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Introduction
Thermal corrosion Cycling is an innovative and cost effective
process of enhancing the mechanical properties of many
materials commonly used in commercial and industrial
technologies. Thermal Cycling has been determined to
significantly increase the corrosion properties of many ferrous
alloys. The salt spray test is a standardized test method used to
check corrosion resistance. Salt spray testing is an accelerated
corrosion test that produces a corrosive attack to the tested
samples. The appearance of corrosion products (oxides) is
evaluated after a period of time. Test duration depends on the
corrosion resistance of the tested material. Salt spray testing is
popular because it is well standardized and reasonably
repeatable. The correlation between the duration in salt spray test
and the expected life of a material is not necessary simple to
interpret as corrosion is a very complicated process and can be
influenced by many external factors. Nevertheless, salt spray test
is widely used in the industrial sector for the evaluation of
corrosion resistance of finished surfaces.
Background
Salt spray was first used for corrosion testing around 1914. This
traditional salt spray specifies a continuous exposure to a 5% salt
fog at 35o C. In spite of all se refinements, re has long been
general agreement that salt spray test results do not correlate
well with corrosion seen in actual atmospheric exposures. As
demand for improved corrosion protection increased, engineers
and scientists attempted to develop test procedures to more
accurately predict corrosion of materials. In England, during
1960s and 1970s, Harrison and Timmons2, 3 developed
ProhesionTM test, which has been found especially useful for
industrial maintenance coatings. More recently, Society of
Block Diagram:
Thermocoupl
e
Temp
Controlle
r
Power
supply
3. Depth=450mm
Main supply -230vac at 50hz
Compressor air 4.6bar above atmospheric pressure.
Water supply connection -1-3 bar above at morphemic
pressure
Specimen holder tray :- specimen holder to is located
inside corrosion chamber in such a way i.e. it will be a net
which will be suitable to provide moisture to tally
material used for chamber will be properly painted or
powder coated so as to avoid corrosion effect salt
About nozzle spray no22le spray nozzle is key point of
system . It is used for spraying moisture in test chamber.
Our approach o this point is hat , it should make
automizer readily accessible to operator and being of
simple two part construction, easily dismantled for cleaning
purpose. But blockages have remain an unavoidable and
irritating fact of life until w here are developing a new design
of auto miser which makes blockages a thing of past.
Pl. follow figure given,
atomizers made up of simply disassembled for cleaning
and maintenance. Manufactured in one of new generation of
high performance plastics, it features an ingeniously
designed integral salt solution filter inb car parted into body
of atomizer.
This works in conjunction with a profit located in salt
solution reservoir, to ensure that even smallest contaminants
Fixture Arrangement :
The fixture assembly that brings all of the system together. These
come in a variety of configurations, vertical, horizontal, tabletop,
freestanding, or mobile cart.
Implementation details:
1. Initially, all the ms angle of calculated dimensions in mm was
taken.
2. Then it was cut into pieces as per the required dimension
3. All these angle pieces were joined together to form top side
frame of the basic structure.
4. Another ms angle with required dimension was taken
5. It is cut into pieces to form a leg pieces
6. Fabricate the legs with the rectangle from one by one to
form the stand structure.
OPERATIONS INVOLVED
Turning
Facing (flat surface)
Drilling
Gas cutting
Shaping
Welding
Tapping
Thread cutting
TURNING
Turning is the operation of reducing a cylindrical surface by
removing material from the outside diameter of a work piece. It is
done by rotating the work piece about the lathe axis and feeding
the tool parallel to the lathe axis. Due to this operation screw rod
and head are done by the turning operation to get the required
shape.
FACING
Machining the end of the work piece to produce flat surface is
called facing. Due to this, the plate can get flat surface have done
by the facing operation.
DRILLING
Drilling is the operation of producing cylindrical hole in work
piece. It is done by rotating the cutting edge of the cutter known
as drill bit. In this Project the jig plates require holes for locating
indexing plate and screw rod, drill bush assembly. These holes are
done by conventional vertical drilling machine.
THREAD CUTTING
Scope of work:
The machines have been designed to support human beings
by helping them to do tedious and back breaking works.
However, the industry has made only the limited use of high
technology production concept. There is general need to nature
the development program in automation and robotics. Machines
Chamber Environments:
Non-ambient environments are usually chamber exposures.
Cycling between different non-ambient environments can be
performed by physically moving the test specimens from one
chamber to another or, in automated chambers, by cycling from
one condition to another. The temperature and relative humidity
should be monitored. Whenever possible, automatic control
systems should be used. Temperature tolerances should be 3C
or better.
Humid Environment:
CCT procedures often call for high humidity environments.
Typically they specify 95 to 100% RH. These may be achieved by
using hot water air and salt spray chamber may sometimes be
used to apply a pure water fog.
7k5
Vout = ------------------- x 5vdc.
12k + 7.5k
Rx
R2
- Vcc
+ Vcc
2k2
10k
Vout
2k2
Vout
adjusted at the central point i.e. wiper of potentiometer. The opamp being in unity gain fashion, generates 300mv at the output.
The signal is equivalent to 30C.
are
shown
on
LCD
module.
This
is
cold
junction
compensation section.
Thermocouple sensor is connected at the input of
difference amplifier.
We do the
- RF
Vout = -------------- (V2-V1)
R1
- RF
Thus, Vout = -------------- (5mv Say) Let R1 = 10k
10k
- RF
100mv = -------------- (5mv)
10k
RF = 200k
But, 200k being not available we use 220k here.
Also, a multi-tern trimpot is provided for getting a flexible gain.
Thus, the signal available at the output of difference amplifier and
the signal available at CJC output are added together in adder
amplifier.
Temperature Calibration:-
2)
3)
Spray Nozzle:
A spray nozzle is a precision device that facilitates dispersion of
liquid into a spray. Nozzles are used for three purposes: to
distribute a liquid over an area, to increase liquid surface area,
and create impact force on a solid surface. A wide variety of spray
nozzle applications use a number of spray characteristics to
describe the spray.
Relay:
A relay is an electrically operated switch. Many relays use
an electromagnet to mechanically operate a switch, but other
operating principles are also used, such assolid-state relays.
Relays are used where it is necessary to control a circuit by a lowpower signal (with complete electrical isolation between control
and controlled circuits), or where several circuits must be
controlled by one signal. The first relays were used in long
distance telegraph circuits as amplifiers: they repeated the signal
coming in from one circuit and re-transmitted it on another circuit.
Relays were used extensively in telephone exchanges and early
computers to perform logical operations.
A type of relay that can handle the high power required to directly
control an electric motor or other loads is called
a contactor. Solid-state relays control power circuits with
no moving parts, instead using a semiconductor device to perform
switching. Relays with calibrated operating characteristics and
sometimes multiple operating coils are used to protect electrical
circuits from overload or faults; in modern electric power systems
Pressure Regulator
Pressure regulating components are formed by various
components, each of which has its own pneumatic symbol:
(i) Filter can remove impurities from compressed air before it is
fed to the pneumatic components.
(ii) Pressure regulator to stabilise the pressure and regulate the
operation of pneumatic components
(iii) Lubricator To provide lubrication for pneumatic components
POWER SUPPLY
Power supply is the first and the most important part of our
project.For our project we require +5v regulated power supply
with maximum current rating 500 mA
Following basic building blocks are required to generated
power supply.
Rectifier
Filter
3 Terminal
Vtg. Regulator
230vac
Reg.o/p
IV
RECTIFIER UNIT:
ADVANTAGES :
Generally a rectifier is required to produce pure D.C. supply for using at various places in
the electronic circuit, However, the o/p of rectifier has pulsating character i.e. if such a D.C. is
applied to electronic circuit it will produce a hum i.e. it will contain A.C. and D.C. components.
The A.C. components are undesirable and must be kept away from the load. To do so a filter
circuit is used which removes (or filter out) the A.C. components reaching the load. Obviously a
filter circuit is installed between rectifier and voltage regulator. In our project we use capacitor
filter because of his low cost, small size and litile weight and good characteristic. Capacitors are
connected in parallel to the rectifier o/p because it passes A.C. but does not pass D.C. at all.
7805
7812
1
T3
D1
D3
D2
D4
230VAC
@50HZ
C1
0-10 , 500 mA
VIN
VOUT
2
GND
1
GND
+5V
3
+
C3
Power output
operating voltage.
Frequency Range
Efficiency and Regulation
Size of core :
Size of core is one of the first consideration in regard of core
and winding configuration used. Generally following formula is
used to find area or size of core.
Ai =
(p1/0.87)
Where
Ai = Area of cross section in sq. cm.
P1 = Primary voltage
In Transformer P1 = P2
P2
so ,
12 X 500 X 10
6w.
w.
Ai
(6/0.87)
2.62
Rectifier design :
= 2 Vm
= 2 X 16.97
= 34V
1
C=
----------------------------4. 3 r f RL
1
C = ------------------- = 1000F
4 3 0.1*50*28
Specifications :-
Check that component agree with the parts list (value and
power of resistors, value and voltage rating of capacitor,
Check all ICs in their sockets (see that there are no pins bent
under any ICs, no near ICs are interchanged etc.)
Check all the polarized components (diodes, capacitor etc)
are fitted correctly.
Check the wiring (watch for off cuts of components leads) at
the same time ensure that there are no short-circuits
between potentiometer, switches, etc. and there immediate
surrounding (other components or the case). Do the same
with mounting hardware such as spacers, nuts and bolts etc.
Ensure that the supply transformer is located as closely as
possible to the circuits (this could have a significant
improvement in the case of critical signal level).
Check that the connections to the earth are there and that
they are of good contact.
Make sure the circuit is working correctly before spending
any time putting it into a case.
And if it breaks down:
PCB DESIGN
Designing of PCB :
I)
II)
III)
IV)
V)
VI)
VII)
VIII)
IX)
X)
XI)
XII)
XIII)
XIV)
XV)
XVI)
COMPOMENT PLACEMENT :
I)
Advantages:
Cyclic corrosion test methods were originally developed as labor
intensive manual procedures. Automated, multi-functional
chambers are now available and can perform CCT tests in a single
chamber. Some of the advantages of automated systems are that
they:
Eliminate manual moving of test specimens from one chamber
to another
Eliminate laborious spraying of test specimens
Eliminate variability in results from excessive specimen handling
Allow more predictable transition times