FABRICATION OF AUTOMATIC PNEUMATIC

CONTROLLED JOB SORTING DEPENDING ON THEIR

HEIGHT

PROJECT REPORT BY:

1. K. RAJESH
2. V. GOPALAKRISHNAN
3. S. MATHIVANAN

4. R. PRAVEEN KUMAR
5. R. SATHISH BABU
6. D. THIYAGARAJAN

GUIDED BY
M. KAMARAJ, M.E.,
Submitted in the partial fulfillment of the requirement for the award of
Diploma in Machinetool maintenance and repair Engineering
during the academic year 2008

AMK POLYTECHNIC COLLEGE

CHENNAI, PIN 602 103.

AMK POLYTECHNIC COLLEGE

CHENNAI

BONAFIDE CERTIFICATE
This is to certify that this Project work on

FABRICATION OF AUTOMATIC PNEUMATIC CONTROLLED JOB

SORTING DEVICE

submitted by . Reg. No.

in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING
This is the bonafide record of work carried out by him under our supervision
during the year 2012
Submitted for the Viva-voce exam held on ..

H.O.D

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. ADHIMOOLAM encouragement and valuable advice.

we

thank

our

Esquired

Head

of

Department

Mr

C.

RAMAKRISHNAN for presenting his felicitations on us.

We are grateful on our Entourages Mr.K.KALIMUTHU for guiding
in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the
Mechanical Engineering Department..

Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.

CONTENTS

CONTENTS

CHAPTER NO.

TITLE

1.

SYNOPSIS

2.

CONSTRUCTION

3.

WORKING PRINCIPLE

4.

ELECTRICAL CIRCUIT DETAILS

5.

MECHANIAL ASSEMBLY DIAGRAM

6.

PNEUMATIC COMPONENTS DETAILS

7.

ELECTRICAL WIRING DIAGRAM

8.

COST ESTIMATION

9.

CONCLUSION

10.

BIBLIOGRAPHY

SYNOPSIS

SYNOPSIS
Objective
To store the material from the landing point to the particular
rack automatically.
To develop industrial automation and assist with CIM
environment.
To promote the unmanned industry.
Project Background
In the present global rationalization and competitive world most of the
industries set up unmanned industry in order to eliminate labor cost
and to increase productivity.
Working Principle
We selected FABRIATION OF AUTOMATIC PNEUMATIC
CONTROLLED JOB SORTING DEVICE as our project work and we
have used principles of Mechatronics in developing this project work..

In

this project the materials are placed on a platform and transported from the
ground floor to upstairs using a Pneumatic cylinder.. The double acting

cylinder is actuated through the 5/3 way solenoid operated directional

control valve .

After reaching the particular platform , the material is

ejected in to the cabin by another AIR cylinder.

There are three magnetic reed sensors placed at each floor for the
purpose of stopping in the platform. The materials are transmitted from one
floor to another floor by sensing their height in the platform which has three
magnetic sensor.

Project Elements
Power Supply
Micro Controller
Double acting cylinder( 2 nos)
5/3 way solenoid operated directional control valve
5/2 way solenoid operated directional control valve
M.S Fabricated stand

Magnetic reed sensor 6 nos

\
Block Diagram
Power
Supply

FLOOR
SELECTION
SENSORS

Micro
Control Unit
Operated at 5
volts DC
Supply

MANETIC
SENSORS
Height sensing
sensors

5/3 WAY
SOLENOID VALVE
5/2 WAY
SOLENOID VALVE

CONSTRUCTION

CONSTRUCTION
This project consists of following parts
1.MICROCONTROLLER based control system
2.Air cylinder.
3.Magnetic reed sensor unit
4. 5/3 Directional controlled solenoid valve.

PNEUMATIC ELEVATOR

DOUBLE ACTING
CYLINDER

M.S.STAND

BASE

AIR CYLINDER

AIR cylinder is pneumatic equipment. In this cylinderis used for sliding

LIFT movement . The cylinder and piston Rod is engaged in single solid
unit. It moves across up and down. Air is supplied to cylinder in A+ and Aposition. Movement of slide is depending upon the pressure of air.

SOLENOID VALVE
Solenoid valve is device, which is used to control the movement of slide.
This is achieved by controlling a coil, when this coil energizes the flow of
the air from compressor through the valve is allowed just by lifting the
stopper with coils magnetic field. We are using 24VDC / 5/3 way solenoid
operated directional control valve for material elevating operation and one
5/2 way solenoid operated directional control valve for ejecting the job. The
solenoid valve is connected to microcontroller output . The valve is
connected to air cylinder through the 6/4 mm polyurethane tube.

MAGNETIC REED SENSOR UNIT;

The magnetic sensors are used for limiting the position of the elevator
cabin.Three sensors are mounted on a plastic plate as shown in figure.

MAGNETIC SENSOR

The

plastic plate with the sensor is mounted on the left side of the

elevatorcabin unit .The height of the plastic plate can be adjusted with the
help of bolt and nuts in order to set the minimum gap between the magnet
and magnetic sensor
.

MAGNETIC PLATE

MAGNETIC
SENSOR 1

MAGNETIC
SENSOR 2

MAGNETIC
SENSOR 3

PLASTIC PLATE

HEIGHT ADJUSTABLE
BOLT NUT

NOVOPAN PLYWOOD

WORKING PRINCIPLE

WORKING PRINCIPLE
MICROCONTROLLER controls the solenoid coil to actuate the cylinder
cabin up and down. To start the operation, the job is placed on the platform
where the height of the job is predicted by the three magnetic sensors. These
sensors sends the signal to the controller for the selection of the storage
cabin . Controller gives the output signal as per the program and drive the
solenoid coil through the 24V relay.

Here we use 5/3 way solenoid operated directional control valve . This valve
is used to stop the piston rod of double acting cylinder at required position
between the A+ and Aposition.

When the cabin crosses the required floor or cabin ,the magnetic
sensor sends the signal to the input of the controller. Controller switch off
the supply to the solenoid coil at the required floor. Then switch on the 5/2
way solenoid valve to actuate the air cylinder in order to eject the job into
the cabin..
. The pressure required to operate this system is 5 to 6 bar.

ELECTRICAL CIRCUIT
DETAILS

CIRCUIT DETAILS
1. Micro controller system
2. Interface Circuit for solenoid valves
3. Power supply (230V A.C. to 12 V and 5V DC)
4. Key Board Circuit

MICRO CONTROLLER SYSTEM:

This system monitors the engine condition by using PIC 16F870 (28
pin IC Package) micro controller. The pin details of micro controller are
shown in figure.

The circuit diagram for this micro controller board is shown below,

MOTHER BOARD CIRCUIT DETAILS

in no 2&5.The pin no 1 is RESET switch..The INPUTS are connected to

port B .The OUTPUTS are connected to PORT C.6 MHZ crystal is
connected to pin no 9,10.

Keypad interface;
Here seven soft microswitches are soldered in the main board and
their connections are shown below.

PORT B (KEYPAD)INPUT & OUTPUT CIRCUIT

POWER SUPPLY 5V DC AND 12V DC;

A 12 0 v step down transformer is used to stepdown 230V AC to

12V AC .This 12V AC supply is converted to 12V DC using four rectifier
diodes. The voltage from the rectifier section is regulated to 12V DC using
7812 IC . From 12V DC the 7805 IC is used for regulating 5V DC for the
power supply of microcontroller.
the power supply circuit is shown in fig.

INTRODUCTION:
All the electronic components starting from diode to Intel ICs only
work with a DC supply ranging from +5V to +12V. We are utilizing for the
same, the cheapest and commonly available energy source of 230V-50Hz
and stepping down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer,
it can either be stepped down or stepped up depending on the value of DC
needed. In our circuit the transformer of 230V/15-0-15V is used to perform
the step down operation where a 230V AC appears as 15V AC across the
secondary winding. Apart from stepping down voltages, it gives isolation
between the power source and power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a
solid state diode. Diode has the property that will let the electron flow easily
in one direction at proper biasing condition. As AC is applied to the diode,
electrons only flow when the anode and cathode is negative. Reversing the

polarity of voltage will not permit electron flow. A commonly used circuit
for supplying large amounts of DCpower is the bridge rectifier. A bridge
rectifier of four diodes (4 x IN4007) are used to achieve full wave
rectification. Two diodes will conduct during the negative cycle and the
other two will conduct during the positive half cycle, and only one diode
conducts. At the same time one of the other two diodes conducts for the
negative voltage that is applied from the bottom winding due to the forward
bias for that diode. In this circuit due to positive half cycle D1 & D2 will
conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of
100Hz. Since each alteration produces a resulting output pulse, frequency =
2 x 50 Hz. The output obtained is not a pure DC and therefore filtration has
to be done.
The DC voltage appearing across the output terminals of the bridge
rectifier will be somewhat less than 90% of the applied rms value. Normally
one alteration of the input voltage will reverse the polarities. Opposite ends
of the transformer will therefore always be 180 degree out of phase with
each other. For a positive cycle, two diodes are connected to the positive
voltage at the top winding.

FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester
always follow the rectifier unit. This capacitor is also called as a decoupling
capacitor or a bypassing capacitor, is used not only to short the ripple with
frequency of 120Hz to ground but also to leave the frequency of the DC to
appear at the output. A load resistor R1 is connected so that a reference to
the ground is maintained. C1, R1 is for bypassing ripples. C2, R2 is used as
a low pass filter, i.e. it passes only low frequency signals and bypasses high
frequency signals. The load resistor should be 1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating
10f/25V

: for maintaining the stability of the voltage at the load side.

0.1f

: for bypassing the high frequency disturbances

BLOCK DIAGRAM FOR POWER SUPPLY

STEP DOWN

TRANSFORMER

BRIDGE

POSITIVE

RECTIFIER

CHARGE
CAPACITOR

5V
REGULATOR

MOTHER
BOARD

VOLTAGE REGULATOR:

DISPLAY
BOARD

12V
REGULATOR

RELAY

The voltage regulators play an important role in any power supply

unit. The primary purpose of a regulator is to aid the rectifier and filter
circuit in providing a constant DC voltage to the device. Power supplies
without regulators have an inherent problem of changing DC voltage values
due to variations in the load or due to fluctuations in the AC linear voltage.
With a regulator connected to the DC output, the voltage can be maintained
within a close tolerant region of the desired output. IC7812 and 7912 is
used in this project for providing +12V and 12V DC supply.

1.

5 TO 12 V DC DRIVE CARD

Here we have to drive the 12V DC load. The 5V signal from the PIC
16F870 micro-controller is fed into the input of interface circuit. SL100
transistor is used here for high speed switching purpose and IRF 540N
MOSFET is connected to the motor to handle the larger current drawn by the
solenoid valve.

MECHANICAL
ASSEMBLY DRAWING

PNEUMATIC ELEVATOR

DOUBLE ACTING
CYLINDER

M.S.STAND

BASE

DESCRIPTION OF
PNEUMATIC
COMPONENTS

DESCRIPTION OF PNEUMATIC
COMPONENTS
1. Double acting air cylinder with piston arrangement.
2. Spool valve (2 position 5 ports valve)
3. Pneumatic fittings
a. Bulk head union
b. Flexible hoses
c. Air compressors
DOUBLE ACTING AIR CYLINDER WITH PISTON
ARRANGEMENT:
It consists of a piston inside a cylindrical housing called a barrel.
Attached to one end of the piston is a rod which the rod end has one port.
This rod end port is used for entrance of air and extends outside one end of
the cylinder. At another end is a port for exit of air.
Double acting cylinder can be extended and retracted pneumatically.
The smallest bore size of an double acting cylinder is 1 1/8 inch. The piston,
which is made of ductile Iron, contains u-cup packing to seal against leakage
between the piston and barrel. The ports are located in the end caps, which
are secured to the barrel by bolts and nuts.

DIRECTING CONTROL VALVES:

A direction control valve is used to change the direction of air flow as
and when required by the system for reversing the machine tool devices. A
direction control valve may be classified, according to the construction of
the internal moving parts, as
1. Rotary spool Type.
2. Sliding Spool Type.
3. Solenoid operated valves
SOLENOID OPERATED VALVES:
Solenoid valves are electromechanical devices like relays and
contractors. A solenoid valve is used to obtain mechanical movement in
machinery by utilizing fluid or air pressure. The fluid or air pressure is
applied to the cylinder piston through a valve operated by a cylindrical
electrical coil. The electrical coil along with its frame and plunger is known
as the solenoid and the assembly of solenoid and mechanical valve is known
as solenoid valve.

The solenoid valve is thus another important

electromechanical device used in control of machines. Solenoid valves are

of two types,

1. Single solenoid spring return operating valve,(5/2)

2. Double solenoid operating valve.

In fig 1 is shown a single solenoid spring return valve in its de-energized

condition. The symbol for the solenoid and the return are also shown. The
solenoid valve is shown connected to the cylinder to help readers understand
the solenoid valve action.
In the de energized condition, the plunger and the valve spool position as
shown in figure 1.

In this position of spool, port P is connected to port A and port B is

connected to tank or exhaust (i.e. atmosphere) if air is used. Spring pressure
(S) keeps the spool in this condition as long as the coil is de energized.
Fluid pressure from port P through port A is applied to the left side of the
cylinder piston. Thus the cylinder piston moves in the right direction.

Now when the solenoid coil is energized, plunger is attracted and it pushes
the spool against spring pressure.
The new position of plunger and spool are shown in fig 2.

In this position of spool, port A gets connected to tank and port P gets
connected to port B. Thus pressure is applied to the cylinder piston from
right and moves the piston rod to the left. At the same time fluid in the other
side is drained out to the tank. When the solenoid coil is again de energized,
the spring (S) will move the spool to its original position as shown in figure
1. Thus, normally when the solenoid coil is de energized the piston rod
remains extended.

PNEUMATIC FITTINGS:
There are no nuts to tighten the tube to the fittings as in the
conventional type of metallic fittings. The tube is connected to the fitting by
a simple push ensuring leak proof connection and can be released by
pressing the cap and does not require any special tooling like spanner to
connect (or) disconnect the tube from the fitting.
SPECIFICATION OF THE FITTING:
Body Material

- Plastic

Collect/Thread Nipple

- Brass

Seal

- Nitrate Rubber

Fluid Used

- Air

Max. Operating Pressure

- 7 Bar

Tolerance on OD of the tubes

- 1 mm

Min. Wall thickness of tubes

- 1 mm.

FLEXIBLE HOSES:
The Pneumatic hoses, which is used when pneumatic components
such as actuators are subjected to movement. Hose is fabricated in layer of
elastomer or synthetic rubber, which permits operation at high pressure. The
standard outside diameter of tubing is 1/16 inch. If the hose is subjected to
rubbing, it should be encased in a protective sleeve.

ADVANTAGES AND LIMITATIONS

ADVANTAGES:

The Pneumatic arm is more efficient in the technical field

Quick response is achived
Simple in constructions
Easy to maintain and repair
Cost of the unit is less when compared to other robotics
No fire hazrd problem due to over loading
Comparatively the operation cost is less
The operation of arm is faster because the media to operate is air
Continuous operation is possible without stopping.
LIMITATIONS:
High torque cannot be obtained.
Load Carrying capacity of this unit is not very high (3 5 kgs).
While working, the compressed air produces noise, therefore a silencer may be
used.

APPLICATIONS

DISCHARGE OF WORKPIECE:

The arm fed has wide application in low cost automation. It can be
used in automated assembly lines to pick-up the finished product from
workstation and place them in the bins. It can also be used to pick-up the
raw material and place them on the conveyor belts and vice versa.

JOB CLAMPING:

This unit can also be used in clamping operations in certain areas of

mass productions where clamping and unclamping have to be done at high
speeds. The applications of this unit is limited to operations which involves
moderate clamping forces.

TRANSFER OF JOBS BETWEEN WORK STATION:

The gripping method used in a low cost automation to move the

workpiece from one workstation to another. The combination of an angular

rotary motion is the principle behind this method. The gripper holds the
work rigidly. The to and fro motion is achieved by means of the actuating
cylinder.

TOOL CHANGING APPLICATION:

When the pneumatic arms are made smaller in size they can be used
in automatic tool changer in CNC turning and drilling machines, by
attaching suitable tool holding device to the rotary cylinder.

PNEUMATIC CIRCUIT
DIAGRAM

PNEUMATIC CIRCUIT DIAGRAM

ELECTRICAL WIRING
DIAGRAM

COST ESTIMATION

COST ESTIMATION

DETAILS

COST Rs.

1. Double acting cylinder unit- 32MM DIA X200MM L

1000

2. Double acting cylinder unit- 20MM DIA X 50MM L

800

3. 5/3 double solenoid directional control valve-1/8INCH

1000

4. 5/2double solenoid directional control valve-1/8 INCH

800

5. M.S. L ANGLE fabricated stand 750W x 300 Bx 600 H MM

600

6. microcontroller unit

1400

7. Novoban Board

200

8. Magnetic sensor unit

200
6000
/-

TOTAL

CONCLUSION

CONCLUSION
We make this project entirely different from other projects. Since
concepts involved in our project is entirely different that a single unit is used
to various purposes, which is not developed by any of other team members.
By doing this project we gained the knowledge of pneumatic system
and how automation can be effectively done with the help of pneumatic
system.
It is concluded that any automation system can be done with the help
of controller& pneumatic system.
We have successfully completed the project work on using pneumatic
control at our Institute.
By doing this project work, we understood the working principle and
uses of various controls, switches, relays etc.
It will be of no doubt that pneumatic system will be an integrated part
of any automation process in any industry.
Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

BIBLIOGRAPHY

1. Low cost automation with pneumatics

FESTO

2. Electro pneumatics

3. Hydraulics & pneumatics for Power Production -

Harry L Stewart

4. Basic pneumatics

- FESTO

FESTO

5. www.google.com
6. Workshop Technology

- Hajra Chowdry

7. Production Technology

-R.S. Khurmi

PHOTO VIEW