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Multi Purpose Pneumatic System

Contents

•

Acknowledgement

• Synopsis

• Description Of The Apparatus

• Specification

• Procedure

• Advantages & Disadvantages

• Application

• Conclusion

• Snap

• Bibliography

Dept. Of Mechanical Engg. 2011-2012




Acknowledgement

We take great pleasure in expressing our gratitude and sincere thanks to all those

people who have guided us to successfully complete our project.

We would like to thank our director Mr. S.M.M. Nadgir and our principal Dr.

Vidyashankar .B.V for their sincere co-operation and giving us the facilities to carry out

our project.

Our approach to this project has been significantly influenced by our head of thedepartment of mechanical engineering, through their constant source of inspiration,

encouragement and valuable guidance given to us during the course of our project .

We also thankful to our guide Mr. Lakshmana T.G of mechanical engineering

department for their valuable advice, constant support and timely guidance given to us andresulting in completion of our project successfully.

Finally, we thank all our classmate and Lectures for their sincere co-operation and

support in all matters concerned with this project.

Submitted by,

MUKESH R LAKMANE

RAJU N.R (A.K.S)

PRADEEPA M.R

SARAVANA





SYNOPSIS

Today’s industrialization world the use of machine is quite common and how

effectively we are going to use a machine is much important. By doing the two

different operations on one machine we can reduce the initial investment, by doing so

we can achieve increase in productivity, reducing human effort and overall increase

in profit.

As the name it self indicate multi means more than one, the pneumatic

machine can do more than one job. First operation is stamping and the second is

thermoplastic welding. Stamping is a process of making some impression on a job or

product by using suitable dies. Thermo plastic welding is a process of joining two

thermo plastic sheets using electrically heated bars in doing so these bars are actuated

by the means of two pneumatically operated double acting cylinders. The double

acting cylinders press together two electrically heated bars and, in doing so, join two

thermo plastic sheets by welding. The operating pressure is set to be 4 bar. By

actuating two push buttons simultaneously made two cylinders to advance in parallel.

The end positions of are interrogated. After time of t=3 second the bar moves back to

initial position. The forward stroke takes time t=1second. Even if one of the push

buttons is released, the cylinders will retracts. This feature is provided for operator's

safety.





Compressor

An air compressor is a device that converts power (usually from an electric motor, a dieselengine or a gasoline engine) into kinetic energy by compressing and pressurizing air,

which, on command, can be released in quick bursts. There are numerous methods of air

compression, divided into either positive-displacement or negative-displacement types.

Positive-displacement air compressors work by forcing air into a chamber whose volume isreduced to compress the air. Piston-type air compressors use this principle by pumping air

into an air chamber through the use of the constant motion of pistons. They use

unidirectional valves to guide air into a chamber, where the air is compressed. Rotaryscrew compressors also use positive-displacement compression by matching two helical

screws that, when turned, guide air into a chamber, the volume of which is reduced as the

screws turn. Vane compressors use a slotted rotor with varied blade placement to guide air

into a chamber and compress the volume.





Negative-displacement air compressors include centrifugal compressors. These devices use

centrifugal force generated by a spinning impeller to accelerate and then decelerate

captured air, which pressurizes it.

Conventional air compressors are used in several different applications:

• To supply high-pressure clean air to fill gas cylinders

• To supply moderate-pressure clean air to a submerged surface supplied diver

• To supply moderate-pressure clean air for driving some office and school building pneumatic HVAC control system valves

• To supply a large amount of moderate-pressure air to power pneumatic tools

• For filling tires

• To produce large volumes of moderate-pressure air for macroscopic industrial

processes (such as oxidation for petroleum coking or cement plant bag house purge

systems).

Most air compressors either are reciprocating piston type, rotary vane or rotary screw.Centrifugal compressors are common in very large applications. There are two main types

of air compressor's pumps: Oil lubed and oil-less. The oil-less system has more technical

development, but they are more expensive, louder and last for less time than the oiled lube

pumps. However, the air delivered has better quality.

Flow Control Valve

100%


http://en.wikipedia.org/wiki/Gas_cylinder

http://en.wikipedia.org/wiki/Surface_supplied_diving

http://en.wikipedia.org/wiki/Pneumatic

http://en.wikipedia.org/wiki/HVAC_control_system

http://en.wikipedia.org/wiki/Pneumatic_tool


http://en.wikipedia.org/wiki/Tire

http://en.wikipedia.org/wiki/Rotary_screw_compressor

http://en.wikipedia.org/wiki/Surface_supplied_diving


http://en.wikipedia.org/wiki/HVAC_control_system


http://en.wikipedia.org/wiki/Tire

http://en.wikipedia.org/wiki/Rotary_screw_compressor

http://en.wikipedia.org/wiki/Gas_cylinder




A flow control valve regulates the flow or pressure of a fluid. Control valves

normally respond to signals generated by independent devices such as flow

meters or temperature gauges.

Control valves are normally fitted with actuators and positioners. Pneumatically-

actuated globe valves and Diaphragm Valves are widely used for control purposes in many

industries, although quarter-turn types such as (modified) ball, gate and butterfly valves arealso used.

Control valves can also work with hydraulic actuators (also known as hydraulic

pilots). These types of valves are also known as Automatic Control Valves. The hydraulic

actuators will respond to changes of pressure or flow and will open/close the valve.

Automatic Control Valves do not require an external power source, meaning that the fluid pressure is enough to open and close the valve. Automatic control valves include: pressure

reducing valves, flow control valves, back-pressure sustaining valves, altitude valves,

and relief valves. An altitude valve controls the level of a tank. The altitude valve willremain open while the tank is not full and it will close when the tanks reaches its maximum

level. The opening and closing of the valve requires no external power source (electric,

pneumatic, or man power), it is done automatically, hence its name.

Process plants consist of hundreds, or even thousands, of control loops allnetworked together to produce a product to be offered for sale. Each of these control loops

is designed to keep some important process variable such as pressure, flow, level,

temperature, etc. within a required operating range to ensure the quality of the end product.Each of these loops receives and internally creates disturbances that detrimentally affect the

process variable, and interaction from other loops in the network provides disturbances that

influence the process variable.

To reduce the effect of these load disturbances, sensors and transmitters collectinformation about the process variable and its relationship to some desired set point. A

controller then processes this information and decides what must be done to get the processvariable back to where it should be after a load disturbance occurs. When all the

measuring, comparing, and calculating are done, some type of final control element mustimplement the strategy selected by the controller. The most common final control element

in the process control industries is the control valve. The control valve manipulates a

flowing fluid, such as gas, steam, water, or chemical compounds, to compensate for theload disturbance and keep the regulated process variable as close as possible to the desired

set point.


http://en.wikipedia.org/wiki/Valve


http://en.wikipedia.org/wiki/Fluid

http://en.wikipedia.org/wiki/Signalling_(telecommunication)

http://en.wikipedia.org/wiki/Flow_meter



http://en.wikipedia.org/wiki/Temperature_gauge

http://en.wikipedia.org/wiki/Actuators



http://en.wikipedia.org/wiki/Globe_valves

http://en.wikipedia.org/wiki/Diaphragm_Valves


http://en.wikipedia.org/wiki/Ball_valve

http://en.wikipedia.org/wiki/Gate_valve


http://en.wikipedia.org/wiki/Butterfly_valve

http://en.wikipedia.org/wiki/Pressure_reducing_valve


http://en.wikipedia.org/wiki/Relief_valve


http://en.wikipedia.org/wiki/Fluid

http://en.wikipedia.org/wiki/Signalling_(telecommunication)



http://en.wikipedia.org/wiki/Temperature_gauge



http://en.wikipedia.org/wiki/Globe_valves


http://en.wikipedia.org/wiki/Ball_valve


http://en.wikipedia.org/wiki/Butterfly_valve



http://en.wikipedia.org/wiki/Relief_valve




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 in stroke.

Stroke length for this design is not limited, however, the piston rod is more vulnerable to

buckling and bending. Addition calculations should be performed as well. by using designdata hand book using some relations b\n cylinder and pressure we can accurately find out

bending and buckling of tie rod

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices

which use the power of compressed gas to produce a force in a reciprocating linear motion.[1]:85

Like hydraulic cylinders, pneumatic cylinders use the stored potential energy of afluid, in this case compressed air, and convert it into kinetic energy as the air expands in an

attempt to reach atmospheric pressure. This air expansion forces a piston to move in thedesired direction. The piston is a disc or cylinder, and the piston rod transfers the force it

develops to the object to be moved.[1] :85 Engineers prefer to use pneumatics sometime

because they are quieter, cleaner, and do not require large amounts or space for fluidstorage.





Because the operating fluid is a gas, leakage from a pneumatic cylinder will not

drip out and contaminate the surroundings, making pneumatics more desirable where

cleanliness is a requirement. For example, in the mechanical puppets of the Disney TikiRoom, pneumatics are used to prevent fluid from dripping onto people below the puppets.

5/2 Direction Control Valve

4 2

5 3

Nomenclature

The spool (sliding type) consists of lands and grooves. The lands block oil flow through thevalve body. The grooves allow oil to flow around the spool and through the valve body.

There are two fundamental positions of directional control valve namely normal

position where valve returns on removal of actuating force and other is working

position which is position of a valve when actuating force is applied.




D


Classification

Directional control valves can be classified according to

number of ports

number of positions

actuating methods

Type of spool.

Example: A 5/2 directional control valve would have five ports and two spool positions.

number of ports

According to total number of entries or exits connected to the valve through which fluid

can enter the valve or leave the valve there are types like two way, three way, four way

valves.

number of positions

Including the normal and working positions which a valve spool can take there are typeslike two position, three position valves.

Actuating Methods

manually operated

Manually operated valves work with simple levers or paddles where the operator applies

force to operate the valve. Spring force is used to recover the position of valve.mechanically operated

Mechanically operated valve apply forces by using cams, wheels, rollers etc. hence these

valves are subjected to wear.

Hydraulically operated

An hydraulically operated DCV works at much higher pressures than its pneumaticequivalent, they must therefore be far more robust in nature so are precision machined from

higher quality and strength materials.

Solenoid operated

They have a Vast Use in hydraulic industry. These valves make use of electromechanical Solenoid for sliding of the spool. electrical power is readily available

and these valves are extensively used but electrical solenoid cannot generate large forcesunless supplied with larger electrical energy which makes there use limited to low

actuating forces. heat generation poses the threat to use of these valves when held in one

position longer.


http://en.wikipedia.org/wiki/Solenoid






D


In practice combination of these actuators. such as low power solenoid valve is used to

operate the other hydraulic valve. here solenoid valve starts the flow of fluid which in turn

operates hydraulic valve.

Type of spool

spool is of two types namely sliding and rotary. Sliding spool is cylindrical in cross sectionlands and grooves are also cylindrical whereas rotary valve has sphere like lands and

grooves in the form of holes drilled through sphere.

specification

They are generally specified using the number of ports and the number of switching positions. It can be represented in general form as np/ns, where np is the number of ports

connected to the direction control valve and ns the number of switching positions.

In addition, the method of actuation and the return method can also be specified. A

hypothetical valve could be specified as 4-way, 3-position direction control valve or 4/3DCV since there are four ports and three switching positions for the valve. In this example,

one port is called the pressure port which is connected to the pump; one port is the tank port and is connected to the tank (or reservoir); and the two remaining ports are called

working ports and are connected to the actuator . Apart from characteristics of valve thefluid suitable for valve, working temperature and viscosity also thought upon before

selecting a particular type of valve.

Symbolic Representation

while working with layouts of hydraulic machinery it is cumbersome to draw actual pictureof every valve and other components. instead of pictures symbols are used for variety of

components in the hydraulic system to highlight the functional aspects. symbol for

directional control valve is made of number of square boxes adjacent to each other depending on the number of positions. connections to the valve are shown on these squares

by capital letters. usually they are named only in their normal position and not repeated in

other positions. actuation system of the valve is also designated in its symbol.

AND LOGIC VALVE


http://en.wikipedia.org/wiki/Actuator







Toggle switch

a switch is an electrical component that can break an electrical circuit, interrupting

the current or diverting it from one conductor to another.

These type of switches are also called as three position switches arranged in on-

off-on condition. These kind of switches are used to control the clockwise & anticlockwise

direction of dc motor.

The most familiar form of switch is a manually operated electromechanical device

with one or more sets of electrical contacts, which are connected to external circuits. Each

set of contacts can be in one of two states: either "closed" meaning the contacts aretouching and electricity can flow between them, or "open", meaning the contacts are

separated and the switch is nonconducting. The mechanism actuating the transition

between these two states (open or closed) can be either a "toggle" (flip switch for

continuous "on" or "off") or "momentary" (push-for "on" or push-for "off") type.

A switch may be directly manipulated by a human as a control signal to a system,

such as a computer keyboard button, or to control power flow in a circuit, such as a light

switch. Automatically operated switches can be used to control the motions of machines,

for example, to indicate that a garage door has reached its full open position or that a

machine tool is in a position to accept another workpiece. Switches may be operated by

process variables such as pressure, temperature, flow, current, voltage, and force, acting

as sensors in a process and used to automatically control a system. For example,

a thermostat is a temperature-operated switch used to control a heating process. A switch

that is operated by another electrical circuit is called a relay. Large switches may be

remotely operated by a motor drive mechanism. Some switches are used to isolate electric

power from a system, providing a visible point of isolation that can be pad-locked if

necessary to prevent accidental operation of a machine during maintenance, or to prevent

electric shock.


http://en.wikipedia.org/wiki/Electrical_component

http://en.wikipedia.org/wiki/Electrical_circuit

http://en.wikipedia.org/wiki/Electric_current


http://en.wikipedia.org/wiki/Electromechanical

http://en.wikipedia.org/wiki/Electrical_contact


http://en.wikipedia.org/wiki/Light_switch


http://en.wikipedia.org/wiki/Sensor

http://en.wikipedia.org/wiki/Thermostat

http://en.wikipedia.org/wiki/Relay

http://en.wikipedia.org/wiki/Electrical_component

http://en.wikipedia.org/wiki/Electrical_circuit


http://en.wikipedia.org/wiki/Electromechanical




http://en.wikipedia.org/wiki/Sensor

http://en.wikipedia.org/wiki/Thermostat

http://en.wikipedia.org/wiki/Relay




Geared motor

The geared instrument DC motor is ideally suited to a wide range of

applications requiring a combination of low speed operation andcompact unit size. The integral iron core dc motor provides smooth

operation and a bi-directional variable speed capability while the gearhead utilizes a multi-stage metal spur gear train and a die cast metal

housing rated for a working torque up to 1.0Nm. The unit, which issuitable for mounting in any attitude, provides reliable operation over awide ambient temperature range and is equipped with a rear shaft

extension to which a speed or position sensor may be attached This unitoffers a range of gear ratio options for operating speeds from 5-100

rpm and is ideally suited to applications where a combination of high

torque, compact size and economic unit price are important designcriteria.

Features -

• ratios from 30:1 to 510:1• Rated torques from 15Ncm to 100Ncm

• 6 or 12Vdc operation

• 6mm Output shaft





Specification

1. Compressor:

Power - 2HP

Speed -800RPM

Max. work pressure -9kg/cm2

Min. work pressure -6kg/cm2

Capacity -165liter

2. Double acting cylinder:

a) cylinder used for stamping

bore dia -25mm

stroke length -50mm

b) Cylinder used for job holding

bore dia -25mmstroke length -50mm

3. AND logic valve:

Technical data ANDOperating temperature

Valve fitting

Pressure range bar

Nominal diameter mm

Recommended coolant

Installation

Mounted

Body

Spool

Seal





ADVANTAGES

• Reducing human effort and errors.

• By using this machine we can reduce initial investment.

• Reducing the lead time.

• Increasing productivity.

• Reducing the maintenance cost.

DISADVANTAGES

• A pneumatic system causes noise pollution.

• We can’t use pneumatic systems for high pressure.





APPLICATIONS

• For thermo-plastic welding or binding operations.

• For stamping operations.

• For industrial applications, like in pharmaceutical industries aluminum industries,etc...


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