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Abstract

PNEUMATIC THREE AXIS TRAILER is nothing but one of the


Lifting system in automobile at the time of emergency. In this
Lifting system pneumatically operated one. Here the additional
pneumatic cylinder and Control Valve is provided in the
automobile itself.
In
this
project,
the
Control
Valve
is
used
to
activate/deactivate the Air input. The Valve is ON at the time of
emergency; the compressed air goes to the pneumatic cylinder.
Then the compressed air passes through the tube, and then
pushes the pneumatic cylinder, so that the Lifting is applied at the
time of Valve in ON position (i.e.-Emergency time).
The speed of the pneumatic cylinder is varied by using flow
control valve. This is the way of controlling Lifting speed of the
Trailer at the time of emergency. In our project, we have to apply
this Pneumatic Modern Trailer Mechanism in Load Lifting Vehicles.

1. INTRODUCTION
Automation can be achieved through computers, hydraulics,
hydraulics, robotics, etc., of these sources, hydraulics form an
attractive medium. Automation plays an important role in
automobile. Nowadays almost all the automobile vehicle is being
atomized in order to product the human being. The automobile
vehicle is being atomized for the following reasons:
To achieve high safety

To reduce man power

To increase the efficiency of the vehicle

To reduce the work load

To reduce the fatigue of workers

To high responsibility

Less Maintenance cost

2.1 PNEUMATICS:
Pneumatics is something that you probably know very little about
yet come across every day without even realising it. Some
examples of everyday pneumatic systems are shown below. How
many do you recognise?

Figure 1
Pneumatics is also used a lot in industry and you would expect to see pneumatic systems in
factories, production lines and processing plants. It can be used to do lots of different jobs such
as moving, holding or shaping objects.

MOVE

HOLD

FORM

PROCESS

Figure 2

Every one of these pneumatic systems makes use of compressed air. Compressed air is quite
simply the air that we breathe forced or squashed into a smaller space. We can use the energy
stored in this compressed air to do things.
To understand how compressed air is able to do things, lets think of a ball. If we blow up the
ball so that it is full, it will contain a lot of compressed air. If we bounce the ball, it will bounce
very high. However, if the ball is burst then the compressed air will escape and the ball will not
bounce as high. Quite simply, the ball bounces because it is using the energy stored in the
compressed air.

Figure 3
Basically, all pneumatic systems make use of compressed air to do work. We can show this in a
systems diagram.

Compressed
air

Pneumatic
system

Figure 4

Work

ADVANTAGES OF PNEUMATICS
There are usually lots of different ways to carry out a task, so it is important to understand some
of the reasons for choosing pneumatic systems.
Clean
Pneumatic systems are clean because they use compressed air. We know already that this is just
the air we breathe forced into small spaces. If a pneumatic system develops a leak, it will be air
that escapes and not oil. This air will not drip or cause a mess and this makes pneumatics suitable
for food production lines.
Safe
Pneumatic systems are very safe compared to other systems. We cannot, for example, use
electronics for paint spraying because many electronic components produce sparks and this could
cause the paint to catch fire.
It is important, however, that we look after and maintain the different components. It is also
important that we follow the correct safety rules.
Reliable
Pneumatic systems are very reliable and can keep working for a long time. Many companies
invest in pneumatics because they know they will not have a lot of breakdowns and that the
equipment will last for a long time.
Economical
If we compare pneumatic systems to other systems, we find that they are cheaper to run. This is
because the components last for a long time and because we are using compressed air. Many
factories already have compressed air for other reasons.
Flexible
Once you have bought the basic components, you can set them up to carry out different tasks.
Pneumatic systems are easy to install and they do not need to be insulated or protected like
electronic systems.
Assignment 1
1. Give three examples of the everyday use of pneumatics.
2. Choose one of your examples from question 1. Draw a system diagram and describe how it
makes use of compressed air.
3. What is compressed air?
4. Think about blowing up a balloon. What happens to the balloon if you let it go? Why does
this happen?
5. Give two reasons why pneumatic systems are used in industry.

SUPPLYING COMPRESSED AIR


We know already that pneumatic systems need compressed air to make them work. A bicycle
pump can produce compressed air. This is all right for inflating the tyres on your bicycle, but can
you imagine trying to blow up all the tyres on a lorry using this? You would soon become tired,
exhausted even.
In order to supply pneumatic systems with compressed air we use a machine called a compressor.
Compressors come in lots of different shapes and sizes but they all work in the same way.

Figure 5
A pump that is driven by a motor, sucks in air from the room and stores it in a tank called the
receiver. You will be able to hear the compressor when it is running. Sometimes though, it will
stop because the receiver is full.
Ask your teacher to see the compressor that will be supplying your compressed air.
Not everyone in your class could connect directly to the compressor, as this is not practical.
Instead, a pipe takes the compressed air from the receiver to various points around the room. We
would normally connect a device called a manifold to these points. The manifold lets us connect
lots of components to the compressed air. It also lets us switch our circuits on and off.
ON

OFF

Figure 6

ACTUATORS
There are a number of different ways that we can operate a 3/2 valve. The most common way is
by using a push button. By pressing the button, the valve changes to the actuated state and allows
main air to flow through to other components. If we release the button, a spring inside returns the
valve to its off state. The symbol for a push button, spring return 3/2 valve is shown below.

Figure 19
Below is a list of the most common types of actuators. They are always drawn onto the standard
symbol for the 3/2 valve.

PLUNGER

ROLLER
TRIP

PUSH
BUTTON

SOLENOID

LEVER

DIAPHRAGM

ROLLER

FOOT
PEDAL

PILOT AIR

SPRING

Figure 20

SIMPLE CIRCUITS USING SINGLE-ACTING CYLINDERS


A city-centre car park has a barrier system to prevent people parking illegally. The car park
attendant checks all the cars entering and leaving the car park. The barrier is raised and lowered
by a single-acting cylinder. The attendant pushes a button to operate the system.

Figure 21
The systems diagram is shown below.
Press
button

3/2 Valve

Cylinder

Figure 22
The pneumatic circuit is shown below.

Figure 23

Barrier
raises

When the button is pressed, the valve changes state and supplies air to the single-acting cylinder.
This causes the piston to outstroke with enough force to raise the barrier.

10

Figure 24
When the button is released, the valve returns to its original state and the piston is able to
instroke ready for the process to begin again.
(a)
(b)
(c)
(d)
(e)

ASSIGNMENT 3
Build the circuit for raising and lowering the car park barrier.
Press the button on the valve and keep it pressed. Explain what happens.
Release the button and explain what happens.
Using the correct terminology, explain how the circuit operates to raise and lower the barrier.
Sometimes the attendant needs to inform the drivers of where to park, especially when it is
very busy. The problem is that when he lets go of the button, the barrier begins to fall.
Someone suggests changing the actuator on the 3/2 valve. What actuator could be used
instead and how does this affect the way the circuit works?

T-PIECE
A T-piece or T-connector is a very simple component that lets us split or divide airflow. It can be
very useful if you want two cylinders to operate at the same time.
AIR OUT

AIR OUT

AIR IN

Figure 25
On circuit diagrams, the T-piece is identified by a dot.
T-piece

11

Figure 26

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Assignment 4
1. A delivery lorry uses a pneumatic braking system. The brakes operate when the driver
presses the foot brake. Two single-acting cylinders should outstroke at the same time and
press against the wheels. The pneumatic circuit is shown below.

Figure 27
(a) Build and test the circuit shown. (You can use a push button, spring return 3/2 valve instead
of a foot pedal.)
(b) Explain the purpose of the T-piece.
2. Four single-acting cylinders are used to clamp large nameplates to a table to allow them to be
engraved. All four cylinders must operate at the same time.
A IR S U P P L Y

Figure 28
(a) Design a pneumatic system to solve this problem.
(b) Build and test your solution.
(c) Explain your choice of actuator.

13

SIMPLE CIRCUITS USING DOUBLE-ACTING CYLINDERS


We know already that double-acting cylinders do not have a spring inside to return them to their
original position. This means that we need to use compressed air to outstroke and instroke the
piston. One way to do this is to connect a 3/2 valve to either side of the double-acting cylinder.
Remember our car park problem. Someone has suggested changing the single-acting cylinder to
a double-acting one.

Figure 29
The pneumatic circuit would now look like this.

Valve A

Valve B

Figure 30
When the attendant actuates valve A by pressing the button, the double-acting cylinder outstrokes
and lifts the barrier. It stays in this position until valve B is actuated. This allows the piston to
instroke and the barrier is lowered.

14

Assignment 5
(a) Build the circuit shown above for raising and lowering the barrier.
(b) Press the button on valve A to outstroke the cylinder. Does the piston instroke when you
release the button?
(c) Press the button on valve B. What happens to the cylinder?
(d) What happens when you press both buttons at the same time?
(e) Actuate valve A again and then try pushing against the piston. Why is it so easy to move?
(f) What type of problems could this cause in this particular circuit?

15

5/2 valves
There are many problems when controlling a double-acting cylinder with two 3/2 valves. You
should have discovered from the last circuit that it is easy to push or pull the piston. This is
because you do not have a constant supply of air to keep the piston in place. When you actuate
the 3/2 valve, it outstrokes the piston. When the 3/2 valve is not actuated, air is free to escape or
exhaust back through the valve. This means that any force or effort placed on the piston will
make it move easily.

Figure 31
A further disadvantage is that the 3/2 valve needs to be actuated until the double-acting cylinder
has fully outstroked or instroked. Releasing the valve before the stroke is complete will mean the
piston will stop short of its final position.
We have greater control over a double-acting cylinder if we control its outstroke and instroke
using a 5/2 valve. This valve has five ports and two states of operation. The ports are always
numbered in the same way.
Port 1 main air
This port is connected to main air just like a 3/2 valve.
Port 2 output connection
This port is usually connected to instroke a double-acting cylinder.
Port 3 exhaust
This port allows air trapped in the double-acting cylinder to escape. Remember, for the cylinder
to instroke and outstroke, air on the other side of the piston must be allowed to escape. If this did
not happen, the piston would not move.
Port 4 output connection
This port is usually connected to outstroke a double-acting cylinder.
Port 5 exhaust
Again, this port lets the air on the other side of the piston escape.
16

A 5/2 valve has two states of operation. One state supplies air to outstroke a double-acting
cylinder and the other state will cause it to instroke.

17

STATE 1 INSTROKE
In this state, the main air flows through the valve from port 1 to port 2. Any air within the
cylinder is able to exhaust through the valve from port 4 to port 5. In this state, a 5/2 valve will
cause a double-acting cylinder to instroke or hold the piston in the negative position. This means
that air is always being supplied to the cylinder.
Study the symbol below and ensure that you understand how the air flows through the valve.
AIR FROM
CYLINDER

AIR TO
CYLINDER

Figure 32
State 2 outstroke
In this state, the main air flows through the valve from port 1 to port 4. Any air on the other side
of the piston is able to exhaust through the valve from port 2 to port 3. In this state, a 5/2 valve
will cause a double-acting cylinder to outstroke and will hold it in the positive position.
Study the symbol below and ensure that you understand how the air flows through the valve.
AIR TO
CYLINDER

AIR FROM
CYLINDER

Figure 33
The complete symbol for a 5/2 valve is shown. The cylinder, main air and exhaust lines are only
ever drawn on one half of the symbol, depending on which part is active in the circuit. It is usual,
however, to draw the symbol so that it would hold a double-acting cylinder in the negative
position.
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Figure 34
Pilot air
5/2 valves can be operated or actuated in the same way as 3/2 valves. However, the most
common way of actuating a 5/2 valve is by pilot air. A pilot air 5/2 valve will change state when
a brief air signal acts at either end of the valve. This signal is most often supplied from a 3/2
valve. In the example shown below, the button on valve A only needs to be pressed for a moment
in order to change the state of the 5/2 valve. The 5/2 valve supplies the double-acting cylinder
with air to make it outstroke.

Valve A

Figure 35
Notice that the pilot airlines to the 5/2 valve are drawn as broken or dashed lines to distinguish
them from the other air lines in the circuit.

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Assignment 6
1. Our car park barrier is gradually improving. The circuit has been changed to look like the one
shown in figure 35.
(a) Build and test the circuit.
(b) Produce a list of all the components used.
(c) Describe how the circuit works.
(d) A door entry system is controlled by pneumatics. The system makes use of a double-acting
cylinder. Part of the circuit diagram is shown below.

Figure 36
2.
(a) Name each of the components A, B and C.
(b) Complete the diagram so that the door will open and close.
(c) Describe how the circuit operates.

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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 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.
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The usual written as


PV = C

(or) PV = 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.
2.2 SELECTION OF PNEUMATICS:
Mechanization is broadly defined as the replacement of
manual effort by mechanical power. Pneumatic is an attractive
medium for low cost mechanization 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 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.
2.3 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. When pneumatic
system is being adopted for the first time, however it wills indeed
the necessary to deal with the question of compressed air supply.
22

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.

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. Compressor may be classified in two
general types:
1. Positive displacement compressor.
2. Turbo compressor
Positive 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
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.
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2.4 RECIPROCATING COMPRESSORS:


Built for either stationary (or) portable service the
reciprocating compressor is by far the most common type.
Reciprocating compressors lap be had is sizes from the smallest
capacities to deliver more than 500 m/min. In single stage
compressor, the air pressure may be of 6 bar machines discharge
of pressure is up to 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 preference 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 .
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material
are discussed below.
3.1 Properties:
The material selected must posses the necessary properties
for the proposed application. The various requirements to be
satisfied can be weight, surface finish, rigidity, ability to withstand
environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials
decisively affect their selection
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a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point,
Thermal Conductivity, Specific heat, coefficient of thermal
expansion, specific gravity, electrical Conductivity, Magnetic
purposes etc.
The various Mechanical properties Concerned are strength in
tensile, compressive shear, bending, tensional and buckling load,
fatigue resistance, impact resistance, elastic limit, endurance
limit, and modulus of elasticity, hardness, wear resistance and
sliding properties.
3.2 Manufacturing Case:
Sometimes the demand for lowest possible manufacturing
cost or surface qualities obtainable by the application of suitable
coating substances may demand the use of special materials.
3.3 Quality Required:
This generally affects the manufacturing process and
ultimately the material. For example, it would never be desirable
to go for casting of a less number of components which can be
fabricated much more economically by welding or hand forging
the steel.
3.4 Availability of Material:
25

Some materials may be scarce or in short supply. It then


becomes obligatory for the designer to use some other material
which though may not be a perfect substitute for the material
designed.
The delivery of materials and the delivery date of product
should also be kept in mind.
3.5 Space Consideration:
Sometimes high strength materials have to be selected
because the forces involved are high and the space limitations are
there.
3.6 Cost:
As in any other problem, in selection of material the cost of
material plays an important part and should not be ignored.
Some times factors like scrap utilization, appearance, and
non-maintenance of the designed part are involved in the
selection of proper materials.

4. COMPONENTS AND DESCRIPTION


4.1 MAJOR PARTS:
The major parts PNEUMATIC THREE AXIS MODERN
TIPPER are described below:
Air compressor
Direction Control Valve
Cylinder
Connecting hoses
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Flow control valve


Bearing with bearing cap
Rotating Plates
4.1.1AIR COMPRESSOR:
The main function of the air compressor is to compress the
air up to the required pressure. The maximum capacity of the
compressor is 10105 to 12 105 N/m2. This is a two stages or
two-cylinder reciprocating air compressor. The two cylinders are
for low and high compression. The air pressure is measured at
various places by the use of pressure gauges. V-belt and pulley
are used to drive the compressor.
Compressors can be broadly classifieds into two groups.
They are:
Positive Displacement Compressor
Dynamic Compressors

4.1.1.1Positive Displacement Compressor:


Successive volumes of air isolated and then compressed to
a higher pressure. There are essential two forms of positive
displacement compressor, reciprocating and rotary.
4.1.1.2Dynamic Compressors:
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These are rotary continuous machines in which a high speed


rotating element accelerates the air and converts the resulting
velocity head into pressure.
Positive displacement compressors work on the principle of
increasing the pressure of a definite volume in an enclosed
chamber. Dynamic (turbo) compressor employs rotating vanes or
impellers to impart velocity and pressure to the flow of the air
being handled. The pressure comes from the dynamic effects
such as centrifugal force.

4.1.2 PRESSURE GAUGE:


Pressure gauge is used for measuring the outlet pressure of
air from the compressor. The gauge used is Bourdon type
pressure gauge. The maximum capacity of this gauge is 10 105
to 12 105 N/m2. The gauge is fitted at the outlet of the air
compressor.

4.1.3 DIRECTIONAL CONTROL VALVES:


4.1.3.1 Pneumatic valves:
The pneumatic cylinder is regulated and controlled by
pneumatic valves. These valves are actuated manually,
mechanically, electrically, pneumatically, and by various
combined mode of actuation.

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4.1.3.2Need of Valves:
DIRECTIONAL CONTROL VALVES To control the to and fro
motion of cylinder, the fluid energy has to be regulated, controlled
and reversed with a predetermined sequence in a pneumatic
system.
Similarly one may have to control the quantity of pressure
and flow rate to generate the desired level of force and speed of
actuators. To achieve these functions, valves are used. Valves are
fluid power elements used for controlling and regulating the
working medium.
The main functions of the valves are:
Start and stop the fluid energy
Control the direction of flow of compressed air
Control the flow rate of the fluid
Control the pressure rating of the fluid
Although various types of valves are available, they are mainly
classified as below:
Direction control valves
Direction control check valves
Flow control valves
Pressure control valves

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The main purpose of a valve in a pneumatic circuit is to


control outputs. Valves can be divided into a number of groups
according to what they control.
4.1.3.3 Directional control valves:
Directional control valve on the receipt of some external
signal, which might be mechanical, electrical or a fluid pressure
pilot signal, charges the direction of or stops, or starts the flow of
fluid in some part of the pneumatic/hydraulic circuit.

4.1.3.4 Pressure Control Valves:


These are used to control the pressure in part of the
pneumatic/hydraulic circuit.
4.1.3.5 Flow Control Valves:
These are used to control the rate of flow of a fluid
through the valve.
A directional control valve on the receipt of some, external
signal, which might be mechanical, electrical or a fluid pilot
signal, changes the direction of stops, or starts the flow of fluid in
some part of the pneumatic/hydraulic circuit. They can be used to
carry out such functions as:
1. Controlling the direction of motion of an actuator
2. Selecting alternative flow paths for a fluid.
3. Stopping and starting the flow of fluid.
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Carrying out logic functions such as AND, OR, NAND


4.1.3.6 Actuators:
An actuator is a device that is used to apply a force to an
object
Fluid power actuators can be classified into two groups:
Linear actuators are used to move an object or apply a
force in a straight line.
Linear actuators can be divided into two types.
They are:
1. Single acting cylinders
2. Double acting cylinders
A single acting cylinder is powered by fluid for the movement
of the piston in one direction with it being returned in the other
direction by an internal spring or an external force, a double
acting cylinder is powered by fluid in both directions.
Rotary actuators are used to move an object in a circular
path. Rotary actuators are the fluid power equivalent of
an electric motor.

4.1.4 PNEUMATIC CYLINDERS:


Cylinders are the one, which offers the rectilinear motion to
mechanical elements. Cylinders are classified as light, medium,
and heavy duty with respect to their application.
4.1.4.1Single Acting Cylinders:
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In this type, the cylinder can produce work only in one


direction. The return movement of the piston is effected by a built
in spring or by application of an external force. The spring is
designed to return the piston to its initial position with a
sufficiently high speed.
Types of single acting cylinders:
Diaphragm cylinder
Rolling diaphragm cylinder
4.1.4.2Double Acting Cylinder:
The force exerted by the compressed air moves the
piston in two directions in a double acting cylinder. They are used
particularly when the piston is required to perform work not only
on the advance movement but also on the return. In principle, the
stroke length is unlimited, although buckling and bending must be
considered before we select a particular size of piston diameter,
rod length and stroke length.
We use cylinders that are double acting type (i.e.) the
compressed air can be passed to either end of the cylinder. These
cylinders are made up of cast iron.

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4.1.5 SEALS:
4.1.5.1 Air Seal:
Air seal is used to prevent the leakage of air pressure from
the cylinder. Normally it is made up of neoprene rubber. If there
are any air leakages in the system, it will reduce the efficiency.
4.1.5.2Wiper Seal:
Wiper seal is provided at the entrance of the cylinder to
avoid dust materials from the environment. It is made up of
neoprene rubber.
4.1.5.3O Ring:
The O rings are fitted into the grooves of piston to
maintain perfect seal between the piston and the cylinder wall.
They are mostly made up of neoprene rubber.
4.1.6 CYLINDER TECHNICAL DATA:
Barrel:
It is made of cold drawn aluminimum honed to 25mm.
Piston Rod:
M.S. hard Chrome plated
Seals:
Nitrile (Buna N) Elastomer
End Covers:
Cast iron graded fine grained from 25mm to 300mm
Piston:
Aluminium.
Media:
Air.
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Temperature Range:
0^c to 85^c
Cushions:
Adjustable standard on 400mm bore and above.
4.1.7 CONNECTORS:
In our system there are two types of connectors used; one
is the hose connector and the other is the reducer. Hose
connectors normally comprise an adapter (connector) hose nipple
and cap nut. These types of connectors are made up of brass or
Aliminium or hardened steel.
Reducers are used to provide inter connection between
two pipes or hoses of different sizes. They may be fitted straight,
tee, V or other configurations. These reducers are made up of
gunmetal or other materials like hardened steel etc.
4.1.8 FLOW CONTROL VALVE:
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.
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.

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4.1.9BEARING WITH BEARING CAP:


The bearings are pressed smoothly to fit into the shafts
because if hammered the bearing may develop cracks. Bearing is
made upof steel material and bearing cap is mild steel.
Ball and roller bearings are used widely in
instruments and machines in order to minimize friction
and power loss. While the concept of the ball bearing
dates back at least to Leonardo da Vinci, their design and
manufacture has become remarkably sophisticated.
This technology was brought to its p resent state
o f perfection only after a long period of research and
development. The benefits of such specialized research
can be obtained when it is possible to use a standardized
bearing of the proper size and type.
However, such bearings cannot be used
indiscriminately without a careful study of the loads and

35

operating conditions. In addition, the bearing must be


provided with adequate mounting, lubrication and sealing.
4.1.10 WHEEL ARRANGEMENT:
The wheels are fitted to the body of the vehicle with the
help of end bearing and bearing caps. The wheels are made up
of fiber material.
4.1.11 TIPPER BODY:
The tipper body is made up of mild steel sheet metal. This
frame is look like a small model trailer.
4.1.12 ROTATING PLATES:
The rotating plates are fixed in the bottom the trailer body, so
that the cylinder will rotates in the required side. The plates are
made up of mild steel materials.

CHAPTER-7
7. DESIGN AND DRAWINGS
7.1

PNEUMATIC CYLINDER

7.1.1 Design of Piston rod:


Load due to air Pressure.
Diameter of the Piston (d) =
Pressure acting (p)

36

40 mm

6 kgf/cm

6 0.981

5.886 bar
=

Material used for rod =

0.5886N/mm2
C 45
(data

book page no 1.12 )


Yield stress (y)

36 kgf/mm

3698.1

3531.6 bar

=
factor of safety

353.16N/mm2

2( data book

page.no 8.19)
Force acting on the rod (F)

Pressure

x Area
=

p x (d / 4)

0.5886 x {( x 40

739.6 N

y / F0 S

353.16 / 2

)/4}
F

Design Stress(y)

=
d

37

176.5N/mm2
4F/ [y]

(4739.6)/

[176.5]
Minimum diameter of rod required for the load =

2.3

mm
We assume diameter of the rod

15 mm

7.1.2 Design of cylinder thickness:


Material used

Assuming internal diameter of the cylinder


Ultimate tensile stress

Cast iron
=

40 mm

250

N/mm
Working Stress

Ultimate tensile stress /

250 / 4

62.5 N/mm2

factor of safety
Assuming factor of safety
Working stress ( ft )
According to LAMES EQUATION
Minimum thickness of cylinder ( t )

= ri {(f t+p)/(ft-p)-1}

Where,
ri

inner radius of cylinder in cm.

ft

Working stress (N/mm)

Working pressure in N/mm

Substituting values we get,


t

2.0 { (62.5 + 0.5886) / (62.5

0.27mm

0.5886) -1}
t

38

We assume thickness of cylinder =

2.5 mm

Inner diameter of barrel

40 mm

Outer diameter of barrel

40 + 2t

40 + ( 2 x 2.5 )

45 mm

Pressure x area

p x /4 (d)

0.5886 x ( / 4) x (40)

739.6 N

(/4) (dp) x ft

7.2 DESIGN OF PISTON ROD:


7.2.1 Diameter of Piston Rod:
Force of piston Rod (F)

Also, force on piston rod (F)


F

(/4) x (dp) x

739.6

(/4) x (dp) x

dp

739.6 x (4/) x

62.5
625
(1/62.5)
=
dp

By standardizing dp

15

3.8 mm

15 mm

160 mm

7.2.2 Length of piston rod:


Approach stroke
39

Length of threads

2 x 20

40mm
Extra length due to front cover

12 mm

Extra length of accommodate head

20 mm

Total length of the piston rod

160 + 40 + 12 +

20
=

232 mm

By standardizing, length of the piston rod

230 mm

7.3 DESIGN OF BALL BEARING:


Bearing No. 6202
(Data book page.no 4.13)
Outer Diameter of Bearing (D)

35 mm

Thickness of Bearing (B)

12 mm

Inner Diameter of the Bearing (d)


r

=
=

15 mm

Corner radii on shaft

and housing
r

1(From design

data book)
Maximum Speed

14,000 rpm

(From design data book)


Mean Diameter (dm)

dm

40

(D + d) / 2

(35 + 15) / 2

25 mm

7.4 WAHL STRESS FACTOR:


(From design
data book page.no 7.100)
Ks

4C 1 +
4C 4

(4 X 2.3) -1 + 0.65
(4 X 2.3 )-4

Ks

0.65

2.3

1.85

7.5 SPECIFICATION
7.5.1 Double acting pneumatic cylinder
Technical Data
Stroke length :

Cylinder stoker length 160 mm =

0.16 m
Quantity

Seals

Nitride (Buna-N) Elastomer

End cones

Cast iron

Piston

EN 8

Media

Air

Temperature

0-80 C

Pressure Range

8 N/m

7.5.2 Flow control Valve


Technical Data
41

Port size

0.635 x 10 m

Pressure

0-8 x 10 N/m

Media

Air

Quantity

7.5.3 Connectors
Technical data
Max working pressure

10 x 10 N/m

Temperature

0-100 C

Fluid media

Air

Material

Brass

7.5.4 Hoses
Technical date
Max pressure

Outer diameter

10 x 10 N/m
:

Inner diameter

42

6 mm = 6 x 10 m

3.5 mm = 3.5 x 10 m

8. WORKING PRINCIPLE
Since pneumatic circuit plays a vital role in this device, it is
very necessary to explain the working of this circuit.
Initially starting with air compresses, its function is to
compress air from a low inlet pressure (usually atmospheric) to a
higher pressure level. This is an accomplished by reducing the
volume of the air.
Air compressors are generally positive displacement units
and are either of the reciprocating piston type or the rotary screw
or rotary vane types. The air compressor used here is a typically
small sized, two-stage compressor unit.

It also consists of a

compressed air tank, electric rotor and pulley drive, pressure


controls and instruments for quick hook up and use.

The

compressor is driver by a 1 HP motor and designed to operate in


10 100 PSI range.

If the pressure exceeds the designed

pressure of the receiver a release value provided releases the


excesses air and thus stays a head of any hazards to take place.
Then having a pressure regulator where the desired pressure
to the operated is set.

Here a variable pressure regulator is

adopted. Through a variety of direction control value are


available, a hand operated spool value with detent is applied.
The spool value used here is 5 ports, 3 positions. There are
two exhaust ports, two outlet ports and one inlet port.

In two

extreme positions only the directions can be changed while the


43

Centro ore is a neutral position and no physical changes are


incurred.
The 2 outlet ports are connected to an actuator (Cylinder).
The pneumatic activates is a double acting, single rod cylinder.
The cylinder output is coupled to further purpose. The piston end
has an air horning effect to prevent sudden thrust at extreme
ends.
8.1 PRINCIPLES OF WORKING
The compressed air from the compressor reaches the
direction control valve. The direction control valve changes
the direction of flow according to the valve position handle.
The compressed air pass through the direction control valve
and it is admitted into the front end of the cylinder block.
The air pushes the piston for the lifting stroke. At the end of
the lifting stroke air from the 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 stroke length of the piston can be changed by making
suitable adjustment in the hand liver valve operating
position.

44

ADVANTAGES, DISADVANTAGES AND


APPLICATIONS
9.1 ADVANTAGES: It requires simple maintenance cares
Checking and cleaning are easy, because of the main
parts are screwed.
Handling is easy.
Manual power not required
Repairing is easy.
Replacement of parts is easy.
9.2 DISADVANTAGES
Initial cost is high.
Separate air tank or compressor is required.
9.3 APPLICATIONS
All hydraulic and pneumatic dipper applications.
Easy to unload the materials

45

CHAPTER-10
10. LIST OF MATERIALS
Sl.
No.
i.
ii.

PARTS
Pneumatic Reciprocating Cylinder
5/2 Direction Control Valve

Qty.

Material

1
1

M.S
Aluminiu
m

iii.
iv.
v.
vi.

Pneumatic Tube
Hose Collar and Reducer
Stand (Frame)
Flow control valve

46

1
1

Brass
Mild steel
Lead-Acid

CHAPTER-11
11. COST ESTIMATION
11.1

MATERIAL COST:

Sl.
No.
i.
ii.
v.

PARTS

Qty.

Material

Amount
(Rs)

Pneumatic Cylinder
5/2 Direction Control

1
1

M.S
Aluminium

Valve
Bearing

Bearing

Fiber

and

Brass

1
1
1
1

Mild steel
Plastic
Aluminum
Lead-Acid

with

vi.
vii.

Cap
Pneumatic Tube
Hose
Collar

Viii
Ix
X
Xi

Reducer
Stand (Frame)
Dash Pad
D.C Motor
Flow control valve
TOTAL

47

CHAPTER-12
12. CONCLUSION
This project work has provided us an excellent opportunity
and experience, to use our limited knowledge. We gained a lot of
practical knowledge regarding, planning, purchasing, assembling
and machining while doing this project work. We feel that the
project work is a good solution to bridge the gates between
institution and industries.
We are proud that we have completed the work with the
limited time successfully. The THREE AXIS PNEUMATIC
MODERN TIPPER is working with satisfactory conditions. We
are able to understand the difficulties in maintaining the
tolerances and also quality. We have done to our ability and skill
making maximum use of available facilities. In conclusion remarks
of our project work, let us add a few more lines about our
impression project work.
Thus we have developed a THREE AXIS PNEUMATIC
MODERN TIPPER which helps to know how to achieve low cost
automation. The operating procedure of this system is very
48

simple, so any person can operate. By using more techniques,


they can be modified and developed according to the
applications.

BIBLIOGRAPHY

1.

G.B.S.

Narang,

Automobile

Engineering,

Khanna

Publishers, Delhi, 1991, pp 671.


2.

William H. Crowse, Automobile Engineering.

3.

MECHANISMS IN MODERN ENGINEERING DESIGN Vol.

PART I
4. ELEMENTS OF WORKSHOP TECHNOLOGY VOL II
-S.K. HAJRA CHOUDHURY
-S.K. BOSE
-A.K. HAJRA CHOUDHERY
5.

STRENGTH OF MATERIALS
49

-I.B. PRASAD

V.

50

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