CHAPTER-1INTRODUCTION

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.

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

1

separately for packaging. Materials can also be repeatedly transferred from the

moving conveyors to the work place and vice versa.

Quality Control and Inspection 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: 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

2

CHAPTER –2

LITERATURE SURVEY

PNEUMATICSThe 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.

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.

3

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) PıVı = 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 reducing maintenance to a low level. It can also have out

standing advantages in terms of safety.

4

PNEUMATIC POWERPneumatic systems use pressurized 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:1. 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.

2. Pneumatic systems are simple and economical.

3. Control of pneumatic systems is easier.

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 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.

5

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.

1. Positive displacement compressor.

2. 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

1. Reciprocating type compressor

2. 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.

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 m³/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.

6

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 control of products using sensor can be widely used

in low cost automation. The manpower requirement is negligible also reducing the

inspection time of material.

7

CHAPTER-3

DESCRIPTION OF COMPONENTS

MAJOR PARTS

The major parts “INSPECTION 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 Electronic Control Unit IR Sensor Collecting Tray Conveyor Belt and Roller Frame Stand Counter

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

8

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 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.

CYLINDER TECHNICAL DATA:

Piston Rod: M.S. hard Chrome plated

Seals: Nitrile (Buna – N) Elastomer

End Covers: Cast iron graded fine grained from 25mm to 300mm

Piston: -Aluminium.

Media: -Air.

9

Temperature Range: 0^c to 85^c

Parts of Pneumatic Cylinder

Piston:The piston is a cylindrical member of certain length which reciprocates

inside the cylinder. The diameter of the piston is slightly less than that of the

cylinder bore diameter and it is fitted to the top of the piston rod. It is one of the

important parts which convert the pressure energy into mechanical power.

The piston is equipped with a ring suitably proportioned and it is relatively

soft rubber which is capable of providing good sealing with low friction at the

operating pressure. The purpose of piston is to provide means of conveying the

pressure of air inside the cylinder to the piston of the oil cylinder.

Generally piston is made up of

Aluminium alloy-light and medium work.

Brass or bronze or CI-Heavy duty.

The piston is single acting spring returned type. The piston moves forward

when the high-pressure air is turned from the right side of cylinder.

The piston moves backward when the solenoid valve is in OFF condition.

The piston should be as strong and rigid as possible. The efficiency and economy

of the machine primarily depends on the working of the piston. It must operate in

the cylinder with a minimum of friction and should be able to withstand the high

compressor force developed in the cylinder and also the shock load during

operation.

10

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

Piston Rod

The piston rod is circular in cross section. It connects piston with piston of

other cylinder. The piston rod is made of mild steel ground and polished. A high

finish is essential on the outer rod surface to minimize wear on the rod seals. The

piston rod is connected to the piston by mechanical fastening. The piston and the

piston rod can be separated if necessary.

One end of the piston rod is connected to the bottom of the piston. The

other end of the piston rod is connected to the other piston rod by means of

coupling. The piston transmits the working force to the oil cylinder through the

piston rod. The piston rod is designed to withstand the high compressive force. It

should avoid bending and withstand shock loads caused by the cutting force. The

piston moves inside the rod seal fixed in the bottom cover plate of the cylinder.

The sealing arrangements prevent the leakage of air from the bottom of the

cylinder while the rod reciprocates through it.

Cylinder Cover Plates

The cylinder should be enclosed to get the applied pressure from the

compressor and act on the pinion. The cylinder is thus closed by the cover plates

on both the ends such that there is no leakage of air. An inlet port is provided on

the top cover plate and an outlet ports on the bottom cover plate. There is also a

hole drilled for the movement of the piston.

11

The cylinder cover plate protects the cylinder from dust and other particle

and maintains the same pressure that is taken from the compressor. The flange has

to hold the piston in both of its extreme positions. The piston hits the top plat

during the return stroke and hits the bottom plate during end of forward stroke. So

the cover plates must be strong enough to withstand the load.

Cylinder Mounting Plates:

It is attached to the cylinder cover plates and also to the carriage with the

help of ‘L’ bends and bolts.

GENERALLY USED MATERIALS

Cylinder Tube Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Plastic Hard drawn brass tube hard drawn brass tube.

2. Hard drawn Aluminium Hard drawn steel tube

Aluminium tube Castings tube.

4. Hard drawn Brass, Bronze, Iron or

Brass tube Castings, welded steel tube

12

End Cover Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium stock Aluminium stock Hard tensile

(Fabricated) (Fabricated) Castings

2. Brass stock Brass stock

(Fabricated) (Fabricated)

3. Aluminium Aluminium, Brass,

Castings iron or steel Castings.

Piston Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1.Aluminium

Castings

Aluminium Castings

Brass (Fabricated)

Aluminium Forgings,

Aluminium Castings.

2. Bronze (Fabricated) Bronze (Fabricated)

3. Iron and Steel

Castings

Brass, Bronze, Iron or

Steel Castings.

13

Mount Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium

Castings

Aluminium, Brass

And Steel Castings

High Tensile

Steel Castings

2. Light Alloy

(Fabricated)

High Tensile

Steel Fabrication

Piston Rod Materials:

MATERIAL FINISH REMARKS

MILD STEEL Ground and polished hardened,

ground and polished.

Generally preferred chrome

plated

STAINLESS STEEL Ground and Polished Less scratch resistant than

chrome plated piston rod

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.

14

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. CoilThe 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.

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. FrameThe 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.

15

3. Solenoid PlungerThe 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. In many applications it is necessary to use

explosion proof solenoids.

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 push the dimensionless materials into the collecting tray which is placed

bellow the conveyor.

16

Fig 1

4. 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.

5.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.

17

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.

6.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 Fleming’s 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.

FLEMING’S 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 due to the current in the conductor supports

18

the main field above the conductor, but opposes the main field below the

conductor.

Conductor

Magnetic flux current carrying Conductor

Fig.2

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 armature will now rotate. The commutator

19

N S

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. Let’s 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 commutator

Brushes

An axle

A field magnet

A DC power supply of some sort

Fig.3

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

20

fundamental law of all magnets: Opposites attract and likes repel. 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.

21

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.

Fig4

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

22

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.

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:

23

Fig.5

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 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

24

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.

25

CHAPTER-4

DESIGN AND DRAWINGS

PNEUMATIC CYLINDER:

Design of Piston rod:Load due to air Pressure.

Diameter of the Piston (d) = 35 mm

Pressure acting (p) = 6 kgf/cm²Material used for rod = C 45

Yield stress (σy) = 36 kgf/mm²Assuming factor of safety = 2

Force acting on the rod (P) = Pressure x Area

= p x (Πd² / 4)

= 6 x ( Π x 3.5² ) / 4

P = 57.73 Kgf

Design Stress(σy) = σy / F0 S

= 36 / 2 = 8 Kgf/mm²= P / (Π d² / 4 )

∴ d = √ 4 p / Π [ σy ]

= √ 4 x 57.73 / Π x 18

= √ 4.02 = 2.02 mm

∴ Minimum diameter of rod required for the load = 2.02 mm

We assume diameter of the rod = 12.5 mm

Design of cylinder thicknessMaterial used = Cast iron

26

Assuming internal diameter of the cylinder = 35 mm

Ultimate tensile stress = 250 N/mm² = 2500 gf/mm²Working Stress = Ultimate tensile stress / factor of

safety

Assuming factor of safety = 4

Working stress ( ft ) = 2500 / 4= 625 Kgf/cm²According to ‘LAMES EQUATION’

Minimum thickness of cylinder ( t ) = ri √ (ft + p) / (ft – p ) -1

Where,

ri =inner radius of cylinder in cm.

ft =Working stress (Kgf/cm²)

p =Working pressure in Kgf/cm²∴ Substituting values we get,

t = 1.75 √ (625+1)/(625-1)-1 t= 0.0168 cm = 0.17 mm

We assume thickness of cylinder= 2.5 mm

Inner diameter of barrel= 35 mm

Outer diameter of barrel= 35 + 2t

= 35 + ( 2 x 2.5 )= 40 mm

Design of Piston rod:

Diameter of Piston Rod: Force of piston Rod (P) = Pressure x area = p x Π/4 (d²)

27

= 6 x (Π / 4) x (3.5)²= 57.73 Kgf

Also, force on piston rod (P) = (Π/4) (dp)² x ft

P = (Π/4) x (dp)² x 625

57.73 = (Π/4) x (dp)² x 625

∴ dp² = 57.73 x (4/Π) x (1/625)

= 0.12

dp = 0.34 cm = 3.4 mm

By standardizing dp = 12.5 mm

Length of piston rod:Approach stroke = 50 mm

Length of threads = 2 x 20 = 40mm

Extra length due to front cover = 12 mm

Extra length of accommodate head = 20 mm

Total length of the piston rod = 50 + 40 + 12 + 20

= 122 mm

By standardizing, length of the piston rod = 130 mm

SPECIFICATION

1. Single acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 50 mm

Quantity : 1

28

Seals : Nitride (Buna-N) Elastomer

End cones : Cast iron

Piston : EN – 8

Media : Air

Temperature : 0-80 º C

Pressure Range : 8 N/m²

2. Solenoid Valve

Technical data

Max pressure range : 0-10 x 10 ⁵ N/m²

Quantity : 3

3. Flow control Valve

Technical DataPort size : 0.635 x 10 ² m

Pressure : 0-8 x 10 ⁵ N/m²

Media : Air

Quantity : 1

4. Connectors

Technical data

Max working pressure : 10 x 10 ⁵ N/m²

Temperature : 0-100 º C

Fluid media : Air

Material : Brass

29

5. Hoses

Technical data

Max pressure : 10 x 10 ⁵ N/m²

Outer diameter : 6 mm = 6 x 10 ˉ ³m

Inner diameter : 3.5 mm = 3.5 x 10 ˉ ³m

Fig6

30

Fig.7

Fig.8

Fig.9

31

Fig.10

Fig.11

32

CHAPTER-5

FABRICATION

Method of Fabrication: 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 length

of the 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 limit sensor

frame stand. This cylinder arrangement is used to remove the dimensionless

material from the conveyor. The pneumatic cylinder is controlled by the flow

control valve, single acting solenoid valve and control unit.

33

CHAPTER-6

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.

The limit sensor switch is vertically fixed on the limit sensor frame stand

by means of rack and pinion arrangement. This sensor is used to measuring the

abnormal height variation of the material. The rack and pinion is used to adjust the

limit switch up and down motion. This arrangement is used to set the height of the

material.

The IR transmitter and IR receiver circuit is used to sense the minute

height variation of 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 limit sensor

frame stand. This cylinder arrangement is used to remove the dimensionless

material from the conveyor. The pneumatic cylinder is controlled by the flow

control valve, single acting solenoid valve and control unit.

34

1 8

2 7 IC 5553 6

4 5

IR TRANSMITTER CIRCUIT:

+Vcc

R4 (47Ω) T1 (BD140) 150K 3 1 2 C3 (100µ/25V) R1 R2 (47Ω) 1.5K R5 4.7Ω L1 IR LED C2 C1 0.01pF 0.1pF

Fig.12

35

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 relay is OFF, so that the solenoid

valve is in OFF condition.

AT ABNORMAL CONDITION:At abnormal dimension 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 relay is ON to the 3/2 solenoid valve, so that the air from the

compressor is goes to the pneumatic cylinder. The dimensionless material is

pushed to the collecting tray by the pneumatic cylinder.

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POWER SUPPLY CIRCUIT:

1 K , ½ W P

D₄ D

230 V 9 V AC + SUPPLY 0 1000 μF 0-15 V

- 9 V D₃ D₂

N

D , D ₂, D₃, D₄ - IN 4007

Fig.13

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 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.

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IN OUT

IC 7812

GND

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 IC’s

IN terminal. The IC’s 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.

VOLTAGE REGULATOR (IC 78XX SERIES)

+ 1 2 + C₂FROM (0-15V) C 470 mF 0.01 mF RECTIFIER V₀ = + 12 V

3

- -

Fig.14

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CHAPTER-7

ADVANTAGES AND LIMITATIONS

ADVANTAGES

The Inspection 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

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.

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CHAPTER-8

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.

Improper Material Removing operation:-

This unit can also be used in improper material collected in a

collecting box. The solenoid operated pneumatic cylinder is used for this

mechanism.

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CHAPTER-9LIST OF MATERIALS

S. No. Description Qty Material

1 Single Acting pneumatic cylinder 1 Aluminium

2 Single Acting 3/2 Solenoid Valve 1 Aluminium

3 Flow control Valve 1 Aluminium

4 Rack and Pinion 1 C.I

5 Limit Sensor Frame stand 1 M.S

6 Limit Sensor 1 -

7 PU Tubes 5 meter Polyurethene

8 Hose Collar 8 Brass

9 Reducer 2 Brass

10 Frame stand 1 M.S

11 Sensor with control Unit 1 -

12 Conveyor Roller 2 M.S

13 Conveyor Belt 1 Rekchin

14 Bearing (6202) 4 Steel

15 Bearing (6205) 2 Steel

16 Bearing Cap 6 M.S

17 Shaft 3 M.S

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CHAPTER-10

COST ESTIMATION1. MATERIAL COST:-

S. No. Description Qty Material Cost (Rs)

1 Single Acting pneumatic cylinder 1 Aluminium 1400

2 Single Acting 3/2 Solenoid Valve 1 Aluminium 310

3 Flow control Valve 1 Aluminium 400

4 Rack and Pinion 1 C.I 2600

5 Limit Sensor Frame stand 1 M.S 400

6 Limit Sensor 1 - 1300

7 PU Tubes 5 meter Polyurethene 150

8 Hose Collar 8 Brass 270

9 Frame stand 1 M.S 500

10 Sensor with control Unit 1 - 2400

11 Conveyor Roller 2 M.S 250

12 Conveyor Belt 1 Rekchin 120

13 Bearing (6202) 4 Steel 50

14 Bearing (6205) 2 Steel 50

15 Bearing Cap 6 M.S 50

16 Shaft 3 M.S 4500

TOTAL = 14750

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2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS

CUTTING:

Cost = 800

3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 14750 +800

= 15550

Overhead Charges = 20% of the manufacturing cost

= 3110

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

= 14750 +800 +3110

= 18660

Total cost for this project =Rs.18660

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CHAPTER-11

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 “INSPECTION 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 “INSPECTION 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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REFERENCES

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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