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AUTOMATIC POWER SAVING PUNCHING CONVEYOR

PROJECT WORK 2011-2012

SUBMITTED BY

M.GANESAN

S.GOWTHAMAN

P.GUNASEKARAN

M.GURUSAMY

C.JANARTHANAN

A.JEEVARATHINM

UNDER THE GUIDENCE OF

Sri.A.SOUNDRRAJAN M.E.,

Submitted in partial fulfillment of the requirement for the award ofDIPLOMAINMECHANICAL ENGINEERING, By the state board of technical

education, government of tamilnadu.

DEPARTMENT OF MECHANICAL ENGINEERINGGOVERNMENT POLYTECHNIC COLLEGE,

COIMBATORE-641014.

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CERTIFICATE

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DEPARTMENT OF MECHANICAL ENGINEERINGGOVERNMENT POLYTECHNIC COLLEGE

COIMBATORE-641014

CERTIFICATE

This is to certify that the project report titled AUTOMATIC POWER

SAVING PUNCHING CONVEYORsubmitted by the following students for the

award of diploma engineering is record of bonafide work carried out by them.

Done by

Mr:

REGISTER NO:

In partial fulfillment of the requirement for the award of

Diplomain Mechanical Engineering

During the Year(2011-2012)

RECORD MARKS:

Guide Head of Department

Submitted for the examination held on ___________

Internal Examiner External Examiner

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ACKNOWLEDGEMENT

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ACKNOWLEDGEMENT

At this pleasing moment of having successfully completed our project, we wish to

convey our sincere thanks and gratitude to We would like to express our sincere thanks

to our principal Smt.S.PADMINI.M.E., for forwarding us to do our project and offering

adequate duration in completing our project.

We are also grateful to the Head of Department Prof.

Sri.S.B.CHANDRAN.M.E., for her constructive suggestions & encouragement during

our project.

With deep sense of gratitude, we extend our earnest & sincere thanks to our

guide Sri.A.SOUNDARRAJAN.M.E, Department of Mechanical for her kind guidance

& encouragement during this project.

We also express our indebt thanks to our TEACHING staffs and OTHER staffs of

MECHANICAL ENGINEERING DEPARTMENT, GOVERNMENT POLYTECHNIC

COLLEGE.

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AUTOMATIC POWER SAVING

PUNCHING CONVEYOR

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CONTENTS

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CONTENTS & LIST OF FIGURES

CHAPTER

NO

TITLE PAGE NO

1. SYNOPSIS 11

2. INTRODUCTION 16

3. LITERATURE SURVEY 19

4. DESCRIPTION OF COMPONENTS 25

5. DESIGN AND 44

6. DRAWINGS 51

7. FABRICATION 59

8. WORKING OPERATION 61

9. ADVANTAGES AND LIMITATIONS 68

10. APPLICATIONS 70

11. LIST OF MATERIAL 72

12. COST ESTIMATION 74

13. CONCLUSION 77

BIBLIOGRAPHY 79

PHOTOGRAPHY 81

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SL. NO. FIGURE NAME PAGE NO

1. PNEUMATIC CYLINDER

SINGLE ACTING CYLINDER 27

2. SOLINOIDE VALVE 33

3. D.C. MOTOR

MAGNETIC FLEX 34

SIMPLE 2POLE DC ELECTRIC MOTOR 36

ARMATURE 38

COMMUTATER AND BRUSHES 38

ELECTRIC MOTOR 39

4. TIMER UNIT 42

5. IC 555 TIMER 64

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Chapter-1

SYNOPSIS

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CHAPTER-1

SYNOPSIS

In our project AUTOMATIC POWER SAVING PUNCHING

CONVEYOR beings with an introduction to pneumatic, its various applications. The

conveyor will operate only the work pieces kept in the conveyor only. The remaining

time the conveyor will be in off condition so that the power is saved.

The conveyor Automation is very useful for material handling in modern

engineering industries. The motor is used to drive the conveyor. The materials are

transferred from one place to another place by using conveyor. In this conveyor itself,

some operation (Example: - Number Punching, Addressing, Tested OK mark) are doing

with the help of pneumatic power. This system gives smooth operation and smooth

movement of the belts to the jobs at required time.

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

Automation can be achieved through computers, hydraulics, pneumatics, robotics,

etc., of these sources, pneumatics form an attractive medium for low cost automation.

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The main advantages of all pneumatic systems are economy and simplicity. Automation

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 calledtransfer machines. The components must be moved automatically from the bins to

various machines sequentially and the final component can be placed separately for

packaging. Materials can also be repeatedly transferred from the moving conveyors to the

work place and vice versa.

Conveyor Automation concept and principle are the most important things in

factory design. Automation 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. Conveyor Automation is a

specialized activity for a modern manufacturing concern. It has been estimated that about

60-70% of the cost production is spent in material transferring activities.

Need for Conveyor Automation:

o Reduction of lab our and material cost

o Reduction of overall cost

o Increased production

o Increased storage capacity

o Increased safety

o Reduction in fatigue

o Improved personnel comfort

ADVANTAGES

The Conveyor Automation is more efficient in the technical field

Quick response is achieved

Simple in construction

Easy to maintain and repair

Cost of the unit is less when compared to other robotics

No fire hazard problem due to over loading

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Comparatively the operation cost is less

Continuous operation is possible without stopping

LIMITATIONSWhile working, the compressed air (For Punching Operation) produces noise

therefore a silencer may be used.

APPLICATIONS

o Discharge of work piece:-

The Conveyor 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

workstation and place them in bins. It can also be used to pick raw material and place

them on the conveyor belts.

oPunching operation:-

This unit can also be used in Punching Operation in the material at high speeds.

The application of these units is limited to operations which involved moderate clamping

forces.

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Chapter-2

INTRODUCTION

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CHAPTER-2

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

Automation 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. Automation

plays an important role in mass production.

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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

packaging. Materials can also be repeatedly transferred from the moving conveyors to the

work place and vice versa.

Automatic power saving punching conveyor concepts is the most important

things in factory design. Automation 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. Automatic power saving

punching conveyor is a specialized activity for a modern manufacturing concern. It has

been estimated that about 60-70% of the cost production is spent in material transferring

activities.

Need for Automatic power saving punching conveyor:

Reduction of labour and material cost

Reduction of overall cost

Increased production Increased safety

To reduce the inspection time

Reduction in fatigue

Improved personnel comfort

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Chapter-3

LITERATURE SURVEY

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CHAPTER3

LITERATURE SURVEY

PNEUMATICS

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.

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

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

and normal ambient temperature. The compressibility of the air was first investigated by

Robert Boyle in 1962 and that found that the product of pressure and volume of a

particular quantity of gas.

The usual written as

PV = C (or) 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.

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

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reducing maintenance to a low level. It can also have out standing advantages in terms of

safety.

PNEUMATIC POWER

Pneumatic systems use pressurised gases to transmit and control power.

Pneumatic systems typically use air as the fluid medium because air is safe, low cost and

readily available.

The Advantages of Pneumatics:

Air used in pneumatic systems can be directly exhausted back in to the

surrounding environment and hence the need of special reservoirs and no-leak

system designs are eliminated.

Pneumatic systems are simple and economical.

Control of pneumatic systems is easier.

The Disadvantages of Pneumatics:

Pneumatic systems exhibit spongy characteristics due to compressibility of air.

Pneumatic pressures are quite low due to compressor design limitations (less that

250 psi).

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

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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.

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.

Positive displacement compressor.

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

Reciprocating type compressor

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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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 .

ULTIMATE AIM

The Automatic power saving punching conveyor can be widely used in low

cost automation. The manpower requirement is negligible also reducing the

manufacturing time of material.

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Chapter-4

DESCRIPTION OF COMPONENTS

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CHAPTER-4

DESCRIPTION OF COMPONENTS

MAJOR PARTS

The major parts AUTOMATIC POWER SAVING PUNCHING

CONVEYOR are described below:

Pneumatic single Acting Cylinder

3/2 Single Acting Solenoid Valve

Flow Control Valve

Hose Collar and PU Connector

Permanent Magnet D.C. Motor

IR Sensor unit

Timer Unit

Conveyor Belt and Roller

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1. PNEUMATIC CYLINDER:-

An air cylinder is an operative device in which the state input energy of

compressed air i.e. pneumatic power is converted in to mechanical output power, by

reducing the pressure of the air to that of the atmosphere.

a) Single acting cylinder

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 piston return stoke single action

cylinder requires only about half the air volume consumed by a double acting for one

operating cycle.

b) Double acting cylinders:

A double acting cylinder is employed in control systems with the full pneumatic

cushioning and it is essential when the cylinder itself is required to retard heavy messes.

This can only be done at the end positions of the piston stock. In all intermediate position

a separate externally 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

stock is required. As a result the sit in the cushioning chamber is again compressed since

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it cannot escape but slowly according to the setting made on reverses. The air freely

enters the cylinder and the piston stokes in the other direction at full force and velocity.

GENERALLY USED MATERIALS

Cylinder Tube Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Plastic Hard drawn brass tube hard drawn brass tube.

2. Hard drawn Aluminium Hard drawn steel tube

Aluminium tube Castings tube.

3. Hard drawn Brass, Bronze, Iron or

Brass tube Castings, welded steel tube

End Cover Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium stock Aluminium stock Hard tensile

(Fabricated) (Fabricated) Castings

2. Brass stock Brass stock

(Fabricated) (Fabricated)

3. Aluminium Aluminium, Brass,

Castings iron or steel Castings.

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Piston Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1.Aluminium

Castings

Aluminium Castings

Brass (Fabricated)

Aluminium Forgings,

Aluminium Castings.

2. Bronze (Fabricated) Bronze (Fabricated)

3. Iron and Steel

Castings

Brass, Bronze, Iron or

Steel Castings.

Mount Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium

Castings

Aluminium, Brass

And Steel Castings

High Tensile

Steel Castings

2. Light Alloy

(Fabricated)

High Tensile

Steel Fabrication

Piston Rod Materials:

MATERIAL FINISH REMARKS

MILD STEEL Ground and polished hardened,

ground and polished.

Generally preferred chrome

plated

STAINLESS STEEL Ground and Polished Less scratch resistant than

chrome plated piston rod

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2. SINGLE ACTING 3/2 SOLENOID VALVE:-

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in the

pneumatic system. The directional valve does this by changing the position of its internal

movable parts. This valve was selected for speedy operation and to reduce the manual

effort and also for the modification of the machine into automatic machine by means of

using a solenoid valve.A solenoid is an electrical device that converts electrical energy

into straight line motion and force. These are also used to operate a mechanical operation

which in turn operates the valve mechanism. Solenoids may be push type or pull type.

The push type solenoid is one 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 make repairs, to do service work or to install them.

Parts of a 3/2 Solenoid Valve

1.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.

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Working of Solenoid Valve:

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 project 3/2 Single acting solenoid valve is used. This solenoid valve is used

to punching, printing or marking operation in to the materials.

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3. 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.

4. HOSE COLLAR AND PU CONNECTOR:

In our pneumatic 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

Al 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.,

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

can with stand at a maximum pressure level of 10 kg/cm2.

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5. D.C. MOTOR (PERMANENT MAGNET):

DESCRIPTION OF DC MOTOR

An 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 experiences a magnetic force whose direction is given by

Flemings left hand rule.

When a motor is in operation, it develops torque. This torque can produce

mechanical rotation. DC motors are also like generators classified into shunt wound or

series wound or compound wound motors.

FLEMINGS LEFT HAND RULE:

Keep 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.

PRINCIPLE OF OPERATION OF DC MOTOR:

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 N

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

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due to the current in the conductor supports the main field above the conductor, but

opposes the main field below the conductor.

Movement of

Conductor

Magnetic flux current carrying

Conductor

The result is to increase the flux density in to the region directly above the

conductor and to reduce the flux 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 flux

lines occurs below the conductor, and the conductor will be pushed upwards.

Now consider a single turn coil carrying a current as shown in the above figure. in

view of the reasons given above, the coil side A will be forced to move downwards,

whereas the coil side B will be forced to move upwards. The forces acting on the coil

sides A and B will be of same magnitude. But their direction is opposite to one another.

As the coil is wound on the armature core which is supported by the bearings, the

N S

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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. DC supply is given to the field

poles for producing flux. The conductors are connected to the DC supply through

brushes. Lets start by looking at the overall plan of a simple 2-pole DC electric motor. A

simple motor has 6 parts, as shown in the diagram below.

An armature or rotor

A commutate or Brushes

An axle

A field magnet

A DC power supply of some sort

An electric motor is all about magnets and magnetism: a motor uses magnets to

create motion. If you have ever played with magnets you know about the fundamental

law of all magnets: Opposites attract and likes repel.

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So if you have 2 bar magnets with their ends marked north and south, then the

North end of one magnet will attract the South end of the other. On the other hand, the

North end of one magnet will repel the North end of the other (and similarly south will

repel south). 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 (or rotor) is an electromagnet, while the field magnet is a permanent magnet

(the field magnet could be an electromagnet as well, but in most small motors it is not to

save power).

Electromagnets and Motors:

To understand how an electric motor works, the key is to understand how the

electromagnet works. An electromagnet is the basis of an electric motor. You can

understand how things work in the motor by imagining the following scenario. Say that

you created a simple electromagnet by wrapping 100 loops of wire around a nail and

connecting it to a battery. The nail would become a magnet and have a North and South

Pole while the battery is connected. Now say that you take your nail electromagnet, run

an axle 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 North end of the nail appeared as shown, the basic law of magnetism tells you

what would happen: The North 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.

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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.You can see that this half-turn

of motion is simple and obvious because of the way magnets

naturally attract and repel one another. The key 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.

You flip the magnetic field simply by changing the direction of the electrons

flowing in the wire (you do that by flipping the battery over). If the field of the

electromagnet flipped at just the right moment at the end of each half-turn of motion, the

electric motor would spin freely.

The Armature:

The armature takes 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

axle, and the commutator is attached to the axle. In the diagram

above you can see three different views of the same armature: front,

side and end-on. In the end-on view the winding is eliminated to make the commutator

more obvious. You can see that the commutator is simply a pair of plates attached to the

axle. These plates provide the two connections for the coil of the electromagnet.

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The Commutator and brushes:

The "flipping the electric field" part of an electric motor is

accomplished by two parts: the commutator and the brushes. The

diagram at the right shows how the commutator and brushes work

together to let current flow to the electromagnet, and also to flip

the direction that the electrons are flowing at just the right

moment. The contacts of the commutator are attached to the axle

of the electromagnet, so they spin with the magnet. The brushes are just two pieces of

springy metal or carbon that make contact with the contacts of the commutator.

Putting It All Together:

When you put all of these parts together, what you have is a complete electric

motor.

In this figure, the armature winding has been left out so that it is easier to see the

commutator in action. The key thing to notice is that as the armature passes through the

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horizontal position, the poles of the electromagnet flip. Because of the flip, the North

Pole of the electromagnet is always above the axle so it can repel the field magnet's North

Pole and attract the field magnet's South Pole. If you ever take apart an electric motor you

will find that it contains the same pieces described above: two small permanent magnets,

a commutator, two brushes and an electromagnet made by winding wire around a piece

of metal. Almost 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 poles:

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 starts; you can imagine the armature getting

"stuck" 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 (directly connects the positive and

negative terminals) for a moment. This shorting wastes energy and drains the

battery needlessly. A three-pole motor solves this problem as 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.

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6. IR SENSOR UNIT:-

The IR TRANSMITTER circuit is to transmite the Infra-Red rays. This Infra-

Red rays are received by the receiver circuit is called IR RECEIVER. If any obstacle

is there in a path, the Infra-Red rays are cutted.

The IR receiver circuir receives the IR rays and giving the control signal to the

control circuit. The control circuit is used to off the solenoid valve at normal condition.

There is any abstacle in their path meand; the control signal is activate the solenoid valve

so that the punching, printing or marking operation occurs. The operating principle of

solenoid valve is already explained in the above chapter.

The IR transmitting circuit is used in many projects. The IR transmitter sends 40

kHz (frequency can be adjusted) carrier under computer control (computer can turn the

IR transmission on and off). IR carriers at around 40 kHz carrier frequencies are widely

used in TV remote controlling and ICs for receiving these signals are quite easily

available.

7. TIMER UNIT:-

The timer unit is used to proper printing operation to the work piece. The timer

having one variable resister is there, you have to vary the off time of the timer unit.The

IR sensor output signal gives the input power supply of the timer unit. The OP-AMP 324

IC is used as a comparator. The comparator is giving the output voltages depends upon

the two input voltage values. In our project one input voltage (Reference Voltages) is

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IC

324

IC

324

IR SENSOR

OUTPUT

given to the PIN number 2 (- ive pin) of 324 IC from the variable resistor (10 K Ohm).

The Variable resistance output is given to the OP-AMP pin number 3 (+ ive pin).

CIRCUIT DIAGRAM:-

1K

9V (ZENER) 10K

10K 2 - 4

1000F 3 + 1

10K 10K

2.2K

LDR 1N4007 5 + 7

10K 6 - 11

SOLENOID N/C BC547 1K

VALVE RELAY

N/O LED 1K

AT NORMEL CONDITION:-

In normal condition the Sensor output signal is zero.. The voltages applied to the

non-inverting terminal (+ ive) is low when compared to the inverting terminal voltages (-

ive). In that time, the OP-AMP output is Vsat. (I.e. -12 Volt). The transistor and relay

are in OFF condition. In that condition, the solenoid valve is off condition.

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AT ABNORMAL CONDITION:-

In Abnormal condition the IR sensor output signal is ON. The voltages applied to the

non-inverting terminal (+ ive) is high when compared to the inverting terminal voltages (-

ive). In that time, the OP-AMP output is +Vsat. (I.e +12 Volt). The transistor and relay

are in ON condition. In that time, the solenoid valve is in ON condition, the printing

operation is done.

8.CONVEYOR BELT AND ROLLER:-

Conveyor belt and roller mechanism is used to transfer the work piece from one place

to the other place. The roller having two end bearings with bearing cap. It is made upof

mild steel.

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Chapter-5

DESIGN AND specifications

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CHAPTER-5

DESIGN AND SPECIFICATIONS

PNEUMATIC CYLINDER:

Design of Piston rod:

Load due to air Pressure.

Diameter of the Piston (d) = 35 mm

Pressure acting (p) = 6 kgf/cm

Material used for rod = C 45

Yield stress (y) = 36 kgf/mm

Assuming factor of safety = 2

Force acting on the rod (P) = Pressure x Area

= p x (d / 4)

= 6 x {( x 3.5 ) / 4 }

P = 57.73 Kgf

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Design Stress (y) = y / F0 S

= 36 / 2 = 8 Kgf/mm

= P / ( d / 4 )

d = 4 p / [ y ]

= 4 x 57.73 / { x 18}

= 4.02 = 2.02 mm

Minimum diameter of rod required for the load = 2.02 mm

We assume diameter of the rod = 12.5 mm

Design of cylinder thickness:

Material used = Cast iron

Assuming internal diameter of the cylinder = 35 mm

Ultimate tensile stress = 250 N/mm = 2500 gf/mm

Working Stress = Ultimate tensile stress / factor of safety

Assuming factor of safety = 4

Working stress ( ft ) = 2500 / 4 = 625 Kgf/cm

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According to LAMES EQUATION

Minimum thickness of cylinder ( t ) = ri { (ft + p) / (ftp ) -1 }

Where,

ri = inner radius of cylinder in cm.

ft = Working stress (Kgf/cm)

p = Working pressure in Kgf/cm

Substituting values we get,

t = 1.75 { (625 + 6) / ( 6256) -1}

t = 0.0168 cm = 0.17 mm

We assume thickness of cylinder = 2.5 mm

Inner diameter of barrel = 35 mm

Outer diameter of barrel = 35 + 2t

= 35 + ( 2 x 2.5 ) = 40 mm

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SPECIFICATION

1. Single acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 50 mm

Quantity : 1

Seals : Nitride (Buna-N) Elastomer

End cones : Cast iron

Piston : EN8

Media : Air

Temperature : 0-80 C

Pressure Range : 8 N/m

2. Solenoid Valve Technical data

Max pressure range : 0-10 x 10 N/m

Quantity : 3

3. Flow control Valve Technical Data

Port size : 0.635 x 10 m

Pressure : 0-8 x 10 N/m

Media : Air

Quantity : 1

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4. Connectors

Technical data

Max working pressure : 10 x 10 N/m

Temperature : 0-100 C

Fluid media : Air

Material : Brass

5. Hoses Technical date

Max pressure : 10 x 10 N/m

Outer diameter : 6 mm = 6 x 10 m

Inner diameter : 3.5 mm = 3.5 x 10 m

6. IC 555 SPECIFICATION

Supply Voltage (Vcc) = 4.5 to 15V

Supply Current (Vcc=5V/2) = 3 to 6mA

Supply Current (Vcc=25V/2) = 10 to 15mA

Output Current = 200mA (maximum)

Power dissipation = 600mw

Operating temperature = 0-70 degree Celsius

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CHAPTER-6

CAD DRAWINGS

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Chapter-7

FABRICATION

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CHAPTER-7

FABRICATION

Method of Fabrication:

The stand (or) base is to carry the whole machine. The two conveyor roller is fixed

to the two ends of the frame stand with the help of end bearing (6202) with bearing cap.

The conveyor roller shaft is coupled to the D.C. 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 IR transmitter and IR receiver circuit is used to sense the work piece material.

It is fixed to the frame stand with a suitable arrangement. The pneumatic cylinder is fixed

to the frame stand by right angles to the sensor. This cylinder arrangement is used to

punch, print or mark the materials transferred from the conveyor. The pneumatic cylinder

is controlled by the flow control valve, single acting solenoid valve and control unit.

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Chapter-8

WORKING OPERATION

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CHAPTER-8

WORKING OPERATION

The 12 volt power supply is used to drive the permanent magnet D.C motor. The

two conveyor roller is fixed to the two ends of the frame stand with the help of end

bearing (6202) with bearing cap. The conveyor roller shaft is coupled to the D.C.

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.

There are two sets of IR sensors are used, one for used to on/off the motor depends

upon the work piece is kept or not in the conveyor. The conveyor will operate only the

work pieces kept in the conveyor only. The remaining time the conveyor will be in off

condition so that the power is saved. Another one IR sensor is used to detect the material

and giving control signal to the control unit. The IR transmitter and IR receiver circuit is

used to sense the material. It is fixed to the frame stand with a suitable arrangement. This

mechanism is also adjustable with the help of bolt and nut. The pneumatic cylinder is

fixed to the frame stand by right angles to the frame stand. This cylinder arrangement is

used to punching, marking or printing into the material from the conveyor. The

pneumatic cylinder is controlled by the flow control valve, single acting solenoid valve

and control unit.

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AT NORMAL CONDITION:

The IR transmitter sensor is transmitting the infrared rays with the help of 555 IC

timer circuit. These infrared rays are received by the IR receiver sensor. The Transistor

T1, T2 and T3 are used as an amplifier section. At normal condition Transistor T5 is OFF

condition. At that time sensor output signal is OFF.

AT MATERIAL CONDITION:

At material conditions the IR transmitter and IR receiver, the resistance across the

Transmitter and receiver is high due to the non-conductivity of the IR waves. So the

output of transistor T5 goes from OFF condition to ON stage. The timer unit relay is ON

to the 3/2 solenoid valve, so that the air from the compressor is goes to the pneumatic

cylinder. The punching or marking or printing operations are done with the help of die

fixed in the piston rod of the pneumatic cylinder.

IC 555 TIMER

The IC SE / NE 555 monolithic circuit is a highly stable controller capable of

producing accurate time delays or oscillations. Additional terminals are provided for

triggering or resetting if desired.

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1 8

2 7

IC

NE 5553 6

4 5

In the timing operations, the time is precisely controlled by one external resistor

and a capacitor, by the operation as an oscillator, the free running frequency and the duty

cycle are both accurately contributed with the external RC constants.

PIN DIAGRAM:

GROUND SUPPLY (Vcc)

TRIGGER DISCHARGE

OUTPUT THERSOLD

RESET CONTROL

PIN NO: 1

It is ground terminal.

PIN NO: 2

The trigger voltage to the lower

comparator is applied. It has constant

voltage that is atleast one third of the

supply voltage, when trigger voltage

falls below this level the flip-flop

changes its state and output becomes

high.

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PIN NO: 3

It is the output terminal, in low state output is equal to zero and when at higher state

output is equal to Vcc.

PIN NO: 4

It controls the flip flop directly. It turns the device to its original position when reset

pin is connected to ground the output is approximately equal to zero. When reset is not

used it is connected to Vcc.

PIN NO: 5

It is the control voltage terminal. It is connected to ground through a capacitor of 0.01

F. Any external voltage at pin: 5 will change both the threshold voltage and the trigger

voltage reference level.

PIN NO: 6

Threshold voltage of upper comparator is applied from this terminal. The resistor Rt

connected to Vcc and pin: 6 is grounded by an external capacitor. The output is high

capacitor charges by resistor Rt. When the capacitor changes to the threshold level, the

output becomes low.

PIN NO: 7

It is the discharge pin for external capacitor. Usually pin: 7 is connected with pin: 6

directly to by a resistor. When the output becomes low then the external capacitor

discharges by internal discharge transistor remains at cut-off and the external capacitor

charges to Vcc.

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PIN NO: 8

It is the positive supply terminal. A dc voltage from +5 to + 15 can be applied.

The important features of IC555 can be summarized as follows.

1. Timing range from microseconds to hours.

2. Mono-stable and Astable operation is possible through IC555.

3. The duty cycle can be adjusted according to our necessity.

4. It has the ability to operate from a wide range of supply Voltage.

5. The output of 555 is compatible with CMOS, DTL and TTL, logic.

But when used with a 5V supply.

6. Triggering and reset inputs are logically compatible.

7. Output can be operated as normal ON and normal OFF.

8. High temperature stability.

9. Unlike RC timers, 555 provide a time intervals that is virtually

independence of supply voltage Vcc. This because that, the charge rate of

CT and the reference voltage to the threshold comparator are all directly

proportional to the supply voltage.

FILTERS

The out voltage is essentially constant. We filter the pulsating voltage by using

RC filter. The capacitor is made sufficiently large to present very low impedance to the

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ripple frequency and infinite impedance to DC prefers. The shunt path through C and the

steady current (IDC) is forced through R developing a DC voltage drop across it. The

ripples are reduced by R&C.

VOLTAGE REGULATOR (IC 78xx SERIES)

The series 78 regulators provide fixed regulated from 5 to 24V. An unregulated

input voltage Vi is filtered by capacitor C1 and connected to the ICs IN terminal. The

ICs OUT terminal provides a regulated +12V which is filtered by capacitor C2. The

third IC terminal is connected to ground. While 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 7812 IC

then provides an output is a regulated +12V DC.

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Chapter-9

ADVANTAGES AND LIMITATIONS

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CHAPTER-9ADVANTAGES AND LIMITATIONS

ADVANTAGES

The Automatic power saving punching conveyor is more efficient in the

technical field

Quick response is achieved

Simple in construction

Easy to maintain and repair

Cost of the unit is less when compared to other robotics

No fire hazard problem due to over loading

Comparatively the operation cost is less

Continuous operation is possible without stopping

LIMITATIONS

While working, the compressed air (For Punching Operation) produces noise

therefore a silencer may be used.

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Chapter-10

APPLICATIONS

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CHAPTER-10

APPLICATIONS

Discharge of work piece:-

The Conveyor 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

workstation and place them in bins. It can also be used to pick raw material and place

them on the conveyor belts.

Punching operation:-

This unit can also be used in Punching Operation in the material at high

speeds. The application of these units is limited to operations which involved moderate

clamping forces.

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Chapter-11

LIST OF MATERIALS

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CHAPTER-11

LIST OF MATERIALS

S. No. Description Qty Material

1 Single Acting pneumatic cylinder 1 Mild Steel

2 Single Acting 3/2 Solenoid Valve 1 Aluminium

3 Flow control Valve 1 Aluminium

4 PU Tubes 1 meter Polyurethane

5 Hose Collar 1 Brass

6 Reducer 1 Brass

7 Frame stand 1 M.S

8 Sensor with control Unit 1 -

9 Conveyor Roller 2 M.S

10 Conveyor Belt 1 Rekchin

11 Bearing (6202) 4 Steel

12 Bearing Cap 4 M.S

13 Shaft 2 M.S

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Chapter-12

COST ESTIMATION

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CHAPTER-12

COST ESTIMATION

1. MATERIAL COST:-

S. No. Description Qty Material Amount (Rs)

1 Single Acting pneumatic cylinder 1 Mild Steel 800

2 Single Acting 3/2 Solenoid Valve 1 Aluminium 600

3 Flow control Valve 1 Aluminium 300

4 PU Tubes 1 meter Polyurethane 100

5 Hose Collar 1 Brass 50

6 Reducer 1 Brass 20

7 Frame stand 1 M.S 1500

8 Sensor with control Unit 1 - 1200

9 Conveyor Roller 2 M.S 500

10 Conveyor Belt 1 Rekchin 550

11 Bearing (6202) 4 Steel 250

12 Bearing Cap 4 M.S 130

13 Shaft 2 M.S 100

TOTAL = 6000

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2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost = 1500

3. OVERHEAD CHARGES

The overhead charges are arrivedby Manufacturing cost

Manufacturing Cost = Material Cost + Labour cost

= 6000+1500

= 7500

Overhead Charges = 20% of the manufacturing cost

= 1500

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

= 6000+1500+1500

= 9000

Total cost for this project = 9000

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Chapter-13

CONCLUSION

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CHAPTER-13

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 AUTOMATIC POWER SAVING PUNCHING CONVEYOR 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 an AUTOMATIC POWER SAVING PUNCHING

CONVEYOR which helps to know how to achieve low cost automation with sensor

arrangement. The operating procedure of this system is very simple, so any person can

operate. By using more techniques, they can be modified and developed according to the

applications.

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BIBLIOGRAPHY

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BIBLIOGRAPHY

Catalogue of Janatics pneumatic product, Janatics Private Limited Coimbatore.

Design data bookcompiled by faculty of mechanical engineering

P.S.G. college of technology,Coimbatore

Festo Didactic KGFundamentals of control technology, Esslingen-1998.

Festo Pneumatic Catlogue - Festo Pvt Ltd.Bangalore.

Werner Deppert/Kurt Stoll., Cutting Cost With Pneumatics, Vogel Buchverlag

Wurzburg, 1998.

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