CHAPTER-1 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.

Need For Automation

utomation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of these sources, pneumatics form an attractive medium for low cost automation. The main advantages of all pneumatic systems are economy and simplicity. utomation plays an important role in mass production. For mass production of the product, the machining operations decide the sequence of machining. The machines designed for producing a particular product are called transfer machines. The components must be moved automatically from the bins to various machines sequentially and the final component can be placed

separately for pac"aging. #aterials can also be repeatedly transferred from the moving conveyors to the wor" place and vice versa. Quality Control and Inspe tion are the most important things in factory design. utomation plays a vital role in mass production of a product, the machining operations decides the sequence of machining. The machines designed for producing a particular product are called transfer machines. $onveyor utomation is a specialized activity for a modern manufacturing concern. It has been estimated that about %&'(&) of the cost production is spent in material transferring activities.

Need !or Con"eyor Automation#

*eduction of labour and material cost *eduction of overall cost Increased production Increased safety To reduce the inspection time *eduction in fatigue Improved personnel comfort

CHAPTER $% &ITERATURE 'UR(E)

PNEU*ATIC'
The word ,pneuma- comes from .ree" 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 wor"ing medium in industry especially the driving and controlling of machines and equipment. /neumatics has for some considerable time between used for carrying out the simplest mechanical tas"s in more recent times has played a more important role in the development of pneumatic technology for automation. /neumatic 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. 0hen 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 "ey part of any facility for supply of compressed air is by means using reciprocating compressor. compressor is a machine that ta"es in air, gas at a certain pressure and delivered the air at a high pressure. $ompressor capacity is the actual quantity of air compressed and delivered and the volume e1pressed is that of the air at inta"e conditions namely at atmosphere pressure and normal ambient temperature.

The compressibility of the air was first investigated by *obert 3oyle in !4%+ and that found that the product of pressure and volume of a particular quantity of gas.

The usual written as /5 6 $ 7or8 /959 6 /+5+

In this equation the pressure is the absolute pressured which for free is about !:.( /si and is of courage capable of maintaining a column of mercury, nearly 2& inches high in an ordinary barometer. ny gas can be used in pneumatic system but air is the mostly used system now a days.

'E&ECTION OF PNEU*ATIC'
#echanization is broadly defined as the replacement of manual effort by mechanical power. /neumatic is an attractive medium for low cost mechanization particularly for sequential 7or8 repetitive operations. #any factories and plants already have a compressed air system, which is capable of providing the power 7or8 energy requirements and the control system 7although equally pneumatic control systems may be economic and can be advantageously applied to other forms of power8. The main advantage of an all pneumatic system are usually economic and simplicity the latter reducing maintenance to a low level. It can also have out standing advantages in terms of safety.

PNEU*ATIC PO+ER
/neumatic systems use pressurized gases to transmit and control power. /neumatic systems typically use air as the fluid medium because air is safe, low cost and readily available.

T,e Ad"anta-es o! Pneumati s#

!. ir used in pneumatic systems can be directly e1hausted bac" in to the surrounding environment and hence the need of special reservoirs and no'lea" system designs are eliminated. +. /neumatic systems are simple and economical. 2. $ontrol of pneumatic systems is easier.

PRODUCTION OF CO*PRE''ED AIR

/neumatic 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. 0hen 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 "ey part of any facility for supply of compressed air is by means using reciprocating compressor. compressor is a machine that ta"es in air, gas at a certain pressure and delivered the air at a high pressure. $ompressor capacity is the actual quantity of air compressed and delivered and the volume e1pressed is that of the air at inta"e conditions namely at atmosphere pressure and normal ambient temperature.

$lean condition of the suction air is one of the factors, which decides the life of a compressor. 0arm and moist suction air will result in increased precipitation of condense from the compressed air. $ompressor may be classified in two general types. !. /ositive displacement compressor. +. Turbo compressor /ositive displacement compressors are most frequently employed for compressed air plant and have proved highly successful and supply air for pneumatic control application. The types of positive compressor !. *eciprocating type compressor +. *otary 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.

RECIPROCATIN. CO*PRE''OR'
3uilt for either stationary 7or8 portable service the reciprocating compressor is by far the most common type. *eciprocating compressors lap be had is sizes from the smallest capacities to deliver more than ;&& m<=min. In single stage compressor, the air pressure may be of % bar machines discharge of pressure is up to !; bars. Discharge pressure in the range of +;& bars can be obtained with high pressure reciprocating compressors that of three > four stages.

Single stage and !+&& stage models are particularly suitable for pneumatic applications , with preference going to the two stage design as soon as the discharge pressure e1ceeds % bar , because it in capable of matching the performance of single stage machine at lower costs per driving powers in the range.

U&TI*ATE AI*
The Automati inspection time of material. ontrol o! produ ts usin- sensor can be widely used

in low cost automation. The manpower requirement is negligible also reducing the

CHAPTER-/ DE'CRIPTION OF CO*PONENT' *A0OR PART'

The ma?or parts @IN'PECTION CON(E)OR1 are described belowA Pneumati sin-le A tin- Cylinder /2% 'in-le A tin- 'olenoid (al"e Flo3 Control (al"e Hose Collar and PU Conne tor Permanent *a-net D4C4 *otor Ele troni Control Unit IR 'ensor Colle tin- Tray Con"eyor 5elt and Roller Frame 'tand Counter

14PNEU*ATIC C)&INDER#n 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.

a6 'in-le a tin- ylinder

Single acting cylinder is only capable of performing an operating medium in only one direction. Single acting cylinders equipped with one inlet for the operating air pressure, can be production in several fundamentally different designs. Single cylinders develop power in one direction only. Therefore no heavy control equipment should be attached to them, which requires to be moved on the
B

piston return sto"e single action cylinder requires only about half the air volume consumed by a double acting for one operating cycle.

76 Dou7le a tin- ylinders#

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 messes. This can only be done at the end positions of the piston stoc". In all intermediate position a separate e1ternally mounted cushioning derive most be provided with the damping feature. The normal escape of air is out off by a cushioning piston before the end of the stoc" is required. s 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 sto"es in the other direction at full force and velocity.

C)&INDER TECHNICA& DATA#

Piston Rod# #.S. hard $hrome plated 'eals# Citrile 73una D C8 Elastomer End Co"ers# $ast iron graded fine grained from +;mm to 2&&mm Piston# - luminium.

*edia# - ir.
4

Temperature Ran-e# &Fc to B;Fc

Parts o! Pneumati Cylinder Piston#

The piston is a cylindrical member of certain length which reciprocates inside the cylinder. The diameter of the piston is slightly less than that of the cylinder bore diameter and it is fitted to the top of the piston rod. It is one of the important parts which convert the pressure energy into mechanical power. The piston is equipped with a ring suitably proportioned and it is relatively soft rubber which is capable of providing good sealing with low friction at the operating pressure. The purpose of piston is to provide means of conveying the pressure of air inside the cylinder to the piston of the oil cylinder. .enerally piston is made up of luminium alloy'light and medium wor".

3rass or bronze or $I'Geavy duty. The piston is single acting spring returned type. The piston moves forward when the high'pressure air is turned from the right side of cylinder. The piston moves bac"ward when the solenoid valve is in HFF condition. The piston should be as strong and rigid as possible. The efficiency and economy of the machine primarily depends on the wor"ing of the piston. It must operate in the cylinder with a minimum of friction and should be able to withstand the high compressor force developed in the cylinder and also the shoc" load during operation.

!&

The piston should posses the following qualities. a. The movement of the piston not creates much noise. b. It should be frictionless. c. It should withstand high pressure.

Piston Rod
The piston rod is circular in cross section. It connects piston with piston of other cylinder. The piston rod is made of mild steel ground and polished. high finish is essential on the outer rod surface to minimize wear on the rod seals. The piston rod is connected to the piston by mechanical fastening. The piston and the piston rod can be separated if necessary. Hne end of the piston rod is connected to the bottom of the piston. The other end of the piston rod is connected to the other piston rod by means of coupling. The piston transmits the wor"ing force to the oil cylinder through the piston rod. The piston rod is designed to withstand the high compressive force. It should avoid bending and withstand shoc" loads caused by the cutting force. The piston moves inside the rod seal fi1ed in the bottom cover plate of the cylinder. The sealing arrangements prevent the lea"age of air from the bottom of the cylinder while the rod reciprocates through it.

Cylinder Co"er Plates

The cylinder should be enclosed to get the applied pressure from the compressor and act on the pinion. The cylinder is thus closed by the cover plates on both the ends such that there is no lea"age of air. hole drilled for the movement of the piston.
!!

n inlet port is provided on

the top cover plate and an outlet ports on the bottom cover plate. There is also a

The cylinder cover plate protects the cylinder from dust and other particle and maintains the same pressure that is ta"en from the compressor. The flange has to hold the piston in both of its e1treme positions. The piston hits the top plat during the return stro"e and hits the bottom plate during end of forward stro"e. So the cover plates must be strong enough to withstand the load.

Cylinder *ountin- Plates#

It is attached to the cylinder cover plates and also to the carriage with the help of ,I- bends and bolts.

.ENERA&&) U'ED *ATERIA&' Cylinder Tu7e *aterials#

&I.HT DUT) !. /lastic +. Gard drawn luminium tube :. Gard drawn 3rass tube

*EDIU* DUT) Gard drawn brass tube luminium $astings

HEA() DUT) hard drawn brass tube. Gard drawn steel tube tube. 3rass, 3ronze, Iron or $astings, welded steel tube

!+

End Co"er *aterials#

&I.HT DUT)

*EDIU* DUT)

HEA() DUT)

!.

luminium stoc" 7Fabricated8

luminium stoc" 7Fabricated8 3rass stoc" 7Fabricated8 luminium, 3rass, iron or steel $astings.

Gard tensile $astings

+. 3rass stoc" 7Fabricated8 2. luminium $astings

Piston *aterials#
&I.HT DUT) *EDIU* DUT) HEA() DUT)

!. luminium $astings +. 2.

luminium $astings 3rass 7Fabricated8 3ronze 7Fabricated8 Iron and Steel $astings

luminium Forgings, luminium $astings. 3ronze 7Fabricated8 3rass, 3ronze, Iron or Steel $astings.

*ount *aterials#
&I.HT DUT) *EDIU* DUT)
!2

HEA() DUT)

!.

luminium

luminium, 3rass nd Steel $astings

Gigh Tensile Steel $astings Gigh Tensile Steel Fabrication

$astings +. Iight lloy 7Fabricated8

Piston Rod *aterials#

*ATERIA& #IID STEEI ST ICIESS STEEI FINI'H RE*AR8' .round and polished hardened, .enerally preferred chrome ground and polished. .round and /olished plated Iess scratch resistant than chrome plated piston rod

%4 'IN.&E ACTIN. /2% 'O&ENOID (A&(E#The directional valve is one of the important parts of a pneumatic system. $ommonly "nown as D$5, 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. 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 in 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.
!:

The name of the parts of the solenoid should be learned so that they can be recognized when called upon to ma"e repairs, to do service wor" or to install them.

Parts o! a /2% 'olenoid (al"e 14 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. $oils are rated in various voltages such as !!; volts $, +2& volts $, :%& volts $, ;(; 5olts $, % 5olts D$, !+ 5olts D$, +: 5olts D$, !!; 5olts D$ > +2& 5olts D$. They are designed for such frequencies as ;& Gz to %& Gz.

%4 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. The wear strips are mounted to the solenoid frame, and are made of materials such as metal or impregnated less fiber cloth.

/4 'olenoid Plun-er
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. t the top of the plunger a pin hole is placed for ma"ing 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 e1plosion proof solenoids.

+or9in- o! 'olenoid (al"e#

The Solenoid 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 pro?ect 2=+ Single acting solenoid valve is used. This solenoid valve is used to push the dimensionless materials into the collecting tray which is placed bellow the conveyor.

Fi- 1

:4 F&O+ CONTRO& (A&(E#

!%

In any fluid power circuit, flow control valve is used to control the speed of the actuator. The floe control can be achieved by varying the area of flow through which the air in passing. 0hen 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.

;4HO'E CO&&AR AND PU CONNECTOR#In our pneumatic system there are two types of connectors usedJ one is the hose connector and the other is the reducer. Gose connectors normally comprise an adapter 7connector8 hose nipple and cap nut. connectors are made up of brass or l or hardened steel. *educers are used to provide inter connection between two pipes or hoses of different sizes. They may be fitted straight, tee, @5K or other configurations. These reducers are made up of gunmetal or other materials li"e hardened steel etc. Goses used in this pneumatic system are made up of polyurethane. These hoses can with stand at a ma1imum pressure level of !& "g=cm+. These types of

<4D4C4 *OTOR =PER*ANENT *A.NET6# DE'CRIPTION OF DC *OTOR

n electric motor is a machine which converts electrical energy to mechanical energy. Its action is based on the principle that when a current' carrying conductor is placed in a magnetic field, it e1periences a magnetic force whose direction is given by Fleming-s left hand rule.

!(

0hen a motor is in operation, it develops torque. This torque can produce mechanical rotation. D$ motors are also li"e generators classified into shunt wound or series wound or compound wound motors.

F&E*IN.>' &EFT HAND RU&E#

Leep the force finger, middle finger and thumb of the left hand mutually perpendicular to one another. If the fore finger indicates the direction of magnetic field and middle finger indicates direction of current in the conductor, then the thumb indicates the direction of the motion of conductor.

PRINCIP&E OF OPERATION OF DC *OTOR#

Figure show a uniform magnetic field in which a straight conductor carrying no current is placed. The conductor is perpendicular to the direction of the magnetic field. The conductor is as carrying a current away from the viewer, but the field due to the C and S poles has been removed. There is no movement of the conductor during the above two conditions. The current carrying conductor is placed in the magnetic field. The field due to the current in the conductor supports the main field above the conductor, but opposes the main field below the conductor.

$onductor

'

!B

*a-neti !lu? Fi-4%

urrent arryinCondu tor

The result is to increase the flu1 density in to the region directly above the conductor and to reduce the flu1 density in the region directly below the conductor. It is found that a force acts on the conductor, trying to push the conductor downwards as shown by the arrow. If the current in the conductor is reversed, the strengthening of flu1 lines occurs below the conductor, and the conductor will be pushed upwards. Cow consider a single turn coil carrying a current as shown in the above figure. in view of the reasons given above, the coil side forces acting on the coil sides will be forced to move downwards, whereas the coil side 3 will be forced to move upwards. The and 3 will be of same magnitude. 3ut their s the coil is wound on the armature core direction is opposite to one another.

which is supported by the bearings, the armature will now rotate. The commutator periodically reverses the direction of current flow through the armature. Therefore the armature will have a continuous rotation. The conductors are wound over a soft iron core. D$ supply is given to the field poles for producing flu1. The conductors are connected to the D$ supply through brushes. Iet-s start by loo"ing at the overall plan of a simple +' pole D$ electric motor. below.

simple motor has % parts, as shown in the diagram

n armature or rotor commutator

!4

3rushes n a1le field magnet D$ power supply of some sort

Fi-4/ n electric motor is all about magnets and magnetismA a motor uses magnets to create motion. If you have ever played with magnets you "now about the fundamental law of all magnetsA Hpposites attract and li"es repel. So if you have + bar magnets with their ends mar"ed north and south, then the Corth end of one magnet will attract the South end of the other. Hn the other hand, the Corth end of one magnet will repel the Corth end of the other 7and similarly south will repel south8. Inside an electric motor these attracting and repelling forces create rotational motion. In the diagram above and below you can see two magnets in the motor, the armature 7or rotor8 is an electromagnet, while the field magnet is a permanent

+&

magnet 7the field magnet could be an electromagnet as well, but in most small motors it is not to save power8.

Ele troma-nets and *otors#

To understand how an electric motor wor"s, the "ey is to understand how the electromagnet wor"s. n electromagnet is the basis of an electric motor. Mou can understand how things wor" in the motor by imagining the following scenario. Say that you created a simple electromagnet by wrapping !&& loops of wire around a nail and connecting it to a battery. The nail would become a magnet and have a Corth and South /ole while the battery is connected. Cow say that you ta"e your nail electromagnet, run an a1le through the middle of it, and you suspended it in the middle of a horseshoe magnet as shown in the figure below. If you were to attach a battery to the electromagnet so that the Corth end of the nail appeared as shown, the basic law of magnetism tells you what would happenA The Corth end of the electromagnet would be repelled from the north end of the horseshoe magnet and attracted to the south end of the horseshoe magnet. The South end of the electromagnet would be repelled in a similar way. The nail would move about half a turn and then stop in the position shown. Mou can see that this half'turn of motion is simple and obvious because of the way magnets naturally attract and repel one another. The "ey to an electric motor is to then go one step further so that, at the moment that this half'turn of motion completes, the field of the electromagnet flips. The flip causes the electromagnet to complete another half'turn of motion.

+!

Mou flip the magnetic field simply by changing the direction of the electrons flowing in the wire 7you do that by flipping the battery over8. If the field of the electromagnet flipped at ?ust the right moment at the end of each half'turn of motion, the electric motor would spin freely.

Fi-:

T,e Armature#
The armature ta"es the place of the nail in an electric motor. The armature is an electromagnet made by coiling thin wire around two or more poles of a metal core. The armature has an a1le, and the commutator is attached to the a1le. In the diagram above you can see three different views of the same armatureA front, side and end'on. In the end'on view the winding is eliminated to ma"e the commutator more obvious. Mou can see that the commutator is simply a pair of plates attached to the a1le. These plates provide the two connections for the coil of the electromagnet.

T,e Commutator and 7rus,es#

++

The Nflipping the electric fieldN part of an electric motor is accomplished by two partsA the ommutator and the 7rus,es. The diagram at the right shows how the commutator and brushes wor" together to let current flow to the electromagnet, and also to flip the direction that the electrons are flowing at ?ust the right moment. The contacts of the commutator are attached to the a1le of the electromagnet, so they spin with the magnet. The brushes are ?ust two pieces of springy metal or carbon that ma"e contact with the contacts of the commutator.

Puttin- It All To-et,er#

Fi-4;

+2

0hen you put all of these parts together, what you have is a complete electric motorA In this figure, the armature winding has been left out so that it is easier to see the commutator in action. The "ey thing to notice is that as the armature passes through the horizontal position, the poles of the electromagnet flip. 3ecause of the flip, the Corth /ole of the electromagnet is always above the a1le so it can repel the field magnetOs Corth /ole and attract the field magnetOs South /ole. If you ever ta"e apart an electric motor you will find that it contains the same pieces described aboveA two small permanent magnets, a commutator, two brushes and an electromagnet made by winding wire around a piece of metal. lmost always, however, the rotor will have three poles rather than the two poles as shown in this article. There are two good reasons for a motor to have three polesA It causes the motor to have better dynamics. In a two'pole motor, if the electromagnet is at the balance point, perfectly horizontal between the two poles of the field magnet when the motor startsJ you can imagine the armature getting Nstuc"N there. That never happens in a three'pole motor. Each time the commutator hits the point where it flips the field in a two'pole motor, the commutator shorts out the battery 7directly connects the positive and negative terminals8 for a moment. This shorting wastes energy and drains the battery needlessly. well. It is possible to have any number of poles, depending on the size of the motor and the specific application it is being used in. three'pole motor solves this problem as

+:

CHAPTER-: DE'I.N AND DRA+IN.' PNEU*ATIC C)&INDER# Desi-n o! Piston rod#

Ioad due to air /ressure. Diameter of the /iston 7d8 6 /ressure acting 7p8 #aterial used for rod Mield stress 7y8
+;

2; mm % "gf=cm $ :; 2% "gf=mm

6 6 6

ssuming factor of safety 6 Force acting on the rod 7/8 6 6 /6 Design Stress7y8 6 6 6 d 6 6 6 0e assume diameter of the rod 6

+ /ressure 1 rea p 1 7d = :8 % 1 P7 1 2.; ) = : Q ;(.(2 Lgf y = F& S 2% = + 6 B Lgf=mm / = 7 d = : 8 : p = R y S : 1 ;(.(2 = P 1 !BQ 4.02 6 6 6 +.&+ mm

#inimum diameter of rod required for the load

+.&+ mm

!+.; mm

Desi-n o! ylinder t,i 9ness

#aterial used ssuming internal diameter of the cylinder Tltimate tensile stress 0or"ing Stress safety ssuming factor of safety 0or"ing stress 7 ft 8 ccording to ,I #ES EUT TIHC#inimum thic"ness of cylinder 7 t 8 0here, ri 6inner radius of cylinder in cm.
+%

6 6 6 6 6 6 6

$ast iron 2; mm

+;& C=mm 6 +;&& gf=mm Tltimate tensile stress = factor of : +;&& = :6 %+; Lgf=cm ri P 7ft V p8 = 7ft D p 8 '! Q

ft 60or"ing stress 7Lgf=cm8 p 60or"ing pressure in Lgf=cm Substituting values we get, t 6 !.(; P (625+1)/(625-1)-1} t6 &.&!%B cm 6 &.!( mm

0e assume thic"ness of cylinder6 +.; mm Inner diameter of barrel6 2; mm Huter diameter of barrel6 2; V +t 6 2; V 7 + 1 +.; 86 :& mm

Desi-n o! Piston rod# Diameter o! Piston Rod#

Force of piston *od 7/8 6 /ressure 1 area 6 p 1 /4 7d8 6 % 1 7 = :8 1 72.;8 6 ;(.(2 Lgf lso, force on piston rod 7/8 6 7=:8 7dp8 1 ft / 6 7W=:8 1 7dp8 1 %+; ;(.(2 6 7W=:8 1 7dp8 1 %+; dp 6 ;(.(2 1 7:=W8 1 7!=%+;8 6 &.!+ dp 6 &.2: cm 6 2.: mm 3y standardizing dp 6 !+.; mm

+(

&en-t, o! piston rod#

pproach stro"e Iength of threads E1tra length due to front cover E1tra length of accommodate head Total length of the piston rod 3y standardizing, length of the piston rod 6 ;& mm 6 + 1 +& 6 :&mm 6 !+ mm 6 +& mm 6 ;& V :& V !+ V +& 6 !++ mm 6 !2& mm

'PECIFICATION 14 'in-le a tin- pneumati ylinder Te ,ni al Data

Stro"e length Uuantity Seals End cones /iston #edia Temperature /ressure *ange A A A A A A A A $ylinder sto"er length ;& mm ! Citride 73una'C8 Elastomer $ast iron EC D B ir &'B& X $ B C=mY

%4 'olenoid (al"e Te ,ni al data

+B

#a1 pressure range Uuantity A

A 2

&'!& 1 !& C=mY

/4 Flo3 ontrol (al"e Te ,ni al Data

/ort size /ressure #edia Uuantity A A A A ! &.%2; 1 !& Z Ym &'B 1 !& C=mY ir

:4 Conne tors Te ,ni al data

#a1 wor"ing pressure Temperature Fluid media #aterial A A A A !& 1 !& C=mY &'!&& X $ ir 3rass

;4 Hoses Te ,ni al data

#a1 pressure Huter diameter Inner diameter A A A !& 1 !& C=mY % mm 6 % 1 !& [ <m 2.; mm 6 2.; 1 !& [ <m

+4

Fi-<

Fi-4@

2&

Fi-4A

Fi-4B

Fi-41C

2!

Fi-411

2+

CHAPTER-; FA5RICATION *et,od o! Fa7ri ation#

The two conveyor roller is fi1ed to the two ends of the frame stand with the help of end bearing 7%+&+8 with bearing cap. The conveyor roller shaft is coupled to the D.$. permanent magnet motor with the help of spur gear mechanism. This total arrangement is used to transfer the material from one place to another place with the help of conveyor. The I* transmitter and I* receiver circuit is used to sense the length of the material. It is fi1ed to the frame stand with a suitable arrangement. The pneumatic cylinder is fi1ed to the frame stand by right angles to the limit sensor frame stand. This cylinder arrangement is used to remove the dimensionless material from the conveyor. The pneumatic cylinder is controlled by the flow control valve, single acting solenoid valve and control unit.

22

CHAPTER-< +OR8IN. OPERATION

The !+ volt power supply is used to drive the permanent magnet D.$ motor. The two conveyor roller is fi1ed to the two ends of the frame stand with the help of end bearing 7%+&+8 with bearing cap. The conveyor roller shaft is coupled to the D.$. permanent magnet motor with the help of spur gear mechanism. This total arrangement is used to transfer the material from one place to another place with the help of conveyor. The limit sensor switch is vertically fi1ed on the limit sensor frame stand by means of rac" and pinion arrangement. This sensor is used to measuring the abnormal height variation of the material. The rac" and pinion is used to ad?ust the limit switch up and down motion. This arrangement is used to set the height of the material. The I* transmitter and I* receiver circuit is used to sense the minute height variation of the material. It is fi1ed to the frame stand with a suitable arrangement. This mechanism is also ad?ustable with the help of bolt and nut. The pneumatic cylinder is fi1ed to the frame stand by right angles to the limit sensor frame stand. This cylinder arrangement is used to remove the dimensionless material from the conveyor. The pneumatic cylinder is controlled by the flow control valve, single acting solenoid valve and control unit.

2:

IR TRAN'*ITTER CIRCUIT#

D( R: =:@6 T1 =5D1:C6 / 1 1;C8 1 A @

% C/ =1CC2%;(6 R% =:@6 R; &1 :4@ IR &ED

% /

R1 14;8

IC ;;;
< : ; C% C4C1pF

C1 C41pF

Fi-41%

2;

AT NOR*A& CONDITION#
The I* transmitter sensor is transmitting the infrared rays with the help of ;;; I$ timer circuit. These infrared rays are received by the I* receiver sensor. The Transistor T!, T+ and T2 are used as an amplifier section. t normal condition Transistor T; is HFF condition. valve is in HFF condition. t that time relay is HFF, so that the solenoid

AT A5NOR*A& CONDITION#
t abnormal dimension conditions the I* transmitter and I* receiver, the resistance across the Transmitter and receiver is high due to the non'conductivity of the I* waves. So the output of transistor T; goes from HFF condition to HC stage. The relay is HC to the 2=+ solenoid valve, so that the air from the compressor is goes to the pneumatic cylinder. The dimensionless material is pushed to the collecting tray by the pneumatic cylinder.

2%

PO+ER 'UPP&) CIRCUIT#

18EF+ P D %/C ( AC 'UPP&) B( D C B( N D D 1CCC HF C-1; ( DG

DGE D E D E D - IN :CC@

Fi-41/

FI&TER'
The out voltage is essentially constant. 0e filter the pulsating voltage by using *$ filter. The capacitor is made sufficiently large to present very low impedance to the ripple frequency and infinite impedance to D$ prefers. The shunt path through $ and the steady current 7ID$8 is forced through * developing a D$ voltage drop across it. The ripples are reduced by *>$.

2(

(O&TA.E RE.U&ATOR =IC @A?? 'ERIE'6

The series (B regulators provide fi1ed regulated from ; to +:5. n

unregulated input voltage 5i is filtered by capacitor $! and connected to the I$-s IC terminal. The I$-s HTT terminal provides a regulated V!+5 which is filtered by capacitor $+. The third I$ terminal is connected to ground. 0hile the input voltage may very over some permissible voltage range, and the output load may vary over some acceptable range, the output voltage remains constant within specified voltage variation limits. The (B!+ I$ then provides an output is a regulated V!+5 D$.

(O&TA.E RE.U&ATOR =IC @AII 'ERIE'6

+
FRO* =C-1;(6 RECTIFIER CG :@C mF

IN

OUT

2
C C4C1 mF

+
( J D 1% (

IC @A1%
.ND

3
' '

Fi-41:

2B

CHAPTER-@ AD(ANTA.E' AND &I*ITATION' AD(ANTA.E'

The Inspection $onveyor is more efficient in the technical field Uuic" response is achieved Simple in construction Easy to maintain and repair $ost of the unit is less when compared to other Co fire hazard problem due to over loading $omparatively the operation cost is less $ontinuous operation is possible without stopping

&I*ITATION'

0hile wor"ing, the compressed air 7For /unching Hperation8 produces noise therefore a silencer may be used.

24

CHAPTER-A APP&ICATION'

Dis ,ar-e o! 3or9 pie e#The $onveyor Feed has a wide application in low cost automation industries. It can be used in automated assembly lines to carry up the finished product from wor"station and place them in bins. It can also be used to pic" raw material and place them on the conveyor belts.

Improper *aterial Remo"in- operation#This unit can also be used in improper material collected in a

collecting bo1. The solenoid operated pneumatic cylinder is used for this mechanism.

:&

CHAPTER-B &I'T OF *ATERIA&'

'4 No4
! + 2 : ; % ( B 4 !& !! !+ !2 !: !; !% !(

Des ription
Single cting pneumatic cylinder Single cting 2=+ Solenoid 5alve Flow control 5alve *ac" and /inion Iimit Sensor Frame stand Iimit Sensor /T Tubes Gose $ollar *educer Frame stand Sensor with control Tnit $onveyor *oller $onveyor 3elt 3earing 7%+&+8 3earing 7%+&;8 3earing $ap Shaft

Qty
! ! ! ! ! ! ; meter B + ! ! + ! : + % 2

*aterial
luminium luminium luminium $.I #.S ' /olyurethene 3rass 3rass #.S ' #.S *e"chin Steel Steel #.S #.S

CHAPTER-1C CO'T E'TI*ATION 14 *ATERIA& CO'T#'4 No4

! + 2 : ; % ( B 4

Des ription
Single cting pneumatic cylinder Single cting 2=+ Solenoid 5alve Flow control 5alve *ac" and /inion Iimit Sensor Frame stand Iimit Sensor /T Tubes Gose $ollar Frame stand
:!

Qty
! ! ! ! ! ! ; meter B !

*aterial
luminium luminium luminium $.I #.S ' /olyurethene 3rass #.S

Cost =Rs6
!:&& 2!& :&& +%&& :&& !2&& !;& +(& ;&&

!& !! !+ !2 !: !; !%

Sensor with control Tnit $onveyor *oller $onveyor 3elt 3earing 7%+&+8 3earing 7%+&;8 3earing $ap Shaft

! + ! : + % 2

' #.S *e"chin Steel Steel #.S #.S

+:&& +;& !+& ;& ;& ;& :;&&

TOTA& J 1:@;C

%4 &A5OUR CO'T
I TGE, D*IIIIC., 0EIDIC., .*ICDIC., /H0E* G $LS 0, . S $TTTIC.A $ost 6 B&&

/4 O(ERHEAD CHAR.E'
The overhead charges are arrived by @#anufacturing costK #anufacturing $ost 6 #aterial $ost V Iabour cost

6 !:(;& VB&& 6 !;;;& Hverhead $harges 6 +&) of the manufacturing cost 6 2!!&

TOTA& CO'T
Total cost 6 #aterial $ost V Iabour cost V Hverhead $harges 6 !:(;& VB&& V2!!&
:+

6 !B%%& Total cost for this pro?ect 6*s.!B%%&

CHAPTER-11 CONC&U'ION
This pro?ect wor" has provided us an e1cellent opportunity and e1perience, to use our limited "nowledge. 0e gained a lot of practical "nowledge regarding, planning, purchasing, assembling and machining while doing this pro?ect wor". 0e feel that the pro?ect wor" is a good solution to bridge the gates between institution and industries. 0e are proud that we have completed the wor" with the limited time successfully. The @IN'PECTION CON(E)OR1 is wor"ing with satisfactory conditions. 0e are able to understand the difficulties in maintaining the tolerances and also quality. 0e have done to our ability and s"ill ma"ing ma1imum use of available facilities. In conclusion remar"s of our pro?ect wor", let us add a few more lines about our impression pro?ect wor". Thus we have developed an @IN'PECTION CON(E)OR which helps to "now how to achieve low cost automation with sensor arrangement. The operating
:2

procedure of this system is very simple, so any person can operate. 3y using more techniques, they can be modified and developed according to the applications.

REFERENCE'

Catalogue of Janatics pneumatic product, \anatics /rivate Iimited $oimbatore. Design data book Dcompiled by faculty of mechanical engineering /.S... college of technology,$oimbatore Festo Didactic L. D Fundamentals of control technology, Esslingen'!44B. Festo Pneumatic Catlogue ' Festo /vt Itd. D 3angalore. 0erner Deppert=Lurt Stoll., Cutting Cost With Pneumatics, 5ogel 3uchverlag 0urzburg, !44B.

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