FABRICATION OF AUTOMATIC PNEUMATIC CLAMPING
AND BENDING MACHINE
S.NO
REGISTER NUMBER
NAME OF THE STUDENT
1
19700363
JAGADISH M
2
19700365
JEEVA K
3
19700367
KARTHICK R
4
19700368
KARTHICK T
5
19700369
LENIN RAJ V
CONTENTS
CONTENTS
Chapter No.
TITLE
1.
INTRODUCTION
2.
SYNOPSIS
3.
CONSTRUCTION
4.
WORKING PRINCIPLE
5.
ELECTRICAL CIRCUIT DETAILS
6.
MECHANICAL ASSEMBLY DIAGRAM
7.
PNEUMATIC CIRCUIT DIAGRAM
8.
PNEUMATIC COMPONENT DETAILS
9.
FINISHING AND PAINTING
10.
COST ESTIMATION
11.
CONCLUSION
12.
BIBILOGRAPHY
13.
PHOTO VIEW
SYNOPSIS
FABRICATION OF AUTOMATIC CLAMPING
AND BENDING MACHINE
SYNOPSIS
To increase the productivity and to overcome skilled labour shortage,
most of the manufacturing industries are going for automation. The main
aim for us to select this project work is to acquire practical knowledge in the
field of automation using Pneumatic system.
We selected “AUTOMATIC PNEUMTAIC CLAMPING AND
BENDING MACHINE ” as our project work and the clamping and bending
is done automatically by the double acting cylinders which are actuated
through the 5/2 way solenoid directional control valves . These solenoid
valve are actuated by the Electronic control circuit .
There are two cylinders are used to clamp and bend the job.. One
cylinder is used for clamping and another cylinder is used for bending
operation. When the push button is pressed the clamping cylinder clamps the
job by air pressure through the 5/2 solenoid operated directional control
valve and the bending cylinder bends the job. The control circuit switches
off the supply to the both the solenoid valves and hence the both the
cylinders are return to original position.
CONSTRUCTION
CONSTRUCTION
This project consist of
1.
2.
3.
4.
5.
M.S. Fabricated stand (For mounting the cylinder)
Base for seating the stand
Clamping cylinder unit
Bending cylinder unit
Electrical control unit
The following figure shows the construction of this project
1. M.S Fabricated Stand:
A
M.S L angle frame is fabricated to a size of 600mmx450mmx
300mm (Length x Height x breath) And it is used as a base plate for the this
project work. And another one number of rectangular M.S. frame of size 150
x 150 x100 mm stool set up mounted in the base frame.
These frames are made with 25 x 25 x 2.5mm 'L' angle M.S material. This
fabricated frame is shown below.
2. JOB MOUNTING BASE:
The job is placed in this base which is made in to size of 150mm x
150mm x 75mm (breath x height x thickness) and it is made with 25mm x
25mm x 3mm M.S angle material.
3. CLAMPING CYLINDER:
The cylinder is mounted just above the work base . This cylinder is
screwed with the plywood which is fixed in the M.S. stand.
4. BENDING CYLINDER UNIT:
This cylinder is mounted parallel to the clamping cylinder unit and it
is also mounted in the same plywood sheet.
5. ELECTRICAL CONTROL PANEL:
The electrical control panel is used to start the machine after placing
the job on the work base. The electrical boards are mounted inside the panel
to set up for automation operation .
This electrical panel gives supply to both the solenoid valves for the
Clamping and bending cylinder.
WORKING PRINCIPLE
WORKING PRINCIPLE
The fig shows the front view of the Pneumatic Clamping And
Bending Machine.
PNEUMATIC CLAMPING AND
BENDING MACHINE
CLAMPING
CYLINDER
BENDING
CYLINDER
WORK
TABLE
JOB
BASE
Before starting the machine set the pressure 6 Bar in the FRL unit and
connect air supply to the 5/2 way Solenoid operated directional control valve
at the pressure port.
Now, Press the ‘ON’ Switch after placing the job in the worktable.
The air supply goes to clamping cylinder, which clamp the job. After
clamping, the microcontroller switch on the supply to the second solenoid
valve which supplies pressurized air to the bending cylinder. The cylinder
moves downward and bends the job. After the bending operation ,the
cylinder returns to the original position by the control of microcontroller.
SKETCHES AND DRAWINGS
SKETCHES AND DRAWINGS
ELECTRICAL CIRCUIT
DIAGRAM
CIRCUIT DETAILS
a) Mother Board:
The figure shows the pin details of PIC 16F 870(28 Pin
package) micro controller. The power supply (5V) is given at Pin
No.20. Pin No.8, 19 are connected to ground. Pin No.9 and 10 are
connected to 6 MHz crystal. Pin No.1 is used for Reset. Pin
No.11 to 18 is Port-C.
PORTB,4-------------START/STOP PUSH BUTTON
The circuit diagram for this micro controller board is shown below,
5 TO 12V DC DRIVE CARD
Here we have to drive the 12V DC load. The 5V signal from the PIC 16F870
micro-controller is fed into the input of interface circuit. SL100 transistor is
used here for high speed switching purpose and IRF 540N MOSFET is
connected to the motor to handle the larger current drawn by the solenoid
valve.
POWER SUPPLY 5V DC AND 12V DC;
A 12 –0 v step down transformer is used to stepdown 230V AC to
12V AC .This 12V AC supply is converted to 12V DC using four rectifier
diodes. The voltage from the rectifier section is regulated to 12V DC using
7812 IC .This voltage is used for supply for the DC motor. From 12V DC
the 7805 IC is used for
regulating 5V DC for the
microcontroller.the power supply circuit is shown in fig.
power supply of
POWER SUPPLY UNIT
INTRODUCTION:
All the electronic components starting from diode to Intel IC’s only
work with a DC supply ranging from +5V to +12V. We are utilizing for the
same, the cheapest and commonly available energy source of 230V-50Hz
and stepping down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer,
it can either be stepped down or stepped up depending on the value of DC
needed. In our circuit the transformer of 230V/15-0-15V is used to perform
the step down operation where a 230V AC appears as 15V AC across the
secondary winding. Apart from stepping down voltages, it gives isolation
between the power source and power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a
solid state diode. Diode has the property that will let the electron flow easily
in one direction at proper biasing condition. As AC is applied to the diode,
electrons only flow when the anode and cathode is negative. Reversing the
polarity of voltage will not permit electron flow. A commonly used circuit
for supplying large amounts of DCpower is the bridge rectifier. A bridge
rectifier of four diodes (4 x IN4007) are used to achieve full wave
rectification. Two diodes will conduct during the negative cycle and the
other two will conduct during the positive half cycle, and only one diode
conducts. At the same time one of the other two diodes conducts for the
negative voltage that is applied from the bottom winding due to the forward
bias for that diode. In this circuit due to positive half cycle D1 & D2 will
conduct to give 0.8V pulsating DC. The DC output has a ripple frequency
of 100Hz. Since each alteration produces a resulting output pulse, frequency
= 2 x 50 Hz. The output obtained is not a pure DC and therefore filtration
has to be done.
The DC voltage appearing across the output terminals of the bridge
rectifier will be somewhat less than 90% of the applied rms value. Normally
one alteration of the input voltage will reverse the polarities. Opposite ends
of the transformer will therefore always be 180 degree out of phase with
each other. For a positive cycle, two diodes are connected to the positive
voltage at the top winding.
FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester
always follow the rectifier unit. This capacitor is also called as a decoupling
capacitor or a bypassing capacitor, is used not only to ‘short’ the ripple with
frequency of 120Hz to ground but also to leave the frequency of the DC to
appear at the output. A load resistor R1 is connected so that a reference to
the ground is maintained. C1, R1 is for bypassing ripples. C2, R2 is used as
a low pass filter, i.e. it passes only low frequency signals and bypasses high
frequency signals. The load resistor should be 1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating
10f/25V
: for maintaining the stability of the voltage at the load side.
0.1f
: for bypassing the high frequency disturbances
VOLTAGE REGULATOR:
The voltage regulators play an important role in any power supply
unit. The primary purpose of a regulator is to aid the rectifier and filter
circuit in providing a constant DC voltage to the device. Power supplies
without regulators have an inherent problem of changing DC voltage values
due to variations in the load or due to fluctuations in the AC linear voltage.
With a regulator connected to the DC output, the voltage can be maintained
within a close tolerant region of the desired output. IC7812 and 7912 is used
in this project for providing +12V and 12V DC supply.
INTRODUCTION TO
PNEUMATICS
INTRODUCTION TO PNEUMATICS
In engineering field may Machines make use of a fluid or compressed air to
develop a force to move or hold an object .
A system which is operated by compressed air is known as Pneumatic
System. It is most widely used the work Piece turning drilling sawing etc.
By the use of Pneumatic System the risk of explosion on fire with
compressed air is minimum high working speed and simple in construction.
PNEUMATIC COMPONENTS
In engineering field, many machines make use of fluid for developing a
force to move or hold an object. A number of fluid can be used in devices
and system. Two commonly used fluids are oil and compressed air. A
system which is operated by compressed air. A system which is operated by
compressed
air
is
know
as
Discrete Control Logic
1. Pneumatic circuits
- Low forces
- Discrete, fixed travel distances
- Rotational or reciprocating motion
Main components: compressor, valves, cylinders
pneumatic
system.
AIR COMPRESSOR
Compressor is a device which gets air fro the atmosphere and
compresses it for increasing the pressure of air. Thus the compressed air.
Thus the compressed air used for many application.
The compression process requires work in put. Hence a compressor is
driven by a prime mover. Generally an electric motor is used as prime
mover. The compressed air from compressor is stored in vessel called
reservoir. Fro reservoir it be conveyed to the desired place through pipe
lines.
2. FLTER
In pneumatic system, an air filter is used to remove all foreign matter.
An air filter dry clean air to flow without resistance various materials are
used for the filter element. The air may be passed thorugh a piece metal, a
pours stone felt resin impregnated paper. In some filters centrifugal action
or cyclone action is used to remove foreign matters.
3. PRESSURE REGULATOR
Constant pressure level is required for the trouble free operation of a
pneumatic control.,
A pressure regulator is fitted downstream of the
compressed air filter. It provides a constant set pressure at the outlet of the
outlet of the regulator. The pressure regulator is also called as pressure
reducing valve or pressure regulating valve.
4. LUBRICATOR
The purpose of an air lubricator is to provide the pneumatic
components with sufficient lubricant. These lubricants must reduce the wear
of the moving parts reduce frictional forces and protect the equipment from
corrosion.
Care should be taken to ensure that sufficient lubrication is provided.
But excessive lubrication should be avoided. .
5. FLR Package (or) FRL Package
The air service unit is a combination of following units.
1. Compressed air filter
2. Compressed air regulator
3. Compressed air lubricator
Air Filter, regulator and lubricator are connected together with close
nipples as one package.
This unit is know as FLR (Filter, regulator,
lubricator.)
6. PRESSURE CONTROL VALVE :
Each hydraulic system is used to operate in a certain pressure range.
Higher pressure causes damage of components. To avoid this pressure
control valves are fitted in the circuits.
7. Direction control valve :
Directional control valves are used to control the direction of flow.
The design principle is a major factor with regard to service life actuating
force switching times etc.
8. Piston and Cylinder
single acting pneumatic cylinder;
PNEUMATIC CITCUIT SYMBOL FOR SINGLE ACTING PNEUMATIC
CYLINDER;
Pneumatic cylinders (sometimes known as air cylinders) are mechanical
devices which produce force, often in combination with movement, and are
powered by compressed gas (typically air).
To perform their function, pneumatic cylinders impart a force by converting
the potential energy of compressed gas into kinetic energy. This is achieved
by the compressed gas being able to expand, without external energy input,
which itself occurs due to the pressure gradient established by the
compressed gas being at a greater pressure than the atmospheric pressure.
This air expansion forces a piston to move in the desired direction. The
piston is a disc or cylinder, and the piston rod transfers the force it develops
to the object to be moved.
When selecting a pneumatic cylinder, you must pay attention to:

how far the piston extends when activated, known as "stroke"

surface area of the piston face, known as "bore size"

action type

pressure rating, such as "50 PSI"

type of connection to each port, such as "1/4" NPT"

must be rated for compressed air use

mounting method
Types
Although pneumatic cylinders will vary in appearance, size and function,
they generally fall into one of the specific categories shown below. However
there are also numerous other types of pneumatic cylinder available, many
of which are designed to fulfill specific and specialised functions.
Single acting cylinders
Single acting cylinders (SAC) use the pressure imparted by compressed air
to create a driving force in one direction (usually out), and a spring to return
to the "home" position
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 instroke.
Other types
Although SACs and DACs are the most common types of pneumatic
cylinder, the following types are not particularly rare:

Rotary air cylinders: actuators that use air to impart a rotary motion

Rodless air cylinders: These have no piston rod. They are actuators
that use a mechanical or magnetic coupling to impart force, typically
to a table or other body that moves along the length of the cylinder
body, but does not extend beyond it.
Sizes
Air cylinders are available in a variety of sizes and can typically range from
a small 2.5 mm air cylinder, which might be used for picking up a small
transistor or other electronic component, to 400 mm diameter air cylinders
which would impart enough force to lift a car. Some pneumatic cylinders
reach 1000 mm in diameter, and are used in place of hydraulic cylinders for
special circumstances where leaking hydraulic oil could impose an extreme
hazard.
Pressure, radius, area and force relationships
Although the diameter of the piston and the force exerted by a cylinder are
related, they are not directly proportional to one another. Additionally, the
typical mathematical relationship between the two assumes that the air
supply does not become saturated. Due to the effective cross sectional area
reduced by the area of the piston rod, the instroke force is less than the
outstroke force when both are powered pneumatically and by same supply of
compressed gas.
The relationship, between force on outstroke, pressure and radius, is as
follows:
This is derived from the relationship, between force, pressure and effective
cross-sectional area, which is:
F = p A\,
With the same symbolic notation of variables as above, but also A represents
the effective cross sectional area.
On instroke, the same relationship between force exerted, pressure and
effective cross sectional area applies as discussed above for outstroke.
However, since the cross sectional area is less than the piston area the
relationship between force, pressure and radius is different. The calculation
isn't more complicated though, since the effective cross sectional area is
merely that of the piston less that of the piston rod.
For instroke, therefore, the relationship between force exerted, pressure,
radius of the piston, and radius of the piston rod, is as follows:
Where:
F represents the force exerted
r1 represents the radius of the piston
r2 represents the radius of the piston rod
π is pi, approximately equal to 3.14159.
VALVE CONNECTORS;
POLYURETHANE TUBE ; shortly say PUN tube;
Manual operations involving heavy lifting.
Pushing or pulling
motions can be firing for the operations and can induce a monotony which
results in lowered production. Cylinders have been designed to carry out
these movements with a pre – determined force and stroke and can be fitted
to synchronize with operation cycles of many machines it is worth wile to
examine the existing plan and methods of movement and to consider the
numberous mechanical applications which the range of pneumatic cylinders
make possible. Quality is to keynote of air cylinder. Engineer them into
you production setup to get the last ounce of power, speed and efficiency to
save time, space and money.
Piston is cylinder part which moves in a cylinder have corresponding
hole on it. To make the strokes effective there is no gap between them or
with a very tiny gap, part of the micron. The cylinder and its piston have a
glazing surface where there is a contact between them for easy motion of
piston and avoiding wear and tear of both.
The outer side of the cylinder
have mountings consists of plate and studs attached with it. But the of these
mountings, the cylinder and piston assembly can fitted on any place of the
piston have threads on it for fastening the other parts (or) accessories
according the operating performed and the application required. We can fit
holding devices, Clamping materials or other metal cutting and forming
ports with which can be movable with the piston.
Pneumatics are used practically in every industry for a wide variety of
manufacturing process, pneumatics equipments are used for multiple
reasons. The best reason is that it is air powered ordinary air turns out to be
very excellent as a fluid power components.
Solenoid Valve :
In order to automate the air flow in our system we have to provide an
electrically controlled valves. Electrical devices can provide more effective
control, less expensive interlocks having many additional safety features and
simplified automatic sequencing when a machine must operate in a
hazardous area, remote actuation is a desirable. The operator can provide
satisfactory control though electrical devices from a remote point with in a
safe area, uding a semi automatic system and these electrical flow control
devices are also in use in full automation by providing proper action signals.
Push and pull actuation can be priced b solenoids. These movements
are used to open and close the pop pet type valves. These actuations are
done according to the signals given to the solenoid coil when the decided by
the program. The outlet of solenoid coil when the decided by the program,.
The outlet of solenoid valve is connected to a spray gun, which is going to
spray the paint.
PNEUMATIC CIRCUIT
DIAGRAM
PNEUMATIC CIRCUIT DIAGRAM
COST ESTIMATION
COST ESTIMATION
1. Double Acting Cylinder (2x800)-------------- 1600.00
2. Solenoid Valve 5/2 Way (2x1100)------------ 1600.00
3. Valve Connectors (10x50) --------- -----------
300.00
4. M.S Stand With plywood ----------------------
1500.00
5. 5-230V Relay card-------------------------------
300.00
6. Electronic CONTROL CIRCUIT ----------
1800.00
7. Power supply (12V D.C )-----------------------
150.00
8. Tube (5 Meters)----------------------------------
100.00
------------------7350.00
-------------------
CONCLUSION
CONCLUSION
By doing this project
“FABRICATION OF AUTOMATIC
PNEUMATIC CLAMPING AND BENDING MACHINE” we have
gained experience in fabrication and we have gathered practical
experience by welding the structures .
By doing this project we gained the knowledge of pneumatic
system and how automation can be effectively done with the help of
pneumatic system.
It is concluded that any automation system can be done with
the help of pneumatic system.
We have successfully completed the project work on using
pneumatic control at our Institute.
It will be of no doubt that pneumatic system will be an integrated
part of any automation process in any industry.
Once again we express our sincere thanks to our staff
members.
BIBLIOGRAPHY
BIBILOGRAPHY
1. Low cost automation with pneumatics
-
FESTO
2. Electro pneumatics
- FESTO
3. Hydraulics & pneumatics for Power Production -
Harry L – Stewart
4. Basic pneumatics
- FESTO
5. www.google.com
6. Workshop Technology
- Hajra Chowdry
7. Production Technology
-R.S. Khurmi