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CHAPTER 1
SYNOPSIS
The main purpose of this project is punching the objects for much application,
like sealing, name punching, plate designing and etc. Here we are designing a
pneumatic spiral punching making machines are necessary for saving the
manufacturing time in the process, pneumatic is act as a main role.
INTRODUCTION
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.
WORKING PRINCIPLE
Pneumatic Cylinder.
Compressor.
Solenoid control valve
Die (male, female) clamp
The main objective is to designing and developing a very compact, punch
making machine. Initially the switch unit operates the compressor which delivers the
air to the solenoid valve at certain pressure. The solenoid controls the flow direction
of air to the pneumatic cylinder. Thus the reciprocating motion of the pneumatic
cylinder creates high force to punch the work piece. This part consists of two parts one
is fixed called upper die, at the base and other is fixed called lower die at the end of
piston rod. This part is moved up and down to provide the force on the object.
Here we used for carrying the objects from one side to another side the object
when it comes, if it detects the object means it will out puts a low pulse to the
controller. Pneumatic is act as punching equipment. We can connect seal or cup cast
with the pneumatic for cup production. Different seals and casts are used for punching
the different shapes. When control unit detects the low pulse from then that will ON
the pneumatic for Punch. After a second the controller will OFF the pneumatic. After
getting the punch from the pneumatic spiral punch making.
ADVANTAGES
It reduces the manual work
It reduces the production time
Uniform application of the load gives perfect removing of the bearing.
Damages to the bearing due to the hammering is prevented
It occupies less floor space
Less skilled operator is sufficient
LIMITATIONS
Initial cost is high
Cylinder stroke length is constant
Need a separate compressor
APPLICATIONS
Pressing Operation in all industries
Paper punching industries
Leather washer operation in all industries
Punching operation also done
CHAPTER 2
LITERATURE REVIEW
This chapter will cover all the information related to this project, such as die
design, piercing punches, pneumatic function and tolerances. Using this information,
the element in the project will be presented to give more understanding about the title,
objective, problem statement and the scope of project. The source that may be taken is
either from book, journal, patent, conference paper, research paper and website.
CHAPTER 3
PNEUMATICS
3.1. INTRODUCTION
Pneumatics is the discipline that deals with the mechanical properties of gases
such as pressure & density & applies the principle to use compressed gas as a source
of power to solve engineering problem. The most widely used compressed gas is air &
thus its use has become synonymous with the term pneumatics. Today the most
important property of the medium air is the simple conversion of pressure into force &
translational displacement using a piston in a circular bore.
3.1 Pneumatic System
Pneumatic systems use pressurized gases to transmit and control power. As the
name implies, pneumatic system typically use air (rather than some other gas) as the
fluid medium because air is safe, low cost and readily available fluid. It is particularly
safe inn environments where an electrical spark could ignite leaks from system
components (Majumdar, 1995).There are several reasons for considering the use of
pneumatic systems instead of hydraulic systems. Liquids exhibit greater inertia than
do gases. Therefore, in hydraulic systems the oil is a potential problem when
accelerating and decelerating actuators and when suddenly opening and closing
valves. Liquids also exhibit greater viscosity than do gases.
This results in larger frictional pressure and power losses. Also, since hydraulic
system use a fluid foreign to the atmosphere, they require special reservoirs and no
leak- system designs. Pneumatic systems use air that is exhausted directly back into
only. Now, compressed air is used in every walk of industrial life starting with
pneumatic cranes to the use of air in the brake systems and so on.
Advantageous of pneumatic:
1. Wide availability of air.
2. Compressibility of air
3. Easy transportability of compressed air in pressure vessels,
containers and in long pipes
4. Fire proof characteristic of the medium
5. Simple construction of pneumatic elements and easy handling
6. High degree of controllability of pressure, speed, and force
7. Possibility of easy but reasonably reliable remote controlling
8. Easier maintenance
9. Explosion-proof characteristic of the medium comparatively cheaper in cost than
other stems
ADVANTAGES OF AIR
Due to low viscosity, air cannot be used to lubricate the machinery it actuates.
However, advances in electronics helped to develop control systems for electric drives
that made them superior to formerly used fluid power actuators. This technology can
also enhance the performance of the pneumatic drives.
Damp Hopper
Stamping
Mining (Door opening & closing)
Material flow
Automobile (Braking System, engine etc.)
Tools (Jackhammer, drills etc.)
Punching
Motion Restriction in CNC machines
Dental Care
Pneumatic gun for bolt tightening
CHAPTER-4
PRINICIPLES OF PNEUMATIC
2.1 INTRODUCTION OF PRINICIPLES OF PNEUMATIC
Pneumatics is a branch of technology that deals with the study and application
of pressurized gas to effect mechanical motion. Pneumatic systems are extensively
used in industry, where factories are commonly plumbed with compressed air or
compressed inert gases. This is because a centrally located and electrically
powered compressor that
other
pneumatic
devices
through solenoid valves is often able to provide motive power in a cheaper, safer,
more flexible, and more reliable way
motors and actuators.
Pneumatics
also
has
of electric
applications
Weight
o Much lighter than motors (as long as several used)
Simple
o Much easier to mount than motors
o Much simpler and more durable than rack and pinion
More rugged
o Cylinders can be stalled indefinitely without damage
o Resistant to impacts
Disadvantage: All the way in or all the way out
2.2.1 COMPRESSOR
Reservoir(s)
Up to two
Store compressed air at 120 psi
Top up before each match
Slow leaks can decrease pressure between pit and field
Tether robot beside field to top up pneumatics
Operation
A pressure regulator's primary function is to match the flow of gas through the
regulator to the demand for gas placed upon the system. If the load flow decreases,
then the regulator flow must decrease also. If the load flow increases, then the
regulator flow must increase in order to keep the controlled pressure from decreasing
due to a shortage of gas in the pressure system.
A pressure regulator includes a restricting element, a loading element, and a
measuring element:
The restricting element is a type of valve. It can be a globe valve, butterfly
valve, poppet valve, or any other type of valve that is capable of operating as a
variable restriction to the flow.
The loading element applies the needed force to the restricting element. It can
be any number of things such as a weight, a spring, a piston actuator, or more
commonly the diaphragm actuator in combination with a spring.
When the actuator is forced against an expansion disk, the force is distributed
among the pressure walls. This allows the gas to flow at the proper rate and not
to be continually vaporized and diluted.
The measuring element determines when the inlet flow is equal to the outlet
flow. The diaphragm is often used as a measuring element because it can also
serve as a combine element.
In the pictured single-stage regulator, a diaphragm is used with a poppet valve to
regulate pressure. As pressure in the upper chamber increases, the diaphragm is
pushed upward, causing the poppet to reduce flow, bringing the pressure back down.
By adjusting the top screw, the downward pressure on the diaphragm can be
pressure across a restriction). Technically speaking, most pressure sensors are really
differential pressure sensors; for example a gauge pressure sensor is merely a
differential pressure sensor in which one side is open to the ambient atmosphere.
to
applied
pressure.
Common
technology
types
are
Silicon
(Monocrystalline), Polysilicon Thin Film, Bonded Metal Foil, Thick Film, and
Sputtered Thin Film. Generally, the strain gauges are connected to form a
Wheatstone bridge circuit to maximize the output of the sensor. This is the most
commonly employed sensing technology for general purpose pressure
Potentiometric
Uses the motion of a wiper along a resistive mechanism to detect the strain
caused by applied pressure.
Other types
These types of electronic pressure sensors use other properties (such as density) to
infer pressure of a gas, or liquid.
Resonant
Uses the changes in resonant frequency in a sensing mechanism to
measure stress, or changes in gas density, caused by applied pressure. This
technology may be used in conjunction with a force collector, such as those in
the category above. Alternatively, resonant technology may be employed by
expose the resonating element itself to the media, whereby the resonant
frequency is dependent upon the density of the media. Sensors have been made
out of vibrating wire, vibrating cylinders, quartz, and silicon MEMS. Generally,
this technology is considered to provide very stable readings over time.
Thermal
Uses the changes in thermal conductivity of a gas due to density changes
to measure pressure. A common example of this type is the Pirani gauge.
Ionization
Measures the flow of charged gas particles (ions) which varies due to density
changes to measure pressure. Common examples are the Hot and Cold Cathode
gauges.
Others
There are numerous other ways to derive pressure from its density (speed of
sound, mass, index of refraction) among others.
4.2.4 CYLINDERS
Pressure = 60 psi
3.14 in2 x 60 psi = 188 lbs
Force while extending greater than while retracting
Cylinder Tips
If you need the piston to stay extended or retracted, add a mechanical latch
Be careful to ensure the piston rod cannot get bent
Hard to get locknuts/lock washers in large sizes, so nuts on pistons likely to come
Loose
seems to regulate air flowing in both directions, but one direction is restricted
a Little more
4.2.6 FITTINGS
CHAPTER-3
PNEUMATIC MECHANISM
3.1 LINEAR MOTION
Advantages
Type
Disadvantages
Electromechanical
be
automated.
Self-contained.
Linear motor
Simple
design.
moving
parts.
Minimum
High
of
speeds
Low force.
Hydraulic
Can
leak.
Requires
position
Wax motor
Smooth operation.
Segmented
spindle
and
repeatable.
CHAPTER-5
PRESSURE CONTROL APPLICATIONS
There are many good reasons for reducing (and sometimes maintaining) steam
pressure. This tutorial details common applications for direct operating, pilot operated,
pneumatic, electric and electro-pneumatic pressure control systems, including the
advantages and disadvantages of each different control method.
Because steam pressure and temperature are related, control of pressure can be
used to control temperature in some processes. This fact is recognized in the
control of sterilizers and autoclaves, and is also used to control surface
temperatures on contact dryers, such as those found in papermaking and
corrugators machines. Pressure control is also the basis of temperature control
in heat exchangers.
For the same heating duty, a heat exchanger designed to operate on lowpressure steam will be larger than one designed to be used on high-pressure
steam. The low-pressure heat exchanger might be less expensive because of a
lower design specification.
The construction of plant means that each item has a maximum allowable
working pressure (MAWP). If this is lower than the maximum possible steam
supply pressure, the pressure must be reduced so that the safe working pressure
of the downstream system is not exceeded.
Many plants use steam at different pressures. A 'stage' system where highpressure condensate from one process is flashed to steam for use in another part
of the process is usually employed to save energy. It may be necessary to
maintain continuity of supply in the low pressure system at times when not
enough flash steam is being generated. A pressure reducing valve is ideally
suited for this purpose.
Description
Advantages:
1. Inexpensive.
2. Small.
3. Easy to install.
Disadvantages:
1. Proportional only control.
3. Wide proportional band means that maximum flow is only achieved when the
downstream pressure has dropped considerably. This means that the reduced
pressure will vary depending on flow rate.
4. Limited in size.
Applications:
Non-critical, moderate load applications with constant running flowrates, for example:
1. Small jacketed pans.
2. Tracer lines.
3. Ironers.
4. Small tanks.
5. Acid baths.
7. Unit heaters.
9. OEM equipment.
Points to note:
1. Different versions for steam, compressed air, and water.
4. A wide proportional band means care is needed if the safety valve needs to be
set close to the working pressure.
The system shown in Figure, works by having the pressure controller set at the
required downstream pressure and operating the steam pressure control valve
accordingly.
The 4-20 mA signals from the pressure transmitter is relayed to the pressure
controller and the saturation temperature computer, from which the computer
continuously calculates the saturation temperature for the downstream pressure,
and transmits a 4-20 mA output signal to the temperature controller in relation to
this temperature.
The temperature controller is configured to accept the 4-20 mA signal from the
computer to determine its set point at 5C to 10C above saturation. In this way, if
the downstream pressure varies due to any of the reasons mentioned above, the
temperature set point will also automatically vary. This will maintain the correct
water/steam ratio under all load or downstream pressure conditions.
CHAPTER-6
ENDING REPORT
6.1 ADVANTAGE
Simplicity of Design And Control
o Machines are easily designed using standard cylinders & other
components. Machines operate by simple ON - OFF type control.
Reliability
o Pneumatic systems tend to have long operating lives and require very
little maintenance.
o Because gas is compressible, the equipment is less likely to be damaged
by shock. The gas in pneumatics absorbs excessive force, whereas the
fluid of hydraulics directly transfers force.
Storage
o Compressed gas can be stored, allowing the use of machines when
electrical power is lost.
Safety
o Very low chance of fire (compared to hydraulic oil).
o Machines can be designed to be overload safe.
6.2 CONCLUSION
Pneumatics is a branch of technology that deals with the study and application
of pressurized gas to effect mechanical motion. Pneumatic systems are extensively
used in industry, where factories are commonly plumbed with compressed air or
compressed inert gases. This is because a centrally located and electrically powered
compressor that powers cylinders and other pneumatic devices through solenoid
valves is often able to provide motive power in a cheaper, safer, more flexible, and
more reliable way than a large number of electric motors and actuators. Pneumatics
also has applications in dentistry, construction, mining, and other areas. Such as
Air brakes on buses and trucks
Air brakes, on trains
Air compressors
Air engines for pneumatically powered vehicles
Barostat systems used in Neuro gastroenterology and for researching
electricity
Cable jetting, a way to install cables in ducts
Compressed-air engine and compressed-air vehicles
Gas-operated reloading
Holman Projector, a pneumatic anti-aircraft weapon
Inflatable structures
Lego pneumatics can be used to build pneumatic models
Particulars
Cost
System Designing
Rs. 2800.00
Components
Rs. 3000.00
Rs. 1000.00
Traveling Expenses
Rs. 300.00
Miscellaneous
Rs. 400.00
TOTAL
5.4 BIBLIOGRAPHY
Rs. 7500.00
1. "Gone with the wind: Tubes are whisking samples across hospital".
Stanford School of Medicine. 2010-01-11. Retrieved 12 February 2010.
2. Buxton, Andrew (2004). Cash Carriers in Shops. Princes Risborough:
Shire Publications. ISBN 978-07478-0615-8.
3. Becker, D.A. (1998). "Characterization and use of the new NIST rapid
pneumatic tube irradiation facility". Journal of Radioanalytical and
Nuclear Chemistry 233: 155160. doi:22 June 10.
4. "Pneumatic
Air
Drive-Thru
McDonald's".
Waymarking
website.