AUTO INDEXING GEAR CUTTING ATTACHMENT FOR

PNEUMATIC SHAPING MACHINE

SYNOPSIS

A shaper is used to machine a single job by using a single point cutting

tool and hence it can not be used for high production rates. This project intends
to use pneumatic shaper for high production of automatic gear cutting with auto
indexing work piece. A small ratchet gear structure has been thus devised to
demonstrate the gear cutting attachment in shaping machines.

The pneumatic source of power with control accessories is used to drive

the ram or the cylinder piston to obtain the forward and return strokes. By this
arrangement the forward/reverse stroke of the pneumatic cylinder is adjustable
type when compared with the conventional machines. We desired a shaping
machine which will automatically index the job and gives automatic tool feed to
the pneumatic cylinder.
INTRODUCTION

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.

Needs for pneumatic power :

Pneumatic system use pressurized gases to transmit and control power, as the
name implies, pneumatic systems typically use air as fluid medium, because air
is a safe, low cost and readily available fluid. It is particularly safe
environments where an electrical spark could ignite leaks from the system
components.
There are several reasons for considering the use of pneumatic system instead of
hydraulic system Liquid exhibit greater inertia than gases. Therefore, in
hydraulic system the weight of the oil is a potential problem. To design and
development a material handling system for automation /semi automation of
industries by using pneumatic control system, which is used for low cost
automation.
LITERATURE REVIEW

3.1 Pneumatics:

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.
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.
Literature survey:

3.1.1 AUTO INDEXING GEAR CUTTING ATTACHMENT FOR

SHAPING MACHINE

M.V.N Srujan Manohar, S.Hari Krishna , University College of

engineering, JNTU Kakinada, A.P, INDIA(2012) :

They have been investigated to use pneumatic shaper for high

production of automatic gear cutting with auto indexing work piece. A
small ratchet gear structure has been thus devised to demonstrate the gear
cutting attachment in shaping machines.

The pneumatic source of power with control accessories is used to

drive the ram or the cylinder piston to obtain the forward and return
strokes. By this arrangement the forward/reverse stroke of the pneumatic
cylinder is adjustable type when compared with the conventional
machines. We desired a shaping machine which will automatically index
the job and gives automatic tool feed to the pneumatic cylinder

3.1.2 DESIGN & FABRICATION OF PNEUMATICALLY

OPERATED PLASTIC INJECTION MOULDING MACHINE

Poonam G. Shukla, Gaurav , P. Shukla Nagpur, India (2013) :

This project intends to use of plastic is increased now days in many

industries like automobile, packaging, medical, etc. The reason behind
this is that the plastic made things are quiet easier to manufacture, handle
and reliable to use. So the plastic goods manufacturing industries are
striving hard to produce good quality products at large scale and cheaper
cost. The hydraulically operated machines solve the problem, but they are
too costlier for small scale and medium scale industries. This paper deals
with design and fabrication of pneumatically operated injection plastic
moulding machine. The manually operated machine is converted into
pneumatically operated machine by applying proper design procedure.

3.1.3 DESIGN AND DEVELOPMENT OF SEMI-

AUTOMATIC CUTTING MACHINE FOR YOUNG
COCONUTS
Satip Rattanapaskorn , Kiattisak Roonprasang , King Mongkut’s
Institute of Technology Ladkrabang, Bangkok 10520, Thailand
(2008) :

The purpose of this research is to design, fabricate, test, and

evaluate the prototype of a semi-automatic young coconut fruit cutting
machine. The design concept is that fruit cutting is accomplished by
pneumatic press on a young coconut sitting on a sharp knife in a vertical
plane. The machine consists of 5 main parts: 1) machine frame,

2) cutting base, 3) knife set, 4) pneumatic system, and 5) tanks receiving

coconut juice and cut fruits. The machine parts contacting edible parts of
the fruit are made of food-grade stainless steel. In operation, a young
coconut is placed on the cutting base and the pneumatic control is
switched on. The coconut is automatically moved to the pressing unit and
cut in half by a knife set. The coconut juice flows down to the tank while
the cut fruits are separated and moved into the other tank.

3.1.4 PNEUMATIC AUTO FEED PUNCHING AND RIVETING

MACHINE

A.S. Aditya Polapragada, K. Sri Varsha, University College of

engineering, JNTU Kakinada, A.P, INDIA:

This projects intends to pneumatic system has gained a large

amount of importance in last few decades. This importance is due to its
accuracy and cost. This convenience in operating the pneumatic system
has made us to design and fabricate this unit as our project. This unit, as
we hope that it can be operated easily with semi-skilled operators.

The pneumatic press tool has an advantage of working in low

pressure, that is even a pressure of 6 bar is enough for operating the unit.
The pressurized air passing through the tubes to the cylinder, forces the
piston out whose power through the linkage is transmitted to the punch.
The work piece thus got is for required dimensions and the piece can be
collected through the land clearance provided in the die. The die used in
this is fixed such that the die of required shape can be used according to
the requirement. This enables us to use different type punch dies resulting
in a wide range of products. Different types of punch as requirement can
be thus got. According to the work material the operating pressure can be
varied

3.1.5 CRITICAL REVIEW:

 1) The above specified projects are work for only specified
operations only.
2) On those machines numbers of operations are not performed.
3) Those machines are not made for multi-purpose.

4) Even similar operations also not performed on those machines,

they are meant for single operations only.

CHAPTER-4

4.1METHODOLOGY

4.1.1DESIGN AND SIMULATION

The design of the equipment is carried out in four stages.
They are:
1. Pneumatic circuit
2. Electronic control system
3. Indexing mechanism
4. Positioning of the equipment

4.1.2DESIGN OF PNEUMATIC CIRCUIT

In order to get the desired output, we require two actuators that operate in
the sequence A+ A- B+ B-. This has been achieved by designing an appropriate
pneumatic circuit as shown below.
Design of pneumatic circuit In the circuit, one of the cylinder is used as
the main cylinder that performs the cutting action and the other is used to drive
the indexing mechanism. There are two 5/3 direction control valves that are
used to control the pneumatic cylinders.

4.1.3DESIGN OF ELECTRONIC CIRCUIT

The electronic system is used to control the timing and sequencing of the
working of the direction control valves. An Arduino UNO 3 micro controller is
used in the circuit for this purpose. The below circuit represents the electronic
control system.
 4.1.4Design of electronic control system
The pneumatic circuit when combined with this control system, completes the
pneumatic shaper. This can be used to perform all the operations that a
conventional shaper does.

4.1.5DESIGN OF THE INDEXING MECHANISM

In order to make the gear cutting attachment more flexible, a new

mechanism has been devised and synthesized. This uses a stencil gear and a
four bar mechanism to index the gear blank that isto be machined. The below
figure depicts the schematic of the mechanism Fig 3 Design of indexing
mechanism In the above mechanism, link 1 is connected to the pneumatic
cylinder that drives the whole indexing mechanism. The link 2 has two stoppers
attached to it such that they are on either sideof link 1 and the link 3 has a tooth
that can engage with the gear. Fig 4 Working of the indexing mechanism The
above motion has been synthesized using displacement equations[1]. Further, to
improve the flexibility of the system a provision has been made to vary the
stoppers’ distance from the center and the effective length of the links can be
changed by fixing the joints at any point on the adjacent link in the holes
provided.
4.1.6POSITIONING OF EQUIPMENT

It is important that the various elements of the equipment are to be positioned

such that their axes lie in the same plane to perform the cutting operation. The
layout of the equipment

4.1.7PNEUMATICS:

The 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 in driving and
controlling of machines and equipment.

Pneumatics has been considered to be used to carry out simple

mechanical tasks. But, in today’s world it is playing an important role by
becoming one of the major sources for automation, and the recent developments
in this field has made it a useful technology in the field of complex automated
applications.

Pneumatic systems operate on a supply of compressed air which must be

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 will indeed be necessary to deal with the section of compressed air supply.

The key part of any pneumatic machine is supply of compressed air is by

means reciprocating compressor. A compressor is a machine that takes in air,
gas at a certain pressure and delivers 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.

4.1.8PNEUMATIC ACTUATOR:

Physical processes proceeding in drives are submitted to the gas laws.

The gas laws are a set of laws that describe the relationship between
thermodynamic temperature (T), pressure

(P) and volume (V) of gases. Three of these laws, Boyle’s law, Charles’s law,
and Gay-Lussac’s law, may be combined to form the combined gas law

P1V1 = P2V2

T1 T2
Which with the addition of Avogadro’s law later gave way to the ideal gas
law. Other important gas laws include Dalton’s law of partial pressures. The
kinetic theory of gases, Graham’s law of effusion and root mean square velocity
explains how individual molecules act in a gas and their relation to pressure,
volume, and temperature. A gas that obeys these gas laws is known exactly as
an ideal gas (or perfect gas). An ideal gas does not exist; however, some gases
follow the laws more closely than the others in given standard conditions.

The most important gas law is the ideal gas law, which states that:
PV = nRT
Other gas laws, such as vander Waals equation, seek to correct the ideal
gas laws to reflect the behaviour of actual gases. Van der Waals equation alters
the ideal gas law to reflect how actual gases function using a series of calculated
values called van der Waals constant Any gas can be used in pneumatic system
but air is the mostly used system now a days.

4.1.9SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatic is an attractive medium for low cost
mechanizations 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 a pneumatic system is it is economically cheap
and simple in design, also reducing maintenance costs. It can also have an out
standing advantage in terms of safety.

4.1.10PNEUMATIC POWER

Pneumatic systems use pressurized gas to transmit and

control power. Pneumatic systems typically use air as the fluid
medium because air is safe, free and readily available.

Advantages of Pneumatics:

1. Air used in pneumatic systems can be directly exhausted in to the

surrounding environment and hence the need of special reservoirs
and no-leak system designs are eliminated.

2. Pneumatic systems are simple in design and economical.

3. Control of pneumatic systems is easier.

Disadvantages of Pneumatics:

1. Pneumatic systems exhibit spongy characteristics due to

compressibility of air.

2. Pneumatic pressures are quite low due to compressor design

limitations (less that 250 psi).

CHAPTER 5
5 DESCRIPTION OF EQUIPMENT

5.1 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.
The key part of any p neumatic system 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 delivers it at a higher 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.
 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.

Positive displacement compressors are most frequently employed

for compressed air plant and have proved highly successful for pneumatic
control application.

The different types of positive compressors are:

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.

5.2 .A RECIPROCATING COMPRESSORS:

Built for either stationary (or) portable service the reciprocating

compressor is by far the most common type. Reciprocating compressors deliver
more than 500 m³/min. In single stage compressor, even if the air pressure is of
6 bar, the machines can discharge pressure of 15 bars. Discharge pressure in the
range of 250 bars can be obtained with high pressure reciprocating compressors
that of three & four stages. Single stage and 1200 stage models are particularly
suitable for pneumatic applications , with preferences 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

Fig 5.2 Air Compressor

5.3 PNEUMATIC CONTROL COMPONENT:

5.3.1 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.

5.3.2.A 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 loads. This can only be done at the end positions of the piston
stock. In all intermediate positions a separate externally mounted cushioning
device must 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.
 Fig 5.3.2 Double Acting Cylinder

5.3.3 SINGLE ACTING CYLINDER:

Single acting cylinder is only capable of performing an operating

medium in only one direction. Single acting cylinders are equipped with one
inlet for the operating air pressure, and can be produced in several designs.
Single cylinders develop power in one direction only.

Therefore no heavy control equipment should be attached to them, which

is required to be moved on the piston return stoke. Single action cylinder
requires only about half the air volume consumed by a double acting for one
operating cycle.

Fig 5.3.3 Single Acting Cylinder

5.3.4 GENERALLY USED MATERIALS FOR CYLINDERS:
Table 3.1 End Cover Materials

S.N
O LIGHT DUTY MEDIUM DUTY HEAVY DUTY
Aluminium
stock Aluminium stock
Hard tensile
1. (Fabricated) (Fabricated) Castings
Brass stock Brass stock
2. (Fabricated) (Fabricated)
Aluminium, Brass,
Aluminium
3. Castings iron or steel Castings.
Table 5.3.4 Cylinder Tube
Materials

S.N
O LIGHT DUTY MEDIUM DUTY HEAVY DUTY
Hard drawn brass
1. Plastic tube Hard drawn brass tube.
Hard drawn
Aluminium
2. tube Aluminium Castings Hard drawn steel tube
Hard drawn Brass, bronze, iron or
castings, welded steel
3. Brass tube tube
Table 5.3.4 Piston
Materials

S.NO LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium Castings Aluminium Forgings,
Aluminium
Castings Brass (Fabricated) Aluminium Castings.
2.
Bronze (Fabricated) Bronze (Fabricated)
 3. Iron and Steel Brass, Bronze, Iron or
Castings Steel Castings.
Table 5.3.4 Mount
Materials

S.N
O LIGHT
DUTY MEDIUM DUTY HEAVY DUTY

Aluminium Aluminium, Brass High Tensile

1.
Castings And Steel Castings Steel Castings

Light Alloy High Tensile

2. (Fabricated) Steel Fabrication

Table 5.3.4 Piston Rod Materials

S.N
O MATERIAL FINISH REMARKS

Ground and polished

MILD STEEL hardened, Generally preferred chrome
1. ground and polished. Plated

STAINLESS
2. STEEL Ground and Polished Less scratch resistant than
chrome plated piston rod

5.4 VALVES:

5.4.1 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.

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 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.

Fig 5.4.1/2 WAY Solenoid Valve

5.4.2 PARTS OF A SOLENOID VALVE:

5.4.2.A. COIL:

The 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.

5.4.2.B. FRAME:
The 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.

5.4.2.C. SOLENOID PLUNGER

The 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.

5.4.2.D WORKING OF SOLENOID VALVE:

The solenoid valve has 5 openings. This ensures easy exhausting of 5/2
valve. The spool of the 5/2 valve slide inside the main bore according to spool
position; the ports get connected and disconnected. The working principle is as
follows
 Fig 5.4.2.D /2 Way Soleniod Valve Sectional View

POSITION-1

When the spool is actuated towards outer direction port ‘P’ gets
connected to ‘B’ and ‘S’ remains closed while ‘A’ gets connected to ‘R’

POISITION-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets
connected to each other and ‘B’ to ‘S’ while port ‘R’ remains close.

5.4.3SOLENOID VALVE (OR) CUT OFF VALVE:

The 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 separate solenoid valve is used for flow direction of vice
cylinder. It is used to flow the air from compressor to the single acting cylinder.

5.4.3.A FLOW CONTROL VALVE:

In any fluid power circuit, flow control valve is used to control the speed
of the actuator.
The flow 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.

Flow control valves facilitate high precision adjustment of flow volumes

and are used to precisely control the piston speed of a drive.
For adjustable speed via exhaust air flow control. The piston moves
between air cushions created through freely flowing supply air and restricted
exhaust air. The benefit is improved operating behavior, even in the event of
load changes
Fig 5.4.3.A Flow Control Valve For Pneumatic Cylinder
5.5 HOSES

Hoses used in this pneumatic system are made up of polyurethane. These

hose can with stand at a maximum pressure level of 10 N/m². Polyurethane
combines the best properties of both plastic and rubber. It offers abrasion and
tear resistance, high tensile and elongation values, and low compression set.

Polyurethane is naturally flexible and exhibits virtually unlimited flexural

abilities. Combining good chemical resistance with excellent weathering
characteristics sets polyurethane apart from most other thermoplastics. It has
exceptional resistance to most gasoline’s, oils, kerosene, and other petrol
embossed chemicals, making it an ideal choice for fuel lines (although additives
in today’s gasoline and petroleum products warrant field testing).

Fig 5.5 Poly Urathane Tubes

5.5.1 APPLICATIONS OF PU TUBE

• Any time condensation can occur with small actuators, air grippers and
air operated valves. Condensation in a pneumatic system will cause
operating failure and affect the life of pneumatic equipment.

• Manufacturers of electrical components.

 • When you need to eliminate water condensation but you can not use a
membrane or desiccant dryer (as you cannot use a fast exhaust).

5.5.2 BENEFITS OF PU TUBE:

• Longer life of other pneumatic equipment.

• Prevents operational failure of small actuators, air grippers and pilot

operated valves due to condensation.

• Avoids corrosion in other pneumatic equipment.

• Diffuses water vapour in the piping to the outside before it liquefies, so

we avoid problems such as dried grease or ozone when using other
types of dryers.

• Easy mounting

5.6 CONNECTORS:

In our system hose connectors are used . Hose connectors normally

comprise an adoptee hose nipple. These types of connectors are made up of
brass (or) Aluminum (or) hardened pneumatic steel. For these type hose
connectors no need of hose clamp these are self-locking hose connectors. a
Multi way four way hose connecter

The universal combination at an attractive price. Can be widely used

thanks to resistant materials. Easy to install thanks to optimised bending radii.
Limited reset effect.Attractively priced: the universal solution for metal fittings.
Perfect for standard pneumatic applications – in many different fields. Wide
range of variants Over 1000 types for maximum flexibility in standard
applications. Hydrolysis resistant For applications in damp environments or in
contact with water at up to 60 °C. Resistant to pressure Secure connection when
used with pressure ranges of up to 14 bar. Economical for pneumatic
installations in the high pressure ranges.
 Fig 5.6 Hose Connector
The powerful combination for applications involving pressure ranges up
to 16 bar For example, for applications with the pressure booster Robust,
flexible and reliable connection for the automotive industry. Fulfils the
requirements Heat resistant For reliable compressed air supply in high
temperature ranges. Whether with 10 bar at 80 °C or 6 bar at 150 °C – always
delivers maximum process security. Anti-static Electrically conductive tubing
combined with a solid-metal fitting Approved for the food Industry Food and
Drug Administration certification for use in the food industry:
Fig 5.6 Four way hose connector

The hydrolysis-resistant combination with increased functions. Designed

to meet the highest demands, This combination shines in applications which
require the highest possible hygiene standards for food. The cost-effective
alternative to stainless steel, perfect for e.g. critical environments such as the
splash zone: resistant to practically all common cleaning agents, with maximum
corrosion protection. Resistant to media Completely resistant to all cleaning
agents and lubricants and even permits the transportation of acids and lyes
without any problems.

Flame-retardant Safe in areas where there is a risk of fire thanks to flame-

retardant properties to Resistant to welding Spatter The economical combination
for applications not in close proximity to welding applications. Also reliable for
applications in direct proximity to welding splatter Double-sheathed tube and
special fitting.

5.7 CONTROL UNIT

A pneumatic multipurpose device is an air-operated device used for many

small operations. It is a portable one. Compressed air is the source of energy for
this device. The compressed air is allowed to pass through the nozzle in such a
way that the rotation obtained is utilized for machining.

The nozzles welded to the fan can be rotated in either direction. The rpm
and torque of the shaft depends upon the pressure of the air admitted so by
varying the pressure, the RPM and torque can be varied. Thick tubes
interconnect the parts. The Clamps are used at the connecting parts to prevent
leakage. In thread parts seals are used to prevent leakage.

The compressed air from the compressor first enters the control unit. In
the control unit the pressure of the air is controlled and sent to the barrel to
rotate the fan in the required direction. The gate valve controls the pressure and
volume of air. Then the pressure is read by a pressure gauge. Later the air is
admitted to the barrel, a shaft is placed and it carries the fan.

The shaft is supported by bearing. The bearings are placed in the

couplings, which covers the end of barrel.

WORKING PRINCIPLE

 The compressed air from the compressor reaches the solenoid valve. The
solenoid valve changes the direction of flow according to the signals from
the timing device.
 The compressed air pass through the 5/2 solenoid valve and it is admitted
into the front end of the cylinder block. The air pushes the piston for the
cutting stroke. At the end of the cutting stroke air from the solenoid valve
reaches the rear end of the cylinder block. The pressure remains the same
but the area is less due to the presence of piston rod. This exerts greater
pressure on the piston, pushing it at a faster rate thus enabling faster
return stroke.
 The compressed air pass through the 3/2 solenoid valve and it is admitted
into the front end of the cylinder block. The air pushes the piston for the
gear changer. At the end of the cutting stroke air from the solenoid valve
reaches the rear end of the cylinder block.
 The pressure remains the same but the area is less due to the presence of
piston rod. This exerts greater pressure on the piston, pushing it at a
faster rate thus enabling faster return stroke.
 The screw attached is fixed to the clapper box frame gives constant loads
which lower the sapper to enable continuous cutting of the work.
 The stroke length of the piston can be changed by making suitable
adjustment in the timer.
5.7.1APPLICATIONS

Small and Medium scale industries

It is very useful in machine shop
Industrial Application

5.7.2LIMITATIONS

 While working, the compressed air produces noise therefore a

silencer may be used.
 High torque can not be obtained
 Load carrying capacity of this unit is not very high

5.7.3ADVANTAGES

 Auto indexing mechanism is used to reduce the production time

 Quick response is achieved
 Simple in construction
 Easy to maintain and repair
 Cost of the unit is less when compared to other Machines
 No fire hazard problem due to over loading
 Comparatively the operation cost is less
 The speed of forward and reverse stroke is varied
 Continuous operation is possible without stopping
CONCLUSION :
In the gear cutting attachment for sapping machine variable speeds can be
obtained by adjusting the timer device and pressure of the compressed air. Since
the mechanism is so simple and versatile it can be handled by any operator,
constriction of the unit is very simple. Handling the machine is easy and smooth
operation is achieved.