1. FABRICATION OF MATERIAL CONVEYING
SYSTEM USING PNEUMATIC CYLINDER
Submitted in partial fulfillment for the requirements for the award
of the degree of the
BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)
By
K.BALAJI 081131201026
K.BASKARAN 081131201038
V.DHANASEKAR 081131201054
R.DHIVAKAR 081131201057
Dr.M.G.R EDUCATIONAL AND RESEARCH INSTITUTE
(Dr .M.G.R DEEMED UNIVERSITY)
MADURAVOYAL,CHENNAI-600 095.
NAME :…………………………………
REG. NO. :………………………………….
SEC : ……………………………………….
DEPARTMENT : ………………………….
Dr. M.G.R. Educational and Research Institute
(Dr. M. G. R. University)
Maduravoyal, Chennai – 600 095.
November 2012.
2. Dr. M.G.R. EDUCATIONAL AND RESEARCH INSTITUTE
Dr. M.G.R. UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
CHENNAI – 600 095.Dr.M.G.R EDUCATIONAL AND RESEARCH INSTITUTE
(Dr .M.G.R DEEMED UNIVERSITY)
MADURAVOYAL,CHENNAI-600 095.
NAME :…………………………………
REG. NO. :………………………………….
SEC : ……………………………………….
DEPARTMENT : ………………………….
BONAFIDE CERTIFICATE
This is to certify that the project work entitled
“FABRICATION OF MATERIAL CONVEYING SYSTEM
USING PNEUMATIC CYLINDER” is a bonafide record of project work
done by,
K.BALAJI 081131201026
K.BASKARAN 081131201038
V.DHANAASEKAR 081131201054
R.DHIVAKAR 081131201057
Students of B.Tech, (Mechanical) during the academic year 2012-2013.
(Signature of the supervisor) (Signature of the Head of the Department)
Mr. G. Rajamahendran, B.E,(M.E), Professor Mr. M. Ganesan,
Lecturer, Dept. of Mechanical Engineering,
Dept. of Mechanical Engineering, Dr. MGR university,
Dr. MGR university.
Submitted for the project Viva-Voice Examination held on ----------------
Internal Examiner External Examiner
3. AAACCCKKKNNNOOOWWWLLLEEEDDDGGGEEEMMMEEENNNTTT
We wish to expand our sincere thanks and our whole-hearted gratitude
to the following persons. At the outset, we would like to convey our grateful
thanks to our Chairman Mr. A.C. Shanmugam, our Pro-Chancellor Mr.
A.C.S. Arun Kumar, our Vice-Chancellor Dr.Padmanaban. We profusely
thank Prof. Mr. Ganeshan, Head of the Department, Mechanical
Engineering, for his imperceptible guidance and implications, without which
our project would not have been sculpted successfully.
We express our heartfelt thanks to Mr. Rajamahendran, for his
invaluable guidance, utmost patience, inspirational coordination and
constant encouragement in completing this project successfully.
We would like to thank all the staff members, students and parents
who have helped us to complete our project as scheduled.
7. INTRODUCTION
In our technical education the project work plays a major role. Every
students is put in to simulated life particularly where the student required to
bring his knowledge, skill and experience of the project work.
It helps how to evolve specifications under given constrains by
systematic approach to the problem a construct a work device. Project work
thus integrates various skills and knowledge attainment during study and
gives orientation towards application.
As the students solve the various problems exposed by the project
work, the students get the confidence to overcome such problems in the
future life. It helps in expanding the thinking and alternatives for future
applications.
9. SYNOPSIS
To increase the productivity and to overcome skilled labour shortage,
most of the manufacturing industries are going for automation. The main
aim for us to select the project work is to acquire practical knowledge in the
field of automation using Pneumatic system.
We selected “ FABRICATION OF MATERIAL CONVEYING SYSTEM
USING PNEUMATIC CYLINDER ” as our project work and we used
principles of converting linear reciprocating motion into rotary motion in
developing this project work, the material handling mechanism is achieved
by reciprocating the double acting cylinder which is controlled by solenoid
operated 5/2 way DC valve which is actuated by ON/OFF relay control
system. Here the linear motion of the piston rod is converted to rotary
motion of the belt conveyor through the chain and sprocket wheel
Mechanism.
Moreover the same set up can be modified to automatic vibrating
machine by simply removing the rotary mechanism and attaching a box or
container to the piston end rod.
11. CONSTRUCTION
This project consists of
1) Belt conveyor assembly
2) ON/OFF relay control
3) 24VDC power supply
4) Chain with sprocket assembly
5) Pneumatic cylinder with solenoid valve
1.M.S. SQUARE CHANNEL FRAME STAND :
This M.S. square angle frame Base stand is fabricated to a size of 450
mm x 900 mm x 500 mm ( L X BX H) and is made with M.S.square
channel material of 18mm X 18mm size having 3mm thickness . All the
above components are kept inside the stand. Four wheels are fitted at the
bottom for its movement. The figure shows the fabricated stand.
12. Belt conveyor assembly;
The belt of 40mm width and 1000mm circumference of nylon
material is rotated by the cycle wheel sprocket.
4.PNEUMATIC CYLINDER UNIT:
In this unit , one air cylinder is used to push the chain in order to
rotate the sprocket wheel. One cylinder is mounted at the bottom of the
wheel . The size of the cylinder is 20 dia X 100 MM stroke. The cylinder
port A,B is connected to the directional control valve of the A,B port
through the flow control valve.
13. 5.CONTROL VALVE;
Here two 5/2 way lever operated DC valve is used for actuating the double
acting cylinder.
14. When the valve is turned ON, the 5/2 way DC valve
directs the air to the air cylinder and the the piston push the job on
the conveyor or eject the job from the conveyor. The piston rod is
return to original position, when the valve is turned OFF.
The sprocket wheel is rotated by a another cylinder which is actuated
through the 5/2 way solenoid operated directional control valve.
15. FLOW CONTROL VALVE;
This flow control valve is used to control the speed of the piston
movement in the cylinder. Two flow control valves are mounted on
each port of A and B of the cylinder jack unit.The below figure shows
the flow control valve.
16. 6.ELECTRICAL RELAY PANEL ;
The electrical wiring diagram is shown below.
ON/OFF relay control ;
RELAY:
SPECPCATION OF RELAY:
a) Nature of supply: dc
b) Coil voltage: 12v
c) No of NO and NC contacts: 1
17. d) No of poles: single pole double throw
e) Shape of contact point: flat
f) Contact point material: silver or silver alloy
g) Type of relay: electro dynamic
The 5/2 way solenoid operated directional control valve is controlled
by the ON/OFF relay control system and hence the cylinder piston rod
reciprocated continuously.
24VDC power supply;
This power supply supplies the 24VDC power to the solenoid coil in the 5/2
way solenoid operated directional control valve .
18. Chain with sprocket assembly;
The piston end rod is connected to the wooden block on which a
chain of small length is fixed in straight horizontal position. The chain and
the cylinder assembly set up on a lengthy wooden block and its height can
be adjusted to fit the ratchet wheel with the help of four vertical bolt
&screws. Ratched wheel is attached to the driving cycle wheel from which
the motion transmitted to the driven wheel through the nylon belt
Pneumaticsystem;
The double acting cylinder is mounted on the plywood board of size
600 x 450 mm using a U- bracket at both the ends placed under the belt
conveyor..
The 5/2 way solenoid operated Direction control valve is fixed on the
Novapan board using a screw head bolts. The pressurized air is connected to
the input port „p‟ of solenoid valve. The output port is connected to the
double acting cylinder.
.
19. The inlet of the solenoid valve is connected to the compressor tank
through FRL unit after setting the pressure to 5 bar.A 24V DC supply is
provided to the solenoid coil through the ON/OFF relay from the DC power
supply..
21. WORKING PRINCIPLE
Before starting the operation of material handling system set the working
pressure to 5 bar from the compressor outlet.. Connect the 230 AC power
supply to the female electrical plug in order to supply the electrical power to
the relay control system and hence the solenoid valve direct the air supply
to the double acting cylinder . The piston in the air cylinder reciprocate to
and fro .
22. When the solenoid coil is ON ,the valve changed the direction of air to the
double acting cylinder. Thus the valve reciprocates to and fro continuously
till power is cut off .This reciprocate motion is converted to rotary motion
with help of ratchet wheel mechanism and the nylon belt moves over the
driving and driven pulley.
The above arrangement can be modified to working as a
VIBRATOR, by simply connecting the any other unit to the piston end
rod.
23.
24. INTRODUCTION TO
PNEUMATICS
INTRODUCTION TO PNEUMATICS
In engineering field may Machines make use of a fluid or compressed air to
develop a force to move or hold an object
A system which is operated by compressed air is known as Pneumatic
System. It is most widely used the work Piece turning drilling sawing etc.
25. By the use of Pneumatic System the risk of explosion on fire with
compressed air is minimum high working speed and simple in construction.
26. PNEUMATIC COMPONENTS
In engineering field, many machines make use of fluid for developing
a force to move or hold an object. A number of fluid can be used in
devices and system. Two commonly used fluids are oil and compressed
air. A system which is operated by compressed air. A system which is
operated by compressed air is know as pneumatic system.
AIR COMPRESSOR
Compressor is a device which gets air fro the atmosphere and
compresses it for increasing the pressure of air. Thus the compressed air.
Thus the compressed air used for many application.
The compression process requires work in put. Hence a compressor is
driven by a prime mover. Generally an electric motor is used as prime
mover. The compressed air from compressor is stored in vessel called
reservoir. Fro reservoir it be conveyed to the desired place through pipe
lines.
27. 2. FLTER
In pneumatic system, an air filter is used to remove all foreign matter.
An air filter dry clean air to flow without resistance various materials are
used for the filter element. The air may be passed thorugh a piece metal, a
pours stone felt resin impregnated paper. In some filters centrifugal action
or cyclone action is used to remove foreign matters.
3. PRESSURE REGULATOR
Constant pressure level is required for the trouble free operation of a
pneumatic control., A pressure regulator is fitted downstream of the
compressed air filter. It provides a constant set pressure at the outlet of the
outlet of the regulator. The pressure regulator is also called as pressure
reducing valve or pressure regulating valve.
4. LUBRICATOR
The purpose of an air lubricator is to provide the pneumatic
components with sufficient lubricant. These lubricants must reduce the wear
of the moving parts reduce frictional forces and protect the equipment from
corrosion.
Care should be taken to ensure that sufficient lubrication is provided.
But excessive lubrication should be avoided.
28. .
5. FLR Package (or) FRL Package
The air service unit is a combination of following units.
1. Compressed air filter
2. Compressed air regulator
3. Compressed air lubricator
Air Filter, regulator and lubricator are connected together with close
nipples as one package. This unit is know as FLR (Filter, regulator,
lubricator.)
6. PRESSURE CONTROL VALVE :
Each hydraulic system is used to operate in a certain pressure range.
Higher pressure causes damage of components. To avoid this pressure
control valves are fitted in the circuits.
7. Direction control valve :
Directional control valves are used to control the direction of flow.
The design principle is a major factor with regard to service life actuating
force switching times etc.
8. Piston and Cylinder
single acting pneumatic cylinder;
29. PNEUMATIC CITCUIT SYMBOL FOR SINGLE ACTING PNEUMATIC
CYLINDER;
Pneumatic cylinders (sometimes known as air cylinders) are mechanical
devices which produce force, often in combination with movement, and are
powered by compressed gas (typically air).
30. To perform their function, pneumatic cylinders impart a force by converting
the potential energy of compressed gas into kinetic energy. This is achieved
by the compressed gas being able to expand, without external energy input,
which itself occurs due to the pressure gradient established by the
compressed gas being at a greater pressure than the atmospheric pressure.
This air expansion forces a piston to move in the desired direction. The
piston is a disc or cylinder, and the piston rod transfers the force it develops
to the object to be moved.
When selecting a pneumatic cylinder, you must pay attention to:
how far the piston extends when activated, known as "stroke"
surface area of the piston face, known as "bore size"
action type
pressure rating, such as "50 PSI"
type of connection to each port, such as "1/4" NPT"
must be rated for compressed air use
mounting method
31. Types
Although pneumatic cylinders will vary in appearance, size and function,
they generally fall into one of the specific categories shown below. However
there are also numerous other types of pneumatic cylinder available, many
of which are designed to fulfill specific and specialised functions.
Single acting cylinders
Single acting cylinders (SAC) use the pressure imparted by compressed air
to create a driving force in one direction (usually out), and a spring to return
to the "home" position
32. Double acting cylinders
Double Acting Cylinders (DAC) use the force of air to move in both extend
and retract strokes. They have two ports to allow air in, one for outstroke
and one for instroke.
Other types
Although SACs and DACs are the most common types of pneumatic
cylinder, the following types are not particularly rare:
Rotary air cylinders: actuators that use air to impart a rotary motion
Rodless air cylinders: These have no piston rod. They are actuators
that use a mechanical or magnetic coupling to impart force, typically
to a table or other body that moves along the length of the cylinder
body, but does not extend beyond it.
Sizes
Air cylinders are available in a variety of sizes and can typically range from
a small 2.5 mm air cylinder, which might be used for picking up a small
transistor or other electronic component, to 400 mm diameter air cylinders
which would impart enough force to lift a car. Some pneumatic cylinders
reach 1000 mm in diameter, and are used in place of hydraulic cylinders for
special circumstances where leaking hydraulic oil could impose an extreme
hazard.
33. Pressure, radius, area and force relationships
Although the diameter of the piston and the force exerted by a cylinder are
related, they are not directly proportional to one another. Additionally, the
typical mathematical relationship between the two assumes that the air
supply does not become saturated. Due to the effective cross sectional area
reduced by the area of the piston rod, the instroke force is less than the
outstroke force when both are powered pneumatically and by same supply of
compressed gas.
The relationship, between force on outstroke, pressure and radius, is as
follows:
This is derived from the relationship, between force, pressure and effective
cross-sectional area, which is:
F = p A,
With the same symbolic notation of variables as above, but also A represents
the effective cross sectional area.
On instroke, the same relationship between force exerted, pressure and
effective cross sectional area applies as discussed above for outstroke.
However, since the cross sectional area is less than the piston area the
34. relationship between force, pressure and radius is different. The calculation
isn't more complicated though, since the effective cross sectional area is
merely that of the piston less that of the piston rod.
For instroke, therefore, the relationship between force exerted, pressure,
radius of the piston, and radius of the piston rod, is as follows:
Where:
F represents the force exerted
r1 represents the radius of the piston
r2 represents the radius of the piston rod
π is pi, approximately equal to 3.14159.
VALVE CONNECTORS;
36. Manual operations involving heavy lifting. Pushing or pulling
motions can be firing for the operations and can induce a monotony which
results in lowered production. Cylinders have been designed to carry out
these movements with a pre – determined force and stroke and can be fitted
to synchronize with operation cycles of many machines it is worth wile to
examine the existing plan and methods of movement and to consider the
numberous mechanical applications which the range of pneumatic cylinders
make possible. Quality is to keynote of air cylinder. Engineer them into
you production setup to get the last ounce of power, speed and efficiency to
save time, space and money.
Piston is cylinder part which moves in a cylinder have corresponding
hole on it. To make the strokes effective there is no gap between them or
with a very tiny gap, part of the micron. The cylinder and its piston have a
glazing surface where there is a contact between them for easy motion of
piston and avoiding wear and tear of both. The outer side of the cylinder
have mountings consists of plate and studs attached with it. But the of these
mountings, the cylinder and piston assembly can fitted on any place of the
piston have threads on it for fastening theother parts (or) accessories
according the operating performed and the application required. We can fit
37. holding devices, Clamping materials or other metal cutting and forming
ports with which can be movable with the piston.
Pneumatics are used practically in every industry for a wide variety of
manufacturing process, pneumatics equipments are used for multiple
reasons. The best reason is that it is air powered ordinary air turns out to be
very excellent as a fluid power components.
Solenoid Valve :
In order to automate the air flow in our system we have to provide an
electrically controlled valves. Electrical devices can provide more effective
control, less expensive interlocks having many additional safety features and
simplified automatic sequencing when a machine must operate in a
hazardous area, remote actuation is a desirable. The operator can provide
satisfactory control though electrical devices from a remote point with in a
safe area, uding a semi automatic system and these electrical flow control
devices are also in use in full automation by providing proper action signals.
Push and pull actuation can be priced b solenoids. These movements
are used to open and close the pop pet type valves. These actuations are
done according to the signals given to the solenoid coil when the decided by
the program. The outlet of solenoiud coil when the decided by the program,.
38. The outlet of solenoid valve is connected to a spray gun, which is going to
spray the paint.
SOLENOID OPERATED VALVES:
Solenoid valves are electromechanical devices like relays and
contractors. A solenoid valve is used to obtain mechanical movement in
machinery by utilizing fluid or air pressure. The fluid or air pressure is
applied to the cylinder piston through a valve operated by a cylindrical
electrical coil. The electrical coil along with its frame and plunger is known
as the solenoid and the assembly of solenoid and mechanical valve is known
as solenoid valve. The solenoid valve is thus another important
electromechanical device used in control of machines. Solenoid valves are
of two types,
1. Single solenoid spring return operating valve,(5/2)
2. Double solenoid operating valve.
In fig 1 is shown a single solenoid spring return valve in its de-energized
condition. The symbol for the solenoid and the return are also shown. The
solenoid valve is shown connected to the cylinder to help readers understand
39. the solenoid valve action. In the de energized condition, the plunger and the
valve spool position as shown in figure 1.
41. In this position of spool, port P is connected to port A and port B is
connected to tank or exhaust (i.e. atmosphere) if air is used. Spring pressure
(S) keeps the spool in this condition as long as the coil is de energized.
Fluid pressure from port P through port A is applied to the left side of the
cylinder piston. Thus the cylinder piston moves in the right direction. Now
when the solenoid coil is energized, plunger is attracted and it pushes the
spool against spring pressure.
The new position of plunger and spool are shown in fig 2.
42. In this position of spool, port A gets connected to tank and port P gets
connected to port B. Thus pressure is applied to the cylinder piston from
right and moves the piston rod to the left. At the same time fluid in the other
side is drained out to the tank. When the solenoid coil is again de energized,
the spring (S) will move the spool to its original position as shown in figure
1. Thus, normally when the solenoid coil is de energized the piston rod
remains extended.
45. PNEUMATIC FITTINGS:
There are no nuts to tighten the tube to the fittings as in the
conventional type of metallic fittings. The tube is connected to the
fitting by a simple push ensuring leak proof connection and can be
released by pressing the cap and does not require any special tooling
like spanner to connect (or) disconnect the tube from the fitting.
46. SPECIFICATION OF THE FITTING:
Body Material - Plastic
Collect/Thread Nipple - Brass
Seal - Nitrate Rubber
Fluid Used - Air
Max. Operating Pressure - 7 Bar
Tolerance on OD of the tubes - 1 mm
Min. Wall thickness of tubes - 1 mm.
47. FLEXIBLE HOSES:
The Pneumatic hoses, which is used when pneumatic
components such as actuators are subjected to movement. Hose is
fabricated in layer of
Elastomer or synthetic rubber, which permits operation at high
pressure. The standard outside diameter of tubing is 1/16 inch. If the
hose is subjected to rubbing, it should be encased in a protective
sleeve.
48. ADVANTAGES AND LIMITATIONS
ADVANTAGES:
The Pneumatic arm is more efficient in the technical field
Quick response is achieved
Simple in constructions
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
The operation of arm is faster because the media to operate is air
Continuous operation is possible without stopping.
LIMITATIONS:
High torque cannot be obtained.
Load Carrying capacity of this unit is not very high (3 – 5 kg/s)
Silencer may be used, to reduce the noise of compressed air
49. APPLICATION
1) DISCHARGE OF WORKPIECE:
The arm fed has wide application in low cost automation. It can be
used in automated assembly lines to pick-up the finished product from
workstation and place them in the bins. It can also be used to pick-up the
raw material and place them on the conveyor belts and vice versa.
2) JOB CLAMPING:
This unit can also be used in clamping operations in certain areas of
mass productions where clamping and unclamping have to be done at high
speeds. The application of this unit is limited to operations, which involves
moderate clamping forces.
50. 3) TRANSFER OF JOBS BETWEEN WORK STATIONS:
The gripping method used in a low cost automation to move the work
piece from one workstation to another. The combination of an angular
rotary motion is the principle behind this method. The gripper holds the
work rigidly. The to and fro motion is achieved by means of the actuating
cylinder.
4) TOOL CHANGING APPLICATION:
When the pneumatic arms are made smaller in size they can be used
in automatic tool changer in CNC turning and drilling machines, by
attaching suitable tool holding device to the rotary cylinder.
52. PENUMATIC SPARE PARTS DETAITS
NAME OF THE PARTS SPECFICATION
1. Double acting cyclinder
( air max make )
2. single solenoid 5/2 way DCValve
3. ON/OFF relay control
4. plywood board
5. Valve Connectors(5 Nos)
6 . Plastic tube (5 metres)
7. pulley(two nos)
8.ratchet wheel
9.electrical plug
10.nylon belt (40mmwidth)
20MM*100MM
1/8 SIZE 24VDC
N/O
12 MM *600*450
18MM*
6 x4 MM
40 mm
40mm
5amps/230v ac
875mm
58. POWER SUPPLY UNIT
INTRODUCTION:
All the electronic components starting from diode to Intel IC‟s only
work with a DC supply ranging from +5V to +12V. We are utilizing for the
same, the cheapest and commonly available energy source of 230V-50Hz
and stepping down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer,
it can either be stepped down or stepped up depending on the value of DC
needed. In our circuit the transformer of 230V/12-0-12V is used to perform
the step down operation where a 230V AC appears as 24V AC across the
secondary winding. Apart from stepping down voltages, it gives isolation
between the power source and power supply circuitries.
59. Power supply 24DC and 12v dc;
A 24 –0 V step down transformer is used to step down 230V AC to
24V AC .This 24V AC supply is converted to 24V DC using four rectifier
diodes. The voltage from the rectifier section is regulated to 12V DC using
7812 IC .This voltage is used for power supply for the ON/OFF relay
control. . The power supply circuit is shown in fig.
67. CONCLUSION
We make this project entirely different from other projects. Since
concepts involved in our project is entirely different that a single unit is used
to various purposes which is not developed by any of other team members.
By doing this project we gained the knowledge of working of
pneumatic system and how automation can be effectively done with the help
of pneumatic system.
It is concluded that any automation system can be done with the help
of electro pneumatic system.
We have successfully completed the project work at our Institute.
By doing this project work, we understood the working principle and
uses of various valves, switches, relays etc.
Once again we express our sincere thanks to our staff members.
