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PROJECT TITLE

A PROJECT REPORT

Submitted to

SUNRISE UNIVERSITY

in partial fulfilment for the award of the diploma of

POLYTECHNIC

In

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SUNRISE UNIVERSITY ALWAR

RAJASTHAN, INDIA

MAY 2014

Annexure1 PROJECT TITLE

A PROJECT REPORT

2

Submitted to SUNRISE UNIVERSITY

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CERTIFICATE

This is to certify that the project report entitled TITLE OF PROJECT WORK

submitted by NAME OF GROUP to the SunRise University Alwar,Rajasthan in partial

fulfilment for the award of Diploma of Polytechnic in Mechanical Engineering is a confide

record of the project work carried out by him under my supervision during the year 2015-

2016.

Submitted to: Submitted by:

Name of incharge Name of student(Roll)

Designation

Name (Project Guide) Designation

SUNRISE UNIVERSITY Bagad Rajput, ALWAR-301030(Raj.)

INDIA

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ACKNOWLEDGEMENT

I take this opportunity to express my profound gratitude and deep to my mentor Mr.

Vinayak Hemadri for his exemplary guidance, monitoring and constant encouragement

throughout the course of this thesis. The blessing, help and guidance given by him time to

time shall carry me a long way on the journey of life in which I am about to embark. I also

take this opportunity to express a deep sense of gratitude to the mentor for his cordial

support, valuable information and guidance, which helped me in completing this task through

various stages.

Lastly, I thank almighty, my parents, and friends for their constant encouragement

without which this assignment would not be completed.

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ABSTRACT

The main target of project is to improve version of a mini pneumatic jack.

This will be more efficient for the user. This machine is pneumatic powered

which has low co-efficient of friction. A pneumatic cylinder erected provides

power to lift up the Jacky. This is a pneumatic powered machine and requires

no other means of power to operate. The required components are Compressor,

Pneumatic cylinder, Solenoid, Control circuit and Jack.

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TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT 5

LIST OF FIGURES 6

LIST OF TABLES 8

CHAPTER 1

1.1 INTRODUCTION 9

1.2 ADVANTAGES 9

1.3 DISADVANTAGE 9

1.4 APPLICATION 9

CHAPTER 2

2.1 BLOCK DIAGRAM 10

2.2 ACTION TYPES 10

CHAPTER 3

3.1 WORKING PRINCIPLE 15

3.2 DESCRIPTION OF JACK WORKING PRINICIPLE 16

3.3 ADVANTAGES OF PNEUMATIC SYSTEMS 19

3.4 REVIEWS 19

3.4.1 FEATURES 19

3.4.2 TOOLS 19

3.4.3 COMPONENTS 19

3.5 FUNCTION 20

3.5.1 SAFETY 20

3.5.2 THE RESERVOIR 20

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3.6 THE COMPRESSOR 20

3.6.1 THE PIPES 20

3.7 HOW IT FLOWS 21

3.8 BASIC PRINCIPLE 21

3.9 APPLICATIONS 21

3.10 PNEUMATIC VS. HYDRAULIC 25

3.11 HIGH-TECH APPLICATIONS 25

CHAPTER 4

4.1 PROPOSED DESIGN THE PNEUMATIC JACK 35

4.2 PROPOSED DESIGN THE PNEUMATIC JACKS

MOUNT PLATE FOR TAPPING 36

4.3 PROPOSED DESIGN THE PNEUMATIC JACK

HAND LEVER WITH SILENCER REDUCING SOUND 37

4.4 PROPOSED DESIGN THE PNEUMATIC

JACK OF CYLINDER DIMENSION 40*50 WITH

PU FITTED FOR POLYURETHANE HOSE 38

4.5 HARDWARE USED IN PROJECT 39

4.6 TOOLS USED IN PROJECT: 39

4.7 ESTIMATION OF THE PROJECT WORK 41

CHAPTER 5

CONCLUSION 42

REFERENCE 43

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LIST OF FIGURES

FIGURE.NO NAME PAGE.NO

1.1.1 Pneumatic Gun 09

2.1.1 Pneumatic Jack 10

3.1.1 Working Of Pneumatic Jack 15

3.1.2 Interior Parts Of Pneumatic Jack 18

4.1 Proposed Design The Pneumatic Jack 35

4.2 Proposed Design The Pneumatic Jacks

Mount Plate For Tapping 36

4.3 Proposed Design The Pneumatic Jack

Hand Lever With Silencer Reducing Sound 37

4.4 Proposed Design The Pneumatic Jack Of

Cylinder Dimension 40*50 With Pu Fitted

For Polyurethane Hose 38

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CHAPTER 1

1.1 INTRODUCTION

A pneumatic cylinder simply converts air pressure into linear motion. 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.

Fig 1.1.1 Pneumatic Gun

1.2 ADVANTAGES

Power can be easily transmission

Less loss in transmission

A single compressor can supply power to many pneumatic Jack.

Low cost

Easy to work and reduces the manual stress

1.3 DISADVANTAGE

Need separate compressor.

1.4 APPLICATION

Used in vehicles instead of screw jack.

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CHAPTER 2

2.1 BLOCK DIAGRAM

Fig 2.1.1 Pneumatic Jack

2.2 Action Types

By "action type", we mean how the cylinder acts when pressure is applied and removed.

A "single-acting" cylinder has a single port for compressed air.

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When air pressure is removed, the cylinder does nothing to retract the piston. Whatever the

piston pushed out must push the piston back in.

A cylinder that is "single-acting with spring return" has hook-ups like the "single-acting"

cylinder. When air pressure is removed, the spring pushes the piston back into the

resting position. In some cases the cylinder is sealed and the trapped air performs as an "air

spring". A single-acting cylinder with spring return requires more air pressure to activate

because you are pushing against both the load and the spring.A "double-acting" cylinder has

two ports for compressed air.

The key part of any facility for supply of compressed air is the compressor. A

compressor is a machine that takes in air, gas or vapours at any certain pressure and delivers

the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered and the

volume expressed is that of the air at intake conditions, namely at atmosphere pressure and

normal ambient temperature.

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Clean condition of the suction air is one of the factors, which decides the life of the

compressors. Warm and moist air will result in Compressors may be classified into two types,

namely

1. Positive displacement compressors

2. Turbo compressors.

Positive displacement compressors are most frequently employed for compressed air plants

and have proved. Highly successful to supply air for pneumatic control application.

The types of positive Compressors are,

a. Reciprocating type compressors

b. Rotary type compressors.

Turbo compressors are employed where large capacity of air is required at low discharge

pressures. They cannot attain pressure necessary for pneumatic control applications unless

built in multi stage designs are seldom en counted in pneumatic service. Basically all

activities or anything in our lives, there must be the advantages and disadvantages to be

caused. And so is in the Pneumatic system.

Infinite availability of the source

Air is the most important thing in the pneumatic system, and as we all know, air is available

in the world around us in unlimited quantities at all times and places.

Easy channelled

Air is a substance that is easily passed or move from one place to another through a small

pipe, the long and winding.

Temperature is flexible

Air can be used flexibly at various temperatures are required, through equipment designed for

specific circumstances, even in quite extreme conditions; the air was still able to work.

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Safe

The air can be loaded more safely than it is not flammable and does not short circuit occurs

(konsleting) or explode, so protection against both of these things pretty easily, unlike the

electrical system that could lead to fires konsleting.

Clean

The air around us are tend to clean without chemicals that are harmful, and also, it can be

minimized or cleaned with some processes, so it is safe to use pneumatic systems to the

pharmaceutical industry, food and beverages and textiles.

The transfer of power and the speed is very easy to set up

Air could move at speeds that can be adjusted from low to high or vice versa. When using a

pneumatic cylinder actuator, the piston speed can reach 3 m / s. For pneumatic motors can

spins at 30,000 rpm, while the turbine engine systems can reach 450,000 rpm.

Can be stored

The air can be stored through the seat tube fed excess air pressure. Moreover, it can be

installed so that the pressure boundary or the safety of the system to be safe.

Easy utilized

Easy air either directly utilized to clean surfaces such as metal and machinery, or indirectly,

ie through pneumatic equipment to produce certain movements.

Requires installation of air-producing equipment.

Compressed air should be well prepared to meet the requirements. Meet certain criteria, such

as dry, clean, and contain the necessary lubricant for pneumatic equipment. Therefore require

installation of pneumatic systems is relatively expensive equipment, such as compressors, air

filter, lube tube, dryer, regulators, etc.

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Easy to leak

One of the properties of pressurized air is like to always occupy the empty space and the air

pressure is maintained in hard work. Therefore we need a seal so that air does not leak. Seal

leakage can cause energy loss. Pneumatic equipment should be equipped with airtight

equipment that compressed air leaks in the system can be minimized.

Potential noise

Pneumatic using open system, meaning that the air that has been used will be thrown out of

the system, the air comes out pretty loud and noisy so will cause noise, especially on the

exhaust tract. The fix is to put a silencer on each dump line.

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CHAPTER 3

3.1 WORKING PRINCIPLE

The working medium adopted is compressed air. The compressed air is transmitted through

tubes to pneumatic cylinder where power is converted into reciprocating motion. The

reciprocating motion is obtained by using an electrically controlled solenoid valve. The input

to the solenoid valve is given through the control unit. The reciprocating motion transmitted

to the jack through the piston which moves on the cylinder. The jack is mounted on the

bottom side of the vehicle chassis as shown in the figure. If the vehicle has to be lifted, the

solenoid valve will be actuated. The load plate will be moved towards the ground. As piston

rod keeps on extending the vehicle will be lifted. Thus using a pneumatic jack the vehicle can

be lifted with ease in operation.

Fig.3.1.1 Working Of Pneumatic Jack

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3.2 DESCRIPTION OF JACK WORKING PRINICIPLE

Work by way of pressurized gas used to create mechanical motion. Hydraulic jacks,

on the other hand, use liquid to affect motion. Both types of jacks are available to consumers;

however, hydraulic jacks are more popular for a number of reasons, and pneumatic jacks are

less readily available due to the drawbacks of pneumatic mechanics. This doesn't mean that a

pneumatic jack is a bad choice, but rather that a comparison between the two products is time

well spent.

Pneumatic systems are mechanical systems that use compressed gasses. They are similar to

hydraulic systems, which are mechanical systems that use liquids in the transfer of forces.

Pneumatic systems are almost everywhere in the modern world. Dentists use pneumatics to

operate drills, carpenters use pneumatics to power air hammers, truckers use pneumatic

brakes and NASA uses pneumatics to control the operation of satellite launch vehicles.

Basic Principles

Pneumatics is basically a method to turn electricity into mechanical motion using compressed

gasses instead of motors or electromagnets. For many applications, this is much more

efficient and practical. Systems typically include an air compressor, which stores compressed

air in a cylinder and release it under electric control. The compressed gas is almost always

ordinary air because it is free and non- toxic. Often the air is slightly modified by taking out

some of the water vapor and adding a small amount of atomized oil to make the gas more

machine friendly.

Applications

Pneumatics systems are widely used for power tools. The power tool that an automobile

mechanic uses to take the lug nuts that hold a tire onto the hub is one example. The mechanic

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can easily take off even the toughest nuts in just a few seconds. There are dozens of other

pneumatic power tools in dentistry, carpentry, machine shops and laboratories. Other

applications include jackhammers, the cylinder delivery systems used by some banks and

various launchers and guns designed to propel objects. One interesting application is a new

French automobile that runs on compressed air. Electricity is used overnight to compress air

into an on board cylinder and the car runs all day with no fuel and no pollution emissions.

Pneumatic vs. Hydraulic

Hydraulic systems usually use oil as the control fluid. Hydraulic systems have the advantage

that they can handle bigger loads, and the disadvantage is that if there is a leak it causes a big

mess and is expensive to fix. A leaks in a pneumatic system means that you vent ordinary air,

which can be replaced for free when the leak is fixed. Pneumatic systems are preferred when

there must be a certain amount of "give" or "play" in the system (gasses are compressible).

Hydraulic systems are preferred when high pressures must be maintained with no fluctuation.

High-Tech Applications

Pneumatics is not a dying technology--far from it. There are at least two high-tech

applications of pneumatics that have a place in our technological future: McKibbens and

pneumatic logic systems. McKibbins are sometimes called "artificial muscles." They are

inflatable rubber tubes surrounded by a wire mesh. When inflated they contract and then

elongate when deflated. They are currently being used to power robotic arms and legs.

Pneumatic logic is the use of complex channels for fluids that act like simple computer

circuits. Pneumatic logic systems have many advantages over electronic systems such as the

fact that radiation does not interfere with them. These systems are currently being used by

NASA to control rocket-stage separation.

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Pneumatic systems compress air or some other gas in order to increase the pressure it

exerts. This high pressure gas is then used to make machine parts move. In the late 19th

century, only wealthy industrialists used pneumatic systems, as only they had the massive

steam engines necessary to run the compression systems of the time. However, in the early

part of the 20th century, smaller and more efficient motors ensured the widespread industrial

usage of pneumatic systems. Even though they have become less widespread since the latter

half of the 20th century, they are still a staple feature of many businesses.

Fig.3.1.2 Interior Parts Of Pneumatic Jack

To understand how pneumatic systems work, it is necessary to understand gases and

compression. The laws of conservation of mass and energy mean that even when a gas is

compressed, it still contains the same amount of energy and number of molecules. Because

they are held in a smaller space, the surface of the gas container experiences more collisions

with the gas molecules. This means that the pressure and volume are inversely proportional to

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each other, according to Brian S. Elliott, author of the "Compressed Air Operations Manual."

If the air is compressed to one-tenth its original volume, it exerts ten times the pressure.

3.3 Advantages of Pneumatic Systems

Pneumatic systems have several advantages. Because they use air to transmit power,

they produce few pollutants. Leaks will not cause spills of toxic chemicals. Pneumatic

machines tend to be very simple. Because they are simple, there are few parts to break and

they need less maintenance than other types of machinery. Because compressed air can be

stored in containers, it is always available, even when the electricity goes out. They also

present very little fire hazard.

3.4 REVIEWs

Pneumatic systems utilize the power of air to do work. Many tools that utilize

pneumatic systems are used in the construction industry because they are so efficient.

3.4.1 Features

Pneumatic systems operate under the compressed air provided by an air source. The

most common and efficient air source utilized by consumers is an air compressor.

3.4.2 Tools

Nearly every traditional power tool is available in a version utilizing compressed air

instead of electricity. Consumers can purchase pneumatic nail guns, staple guns, buffers,

jackhammers and wrenches.

3.4.3 Components

Along with the actual pneumatic tool and the air compressor, pneumatic systems require

some level of hosing to transfer the compressed air to the tool. The Canada Center for

Occupational Health and Safety recommends only using abrasion-resistant hosing in

pneumatic systems.

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3.5 Function

Air compressors are powered by electricity. Air is compressed in a tank to a specific

pressure per square inch (PSI). Tools can tap into this compressed air via specially designed

hoses and drive nails or pound a hammer for example.

3.5.1 Safety

The Tool Hut recommends employing hearing protection near or while operating

pneumatic equipment. All components of the pneumatic system should be maintained

regularly according to American Pneumatic Tools.

3.5.2 The Reservoir

The reservoir is used to hold the fuel for the compressor. Air is used most often in

construction and other applications where pneumatics features prominently, but other gases

may also be used. From the reservoir, fuel is pumped into the compressor, and then the

reservoir receives "waste" fuel back from the compressor to be used again in a repeating

cycle.

3.6 The Compressor

A compressor consists of a piston inside a cylinder. When it receives the gas from the

reservoir, the piston presses on the fuel to compress it beyond the 100 lbs. per square inch

(psi) that it was originally put into the reservoir at (fpef.org). Once the piston compresses the

gas enough, a door leading into the piping system opens and the fuel heads on its way to the

point of power generation.

3.6.1 The Pipes

The pipes leading from the compressor to the point of power generation are where the

most leakage in pressure occurs, according to S.R. Majumdar, author of "Pneumatic Systems:

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Principles and Maintenance," so it is imperative that your pipes be equipped with valves to

monitor and regulate the pressure, flow and direction of the fuel gas.

3.7 How it flows

The compressor receives air from the reservoir and increases it from 100 psi until a

door leading into the pipes opens. Compressed air is pushed through a limiting valve and past

a second reservoir, where excess air is stored and pressure relieved, while enough air to elicit

mechanical motion at the end of the circuit moves on through the rest of the pipes.

Pneumatic systems are mechanical systems that use compressed gasses. They are similar to

hydraulic systems, which are mechanical systems that use liquids in the transfer of forces.

Pneumatic systems are almost everywhere in the modern world. Dentists use pneumatics to

operate drills, carpenters use pneumatics to power air hammers, truckers use pneumatic

brakes and NASA uses pneumatics to control the operation of satellite launch vehicles.

3.8 Basic Principle:

Pneumatics is basically a method to turn electricity into mechanical motion using

compressed gasses instead of motors or electromagnets. For many applications, this is much

more efficient and practical. Systems typically include an air compressor, which stores

compressed air in a cylinder and release it under electric control. The compressed gas is

almost always ordinary air because it is free and non- toxic. Often the air is slightly modified

by taking out some of the water vapour and adding a small amount of atomized oil to make

the gas more machines friendly.

3.9 Applications

Pneumatics systems are widely used for power tools. The power tool that an

automobile mechanic uses to take the lug nuts that hold a tire onto the hub is one example.

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The mechanic can easily take off even the toughest nuts in just a few seconds. There are

dozens of other pneumatic power tools in dentistry, carpentry, machine shops and

laboratories.

Other applications include jackhammers, the cylinder delivery systems used by some

banks and various launchers and guns designed to propel objects. One interesting application

is a new French automobile that runs on compressed air. Electricity is used overnight to

compress air into an on board cylinder and the car runs all day with no fuel and no pollution

emissions.

Easy condenses

Pressurized air is easily condensed, so before entering the system must be processed first in

order to meet certain requirements, such as dry, have enough pressure, and contains a small

amount of lubricant to reduce friction in the valves and actuators.

Expected after knowing the advantages and disadvantages of the use of compressed

air we can make the anticipation that these losses can be avoided.

Despite the immense capabilities of hydraulics presented in terms of moving higher

loads and in other industrial utilization, pneumatics are still in wide use today. The article

discusses some applications and advantages of pneumatics in industry.

Pneumatics is study of mechanical motion caused by pressurized gases and how this

motion can be used to perform engineering tasks. Pneumatics is used mainly in mining and

general construction works. Pneumatic devices are used frequently in the dentistry industry

across the world. On the other hand, hydraulics means use of pressurized fluids to execute a

mechanical task. Hydraulics is frequently used in the concepts of turbines, dams, and rivers.

Air brakes in buses, air compressors, compressed air engines, jackhammers, and vacuum

pumps are some of the most commonly used types of mechanical equipment that are based on

pneumatics technology. Commonly seen hydraulics based equipment types are hydraulic

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presses, hydraulic hoppers, hydraulic cylinders, and hydraulic rams. In the subsequent

sections of this article, you will learn how a pneumatic system works, what its best features

are, and its major advantages over hydraulic systems.

In order to affect mechanical motion, pneumatics employs compression of gases,

based on the working principles of fluid dynamics in the concept of pressure. Any equipment

employing pneumatics uses an interconnecting set of components: a pneumatic circuit

consisting of active components such as gas compressor, transition lines, air tanks, hoses,

open atmosphere, and passive components. Compressed air is supplied by the compressor and

is transmitted through a series of hoses. Air flows are regulated by valves and the pneumatic

cylinder transfers the energy provided by the compressed gas to mechanical energy. Aside

from compressed air, inert gases are also applied particularly for self-contained systems.

Pneumatics is applied in a wide range in industries, even in mining and dentistry. The

majority of industries use gas pressures of about 80 to 100 pounds per square inch.

Over pneumatics, hydraulics is capable of moving heavier loads and having greater

force, and since its working fluids are incompressible, it minimum spring actions. But at the

same time pneumatics are cleaner; the system uses no return lines and gases are exhausted to

the atmosphere. Thus leaks will be of less concern since the working fluid of pneumatics is

air, unlike oil in hydraulics. Its working fluid is also widely available and most factories are

pre-plumbed for compressed air distribution, hence pneumatic equipment is easier to set-up.

To control the system, only ON and OFF are used and the system consists only of standard

cylinders and other components, making it simpler than hydraulics. Pneumatic

systems require low maintenance and have long operating lives. Lastly the working fluid of

the pneumatic system absorbs excessive force, leading to less frequent damage to equipment.

Compressible gases are also easy to store and safer; no fire hazard is presented and machines

could be made to be overload safe.

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Advantages of Pneumatics over Hydraulics

Like hydraulics, pneumatics is a type of fluid power application where instead of an

incompressible liquid, pneumatics employ gas in their system. Hydraulics present

certain advantages over pneumatics, but in a given application, pneumatic powered

equipment is more suitable, particularly in industries where the factory units are plumbed for

compressed air.

The air used in pneumatic devices is dried and free from moisture so that it does not create

any problem to the internal parts of the system. Moreover, to avoid corrosive actions, oil or

lubricants are added so that friction effects can be reduced. Compressed air is used in most of

the machines and in some cases compressed carbon dioxide is used. As most of the

pneumatic devices are air based, they have a less complicated design and can be made of

inexpensive material. Mass production techniques can be adopted to produce pneumatic

systems, which not only save money but save time too.

Other major advantages are listed below.

1. Initial cost is less; hydraulics equipment cost as much as twice the price of pneumatic

equipment.

2. A pneumatic water treatment automation system reduces the costs of installation and

operation compared with conventional electrical installations. For opening and closing of

underwater valves, pneumatic systems work well because they can sustain overload

pressure conditions.

3. Pneumatic actuators also have long life and perform well with negligible maintenance

requirement throughout their life cycle.

4. Very suitable for power transmission when distance of transmission is more.

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The major disadvantage of pneumatic systems is that they cannot be employed for tasks

that require working under high pressures. However, modern technology is working on

finding better solutions to this address this problem so that heavy engineering tasks can be

executed using pneumatic devices. In a nutshell, in order to execute low scale engineering

and mechanical tasks, pneumatic devices would be the best suited and a viable alternative

over hydraulic systems.

3.10 Pneumatic vs. Hydraulic

Hydraulic systems usually use oil as the control fluid. Hydraulic systems have the advantage

that they can handle bigger loads, and the disadvantage is that if there is a leak it causes a big

mess and is expensive to fix.. Pneumatic systems are preferred when there must be a certain

amount of "give" or "play" in the system (gasses are compressible). Hydraulic systems are

preferred when high pressures must be maintained with no fluctuation.

3.11 High-Tech Applications

Pneumatics is not a dying technology--far from it. There are at least two high-tech

applications of pneumatics that have a place in our technological future: McKibbens and

pneumatic logic systems. They are currently being used to power robotic arms and legs.

Pneumatic logic is the use of complex channels for fluids that act like simple computer

circuits. Pneumatic logic systems have many advantages over electronic systems such as the

fact that radiation does not interfere with them. These systems are currently being used by

NASA to control rocket-stage separation.

The different number of rays by means the number of controlled connection of the

valve. Inlet connection to the compressed air supplies outlet connections to the air consumer

and exhaust connection to the atmosphere. The solenoid valve is used to control the air flow

direction. This is the direction control valve in our project.

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Pneumatic systems require air to operate successfully. As a result of air being extremely

abundant, and free, it is easy to restock the system. Safety: As a result of pneumatic systems

running on air, safety hazards are significantly reduced. There are limited occurrences of fires

because air is non-flammable, and leakages in the system do not negatively effect the outside

environment

Cost effectiveness: The initial cost of manufacturing a pneumatic device is minimal as a

result of the low cost design materials. Plastics, zinc, and aluminium are all relatively

affordable materials that are commonly found in pneumatic designs.

Cleanliness- As a result of the system being powered solely by air, the pneumatic device

typically requires limited cleaning. Pressurized air constantly pushes out dirt or debris that

get stuck in the system. If there is a blockage, the simplicity of the design also helps. Due to

the limited amounts of tubes, the system can be easily disassembled and cleaned.

Maintenance- In order for the system to properly operate it must be lubricated with oil

consistently but they have less plumbing than hydraulic systems. Control and Speed- Air is a

compressible gas, which makes control and speed in a pneumatic system more difficult, in

comparison to electric or hydraulic systems. When specific speeds are needed, additional

devices have to be attached to the pneumatic system in order to procure the desired result.

Maintenance- Pneumatic systems are less durable that hydraulic counterparts. Due to

moisture accumulation the system can freeze up. Safety: Pipes that feed the system air have

the ability to move on uncontrollably on their own, which could cause serious injuries to

those nearby

The word pneumatics is a derivative of the Greek word pneuma, which means air,

wind, or breath. Pneumatics can be defined as that branch of engineering science that pertains

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to gaseous pressure and flow. As used in this manual, pneumatics is the portion of fluid

power in which compressed air, or other gas, is used to transmit and control power to

actuating mechanisms. This section discusses the basic principles of pneumatics,

characteristics of gases, heavy-duty air compressors, and air compressor maintenance. It also

discusses the hazards of pneumatics, methods of controlling contamination, and safety

precautions associated with compressed gases.

Basic Principles of Pneumatics Gases differ from liquids in that they have no definite

volume, that is, regardless of the size or shape of a vessel, a gas will completely fill it. Gases

are highly compressible, while liquids are only slightly so. Also, gases are lighter than equal

volumes of liquids, making gases less dense than liquids.

Boyles Law When the automobile tire is initially inflated, air that normally occupies

a specific volume is compressed into a smaller volume inside the tire. This increases the

pressure on the inside of the tire. Charles Boyle, an English scientist, was among the first to

experiment with the pressure-volume relationship of gas. During an experiment when he

compressed a volume of air, he found that the volume decreased as pressure increased, and

by doubling the force exerted on the air, he could decrease the volume of the air by half

Temperature is a dominant factor affecting the physical properties of gases. It is of particular

concern in calculating changes in the state of gases. Therefore, the experiment must be

performed at a constant temperature. The relationship between pressure and volume is known

as Boyle's law. Boyle's law states when the temperature of a gas is constant, the volume of an

enclosed gas varies inversely with pressure. Boyle's law assumes conditions of constant

temperature. In actual situations this is rarely the case. Temperature changes continually and

affects the volume of a given mass of gas.

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Charles Law Jacques Charles, a French physicist, provided much of the foundation

for modem kinetic theory of gases. Through experiments, he found that all gases expand and

contract proportionally to the change in absolute temperature, providing the pressure remains

constant. The relationship between volume and temperature is known as Charles's law.

Charles's law states that the volume of a gas is proportional to its absolute temperature if

constant pressure is maintained.

Kinetic Theory of Gases In an attempt to explain the compressibility of gases,

consider the container shown in as containing a gas. At any given time, some molecules are

moving in one direction, some are travelling. Gas compressed to half its original size by a

doubled force. Figure 9-36 Molecular bombardment that creates pressure. NAVEDTRA

14264A 9-32 directions, and some may be in a state of rest. The average effect of the

molecules bombarding each container wall corresponds to the pressure of the gas. As more

gas is pumped into the container, more molecules are available to bombard the walls, thus the

pressure in the container increases. Increasing the speed with which the molecules hit the

walls can also increase the gas pressure in a container. If the temperature of the gas is raised,

the molecules move faster, causing an increase in pressure. This can be shown by considering

the automobile tire. When you take a long drive on a hot day, the pressure in the tires

increases, and a tire that appeared to be soft in cool morning temperature may appear normal

at a higher midday temperature.

Compressibility and Expansion of Gases Gases can be readily compressed and are

assumed to be perfectly elastic. This combination of properties gives gas the ability to yield

to a force and return promptly to its original condition when the force is removed. These are

the properties of air that are used in pneumatic tires, tennis balls, and other deformable

objects whose shapes are maintained by compressed air.

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Pneumatic Gases serve the same purpose in pneumatic systems as liquids serve in

hydraulic systems. Therefore, many of the same qualities that are considered when selecting a

liquid for a hydraulic system must be considered when selecting a gas for a pneumatic

system.

Qualities The ideal fluid medium for a pneumatic system must be a readily available

gas that is non-poisonous, chemically stable, non-flammable, and free from any acids that can

cause corrosion of system components. It should be a gas that will not support combustion of

other elements. Gases that have these desired qualities may not have the required lubricating

power. Therefore, lubrication of the components must be arranged by other means. For

example, some air compressors are provided with a lubricating system, some components are

lubricated upon installation, or in some cases lubrication is introduced into the air supply line

(inline oilers). Two gases that meet these qualities and are most commonly used in pneumatic

systems are compressed air and nitrogen. Since nitrogen is used very little except in gas-

charged accumulators, we will discuss only compressed air.

Compressed Air Compressed air is a mixture of all gases contained in the atmosphere.

However, in this manual it is referred to as one of the gases used as a fluid medium for

pneumatic systems. The unlimited supply of air and the ease of compression make

compressed air the most widely used fluid for pneumatic systems. Although moisture and

solid particles must be removed from the air, a pneumatic system does not require the

extensive distillation or separation process required in the production of other gases.

Compressed air has most of the desired characteristics of a gas for pneumatic systems. It is

non-poisonous and non-flammable but does contain oxygen, which supports combustion. The

most undesirable quality of compressed air as a fluid medium for a pneumatic system is

moisture content. The atmosphere contains varying amounts of moisture in vapour form.

Changes in the temperature of compressed air will cause condensation of moisture in the

30

system. This condensed moisture can be very harmful to the system and may freeze the line

and components during cold weather. Moisture separators and hair dryers are installed in the

lines to minimize or eliminate moisture in systems where moisture would deteriorate system

performance. An air compressor provides the supply of compressed air at the required

volume and pressure. In most systems the compressor is part of the system with distribution

lines leading from the compressor to the devices to be operated. Compressed air systems are

categorized by their operating pressure as follows:

High-pressure (HP)3,000 to 5,000 psi

Medium-pressure (MP )151 to 1,000 psi

Low-pressure (LP)150 psi and below

Heavy-Duty Air Compressors are used in pneumatic systems to provide requirements

similar to those required by pumps in hydraulic systems. They furnish compressed air as

required to operate the units of the pneumatic systems. Even though manufactured by

different companies, most compressors are quite similar. They are governed by a pressure

control system that can be adjusted to compress air to the maximum pressure. Rotary the

rotary compressor has a number of vanes held captive in slots in the rotor. These vanes slide

in and out of the slots, as the rotor rotates an end view of the vanes in the slots. The rotor

revolves about the centre of the shaft that is offset from the centre of the pumping casing.

Centrifugal force acting on the rotating vanes maintains contact Rotary compressor operation.

This feature causes the vanes to slide in and out of the slots as the rotor turns. Notice in the

variation in the clearance between the vanes and the bottom of the slots, as the rotor revolves.

The vanes divide the crescent-shaped space between the offset rotor and the pump casing into

compartments that increase in size and then decrease in size as the rotor rotates. Free air

enters each compartment as successive vanes pass across the air intake. This air is carried

31

around in each compartment and is discharged at a higher pressure due to the decreasing

compartment size (volume) of the moving compartments as they progress from one end to the

other of the crescent-shaped space. The compressor is lubricated by oil circulating throughout

the unit. All oil is removed from the air by an oil separator before the compressed air leaves

the service valves

Screw The screw compressors used in the NCF are direct drive, two-stage machines

with two precisely matched spiral-grooved rotors The rotors provide positive displacement

internal compression smoothly and without surging. Oil is injected into the compressor unit

and mixes directly with the air as the rotors turn, compressing the air. The oil has three

primary functions:

As a coolant, it controls the rise in air temperature normally associated with the heat

of compression.

It seals the leakage paths between the rotors and the stator and also between the

rotors themselves.

It acts as lubricating film between the rotors, allowing one rotor to directly drive the

other, which is an idler. After the air/oil mixture is discharged from the compressor unit, the

oil is separated from the air. The oil that mixes with the air during compression passes into

the receiver-separator where it is removed and returned to the oil cooler in preparation for re-

injection. All large volume compressors have protection devices that shut them down

automatically when any of the following conditions develop

: The engine oil pressure drops below a certain point.

The engine coolant rises above a predetermined temperature.

The compressor discharge rises above a certain temperature.

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Any of the protective safety circuits develop a malfunction. Other features that may

be observed in the operation of the air compressors is a governor system whereby the engine

speed is reduced when less than full air delivery is used.

An engine- and compression-control system prevents excessive build-up in the

receiver Screw compressor. When air is compressed, heat is generated. This heat causes the

air to expand, thus requiring an increase in power for further compression. If this heat is

successfully removed between stages of compression, the total power required for additional

compression may be reduced by as much as 15 percent. In multistage reciprocating

compressors, this heat is removed by means of intercoolers that are heat exchangers placed

between each compression stage. Rotary air compressors are cooled by oil and do not use

intercoolers After coolers It is obvious that the presence of water or moisture in an air line is

not desirable. The water is carried along through the line into the tool where the water washes

away the lubricating oil, causing the tool to run sluggishly and increases maintenance.

The effect is particularly pronounced in the case of high-speed tools where the

wearing surfaces are limited in size, and excessive wear reduces efficiency by creating

internal air leakage. Further problems may result from the decrease in temperature caused by

the sudden expansion of air at the tool. This low temperature creates condensation that

freezes around the valves, ports, and outlets. This condition obviously impairs the operational

efficiency of the tool and cannot be allowed. The most satisfactory means of minimizing

these conditions is the removal of the moisture from the air immediately after compression

and before the air enters the distribution system. This may be accomplished in reciprocating

compressors through the use of an after cooler that is an air radiator that transfers heat from

the compressed air to the atmosphere. The after cooler reduces the temperature of the

compressed air to the condensation point where most of the moisture is removed. Cooling the

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air not only eliminates the difficulties which moisture causes at points where air is used but

also ensures better distribution

Receiver Tank The receiver tank is of welded steel construction and is installed on the

discharge side of the compressor. It acts as a surge tank as well as a condensation chamber

for the removal of oil and water vapours. It stores enough air during operation to actuate the

pressure control system and is fitted with at least one service valve, a drain or blow-by valve,

and a safety valve. Pressure-Control System All portable air compressors are governed by a

pressure-control system. The control system is designed to balance the compressor's air

delivery and engine speed with varied demands for compressed air. The rotary compressor

output is governed by varying the engine speed. The engine will operate at the speed required

to compress enough air to supply the demand at a fairly constant pressure. When the engine

has slowed to idling speed as a result of low demand, a valve controls the amount of free air

that may enter the compressor. A screw compressor output is governed by automatic control

that provides smooth, steeples capacity regulation from full load to no load in response to the

demand for air. From a full load down to no load is accomplished by a floating-speed engine

control in combination with the variable-inlet compressor.

Air Compressor Maintenance A number of built-in features make portable

compressors easy to maintain:

An automatic blow down valve for releasing air pressure when the engine is

stopped.

A valve for draining moisture that accumulates in the receiver tank.

A drain cock at the bottom of the piping at the bottom of the oil storage tank.

An air filter service indicator to show when the filter needs servicing.

34

A demister, or special filter, that separates lubricating oil from compressed air.

Remember: a good maintenance program is the key to a long machine life. So it is up to both

the operator and the mechanic to ensure that the maintenance is performed on time, every

time.

Air Cleaner Servicing The air cleaner contains a primary and secondary dry filter

element An air filter restriction indicator is located at the rear of the air filter housing to alert

the operator of the need to service the filters. When a red band appears in the air filter

restriction indicator, secure the compressor and service the filters. Use compressed air to

clean the primary element; however, never let the air pressure exceed 30 psi. The secondary

filter is not cleanable and should be replaced when necessary. Reverse flush the primary

element by directing compressed air up from the inside out. Continue reverse flushing until

all dust is removed. Should any oil or greasy dirt remain on the filter surface, replace the

element.

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CHAPTER 4

FABRICATION OF THE PNEUMATIC JACK

4.1 PROPOSED DESIGN THE PNEUMATIC JACK

36

4.2 PROPOSED DESIGN THE PNEUMATIC JACKS MOUNT PLATE

FOR TAPPING

37

4.3 PROPOSED DESIGN THE PNEUMATIC JACK HAND LEVER

WITH SILENCER REDUCING SOUND

38

4.4 PROPOSED DESIGN THE PNEUMATIC JACK OF CYLINDER

DIMENSION 40*50 WITH PU FITTED FOR POLYURETHANE HOSE

39

4.5 HARDWARE USED IN PROJECT:

Fabricated Pneumatic Jack

Mounting Plate

Threaded Screw

Base Plate

Bearing

Coupling

Movable Joints

Steel Plates For Supporting

Welding Electrodes

Cylinder worming

Cylinder stroke

Motor

Hardwares To Fit

Power Supply

Switch

PU fitting

Teflon tape

Polyurethane hose

4.6 TOOLS USED IN PROJECT:

Welding Machine

40

Screw driver

Spanner

Soldering Rod

Soldering flux

Cutter

Lathe

Knurling Tool

Tapper Tool

41

4.7 ESTIMATION OF THE PROJECT WORK:

HARDWARE WORKS ESTIMATION OF COST

CYLINDER 40*50 FITTING 1750

STROKE LENGTH OIL CASTED 850

SILENCE 200

HAND LEVER 750

MOUNTED PLASTIC HANDLE 150

PU FITTING 200

POLYURETHANE HOSE 250

HS TEFLON TAPE 50

STEEL SHEET COATING 450

CYLINDER RINGS 500

INNER WINDINGS 200

LATHE WORK 175

WELDING 225

OTHER EXPENSES 250

TOTAL 6000

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CHAPTER 5

CONCLUSION

This is a pneumatic powered machine and requires no other means of power to

operate. The required components are Compressor, Pneumatic cylinder, Solenoid, Control

circuit and Jack.

Pneumatic systems have several advantages. Because they use air to transmit power,

they produce few pollutants. Leaks will not cause spills of toxic chemicals. Pneumatic

machines tend to be very simple. Because they are simple, there are few parts to break and

they need less maintenance than other types of machinery. Because compressed air can be

stored in containers, it is always available, even when the electricity goes out. They also

present very little fire hazard.

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REFERENCE

TEXT BOOK

R.S KHURMI

WEBSITE

Production Technology - R.B. Gupta

Manufacturing Process - R.B. Gupta B.K. Gupta

Pneumatic Control - Werner Deepest, Kust Stoll

A Text Book on Machine Design - R.S. Khurmi

Press Working Shecklos, S.Elanger

PSG Design Data - PSG Mech. Dept

Catalogue of Janatics pneumatic product,

Janatics Private Limited Coimbatore

P.S.G. College of technology, Coimbatore

Design data book Complied by faculty of mechanical engineering

Basic PrinciplesApplicationsPneumatic vs. HydraulicHigh-Tech ApplicationsAdvantages of Pneumatics over Hydraulics