with the full pneumatic cushioning and it is essential when the cylinder itself is required to retard heavy messes. This can only be done at the end positions of the piston stock. In all intermediate position a separate externally mounted cushioning derive most be provided with the damping feature. The normal escape of air is out off by a cushioning piston before the end of the stock is required. As a result the sit in the cushioning chamber is again compressed since
26

it cannot escape but slowly according to the setting made on reverses. The air freely enters the cylinder and the piston stokes in the other direction at full force and velocity. GENERALLY USED MATERIALS Cylinder Tube Materials: LIGHT DUTY 1. Plastic 2. Hard drawn Aluminium tube 3. Hard drawn Brass tube End Cover Materials: LIGHT DUTY 1. Aluminium stock (Fabricated) 2. Brass stock (Fabricated) 3. Aluminium Castings MEDIUM DUTY Aluminium stock (Fabricated) Brass stock (Fabricated) Aluminium, Brass, iron or steel Castings. HEAVY DUTY Hard tensile Castings MEDIUM DUTY Hard drawn brass tube Aluminium Castings HEAVY DUTY hard drawn brass tube. Hard drawn steel tube tube. Brass, Bronze, Iron or Castings, welded steel tube

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Piston Materials: LIGHT DUTY 1.Aluminium Castings 2. 3. MEDIUM DUTY Aluminium Castings Brass (Fabricated) Bronze (Fabricated) Iron and Steel Castings HEAVY DUTY Aluminium Forgings, Aluminium Castings. Bronze (Fabricated) Brass, Bronze, Iron or Steel Castings.

Mount Materials: LIGHT DUTY 1. Aluminium Castings 2. Light Alloy (Fabricated) MEDIUM DUTY Aluminium, Brass And Steel Castings HEAVY DUTY High Tensile Steel Castings High Tensile Steel Fabrication

Piston Rod Materials: MATERIAL MILD STEEL FINISH REMARKS

Ground and polished hardened, Generally preferred chrome ground and polished. plated Less scratch resistant than chrome plated piston rod

STAINLESS STEEL

Ground and Polished

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2. SINGLE ACTING 3/2 SOLENOID VALVE:-

The directional valve is one of the important parts of a pneumatic system. Commonly known as DCV, this valve is used to control the direction of air flow in the pneumatic system. The directional valve does this by changing the position of its internal movable parts. This valve 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 valve.A solenoid is an electrical device that converts electrical energy into straight line motion and force. These are also used to operate a mechanical operation which in turn operates the valve mechanism. Solenoids may be push type or pull type. The push type solenoid is one in which the plunger is pushed when the solenoid is energized electrically. The pull type solenoid is one is which the plunger is pulled when the solenoid is energized. The name of the parts of the solenoid should be learned so that they can be recognized when called upon to make repairs, to do service work or to install them. Parts of a 3/2 Solenoid Valve 1. Coil The solenoid coil is made of copper wire. The layers of wire are separated by insulating layer. The entire solenoid coil is covered with a varnish that is not affected by solvents, moisture, cutting oil or often fluids.
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Coils are rated in various voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are designed for such frequencies as 50 Hz to 60 Hz. 2. Frame The solenoid frame serves several purposes. Since it is made of laminated sheets, it is magnetized when the current passes through the coil. The magnetized coil attracts the metal plunger to move. The frame has provisions for attaching the mounting. They are usually bolted or welded to the frame. The frame has provisions for receivers, the plunger. The wear strips are mounted to the solenoid frame, and are made of materials such as metal or impregnated less fiber cloth. 3. Solenoid Plunger The Solenoid plunger is the mover mechanism of the solenoid. The plunger is made of steel laminations which are riveted together under high pressure, so that there will be no movement of the lamination with respect to one another. At the top of the plunger a pin hole is placed for making a connection to some device. The solenoid plunger is moved by a magnetic force in one direction and is usually returned by spring action. Solenoid operated valves are usually provided with cover over either the solenoid or the entire valve. This protects the solenoid from dirt and other foreign matter, and protects the actuator. solenoids.
30

In many applications it is necessary to use explosion proof

Working of Solenoid Valve: The Solenoid control valve is used to control the flow direction is called cut off valve or solenoid valve. This solenoid cut off valve is controlled by the electronic control unit. In our project 3/2 Single acting solenoid valve is used. This solenoid valve is used to punching, printing or marking operation in to the materials.

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3. FLOW CONTROL VALVE: In any fluid power circuit, flow control valve is used to control the speed of the actuator. The floe control can be achieved by varying the area of flow through which the air in passing. When area is increased, more quantity of air will be sent to actuator as a result its speed will increase. If the quantity of air entering into the actuator is reduced, the speed of the actuator is reduced. 4. HOSE COLLAR AND PU CONNECTOR: In our pneumatic system there are two types of connectors used; one is the hose connector and the other is the reducer. Hose connectors normally comprise an adapter (connector) hose nipple and cap nut. These types of connectors are made up of brass or Al or hardened steel. Reducers are used to provide inter connection between two pipes or hoses of different sizes. They may be fitted straight, tee, V or other configurations. These reducers are made up of gunmetal or other materials like hardened steel etc., Hoses used in this pneumatic system are made up of polyurethane. These hoses can with stand at a maximum pressure level of 10 kg/cm2.

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5. D.C. MOTOR (PERMANENT MAGNET): DESCRIPTION OF DC MOTOR An electric motor is a machine which converts electrical energy to mechanical energy. Its action is based on the principle that when a current-carrying conductor is placed in a magnetic field, it experiences a magnetic force whose direction is given by Flemings left hand rule. When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound or series wound or compound wound motors. FLEMINGS LEFT HAND RULE: Keep the force finger, middle finger and thumb of the left hand mutually perpendicular to one another. If the fore finger indicates the direction of magnetic field and middle finger indicates direction of current in the conductor, then the thumb indicates the direction of the motion of conductor. PRINCIPLE OF OPERATION OF DC MOTOR: Figure show a uniform magnetic field in which a straight conductor carrying no current is placed. The conductor is perpendicular to the direction of the magnetic field. The conductor is as carrying a current away from the viewer, but the field due to the N and S poles has been removed. There is no movement of the conductor during the above two conditions. The current carrying conductor is placed in the magnetic field. The field

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due to the current in the conductor supports the main field above the conductor, but opposes the main field below the conductor.

Movement of Conductor

Magnetic flux

current carrying Conductor

The result is to increase the flux density in to the region directly above the conductor and to reduce the flux density in the region directly below the conductor. It is found that a force acts on the conductor, trying to push the conductor downwards as shown by the arrow. If the current in the conductor is reversed, the strengthening of flux lines occurs below the conductor, and the conductor will be pushed upwards. Now consider a single turn coil carrying a current as shown in the above figure. in view of the reasons given above, the coil side A will be forced to move downwards, whereas the coil side B will be forced to move upwards. The forces acting on the coil sides A and B will be of same magnitude. But their direction is opposite to one another. As the coil is wound on the armature core which is supported by the bearings, the
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armature will now rotate. The commutator periodically reverses the direction of current flow through the armature. Therefore the armature will have a continuous rotation. The conductors are wound over a soft iron core. DC supply is given to the field poles for producing flux. The conductors are connected to the DC supply through brushes. Lets start by looking at the overall plan of a simple 2-pole DC electric motor. A simple motor has 6 parts, as shown in the diagram below. An armature or rotor A commutate or Brushes An axle A field magnet A DC power supply of some sort

An electric motor is all about magnets and magnetism: a motor uses magnets to create motion. If you have ever played with magnets you know about the fundamental law of all magnets: Opposites attract and likes repel.

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So if you have 2 bar magnets with their ends marked north and south, then the North end of one magnet will attract the South end of the other. On the other hand, the North end of one magnet will repel the North end of the other (and similarly south will repel south). Inside an electric motor these attracting and repelling forces create rotational motion. In the diagram above and below you can see two magnets in the motor, the armature (or rotor) is an electromagnet, while the field magnet is a permanent magnet (the field magnet could be an electromagnet as well, but in most small motors it is not to save power).

Electromagnets and Motors: To understand how an electric motor works, the key is to understand how the electromagnet works. An electromagnet is the basis of an electric motor. You can understand how things work in the motor by imagining the following scenario. Say that you created a simple electromagnet by wrapping 100 loops of wire around a nail and connecting it to a battery. The nail would become a magnet and have a North and South Pole while the battery is connected. Now say that you take your nail electromagnet, run an axle through the middle of it, and you suspended it in the middle of a horseshoe magnet as shown in the figure below. If you were to attach a battery to the electromagnet so that the North end of the nail appeared as shown, the basic law of magnetism tells you what would happen: The North end of the electromagnet would be repelled from the north end of the horseshoe magnet and attracted to the south end of the horseshoe magnet.
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The South end of the electromagnet would be repelled in a similar way. The nail would move about half a turn and then stop in the position shown.You can see that this half-turn of motion is simple and obvious because of the way magnets naturally attract and repel one another. The key to an electric motor is to then go one step further so that, at the moment that this half-turn of motion completes, the field of the electromagnet flips. The flip causes the electromagnet to complete another half-turn of motion. You flip the magnetic field simply by changing the direction of the electrons flowing in the wire (you do that by flipping the battery over). If the field of the electromagnet flipped at just the right moment at the end of each half-turn of motion, the electric motor would spin freely.

The Armature: The armature takes the place of the nail in an electric motor. The armature is an electromagnet made by coiling thin wire around two or more poles of a metal core. The armature has an axle, and the commutator is attached to the axle. In the diagram above you can see three different views of the same armature: front, side and end-on. In the end-on view the winding is eliminated to make the commutator more obvious. You can see that the commutator is simply a pair of plates attached to the axle. These plates provide the two connections for the coil of the electromagnet.
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The Commutator and brushes: The "flipping the electric field" part of an electric motor is accomplished by two parts: the commutator and the brushes. The diagram at the right shows how the commutator and brushes work together to let current flow to the electromagnet, and also to flip the direction that the electrons are flowing at just the right moment. The contacts of the commutator are attached to the axle of the electromagnet, so they spin with the magnet. The brushes are just two pieces of springy metal or carbon that make contact with the contacts of the commutator.

Putting It All Together: When you put all of these parts together, what you have is a complete electric motor.

In this figure, the armature winding has been left out so that it is easier to see the commutator in action. The key thing to notice is that as the armature passes through the
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horizontal position, the poles of the electromagnet flip. Because of the flip, the North Pole of the electromagnet is always above the axle so it can repel the field magnet's North Pole and attract the field magnet's South Pole. If you ever take apart an electric motor you will find that it contains the same pieces described above: two small permanent magnets, a commutator, two brushes and an electromagnet made by winding wire around a piece of metal. Almost always, however, the rotor will have three poles rather than the two poles as shown in this article. There are two good reasons for a motor to have three poles: It causes the motor to have better dynamics. In a two-pole motor, if the electromagnet is at the balance point, perfectly horizontal between the two poles of the field magnet when the motor starts; you can imagine the armature getting "stuck" there. That never happens in a three-pole motor. Each time the commutator hits the point where it flips the field in a two-pole motor, the commutator shorts out the battery (directly connects the positive and negative terminals) for a moment. This shorting wastes energy and drains the battery needlessly. A three-pole motor solves this problem as well. It is possible to have any number of poles, depending on the size of the motor and the specific application it is being used in.

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6. IR SENSOR UNIT:-

The IR TRANSMITTER circuit is to transmite the Infra-Red rays. This InfraRed rays are received by the receiver circuit is called IR RECEIVER. If any obstacle is there in a path, the Infra-Red rays are cutted. The IR receiver circuir receives the IR rays and giving the control signal to the control circuit. The control circuit is used to off the solenoid valve at normal condition. There is any abstacle in their path meand; the control signal is activate the solenoid valve so that the punching, printing or marking operation occurs. The operating principle of solenoid valve is already explained in the above chapter. The IR transmitting circuit is used in many projects. The IR transmitter sends 40 kHz (frequency can be adjusted) carrier under computer control (computer can turn the IR transmission on and off). IR carriers at around 40 kHz carrier frequencies are widely used in TV remote controlling and ICs for receiving these signals are quite easily available.

7. TIMER UNIT:The timer unit is used to proper printing operation to the work piece. The timer having one variable resister is there, you have to vary the off time of the timer unit.The IR sensor output signal gives the input power supply of the timer unit. The OP-AMP 324 IC is used as a comparator. The comparator is giving the output voltages depends upon the two input voltage values. In our project one input voltage (Reference Voltages) is

40

given to the PIN number 2 (- ive pin) of 324 IC from the variable resistor (10 K Ohm). The Variable resistance output is given to the OP-AMP pin number 3 (+ ive pin).

CIRCUIT DIAGRAM:1K 9V (ZENER) 10K 10K IR SENSOR OUTPUT 1000F 10K 2.2K 2 3 4 1

IC + 324 10K

LDR

1N4007 10K

5 + IC 6 - 32411 1K

SOLENOID VALVE

N/C RELAY N/O

BC547

LED

1K

AT NORMEL CONDITION:In normal condition the Sensor output signal is zero.. The voltages applied to the non-inverting terminal (+ ive) is low when compared to the inverting terminal voltages (ive). In that time, the OP-AMP output is Vsat. (I.e. -12 Volt). The transistor and relay are in OFF condition. In that condition, the solenoid valve is off condition.
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AT ABNORMAL CONDITION:-

In Abnormal condition the IR sensor output signal is ON. The voltages applied to the non-inverting terminal (+ ive) is high when compared to the inverting terminal voltages (ive). In that time, the OP-AMP output is +Vsat. (I.e +12 Volt). The transistor and relay are in ON condition. In that time, the solenoid valve is in ON condition, the printing operation is done. 8.CONVEYOR BELT AND ROLLER:-

Conveyor belt and roller mechanism is used to transfer the work piece from one place to the other place. The roller having two end bearings with bearing cap. It is made upof mild steel.

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Chapter-5

DESIGN AND specifications

43

CHAPTER-5 DESIGN AND SPECIFICATIONS

PNEUMATIC CYLINDER: Design of Piston rod:

Load due to air Pressure.

Diameter of the Piston (d) Pressure acting (p) Material used for rod Yield stress (y) Assuming factor of safety

= = = = =

35 mm 6 kgf/cm C 45 36 kgf/mm 2

Force acting on the rod (P) = = = P =

Pressure x Area p x (d / 4) 6 x {( x 3.5 ) / 4 } 57.73 Kgf

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Design Stress (y)

= = = d = = =

y / F0 S 36 / 2 = 8 Kgf/mm

P / ( d / 4 ) 4 p / [ y ] 4 x 57.73 / { x 18} 4.02 = = = 2.02 mm

Minimum diameter of rod required for the load We assume diameter of the rod

2.02 mm 12.5 mm

Design of cylinder thickness:

Material used Assuming internal diameter of the cylinder Ultimate tensile stress Working Stress Assuming factor of safety Working stress ( ft ) = = = =

= =

Cast iron 35 mm = 2500 gf/mm

250 N/mm

Ultimate tensile stress / factor of safety 4 2500 / 4 = 625 Kgf/cm

45

According to LAMES EQUATION

Minimum thickness of cylinder ( t ) Where, ri ft p = = =

ri { (ft + p) / (ft p ) -1 }

inner radius of cylinder in cm. Working stress (Kgf/cm) Working pressure in Kgf/cm

Substituting values we get, t t = = 1.75 { (625 + 6) / ( 625 6) -1} 0.0168 cm = 0.17 mm

We assume thickness of cylinder Inner diameter of barrel Outer diameter of barrel

= = =

2.5 mm 35 mm 35 + 2t

35 + ( 2 x 2.5 ) =

40 mm

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Design of Piston rod: Diameter of Piston Rod: Force of piston Rod (P) = = = Also, force on piston rod (P) P 57.73 dp = = = = dp = = Pressure x area = 6 x ( / 4) x (3.5) 57.73 Kgf (/4) (dp) x ft p x /4 (d)

(/4) x (dp) x 625 (/4) x (dp) x 625 57.73 x (4/) x (1/625) 0.12 0.34 cm = = 12.5 mm 3.4 mm

By standardizing dp Length of piston rod: Approach stroke Length of threads

= = = = = =

50 mm 2 x 20 = 12 mm 20 mm 50 + 40 + 12 + 20 122 mm 130 mm 40mm

Extra length due to front cover Extra length of accommodate head Total length of the piston rod

By standardizing, length of the piston rod

47

SPECIFICATION
1. Single acting pneumatic cylinder Technical Data Stroke length Quantity Seals End cones Piston Media Temperature Pressure Range : : : : : : : : Cylinder stoker length 50 mm 1 Nitride (Buna-N) Elastomer Cast iron EN 8 Air 0-80 C 8 N/m

2. Solenoid Valve

Technical data

Max pressure range : Quantity 3. Flow control Valve Port size Pressure Media Quantity :

0-10 x 10 N/m 3

Technical Data : : : : 0.635 x 10 m 0-8 x 10 N/m Air 1

48

4. Connectors
Technical data

Max working pressure Temperature Fluid media Material

: : : :

10 x 10 N/m 0-100 C Air Brass

5. Hoses Max pressure Outer diameter Inner diameter

Technical date

: : :

10 x 10 N/m 6 mm = 6 x 10 m 3.5 mm = 3.5 x 10 m

6. IC 555 SPECIFICATION

Supply Voltage (Vcc) Supply Current (Vcc=5V/2) Supply Current (Vcc=25V/2) Output Current Power dissipation Operating temperature

= = = = = =

4.5 to 15V 3 to 6mA 10 to 15mA 200mA (maximum) 600mw 0-70 degree Celsius

49

CHAPTER-6

CAD DRAWINGS
50

51

52

53

54

55

56

57

Chapter-7

FABRICATION
58

CHAPTER-7 FABRICATION

Method of Fabrication:

The stand (or) base is to carry the whole machine. The two conveyor roller is fixed to the two ends of the frame stand with the help of end bearing (6202) with bearing cap. The conveyor roller shaft is coupled to the D.C. permanent magnet motor with the help of spur gear mechanism. This total arrangement is used to transfer the material from one place to another place with the help of conveyor.

The IR transmitter and IR receiver circuit is used to sense the work piece material. It is fixed to the frame stand with a suitable arrangement. The pneumatic cylinder is fixed to the frame stand by right angles to the sensor. This cylinder arrangement is used to punch, print or mark the materials transferred from the conveyor. The pneumatic cylinder is controlled by the flow control valve, single acting solenoid valve and control unit.

59

Chapter-8

WORKING OPERATION
60

CHAPTER-8 WORKING OPERATION

The 12 volt power supply is used to drive the permanent magnet D.C motor. The two conveyor roller is fixed to the two ends of the frame stand with the help of end bearing (6202) with bearing cap. The conveyor roller shaft is coupled to the D.C. permanent magnet motor with the help of spur gear mechanism. This total arrangement is used to transfer the material from one place to another place with the help of conveyor. There are two sets of IR sensors are used, one for used to on/off the motor depends upon the work piece is kept or not in the conveyor. The conveyor will operate only the work pieces kept in the conveyor only. The remaining time the conveyor will be in off condition so that the power is saved. Another one IR sensor is used to detect the material and giving control signal to the control unit. The IR transmitter and IR receiver circuit is used to sense the material. It is fixed to the frame stand with a suitable arrangement. This mechanism is also adjustable with the help of bolt and nut. The pneumatic cylinder is fixed to the frame stand by right angles to the frame stand. This cylinder arrangement is used to punching, marking or printing into the material from the conveyor. The pneumatic cylinder is controlled by the flow control valve, single acting solenoid valve and control unit.

61

AT NORMAL CONDITION:

The IR transmitter sensor is transmitting the infrared rays with the help of 555 IC timer circuit. These infrared rays are received by the IR receiver sensor. The Transistor T1, T2 and T3 are used as an amplifier section. At normal condition Transistor T5 is OFF condition. At that time sensor output signal is OFF.

AT MATERIAL CONDITION:

At material conditions the IR transmitter and IR receiver, the resistance across the Transmitter and receiver is high due to the non-conductivity of the IR waves. So the output of transistor T5 goes from OFF condition to ON stage. The timer unit relay is ON to the 3/2 solenoid valve, so that the air from the compressor is goes to the pneumatic cylinder. The punching or marking or printing operations are done with the help of die fixed in the piston rod of the pneumatic cylinder.

IC 555 TIMER

The IC SE / NE 555 monolithic circuit is a highly stable controller capable of producing accurate time delays or oscillations. Additional terminals are provided for triggering or resetting if desired.

62

In the timing operations, the time is precisely controlled by one external resistor and a capacitor, by the operation as an oscillator, the free running frequency and the duty cycle are both accurately contributed with the external RC constants. PIN DIAGRAM: GROUND
1 8

SUPPLY (Vcc)

TRIGGER

2 IC NE 555

DISCHARGE

OUTPUT

THERSOLD

RESET

CONTROL

PIN NO: 1 It is ground terminal.

PIN NO: 2 The trigger voltage to the lower comparator is applied. It has constant voltage that is atleast one third of the supply voltage, when trigger voltage falls below this level the flip-flop changes its state and output becomes high.

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PIN NO: 3 It is the output terminal, in low state output is equal to zero and when at higher state output is equal to Vcc. PIN NO: 4 It controls the flip flop directly. It turns the device to its original position when reset pin is connected to ground the output is approximately equal to zero. When reset is not used it is connected to Vcc. PIN NO: 5 It is the control voltage terminal. It is connected to ground through a capacitor of 0.01 F. Any external voltage at pin: 5 will change both the threshold voltage and the trigger voltage reference level. PIN NO: 6 Threshold voltage of upper comparator is applied from this terminal. The resistor Rt connected to Vcc and pin: 6 is grounded by an external capacitor. The output is high capacitor charges by resistor Rt. When the capacitor changes to the threshold level, the output becomes low. PIN NO: 7 It is the discharge pin for external capacitor. Usually pin: 7 is connected with pin: 6 directly to by a resistor. When the output becomes low then the external capacitor discharges by internal discharge transistor remains at cut-off and the external capacitor charges to Vcc.

64

PIN NO: 8 It is the positive supply terminal. A dc voltage from +5 to + 15 can be applied.

The important features of IC555 can be summarized as follows. 1. 2. 3. 4. 5. Timing range from microseconds to hours. Mono-stable and Astable operation is possible through IC555. The duty cycle can be adjusted according to our necessity. It has the ability to operate from a wide range of supply Voltage. The output of 555 is compatible with CMOS, DTL and TTL, logic.

But when used with a 5V supply. 6. 7. 8. 9. Triggering and reset inputs are logically compatible. Output can be operated as normal ON and normal OFF. High temperature stability. Unlike RC timers, 555 provide a time intervals that is virtually

independence of supply voltage Vcc. This because that, the charge rate of CT and the reference voltage to the threshold comparator are all directly proportional to the supply voltage.
FILTERS

The out voltage is essentially constant. We filter the pulsating voltage by using RC filter. The capacitor is made sufficiently large to present very low impedance to the

65

ripple frequency and infinite impedance to DC prefers. The shunt path through C and the steady current (IDC) is forced through R developing a DC voltage drop across it. The ripples are reduced by R&C.
VOLTAGE REGULATOR (IC 78xx SERIES)

The series 78 regulators provide fixed regulated from 5 to 24V. An unregulated input voltage Vi is filtered by capacitor C1 and connected to the ICs IN terminal. The ICs OUT terminal provides a regulated +12V which is filtered by capacitor C2. The third IC terminal is connected to ground. While the input voltage may very over some permissible voltage range, and the output load may vary over some acceptable range, the output voltage remains constant within specified voltage variation limits. The 7812 IC then provides an output is a regulated +12V DC.

66

Chapter-9

ADVANTAGES AND LIMITATIONS

67

CHAPTER-9

ADVANTAGES AND LIMITATIONS

ADVANTAGES

The Automatic power saving punching conveyor is more efficient in the technical field Quick response is achieved Simple in construction Easy to maintain and repair Cost of the unit is less when compared to other robotics No fire hazard problem due to over loading Comparatively the operation cost is less Continuous operation is possible without stopping

LIMITATIONS

While working, the compressed air (For Punching Operation) produces noise therefore a silencer may be used.

68

Chapter-10

APPLICATIONS
69

CHAPTER-10 APPLICATIONS

Discharge of work piece:-

The Conveyor Feed has a wide application in low cost automation industries. It can be used in automated assembly lines to carry up the finished product from workstation and place them in bins. It can also be used to pick raw material and place them on the conveyor belts.

Punching operation:-

This unit can also be used in Punching Operation in the material at high speeds. The application of these units is limited to operations which involved moderate clamping forces.

70

Chapter-11

LIST OF MATERIALS

71

CHAPTER-11 LIST OF MATERIALS

S. No.
1 2 3 4 5 6 7 8 9 10 11 12 13

Description
Single Acting pneumatic cylinder Single Acting 3/2 Solenoid Valve Flow control Valve PU Tubes Hose Collar Reducer Frame stand Sensor with control Unit Conveyor Roller Conveyor Belt Bearing (6202) Bearing Cap Shaft

Qty
1 1 1 1 meter 1 1 1 1 2 1 4 4 2

Material
Mild Steel Aluminium Aluminium Polyurethane Brass Brass M.S M.S Rekchin Steel M.S M.S

72

Chapter-12

COST ESTIMATION
73

CHAPTER-12 COST ESTIMATION

1. MATERIAL COST:S. No.
1 2 3 4 5 6 7 8 9 10 11 12 13

Description
Single Acting pneumatic cylinder Single Acting 3/2 Solenoid Valve Flow control Valve PU Tubes Hose Collar Reducer Frame stand Sensor with control Unit Conveyor Roller Conveyor Belt Bearing (6202) Bearing Cap Shaft

Qty
1 1 1 1 meter 1 1 1 1 2 1 4 4 2

Material
Mild Steel Aluminium Aluminium Polyurethane Brass Brass M.S M.S Rekchin Steel M.S M.S

Amount (Rs)
800 600 300 100 50 20 1500 1200 500 550 250 130 100

TOTAL

= 6000

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2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING: Cost = 1500

3. OVERHEAD CHARGES The overhead charges are arrived by Manufacturing cost

Manufacturing Cost = = =

Material Cost + Labour cost 6000+1500 7500

Overhead Charges = =

20% of the manufacturing cost 1500

TOTAL COST

Total cost

= = =

Material Cost + Labour cost + Overhead Charges 6000+1500+1500 9000

Total cost for this project = 9000

75

Chapter-13

CONCLUSION
76

CHAPTER-13 CONCLUSION

This project work has provided us an excellent opportunity and experience, to use our limited knowledge. We gained a lot of practical knowledge regarding, planning, purchasing, assembling and machining while doing this project work. We feel that the project work is a good solution to bridge the gates between institution and industries.

We are proud that we have completed the work with the limited time successfully. The AUTOMATIC POWER SAVING PUNCHING CONVEYOR is working with satisfactory conditions. We are able to understand the difficulties in maintaining the tolerances and also quality. We have done to our ability and skill making maximum use of available facilities. In conclusion remarks of our project work, let us add a few more lines about our impression project work.

Thus we have developed an AUTOMATIC POWER SAVING PUNCHING CONVEYOR which helps to know how to achieve low cost automation with sensor arrangement. The operating procedure of this system is very simple, so any person can operate. By using more techniques, they can be modified and developed according to the applications.

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BIBLIOGRAPHY
78

BIBLIOGRAPHY

Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore. Design data book compiled by faculty of mechanical engineering P.S.G. college of technology,Coimbatore Festo Didactic KG Fundamentals of control technology, Esslingen-1998. Festo Pneumatic Catlogue - Festo Pvt Ltd. Bangalore. Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag Wurzburg, 1998.

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PHOTOGRAPHY
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